Assembly and Installation of Conventional Duo-Cone Seals{7561, 7561} Caterpillar


Assembly and Installation of Conventional Duo-Cone Seals{7561, 7561}

Usage:

769C 01X

Information for equipment:


POWER TRAIN
AXLE GP

Assembly and Installation of Conventional Duo-Cone Seals{7561, 7561} Assembly and Installation of Conventional Duo-Cone Seals{7561, 7561}
Tool and Specification Chart for Conventional Duo-Cone Seal Groups {0599, 7561} Tool and Specification Chart for Conventional Duo-Cone Seal Groups {0599, 7561}
Installation of Conventional Duo-Cone Seals{7561} Installation of Conventional Duo-Cone Seals{7561}
Installation of Inverted Duo-Cone Seals{7561} Installation of Inverted Duo-Cone Seals{7561}
Effectivity of the Upgrades to Remanufactured Transmissions, Torque Converters, and Wheel Assemblies{3030, 3101, 4051} Effectivity of the Upgrades to Remanufactured Transmissions, Torque Converters, and Wheel Assemblies{3030, 3101, 4051}
Inspection of the Duo-cone Seal Gp{4050, 4051, 7561} Inspection of the Duo-cone Seal Gp{4050, 4051, 7561}

Rear Axle Housing 768C TRACTOR & 769C TRUCK POWER TRAIN
Rear Axle Housing 768C TRACTOR & 769C TRUCK POWER TRAIN
Rear Axle Housing 768C TRACTOR & 769C TRUCK POWER TRAIN

Specifications for Inspection of Driveline Fasteners {3030, 3101, 3159, 3253, 3258, 3278, 4050} Specifications for Inspection of Driveline Fasteners {3030, 3101, 3159, 3253, 3258, 3278, 4050}
Torque Converter, Divider, Drive Line, and Drive Axle Reuse and Salvage Manual Contents {0374, 3000, 3050, 3100, 3250, 3251, 3253, 3258} Torque Converter, Divider, Drive Line, and Drive Axle Reuse and Salvage Manual Contents {0374, 3000, 3050, 3100, 3250, 3251, 3253, 3258}

Proper Oil Changing Procedures {1000, 1308, 1316, 1325, 1348, 3000, 3004, 3005, 3030, 3064, 3067, 3080, 3081, 4000, 4001, 4050, 4051, 5050, 5056, 5068, 5095} Proper Oil Changing Procedures {1000, 1308, 1316, 1325, 1348, 3000, 3004, 3005, 3030, 3064, 3067, 3080, 3081, 4000, 4001, 4050, 4051, 5050, 5056, 5068, 5095}
Obtaining Oil Sample for Analysis {1302, 1348, 3030, 3080, 3278, 4011, 4070, 5050, 5056, 5095, 7542} Obtaining Oil Sample for Analysis {1302, 1348, 3030, 3080, 3278, 4011, 4070, 5050, 5056, 5095, 7542}
Filtration Procedure for Off-Highway Truck (769-777) Rear Axle Oil {0680, 0768, 3260, 4050} Filtration Procedure for Off-Highway Truck (769-777) Rear Axle Oil {0680, 0768, 3260, 4050}
Procedure for Filtering Final Drives, Rear Axles, and Differentials on Caterpillar Machines {0680, 0768, 3258, 3260, 4050} Procedure for Filtering Final Drives, Rear Axles, and Differentials on Caterpillar Machines {0680, 0768, 3258, 3260, 4050}

Stabilizer Rod 768C TRACTOR & 769C TRUCK POWER TRAIN
Rear Axle Housing And Differential 768C TRACTOR & 769C TRUCK POWER TRAIN
Front Wheels, Bearings And Duo-Cone Seals 768C & 769C TRACTOR & 769C TRUCK VEHICLE SYSTEMS
Duo-Cone Floating Seals 768C & 769C TRACTOR & 769C TRUCK VEHICLE SYSTEMS
Assembly & Installation Of Conventional Duo-Cone Seals 768C TRACTOR & 769C TRUCK POWER TRAIN
Rear Wheel Bearings And Duo-Cone Seals 768C TRACTOR & 769C TRUCK POWER TRAIN
Rear Axle Housings 768C TRACTOR & 769C TRUCK POWER TRAIN
Stabilizer Rod 768C TRACTOR & 769C TRUCK POWER TRAIN
Rear Axle Housing And Differential 768C TRACTOR & 769C TRUCK POWER TRAIN
Assembly & Installation Of Conventional Duo-Cone Seals 768C TRACTOR & 769C TRUCK MACHINE SYSTEMS
Rear Wheel Bearings And Duo-Cone Seals 768C TRACTOR & 769C TRUCK POWER TRAIN DISASSEMBLY & ASSEMBLY
Rear Axle Housing 768C TRACTOR & 769C TRUCK POWER TRAIN DISASSEMBLY & ASSEMBLY
Rear Axle Housing And Differential 768C TRACTOR & 769C TRUCK POWER TRAIN DISASSEMBLY & ASSEMBLY
Front Wheel Bearings And Duo-Cone Seal (Earlier) 769C TRUCK VEHICLE SYSTEMS
Front Wheel Bearings And Duo-Cone Seal (Later) 769C TRUCK VEHICLE SYSTEMS

Washers Added To Prevent Broken Bolts In Stabilizer Rod Joints (Connections) On Rear Axle Housing{3260,3268} 1981/01/26
Lateral Stabilizer Bracket Available As A Replacement Part{7051,7203} 1981/11/23
New Outer Duo-Cone Seal Groups Used In Service And Parking Brake Groups{4208,4251,4267} 1982/04/05
Prevent Damage To Brake Lining Before And During Installation{4254,4001} 1983/07/04
New Bolts And Axle Housings Used{3260} 1983/08/15
Toric Ring Seals Available For Duo-Cone Seals In Service And Parking Brake Group{4208,4250} 1984/07/16
New Duo-Cone Seal Groups Used in Service and Parking Brake Groups{4251,7561} 1985/11/25
New Duo-Cone Seal Groups Prevent Oil Transfer{4292,4278} 1986/08/18
Lists Of Duo-Cone Seals And Oil Recommendations{3258,4050,4208} 1988/09/05
Stronger, Longer Ring Gear Retainers For Final Drives {4054,4084} 1988/11/28
Longer Nipple Prevents Mud From Covering Rear Axle Housing Breather{3260} 1990/02/12
Maintenance Interval For Steering Components, Hoist Cylinder Bearings And Rear Axle Housing "A" Frame Bearings Has Changed{7521,7551} 1994/07/25
Effectivity Of Upgrades To Remanufactured Transmissions, Torque Converters And Wheel Assemblies {3001,4051} 1996/10/07
Duo-Cone Seal Assemblies With A Toric Available For Tractors And Trucks{4006,7555,4251,7561} 1997/08/04
High Pressure Washer Available For Final Drives And Axle Housings Of Off-Highway Trucks {0680,4050,3260} 1998/02/02
Off-Highway Truck Duo-Cone Seal Service Tools And Installation Video Now Available{7561} 1999/02/01
Change in Oil Change Interval for the Final Drive and the Rear Axle in Off-Highway Trucks {4000, 4050, 7000, 7560, 7581} 2011/03/07
Product Information Guide, SEBF1015, "Improving Component Durability" , "Final Drives and Differentials" is now available {3258, 3282, 4050} 2004/04/12
Effectivity of Upgrades to Remanufactured Transmissions, Torque Converters and Wheel Assemblies {3030, 3101, 4051} 2007/04/02
Reuse Information on the Components in the Drive Train {3278, 4050} 2008/03/31
Available Seal Assembly For Off-Highway Truck Wheel And Brake Assembly Requires Proper Installation In Order To Improve Seal Reliability. {4051, 4251, 4267} 2009/02/16
Determining the Severity of a Leak of the Duo-cone Seal Gp {4050, 4051, 7561} 2010/02/25
Cat Reman Announces the Addition of Power Train Components for Mining Trucks {3030, 3258, 4008, 4051, 4201, 4251, 4267} 2015/05/28


Product: All Machines

Introduction

This special instruction provides the procedure for assembling and installing conventional Duo-Cone Seals.

When the Duo-Cone Seals are installed and assembled, you must use the correct procedures. The Duo-Cone Seal may fail from one or more mistakes that are made during assembly or during installation of the seal components.

Reference: Special Instruction, SEHS8484, "Tool and Specification Chart for Conventional Duo-Cone Seals"

Required Tools

Use the tools in Table 1 in order to correctly measure the spacing of the Duo-Cone Seals after the seals are installed.

Table 1
Required Tools    
Item     Qty.     Part Number     Description    
10     1     6V-3075     Dial Indicator    
11     1     6V-6167     Contact Point    
12     1     3P-1565     Collet Assembly    
13     1     165-8958     Dial Indicator Base    

Correct Assembly of Conventional Duo-Cone Seals




Illustration 1g00446486

(1) Seal ring

(2) Rubber toric ring

(3) Housing retaining lip

(4) Housing ramp

(5) Seal ring housing

(6) Seal ring face

(7) Seal ring ramp

(8) Seal ring retaining lip

(9) Installation tool

Assembly and Installation Procedure

    ------ WARNING! ------

    Avoid prolonged skin contact with isopropyl alcohol. Avoid breathing the vapors in enclosed areas without adequate ventilation and do not smoke.

    Isopropyl alcohol is flammable. Do not use near open flame, welding operations, or around heated surfaces exceeding 482°C (900°F).

    ----------------------

  1. Remove any film, dust or other foreign matter from the following components:

    • Rubber toric ring (2)

    • Housing ramp (4)

    • Seal ring ramp (7)

    • Housing retaining lip (3)

    • Seal ring retaining lip (8)

    • Seal ring housing (5)

    Note: Seal rings have very sharp edges. Protective gloves should be worn in order to prevent injury.

    Use isopropyl alcohol or other approved cleaning agents. Use a clean lint free cloth for wiping. All components should be completely dry before proceeding.

    Note: Never permit oil to contact rubber toric ring (2), housing ramp (4) or seal ring ramp (7) before both seal rings (1) are assembled in the final position.




    Illustration 2g00534617



    Illustration 3g00446488

  1. Put rubber toric ring (2) on seal ring (1). Make sure that the rubber toric ring is positioned at the bottom of seal ring ramp (7). The rubber toric ring must rest against retaining lip (8). The rubber toric ring must be straight in the seal ring. The rubber toric ring must not be twisted.

    Note: Be careful when you are working on the rubber toric ring. Nicks, cuts or scratches may cause leaks.

  1. Refer to Special Instruction, SEHS8484, "Tool and Specification Chart for Conventional Duo-Cone Seals" in order to select the proper installation tool.



    Illustration 4g00534621

    Use towels or a mat (A) that is made of foam to aid with installing the toric ring (2) .

  1. Install rubber toric ring (2) on seal ring (1) with installation tool (9). Lightly dampen the lower half of rubber toric ring (2) with an appropriate lubricant. Refer to the ""Acceptable Lubricants for Assembly" " section that is in this publication for additional information. Use the following techniques in order to dampen the rubber toric ring:

    • Wipe the seal with a lint free cloth.

    • Place towels or a mat that is made of foam at the bottom of a container. Soak the towels or the mat with the lubricant. Dip the rubber toric seal in the container.

    Note: Periodically inspect the installation tool for damage. If necessary, replace the installation tool .




    Illustration 5g00534622

  1. Make sure that the lower half of rubber toric ring (2) is still wet. Use installation tool (9) in order to position seal ring (1) and rubber toric ring (2) squarely against seal ring housing (5). Make sure that you use sudden pressure and even pressure when you press a toric ring that has a small diameter. Press rubber toric ring (2) under housing retaining lip (3) that is part of seal ring housing (5). Use the following steps in order to install a rubber toric ring that has a large diameter:

    • Push the rubber toric ring over the seal ring retaining lip on one side.

    • Tap the installation tool with a rubber mallet on the opposite side of the rubber toric ring. Tap until the rubber toric ring is past the seal ring retaining lip of the housing.




    Illustration 6g00534720

    (B) Assembled height

    (10) Dial indicator

    (11) Contact point

    (12) Collet assembly

    (13) Dial indicator base (plastic)

  1. Check assembled height (B) at four locations that are 90 degrees from each other. Use a calibrated 6V-3075 Dial Indicator and the related tools in Table 1 in order to measure the assembled height. The difference in height must not exceed 1.0 mm (0.04 inch). Refer to Illustration 6.



    Illustration 7g00446492

  1. Do not adjust the seal ring (1) by pushing on the seal ring or by pulling on the seal ring. Use installation tool (9) in order to push down on the seal.



    Illustration 8g00446493



    Illustration 9g00446494

    Examples of incorrect assembly

  1. Rubber toric ring (2) may twist during installation if the seal is not completely wet or if there are burrs or fins on housing retaining lip (3) that is part of seal ring housing (5). Misalignments, twists and bulges of the rubber toric ring will cause Duo-Cone Seal failures. If correct installation is not obvious, remove the toric ring from the housing and repeat the installation procedure.



    Illustration 10g00446495

  1. Wipe seal ring face (6) that is part of seal rings (1) by using a lint free cloth. No particles of any kind are permissible on the sealing surfaces. A small piece of paper from a paper towel can force apart the seal ring face, which will cause a leak.

    Note: Rubber toric ring (2) must never slip on the ramps of seal ring (1) or the ramps of seal ring housing (5). In order to prevent slippage, allow adequate time for evaporation of the lubricant before proceeding with the procedure. Once the rubber toric ring is correctly positioned, the rubber toric ring must roll only on the ramps.




    Illustration 11g00534623

  1. Apply a thin film of clean oil on the entire seal ring face of one or both seals. Use a lint free cloth or brush in order to distribute the oil evenly. Be careful not to get any oil on the rubber toric rings. Lubricate the seal faces by using the same oil that was used during assembly. Dye may have been used in the oil that was used during assembly. Use the same kind of oil without dye in order to lubricate the seal faces.



    Illustration 12g00446497

  1. Make sure that both seal ring housings (5) are in correct alignment and that the seal ring housings are concentric. Move the parts slowly and move the parts carefully toward each other.

    Note: Do not force the seal ring and the seal ring housing together in a sudden manner. The seal component could be scratched or the seal component could be broken if the components are slammed together.

  1. Tighten the bolts after the components are in the correct position.

Acceptable Lubricants for Assembly

------ WARNING! ------

Avoid prolonged skin contact with isopropyl alcohol. Avoid breathing the vapors in enclosed areas without adequate ventilation and do not smoke.

Isopropyl alcohol is flammable. Do not use near open flame, welding operations, or around heated surfaces exceeding 482°C (900°F).

----------------------

Note: Do not use any liquid that leaves an oil film. Do not use any liquid that does not evaporate quickly. All of the guidelines for safety and all of the guidelines for disposal must be followed when you use a flammable liquid. The following liquids are acceptable lubricants for assembly:

  • Quaker Solvo Clean 68-0

  • Houghto-Grind 60 CT

  • Isopropyl alcohol

Some seal kits come with silicone toric rings. As an option to using liquid lubricants to install silicone toric rings, the rings can be chilled for easier installation. This will allow the toric ring to contract for easier installation.

If chilling is desired, Seals should be placed in a freezer for 5 minutes prior to installation. Temperature in the freezer should be between -40°C (-40°F) to -18°C (0°F). Contraction will be sufficient to allow installation. The seals should be allowed to warm to room temperature prior to further assembly.

Result of Incorrect Assembly




Illustration 13g00446498

The slipping of the rubber toric ring on the housing ramp or on the seal ring ramp may result in uneven pressure on the seal face. Uneven pressure on the seal face causes galling, scoring, and leakage.

If the rubber toric ring slips at one location but not all the way around the seal ring, the toric ring will twist.

The twisted toric ring could be cocked. Seals that are cocked will cause uneven pressure on the seal face. Seals that are cocked may also cause possible galling, scoring, and leakage.

The twisted toric ring could oscillate when the ring is rotated. Seals that oscillate may allow dirt into the seal joint. This is caused by the pumping action that is created by the toric ring that is oscillating.




Illustration 14g00446499

Illustration 14 shows a toric ring that is assembled incorrectly. The upper housing is stationary. The lower housing is rotating.




Illustration 15g00446500

Illustration 15 shows the same seal after the lower housing has rotated 180 degrees. In this position, there will be high pressure at point (B) and at point (X). These points of high pressure may result in galling of the toric rings. There will be low pressure at point (A) and at point (Y) which will result in possible leakage.

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