- Caterpillar Products: All
Introduction
European Union Compliant, CE Marked
Important Safety Information
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| Illustration 1 | g02139237 |
Think Safety | |
Most accidents that involve product operation, maintenance, and repair are caused by failure to observe basic safety rules or precautions. An accident can often be avoided by recognizing potentially hazardous situations before an accident occurs. A person must be alert to potential hazards. This person should also have the necessary training, skills, and tools to perform these functions properly.
Improper operation, lubrication, maintenance, or repair of this product can be dangerous and could result in injury or death.
Do not operate or perform any lubrication, maintenance, or repair on this product until you have read and understood the operation, lubrication, maintenance, and repair information.
Safety precautions and warnings are provided in this manual and on the product. If these hazard warnings are not heeded, bodily injury or death could occur to you or to other persons.
The hazards are identified by the Safety Alert Symbol and followed by a Signal Word such as "DANGER","WARNING", or "CAUTION". The Safety Alert "WARNING" label is shown below.
A non-exhaustive list of operations that may cause product damage are identified by "NOTICE" labels on the product and in this publication.
Caterpillar cannot anticipate every possible circumstance that might involve a potential hazard. The warnings in this publication and on the product are therefore, not all inclusive. If a tool, procedure, work method, or operating technique that is not recommended by Caterpillar is used, the operator must be sure that the procedures are safe. The operator must also be sure that the product will not be damaged or made unsafe by any unspecified procedures.
The information, specifications, and illustrations in this publication are based on information that was available at the time that the publication was written. The specifications, torque, pressures, measurements, adjustments, illustrations, and other items can change at any time. These changes can affect the service that is given to the product. Obtain the complete and most current information before you start any job.
When replacement parts are required for this product, Caterpillar recommends using Cat replacement parts or parts with equivalent specifications including, but not limited to physical dimensions, type, strength, and material.
Literature Information
This manual contains safety information, operation instructions and maintenance information and should be stored with the tool group.
Some photographs or illustrations in this publication may show details that can be different from your service tool. Guards and covers might have been removed for illustrative purposes.
Continuing improvement and advancement of product design might have caused changes to your service tool, which are not included in this publication.
Whenever a question arises regarding your service tool or this publication, consult Dealer Service Tools (DST) for the latest available information.
Safety Section
The Safety Section lists basic safety precautions.
Read and understand the basic precautions listed in the Safety Section before operating or performing maintenance and repair on this service tool.
General Information Section
The General Information Section describes tooling functions and features. This section provides useful information on individual parts, additional tooling, and resources.
Operation Section
The Operation Section is a reference for the new operator and a refresher for the experienced operator.
Photographs and illustrations guide the operator through correct procedures for using the tool group.
Operating techniques outlined in this publication are basic. Skill and techniques develop as the operator gains knowledge of the service tool and tool capabilities.
Maintenance Section
The Maintenance Section is a guide to tool inspection, cleaning, storage, and tool disposal
Safety Section
Safety Icon Nomenclature
Personal Protection/Important Information
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| Illustration 2 | g02166423 |
Personal Protection/Important Information | |
Hazard Avoidance
| Crushing Hazard (foot) |
| Crushing Hazard (hand) |
| Pinch Point |
| Working Load Limit (WLL) mark - Do not use lifting device unless load identification (WLL) markings are legible. |
Safety Section
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Personal injury or death can result from escaping fluid under pressure. Escaping fluid under pressure, even a very small pin-hole size leak, can penetrate body tissue and cause serious injury and possible death. If fluid is injected into your skin, it must be treated immediately by a doctor familiar with this type of injury. Always use a board or cardboard when checking for a leak. |
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| NOTICE |
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Care must be taken to ensure that fluids are contained during performance of inspection, maintenance, testing, adjusting, and repair of the product. Be prepared to collect the fluid with suitable containers before opening any compartment or disassembling any component containing fluids. Refer to Special Publication, NENG2500, "Dealer Service Tool Catalog" for tools and supplies suitable to collect and contain fluids on Cat products. Dispose of all fluids according to local regulations and mandates. |
Introduction
The 229-3612 Hydraulic Control Valve Seat Repair Kit was developed to repair and restore worn and leaking hydraulic line relief valve seats in the hydraulic control valve body. The kit contains four carbide cutters, four threaded inserts, and a tool body designed to restore the valve body seat angle to factory specifications. A case, foam insert, and operating instructions are also included in the kit.
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| Illustration 3 | g03055096 |
229-3612 Hydraulic Valve Seat Repair Kit | |
| Chart A 229-3612 Hydraulic Valve Seat Repair Kit |
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| Item | Part No. | Description |
| 1 | ----- | Tool Body |
| 2 | 229-3615 | Cutter, 1 1/16 inch threaded port |
| 3 | 229-3613 | Adapter Assembly, 1 1/16 12 inch threaded port |
| 4 | 229-3616 | Cutter, 1 5/16 inch threaded port |
| 5 | 229-3618 | Adapter Assembly, 1 5/16 - 12 inch threaded port |
| 6 | 229-3617 | Cutter, 1 5/8 inch threaded port |
| 7 | 229-3619 | Adapter Assembly, 1 5/8 - 12 inch threaded port |
| 8 | 229-3620 | Foam insert |
| 9 | 6V-3072 | Storage Case |
| 6W-7301 | Retaining Ring | |
| 4B-4280 | Washer | |
| 10 | 361-1591 | Adapter, M27 x 1.5 Threaded Port |
| 11 | 361-1593 | Cutter, M27 x 1.5 Threaded Port |
Rework Procedure
To prevent hydraulic oil contamination during the rework procedure, insert a small piece of 166-6384 Lint-Free Critical Task Wipe into the relief valve ports. Seal all openings into the valve to prevent metal shavings from entering the valve body and the hydraulic system. For additional protection against contamination, the tip of the tool body contains a magnet which attracts small metal particles to the cutter. After the procedure is completed, remove any metal shavings from the ports, the task wipe, and flush the port with 138-8440 Component Cleaner to prevent contamination of the hydraulic system.
Only apply light hand pressure while performing the repair operation. Excess force and rotation will damage the seat and control valve body.
- Clean the area around the affected line relief valve to remove any dirt or debris.
- Remove line relief valve (2) from hydraulic control valve body (1) .
Note: Check the valve seat face of the line relief valve for damage, wear, or erosion and replace the valve, if necessary. Damage to the valve seat and valve may also indicate contamination within the hydraulic system.
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| Illustration 4 | g03055356 |
(1) Main Control Valve (2) Typical Line Relief | |
- Measure the diameter of the relief valve port and select the proper adapter and cutter from the 229-3612 Repair Kit .
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| Illustration 5 | g03056737 |
Select Adapter | |
- Assemble selected adapter (4) onto tool body (3) and tighten the adapter with a suitable wrench.
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| Illustration 6 | g03057077 |
(3) Tool Body (4) Adapter (5) Cutter | |
- Assemble selected cutter (5) on the stem of the tool body and tighten with a suitable wrench.
- Insert a small piece of 166-6384 Lint-Free Critical Task Wipe into all openings in the port of the hydraulic control valve body.
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| Illustration 7 | g03057156 |
Insert Task Wipes into Valve Ports | |
- Install tool assembly (3) in the hydraulic control valve body port and hand tighten with a suitable wrench.
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| Illustration 8 | g03057316 |
(1) Valve Body (3) Tool Body Assembly (4) Adapter (5) Cutter | |
- Using slight downward hand-pressure, rotate the knob of tool body (3) clockwise 2 to 3 complete rotations or until the carbide cutter has removed the necessary material to restore the valve seat. A maximum of 0.5 mm (.020 inch) may be removed from the seat.
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| Illustration 9 | g03057336 |
(1) Valve Body (3) Tool Body Assembly | |
- Remove the tool body from the control valve body port.
- Check the valve seat to ensure a complete seal.
- Coat the seat face of the relief valve with 9U-6075 Toolmaker's Ink or 9U-6076 Toolmaker's Ink .
- Install the relief valve and tighten it to the specified torque.
- Remove the valve and visually inspect the valve seat in the valve body.
- If the blue ink has transferred from the seat face of the relief valve to the valve seat in the valve body in a continuous, non-interrupted line, then the seal face is restored.
- If the blue ink line is not continuous, reinstall the tool and remove additional material.
- If the blue ink does not transfer, too much material has been removed and the valve body must be replaced.
- If the blue ink has transferred from the seat face of the relief valve to the valve seat in the valve body in a continuous, non-interrupted line, then the seal face is restored.
Show/hide table
Illustration 10 g03057417
Check for Complete Seal using Toolmakers Ink
- If the valve body is reusable, remove the toolmaker's ink from the valve seat and the relief valve using 9U-6077 Toolmakers Ink Remover .
- Use 138-8440 Component Cleaner to flush the port and remove any excess debris from the control valve body. Use a 5P-1720 Seal Pick and carefully remove any metal shavings and the lint-free critical task wipe from the control valve port.
Note: Stamp or mark the valve to show how many times this process has been done.
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| Illustration 11 | g03057568 |
Remove Foreign Object and Flush With Cleaner | |
- Install relief valve (2) into control valve body (1) and tighten it to recommended torque specifications.
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| Illustration 12 | g03057636 |
(1) Valve Body (2) Relief Valve | |
- Before operating the machine, install a high-efficiency clean-out filter. Start the machine, and without using any implements, let the machine run for 30 minutes. For additional information on high-efficiency clean out filters, refer to PEHP5042 Clean Out Filters.
- Finally, take an S O S oil sample to determine if the hydraulic system requires further cleaning. If the system is contaminated, it can be cleaned using a Cat Kidney Loop Filtration System.
Note: For additional information on specific applications, refer to the appropriate service manual.
Additional Contact Information
For additional product support questions concerning this tool, contact the Cat Dealer Service Tools Hotline at:
USA: 1-800-542-8665, Option 1
International: 1-309-578-7372
Email: dealerservicetool_hotline@cat.com