O-Rings - Radial, Fitting Assembly O-Rings and Other O-Ring Applications {0599, 0738, 4000, 4250, 4300, 5050, 5057, 7555} Caterpillar


O-Rings - Radial, Fitting Assembly O-Rings and Other O-Ring Applications {0599, 0738, 4000, 4250, 4300, 5050, 5057, 7555}

Usage:

MT700 018
Agricultural Tractor
All
Asphalt Paver
All
Backhoe Loader
All
Challenger
All
Cold Planer
All
Combine
All
Compact Track Loader
All
Compact Wheel Loader
All
Earthmoving Compactor
All
Excavator
All
Forest Products
All
Integrated Toolcarrier
All
Landfill Compactor
All
Load Haul Dump
All
Mini Hydraulic Excavator
All
Motor Grader
All
Multi Terrain Loader
All
Off-Highway Truck/Tractor
All
Paving Compactor
All
Pipelayer
All
Road Reclaimer/Soil Stabilizer
All
Skid Steer Loader
All
Soil Compactor
All
Telehandler
All
Track Feller Buncher
Blount Branded
Caterpillar
Timberking Branded
Track-Type Loader
All
Track-Type Skidder
All
Track-Type Tractor
All
Underground Articulated Truck
All
Wheel Dozer
All
Wheel Feller Buncher
All
Wheel Loader
All
Wheel Skidder
All
Wheel Tractor-Scraper
All

Introduction

Table 1
Revision  Summary of Changes in SEBF9248 
00  Created to SIS Authoring format 

© 2012 Caterpillar All Rights Reserved. This guideline is for the use of Cat dealers only. Unauthorized use of this document or the proprietary processes therein without permission may be violation of intellectual property law.

This Guideline contains the necessary information to allow a dealer to establish a parts reusability program. Reuse and salvage information enables Caterpillar dealers and customers to benefit from cost reductions. Every effort has been made to provide the most current information that is known to Caterpillar. Continuing improvement and advancement of product design might have caused changes to your product which are not included in this publication. This Reuse and Salvage Guideline must be used with the latest technical information that is available from Caterpillar.

For questions or additional information concerning this guideline, submit a form for feedback in the Service Information System. To address an urgent issue, use the following resources to communicate your request to Caterpillar Repair Process Engineering:

  • Caterpillar Dealer Technical Communicator

  • Dealer Solution Network

  • Caterpillar Technical Representative

  • Knowledge Network

Canceled Part Numbers and Replaced Part Numbers

This document may not include canceled part numbers and replaced part numbers. Use NPR on SIS for information about canceled part numbers and replaced part numbers. NPR will provide the current part numbers for replaced parts

Summary

This document describes the procedures for properly storing, handling, and installing O-Rings.

Important Safety Information

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 is dangerous. Improper methods could result in injury or death.

Do not operate or perform any lubrication, maintenance, or repair of this product, until you understand 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.

Hazards are identified by a safety alert symbol. Safety alert symbols are followed by a signal word such as "Warning" that is shown below.



Illustration 1g01032906

The following is the meaning of this safety alert symbol:

  • Pay attention!

  • Become Alert!

  • Your safety is involved

The message that appears under the warning explains the hazard. The message will be written or pictorially shown.

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. Therefore, the warnings in this publication and on the product are not all inclusive. If a tool, a procedure, a work method, or an operating technique that is not recommended by Caterpillar is used, ensure that all personnel around the machine are safe. Ensure that the product will not be damaged or that the product will not be made unsafe by the operation, lubrication, maintenance, or repair procedures.

All of the information, specifications, and illustrations that are in this publication are based on information that was available at the time of publication. The following specifications could change at any time: specifications, torque, pressures, measurement, adjustments, illustrations and other items. These changes can affect the service that is given to the product. Obtain the most current and complete information before you start any job. Caterpillar dealers have the most current information that is available.

Safety

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

Sudden movement of the machine or release of oil under pressure can cause injury to persons on or near the machine.

To prevent possible injury, perform the procedure that follows before testing and adjusting the steering system.


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

Personal injury can result from hydraulic oil pressure and hot oil.

Hydraulic oil pressure can remain in the hydraulic system after the engine has been stopped. Serious injury can be caused if this pressure is not released before any service is done on the hydraulic system.

Make sure all of the attachments have been lowered, oil is cool before removing any components or lines. Remove the oil filler cap only when the engine is stopped, and the filler cap is cool enough to touch with your bare hand.



NOTICE

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.


References

Table 2
Media Number  Title 
NEHS2500  Dealer Service Tool Catalog 
PEBJ0002  Cat dealer Contamination Control and Compliance Guide 

Tooling and Equipment

Table 3
Required Tooling 
Part Number  Description 
169-5420  Cleaner 
265-2265  Lint Free Wipes 
207-1600  Lubricant 
369-9450  Petro Gel Grease 

O-Rings Installed on STOR/ORFS Fittings (Fitting/Adaptor Assemblies)

Background

Commonly used fluid line connectors are:

  • Straight Threaded O-Rings (STOR)

  • O-Ring Face Seal (ORFS)

  • Bolt Flanges (SAE Code 61, 62, and CAT Flange)

Note: Radial O-ring seals and conventional face seals are not fluid connectors.

O-ring sealing depends on proper seating of the seal in the groove, maintaining this condition during assembly of the joint and proper torque on the connection. Improper assembly practices increase the likelihood of leaking joints.

Assembly Aids

Retention compounds and lubricants must not be used on STOR/ORFS. Applications requiring the use of a retention compound need validated for seal compatibility with the retention compound by Caterpillar before use.

Assembly Tooling

O-rings may be installed into a fitting or adapter without the use of a tool. However, installing a seal without the use of a tool places the seal at extreme risk of damage. Caterpillar recommends using appropriate tooling for the installation of O-rings.

Types of Installation Tooling

STOR Installation Tool



Illustration 2g03324950
STOR Installation Tools
(1) Tooling head
(2) Head edge

When installing an O-ring over a threaded fitting, protect the seal from damage from threads. To assist the assembly and protect the seal, an installation tool must be used. The seal protector slides over the threads and allows for an O-ring to be installed. The seal protector reduces the risk of a leak due to nicks, cuts, gouges, and twisting of the seal. Refer to Illustration 2.



Illustration 3g03325573
Anatomy of a STOR/ORFS Fitting
(3) Nut
(4) STOR O-Ring
(5) ORFS O-Ring
(6) Washer

The tooling listed in Table 4 can be ordered from Caterpillar using the part numbers.

Table 4
Cat Part Number  Fitting Size 
336-0739  -3 
336-0740  -4 
336-0741  -6 
336-0742  -8 
336-0744  -10 
336-0750  -12 
336-0767  -14 
336-0784  -16 
336-0787  -20 

ORFS Insertion Tool



Illustration 4g03325587
Anatomy of ORFS O-Ring Insertion Tool
(7) Plunger platform


Illustration 5g03325602
Anatomy of ORFS O-Ring Insertion Tool
(8) O-Ring slot
(9) Plunger/trigger

The ORFS insertion tool can be procured as outlined in the Dealer Service Tools 2011 Catalog: Vehicle System Tool Section. Tool part numbers for ordering are shown in Table 5.

Table 5
CAT Part #  Dealer Number  Fitting Size 
179-6884  2-011  -4 
179-6885  2-012  -6 
179-6886  2-014  -8 
179-6887  2-016  -10 
179-6888  2-018  -12 
179-6889  2-021  -16 
179-6890  2-025  -20 
179-6891  2-029  -24 

Possible Tooling Damage



Illustration 6g03325609
STOR Tooling damage - nicks, material gouges, and chatter marks along tool head

Material damage to the surface in which the seal will ride is typically in the form of missing material, nicks, and gouges. Damage happens when the tool is forced over the cone for proper seal seating. Illustration 6 shows tool damage due to improper storage.

Storing Assembly Tooling

STOR installation tooling shall be stored in a manner that will minimize the risk of damage to the outside diameter (shaft).

The best-practice tool storage device is one that will:

  • Segregate the tool preventing contact from other tooling.

  • Include a soft surface to prevent metal to metal contact.

  • Hold the tool at the inner diameter of the cone shaft rather than the outside diameter.

  • Provide proper tool identification.


Illustration 7g03325621
Example STOR Installation Tool Storage

Illustration 7 shows an example of STOR tooling storage board.

Note: In this example, the tool is being stored using the outer diameter of the shaft, placing tool at risk for damage.



Illustration 8g03325624

DO NOT stack tools on top of each other. Refer to Illustration 8.



Illustration 9g03325625


Illustration 10g03325626

DO NOT store tooling on top of seals or other parts. Refer to Illustration 9 and Illustration 10.

Tooling Care

Before using the tooling, check the tool for damage. Tools with damage such as nicks, gouges, missing material, or deformation must be replaced immediately.

Tools should be cleaned daily to remove contamination. If contamination is present, use a clean 265-2256 Lint Free Wipe to remove the debris. To maintain cleanliness and prevent tool damage, storage fixtures should be cleaned as a part of daily 5S activities.

Note: 5S activities refer to CPS For Dealers related to “Sort, Set, Shine, Standardize, and Sustain”.

Tooling Inspection

Before use, inspect tooling for contamination and damage in the form of nicks, gouges, or missing material.

Improperly maintained cone and pusher tooling can cause seal damage that may be in the form of cuts, nicks, or tearing of seal. Damage to the seal increases the risk of leaks.

If damage to the cone or pusher is present, stop using the tool immediately. Report the issue to the dealer service manager or leadman for immediate replacement.

Tooling - Critical Maintenance & Damage Reporting Process

Routine Maintenance

All seal-specific tooling should be placed on a routine maintenance schedule similar to the torque-tooling schedule.

Reporting Damage

A formal reporting process should be established at every dealer to report damaged tooling.

Replacement Tooling

To reduce the risk of downtime and use of an unapproved tool, replacement tooling should be available for immediate use. Damaged tools should be replaced immediately since using a damaged tool increases the risk of seal damage or leaks.

Assembly

ORFS Assembly

When using an O-ring insertion tool:

  1. Select the appropriate insertion tool.

  2. Verify that the tool is clean and undamaged.

ORFS Assembly Procedure

Follow the steps below for proper tool use and assembly of an O-ring into the ORFS groove.

  1. Complete a 1-second inspection of the seal, fitting, and tool for damage. A 1-second inspection is a quick visual review of the part and mating component for damage or debris. This inspection is to help identify part issues before assembling the parts to the components.


    Illustration 11g03325735
    Insert O-ring

  2. Insert the O-ring through the O-ring slot near the top of the ORFS insertion tool.


    Illustration 12g03325751
    O-ring on plunger platform

  3. Check to see that the O-ring is properly placed on the plunger platform.


    Illustration 13g03325779
    Plunger Pressed

  4. Place the ORFS end of the fitting into the tool and depress the plunger/trigger.

  5. Remove the tool from the fitting.


    Illustration 14g03325784
    O-ring installed

  6. Verify that the O-ring has been properly placed into the groove.


    Illustration 15g03325825
    Finger sweep check

  7. Conduct a “finger sweep” by placing a finger on top of the installed seal. Gently push down on top of the seal and run the finger around the circumference of the seal.

    Note: The finger sweep helps ensure that the seal is properly placed and fully depressed into the groove of the ORFS fitting.

  8. Complete a final visual inspection of the seal seating after the finger sweep.

  9. Cap ORFS end for contamination prevention where applicable.


    Illustration 16g03325832

  10. Before and after completing the finger sweep, verify that the seal has been properly seated in the groove.


Illustration 17g03325835


Illustration 18g03325839

Illustration 17 and Illustration 18 demonstrate improperly seated seals.



Illustration 19g03325846
Cutting damage


Illustration 20g03325849
Pinching damage

Improper seal installation increases the risk of leaks due to damage by cutting, pinching, or tearing of the seal after assembly. Installation damage can increase in size when the connection is pressurized resulting in a leak. Refer to Illustration 19 and Illustration 20.

STOR Assembly

An assembly tool must be used to protect the seal from damage due to thread contact. Threads may cut or tear the seal during installation.

When using a STOR installation tool:

  1. Select the appropriate installation tool.

  2. Verify that the tool is clean and undamaged.

STOR Assembly Procedure

Follow the steps below for proper tool use and assembly of an O-ring onto the STOR end of a fitting or adapter.

  1. Complete a 1-second inspection of the seal, fitting, and tool for damage. A 1-second inspection is a quick visual review of the part and mating component for damage or debris. This inspection helps identify part issues before assembling the parts to the components.


    Illustration 21g03325857

  2. Ensure that the locknut on adjustable STOR fittings is positioned above the O-ring groove. The Locknut must be in contact with the fitting body. Refer to Illustration 21.


    Illustration 22g03325861
    Installation of O-ring on tool

  3. Place O-ring over the tool.


    Illustration 23g03325865
    Installation tool on fitting

  4. Place the tool over the fitting threads.


    Illustration 24g03325869
    Installation of O-ring in fitting

  5. Glide seal onto fitting taking care to prevent twisting. If the O-ring is twisted when seated, the O-ring can fail prematurely due to high strain. If a twist is observed, remove the seal and install again.

    Note: In most cases, the O-ring that is to be installed onto a fitting should have PTFE (polytetrafluoroethylene) coating. PTFE is a custom coating applied to an O-ring to ease assembly installation. PTFE is more commonly referred to as Teflon from Dupont.



    Illustration 25g03325878
    Removal of tool

  6. Remove the tooling from the fitting.

  7. Inspect the seating of the seal.


    Illustration 26g03325910

  8. The seal should be placed over the O-ring groove and resting on washer, as shown in Illustration 26.

Assembly Storage

Assembled product should be stored in conformance with Cat dealer Contamination Control and Compliance Guide, PEBJ0002.

O-Rings Installed in Face Seal Joints (Non-Adaptor Applications)

Background

O-ring sealing depends on proper seating of the seal in the groove and maintaining this condition during assembly of the joint. Improper assembly practices increase the likelihood of creating leaks.

Handling

O-rings should not be stretched or twisted beyond what is necessary for installation. O-rings should not be deformed in any manner.

Contact of the O-ring with threads or other sharp objects should be prevented as contact risks cutting, nicking, or damaging the seal.

Assembly Aid - Retention Compounds

When O-rings and other elastomeric seals are assembled in face grooves that are vertical or inverted, a retention compound may be needed to keep the seal in place.

Caterpillar no longer recommends the use of Petroleum Jelly (Vaseline®) to install O-rings or gaskets. The reason is that Petroleum Jelly is NOT compatible with all elastomeric (rubber) materials that Caterpillar O-rings and gaskets are made from.

The correct product that should be used for assembly of O-rings is 207-1600 Rubber Lubricant or 369-9450 Petro Gel Grease.

Note: Captive grooves (dovetail grooves and ORFS fittings) have a built-in retention mechanism. Retention compounds or lubricants must not be used for captive grooves.

Retention compound should be stored in a clean, closable container that is kept closed between uses. Refer to PEBJ0002.

Retention Compound Application

Retention compounds are tacky semi-solids that should be used only on inverted and vertical o-ring face seal joints.

Application of retention compound directly to the seal does not ensure proper retention in groove. Proper application procedure must be followed.



Illustration 27g03325946
Correct application location for retention compound

Do not install a seal into a groove and then apply retention compound to the top surface of the seal. The seal will not retain properly in the groove. Retention compounds should be applied sparingly (pea-size beads) into the bottom of the O-ring groove. Use the minimum amount of compound necessary to retain the O-ring during assembly. Refer to Illustration 27.



Illustration 28g03325941
Incorrect application of retention compound to O-rings

The required amount of retention compound will vary depending upon O-ring size. The work instructions should specify the location and number of retention compound beads to be applied for retention of O-rings. Illustration 28 provides an example of incorrect application of retention compound after seal installation.



Illustration 29g03325949
Overfilling groove with retention compound

Overfilling the groove can cause the seal to be displaced. Overfilling may result in the compound getting into areas such as threads. Overfilling may have an adverse effect on torque and incur high cost of assembly.

Do not apply retention compounds with brushes or fingers, which can introduce contamination into the system. Use a proper dispensing method as indicated above for proper application.

Do not apply retention compounds by submerging parts in a bag or box. Follow guidelines outlined in PEBJ0002.

Apply retention compounds prior to assembly. Do not preassemble components where retention compounds are used.



Illustration 30g03325950
Components preworked and stacked

Do not prework components or stack assembled parts. This action increases the risk of contamination and seal damage. Refer to Illustration 30.

If the retention compound squishes out of a joint or groove, too much has been applied. Use a 265-2256 Lint Free Wipe to remove excess retention compound and clean surface thoroughly.

Assembly

  1. Visually inspect the mating parts to ensure that all surfaces are clean and free of damage such as nicks or burrs.

    Note: When O-rings and other elastomeric seals are assembled in face grooves that are vertical or inverted, a retention compound may be needed to keep the seal in place.

  2. Install the O-ring immediately before the joint is assembled to reduce chances of the O-ring falling out.

  3. Place the O-ring in the groove and verify that O-ring is fully placed or seated. Avoid spiraling the O-ring during installation.

  4. Install mating face perpendicular to the plane of the groove. Do not slide mating face across the O-ring.

  5. Torque all mating component fasteners immediately.

O-Rings Installed in Radial Seal Joints

Background



Illustration 31g03326004
Radial O-ring application on an injector

Radial sealing depends upon proper seating of the seal in the groove and maintaining this condition during assembly of the joint. Improper assembly practices increase the likelihood of leaking joints. An example of a radial O-ring application is shown in Illustration 31. This document addresses both Seal-in-Bore (housing) and Seal-in-Piston (shaft) designs. Refer to Illustration 32 and Illustration 33.



Illustration 32g03326013
Seal in Bore


Illustration 33g03326019
Seal in Groove

Handling

O-rings should not be stretched or twisted beyond what is necessary for installation. O-rings should not be deformed in any manner.

Contact of the O-ring with threads or other sharp objects should be prevented. Contact with threads risks cutting, nicking, or damaging the seal.

Assembly Aids - Seal Lubricants

When O-rings and other elastomeric seals are assembled into radial seal joints, a lubricant is necessary to reduce spiraling, skiving, cutting, and abrasion. Lubricants also reduce the force required to assemble the joint.

Lubricants should be stored in properly identified, clean, closable containers that are kept closed between uses. Refer to PEBJ0002 for further information.

Do not use petroleum (Vaseline®), any adhesive, or unapproved grease as a lubricant.

Lubricants should not be used on PTFE coated seals or STOR/ORFS seals.

Assembly Aid - Approved Seal Lubricants

PTFE Coating

PTFE coating is a dry lubricant that should be used on all radial seals. The PTFE coating is added by the manufacturer.

P-80

P-80 may be used as a universal seal lubricant. P-80 is compatible with all sealing elastomers. P-80 dries quickly making the lubricant unlikely to drip out and create the false appearance of a fluid leak.

P-80 must NOT be used on STOR/ORFS seals. P-80 or any other lubricant used on a STOR/ORFS can affect final torque and cause thread stretching.

The use of P-80 on all other PTFE coated seals is acceptable.

Fluid Being Sealed

For oil and fuel joints, the fluid being sealed may be used as a lubricant.

Note: Lubricants must not be used on fluid line connectors (STOR/ORFS) fittings.

Low Pressure AC Line Lubricants

For low-pressure air conditioner lines, use McMaster Carr 3190K281 approved lubricant.

Lubricant Dispensers



Illustration 34g03326039
Spray Bottle

The recommended method for applying a lubricant is with a small nozzle spray bottle.

Note: Dispose of lubricant containers that have become internally contaminated.

Lubricant Application

Lubricants are low viscosity fluids that should be used only on radial seal joints.

Seal lubricant should always be applied to the primary sealing surface. For example, if the seal is in a groove in the shaft, then the bore is the primary sealing surface. Optionally, lubricant may also be applied to the seal.

Apply wet lubricants at the time of assembly. Do not apply the lubricant in advance.

The application of lubricants should not introduce debris onto the seal or sealing surface.

Do not apply seal lubricants with brushes or fingers. This action may introduce contamination into the system. Avoid the use of brushes that shed fibers.

When using lubricant dispensers such as spray bottles, exercise extreme caution and prevent overspray onto other areas such as threads. Overspray can have an adverse effect on torque. Cover all components that must not be lubricated before lubricating. Refer to PEBJ0002.

Before using P-80 lubricant, shake well to ensure proper mixing of lubricant.

Apply lubricants only at the time of assembly. Lubricants, especially P-80, may dry up or leak out of the joint if applied in advance.

For low-pressure air conditioner lines, lubricate the O-ring with the mineral oil.

Tooling Inspection

Inspect tooling before use for contamination and damage in the form of nicks, gouges, or missing material.

Improperly maintained cone and pusher tooling can cause seal damage that may be in the form of cuts, nicks, or tearing of seal. Damage to the seal increases the risk of leaks.

If damage to the cone or pusher is present, stop using the tool immediately. Report the issue to the supervisor and processor/planner for immediate replacement.

Assembly Tooling

Routine Maintenance

All seal-specific tooling should be placed on a routine maintenance schedule similar to the torque-tooling schedule.

Reporting Damage

A formal reporting process should be established at every dealer to report damaged tooling.

Replacement Tooling

To reduce the risk of downtime and use of an unapproved tool, replacement tooling should be available for immediate use. Damaged tools should be replaced immediately since using a damaged tool increases the risk of seal damage or leaks.

Assembly



Illustration 35g03326078
Cleaning of groove for brake seal

  1. Visually inspect mating parts for contamination or damage such as nicks, scratches, or burrs. Use a 265-2256 Lint Free Wipe to remove contamination if present from the groove. Follow the guidelines in PEBJ0002. Refer to Illustration 35.

  2. Install the seal in the groove. Do not stretch or deform the seal any more than is necessary. Do not allow the seal to contact threads or other sharp objects. Verify that the seal is fully seated. Avoid spiraling seal during installation. The seal should be pushed into position rather than rolled. Use an approved assembly aid when appropriate.

  3. For installation of two-piece seals, first install the rubber energizer. Then install the cap piece over the rubber energizer.

  4. Lubricate the seal with the fluid being sealed before installing the seal.

  5. Lubricate the seal prior to assembly to reduce the risk of contamination, run-off, or dry out of seal lubricant.

    Note: Do not install contaminated seals.

    Note: Contaminated seals that cannot be removed and installed again using the proper assembly techniques must be cleaned thoroughly using a 265-2256 Lint Free Wipe to reduce the risk of damage to the seal. Contaminated seals that are removed should be scrapped using the non-conforming material process to prevent risk of contamination to the system.

  6. For groove-in-bore applications, lubricate the inside diameter of the seal.

  7. For groove-in-piston applications, lubricate the outside diameter of the seal.

  8. Take care when inserting the shaft into the bore. Make sure that the mating parts are properly aligned prior to insertion. Assemble at a slow, uniform rate. Do not use impact tools such as hammers when installing assemblies using radial seals.

  9. For larger piston/bore diameters, use a hydraulic press to ensure proper seating of the seal and piston to bore alignment. Consider installing shaft (piston) vertically into the housing to better center the shaft in the housing for some larger piston/bore diameter applications.

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