Installation &

Maintenance of
Seals
 Contents 3

Page

1. Introduction 4

2. Installation & Maintenance 5

3. Depth Caliper 6

4. O-Ring Hook 7

5. Piston Seal Installation 8

6. Rod Seal Installation 10

7. Rotary Seal Installation 11

8. Split Seal Installation 12

9. Spare-O-Lube 13

10. Training Programme 14

4 Introduction

Removal of worn out seals and installation of new seals, if not done properly will
result in seal failure. Seal removal and installation should be done with the right
tools and fixtures. If not there is every chance of the seal getting damaged,
resulting in higher cost of repairing/replacing the machine element.

Spareage India's No. 1 seal manufacturer understands this, and has introduced
a set of tools to help you in the removal and installation of seals.

1. Depth Caliper for Measuring Groove Depth.

2. 'O' Ring Hooks for Removing 'O' Rings from seat.
3. Seal Twistor for Installation of Rod Seals.
4. Seal Constrictor for Installation of Piston Seals.
5. Special Spare-O-Lube lubricant for seal installation.

This booklet describes the correct methods of installation of various types of

seals and 'O' Rings. Our service team is always available to assist.
 Installation & Maintenance 5

Tips to enhance the life of Seals:

• Do not store seals on the shop floor.

• The seals should be stored properly in a cool area and at Relative Humidity of
40% - 70%.
• Packing must be air tight and intact. Seal lip should not be distorted by
handling or hanging on a peg or nail.
• Correct installation tools must be used.
• The sealing area should be clean and free of grit or contamination.
• The correct seal profile should be used as per the application.
• Ensure the operating temperature does not exceed the limit of the sealing
material.
• Lubricant, including additives, must be compatible with the material of the
seal (Check compatibility chart in the Spareage catalogue or website
www.spareage.com).
• The leading edge of the shaft should be chamfered.
• Tolerance for the shaft diameter must be within the range of the seal being
used.
• Whenever possible, equipment should be vented to the atmosphere to
prevent pressure build up.
• Worn-out seals must not be used / reused.

Installation Instructions

The following points should be observed before installation of the seals:

• Check whether housing or rod has a lead-in chamfer: If not, use an installation
sleeve.
• Debur and chamfer or round sharp edges. Cover the tips of any screw
threads.
• Remove machining residues such as chips, dirt and other foreign particles
and carefully clean all parts
• The seals can be installed more easily if they are greased or oiled. Attention
must be paid to the compatibility of the seal materials with these lubricants.
Use only grease without solid additives (e.g. molybdenum disulphide or zinc
sulphide)
• Do not use installation tools with sharp edges.
6 Depth Caliper

It is generally difficult to measure the seal groove depth. With the inside calipers
the measurement is not precise. Spareage has introduced depth calipers, a
specially designed instrument that can measure groove depth easily and
accurately.

5 Easy steps to groove measurement :

1. Choose the suitable pin to put in the upper of the lower hole.
2. Push the pin to reset the graduation to zero.
3. Down to gland hole to measure the depth of groove.
4. Measure the other side of the pin.
5. Depth = Length of pin-measurement.
 O-Ring Hook 7

Avoid Metal Part Damage

When Picking Seals & O-rings.

Removing 'O' Rings from the seat with steel implements poses the real danger
of damaging the 'O' Ring seat. With Spareages 'O' Ring Hooks the removal of
‘O' rings is simple, and safe. The 'O' Ring hooks come in a set of 4, with different
profiles. The design of the hooks is such that it does not damage the seat.
Knurled handle provides firm grip.
8 Piston Seal Installation

Piston Head
Cylinder Bore
Dimensional Requirements:-
1) Piston Head Dia = d
2) Piston Head Length = L
3) Piston Head Total Length = L1
(in case of Nut fitted)

Following is the methods to Install

Spareage PTA, PTC, PTE, PTH,
Guide Rings Groove Guide Ring Groove (Teflon Seal Rings)

Loading Mandrel

Step 1
Stretch O-Ring and install in the
groove.

Place loading mandrel onto piston

head.

Loading Mandrel
Glyd
Pusher
Ring
Step 2
Place Teflon ring on the loading
mandrel

Glyd Ring

Place Pusher & push the Teflon

ring upto the groove. Teflon ring
will evenly expand and slide on
the loading mandrel & fit into
the groove without damage.

O'RING LOADING MANDREL PUSHER

*Loading Mandrel & Customised Pusher supplied on request.

 Piston Seal Installation 9

Piston Seal Constrictor

Correct Method of Installing Teflon Ring:

Spareage has introduced Piston Seal Constrictors for

use with Teflon Combination Seals. This easy to use
device eliminates chances of seal / seat damage.

For combination seals, correct the Teflon ring after

installing the ring in the fitting groove. Seal constrictor
can be used upto 400mm diameter.

To re-size the expanded Teflon ring, use piston constrictor, following the
steps as shown in figure 1,2 & 3 below.

Step 1

Prepare a twist bar and adapter as

shown in the figure. Set the twist bar
and adapter as shown. Then set the
Teflon ring in the center of the band.

Step 2

Hold for 10 seconds or more.

Step 3

Installation is completed by the

above steps. The internal and external
circumference faces of the Teflon
ring affect sealing performance. So be
careful not to scratch the ring.
10 Rod Seal Installation

Seal Twistor

Most failures of quality seals are caused by bad

installations. Complicated groove design adds to
the problem, invariably damaging either the seals
or the seat. It is therefore necessary to use the right
installation technique, with the right set of tools.

Spareage has introduced SEAL TWISTOR, a special tool that helps you to
install rod seals easily and efficiently. SEAL TWISTOR turns seal to an omega
shape without an acute angle (not suitable for fragile materials). It makes the
size of the seal smaller than the gland hole diameter. Seal can cross over the
chamfers safely and then rebounds in the groove.

Size Range

SPECIFICATION S M L XL
22 to 0.7" to 30 to 1.187" to 50 to 2" to 70 to 2.75" to
Ø GLAND HOLE
30mm 1.187" 50mm 2" 70mm 2.75" 165mm 6.5"
Cross Section Max. 5mm 0.187" 6mm 0.234" 10mm 0.375" 17.5mm 0.187"

4 Easy steps to install Rod Seals with Seal Twistor:

1. Fix the handle in the stand hole. 2. Twist the seal with guiding hand
Then put two arms inside the seal. to prevent it from popping out.

3. Hold the handles, then put the seal 4. Turn handles back, then pull
into the gland hole carefully. TWISTOR out to rebound the
seal in the groove.
 Rotary Seal Installation 11

Various force fit situations of the rotary shaft seal with suitable
installation tools or devices.

Installation Instructions

The following points must be

observed when installing rotary shaft
lip seals:
B
• Before installing, clean the
installation grooves. Shaft and seal
must be greased or oiled for rubber
seals

• Sharp-edged transitions must

C either be chamfered or rounded or
else covered

• When pressing in the seal, take

care that the seal ring is not twisted

• The pressing force must be applied

D as close as possible to the outer
Dis-
assembling
circumference of the seal
bore
• After installation, the seal must be
concentric and at right angles to the
shaft

• The end face of the mounting bore

E is generally used as the contact
Dis-
assembling surface; the seal can also be fixed
bore
with a shoulder or a spacer washer.

Installation aids for fitting rotary shaft seals

HOUSING

Improper method
12 Split Seal Installation

Spareage Split Seals

• Split Seals are used to reduce downtime in replacing seals, especially

during shut down time, without removing heavy couplings or parts.

• Should be used in applications such as bearings mounted on shafts, gear

box couplings, fly wheels or heavy equipment in various industries.

• Spareage can provide specially moulded split seals which should be used
with a retainer plate.

Installation Procedure:

1) Install split end first in the housing.

2) Press rest of the fabric body of the seal in the housing.
3) Ensure the fit is tight. Fix retainer plate.

Note : Retainer Plate is mandatory in split seal installation

Split Seals
 Spare-O-Lube 13

Spare-O-Lube

Spare-O-Lube is a stiff non-melting silicone lubricant developed specially for use

with various rubber polymers. Spare-O-Lube can also be used over a wider
temperature range and in most cases will provide improved environmental
protection to the elastomer.

• Can be used in both High Pressure and Vacuum Systems.

• Non-toxic and non-irritating.
• Suitable for temperature range of -400C to + 2250C.
• Can be used with a variety of fluid media as it is inert.

It is recommended that Spare-O-Lube be used sparingly as only a thin film on

seals is sufficient for optimum results.
14 Training Programme

Spareage Training Programme offers comprehensive training for use of

Hydraulic, Pneumatic and Rotary seals in the application. The purpose of this
programme is to select proper and better sealing solutions for the hardware
which helps to decrease the losses and consumption of costly fluids used in the
hardware and to provide guidance for proper seal installation for reducing down
time and to achieve maximum life of the component.

This training can be used as a part of ISO, ASME or other certification

programmes.

Each attendee on successfully completing the theoretical and practical portions

of the final examination is awarded a certificate of competency (optional).

Training Programme:
Part - I:
* Presentation of the Spareage organisation.
* Objectives of the training programmes.
Part - II:
* Introduction of Seals for Hydraulic, Pneumatic & Rotary applications,
'O' Rings & Backup Rings.
* Construction of Hydraulic & Pneumatic Cylinders.
Part - III:
* Materials
* Identification of Polymers
Part - IV:
* Effect of Pressure, Speed & Load on Hydraulic, Pneumatic, Rotary Seals &
'O' Rings
* Use of Dust Lip Seals to prevent Fluid contamination.
* Selection of Seals.
Part - V:
* Reducing downtime in replacing seals.
* Installations of Seals (Hydraulic, Pneumatic & Rotary)
* Uses of filter for Hydraulic and Pneumatic systems.
* Causes of seals failure.
Part - VI:
* Reducing inventory by JIT.
* Storage & cleaning of seals.
Part - VII:
* Processing of orders & its flow.
* Technical services.
 Training Programme 15

Visits:
* Production, Inspection & Technical Office.
* Question hour.

Optional :
* Theoretical and practical examinations.
* Training evaluation.

Objectives:
Part - I:
* About SPAREAGE * its working system.
* To understand better sealing solutions.
Part - II:
* Difference between Hydraulic & Pneumatic seals profiles with samples.
* Understand the seal combination of Hydraulic & Pneumatic in cylinder.
Part - III:
* Samples of different raw materials, materials compound properties, selection
of materials, chemical compatibility, lubrication property, temperature
resistance, commonly used materials.
* Different polymer identification, demo of identification tests conducted.
Part - IV:
* Pressure effects, extrusion gaps, use of backup ring, materials selection for
speed, high compression strength guides with suitable material for load in
Hydraulic and Pneumatic cylinder.
* Wiper seal profiles for Hydraulic & Pneumatic seals, Dust lip profiles for rotary
seals. V-Ring for rotary applications.
Part - V:
* Split type seal profiles of Hydraulic & Rotary Seals.
* Installation methods, split seals samples, fittings tools, precautions of
installation, demo of fitting tools with samples.
* To provide proper lubrications.
* Reasons of failure with samples of failed seals.
Part - VI:
* About SPAREAGE Express service
* How to store the seals to get maximum shelf life during storage.
Part - VII:
* Internal job card flow process
* Field Engineer's team & representatives.
 R

AN ISO 9001 COMPANY

The Catalogue
COPYRIGHT BY :
SPARE-AGE INDIA (P) LTD.
Oil Seal House,
Wagle Industrial Estate,
Thane - 400 604, INDIA.
Tel. : +91-22-5800972 (10 lines)
Fax : +91-22-5823991
www.spareage.com
e-mail : sales@spareage.com
R

SEALS
ESTD. 1959
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HT 1.
S N
RE IO
SE RS
RV VE
E M
D. RO
SPAR CD
E-AG E INDIA (P ) LTD.

Also please refer to Spareage

­ Rotary Shaft Seals Catalogue
­ Hydraulic Seals Catalogue
­ O - Ring Catalogue
­ Stock List
­ Spareage CD Catalogue

Spareage Seals Ltd.,

Oil Seal House, Road No. 28, Wagle Estate, Thane (W), Mumbai - 400 604, INDIA.
Tel.: +91-22-25800972 (10 lines) • Fax: +91-22-25823991 / 25827480.
Email: sales@spareage.com • Website: www.spareage.com