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11/29/21, 10:04 AM SIS 2.

2012/05/23 O-Ring Seals - Install - RADIAL, FITTING ASSEMBLY O-RINGS & OTHER O-RING APPLICATIONS (UENR3262-00)

SMCS - 7555 i04905677

O-RINGS INSTALLED IN STOR/ORFS FITTINGS (FITTING/ADAPTOR


ASSEMBLIES)

Illustration 1 g03150156

Background
Commonly used fluid line connectors are:

1. Straight Threaded O-Rings (STOR)

2. O-ring Face Seal (ORFS)

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

Radial O-ring seals and conventional face seals are not fluid line 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 to be validated for seal compatibility with the retention compound by Caterpillar before use.

Assembly Tooling
O-rings may be installed into a fitting/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. It is recommended that appropriate tooling should be used for the installation of O-rings.

Types of Installation Tooling


STOR Installation Tool

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Illustration 2 g03150192
STOR installation tools

(1) Tooling head

(2) Head edge

Illustration 3 g03150193
Anatomy of an STOR/ORFS Fitting

(3) STOR O-ring

(4) Nut

(5) Washer

(6) ORFS O-ring

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

Tool Ordering Information


The tooling listed below can be ordered from Caterpillar using the part numbers in Table 1.

Fitting Size     CAT Part Number    


(-3)     336-0739    
(-4)     336-0740    
(-6)     336-0741    
(-8)     336-0742    
(-10)     336-0744    
(-12)     336-0750    
(-14)     336-0767    
(-16)     336-0784    
(-20)     336-0787    

Table 1
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ORFS Insertion Tool

Illustration 4 g03150194
Anatomy of ORFS O-Ring insertion tool

(7) Plunger platform

Illustration 5 g03150195
Anatomy of ORFS O-Ring insertion tool

(8) O-ring slot

(9) Plunger/trigger

This tool (Illustration 4) helps to place an O-ring into the fitting groove with minimal risk of damage to the seal.

Tool Ordering Information

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Illustration 6 g03150196
Typical installer

The ORFS insertion tool can be procured as outlined in the "Dealer Service Tools 2006 Catalog": Vehicle System Tool Section. Tool part numbers
for ordering are shown in Table 2.

Fitting Size     CAT Part Number     Dealer Number    


(-4)     179-6884     2-011    
(-6)     179-6885     2-012    
(-8)     179-6886     2-014    
(-10)     179-6887     2-016    
(-12)     179-6888     2-018    
(-16)     179-6889     2-021    
(-20)     179-6890     2-025    
(-24)     179-6891     2-029    

Table 2

Tooling - Possible Damage

Illustration 7 g03150197
STOR tooling damage

Nicks, material gouges, and chatter marks along tool head.

(10) Tool damage

Material damage to the surface in which the seal will ride is typically in the form of missing material, nicks, gouges, and so on, when forced over the
cone for proper seal seating. Illustration 7 shows tool damage (10) due to improper storage.

Assembly Tooling - Storage


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 outside diameter.

Provide proper tool identification.

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Illustration 8 g03150198
STOR Installation Tool Storage

Illustration 8 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 9 g03150199
Tools stacked on each other

Tools shall not be stacked on top of each other (Illustration 9).

Illustration 10 g03150200
Tools stacked on parts

Tools shall not be stored on top of seals or other parts (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 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".

For more details refer to:

https://dealer.cat.com/cda/files/2498665/7/030%20R_Module %2017%205S_Visual%20Workplace%20v3.ppt

Recommended Cleaning Wipes:


Chemtool CT Clean 15861 Wipe With Cleaner - Caterpillar Part Number 169-5420 .

Chemtool Lint-Free Wipes - Caterpillar Part Number 265-2256 .

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Kimtex Lint-Free Polypropylene Towels - Dealer Tools & Supplies: 265-2256 (06179 Kimtech Pure* W5)

New Pig low-lint wipes, Part Number WIP230, or WIP232 from New Pig Corporation.

TOOLING - INSPECTION
Inspect tooling before use for contamination and damage that 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 the cone or pusher is damaged, 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 shall be established at every dealer to report damaged tooling.

Replacement Tooling - To reduce the risk of downtime and use of an unapproved tool due to tooling damage, replacement tooling shall be in
inventory and 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:

Select the appropriate insertion tool

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. The 1 second inspection identify part issues before assembling the parts to the components.

Illustration 11 g03150201
Insert O-ring

2. Insert the O-ring (1) through O-ring slot near top of ORFS insertion tool.

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Illustration 12 g03150202
O-Ring on plunger platform

3. Check to see that the O-ring is properly placed on plunger platform (2) .

Illustration 13 g03150203
Plunger pressed

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

Illustration 14 g03150204
O-Ring installed

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

Illustration 15 g03150205
Finger sweep check

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6. Conduct a "finger sweep" by placing a finger on top of the installed seal, while gently pushing down on top of the seal and running 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.

Illustration 16 g03150206
Visual inspection

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

8. Cap ORFS end for contamination prevention where applicable.

Illustration 17 g03150207
Fully seated seal

Illustration 18 g03150208
Incorrectly seated seal

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Illustration 19 g03150209
Incorrectly seated seal

9. Before and after completing the finger sweep, verify that the seal has been properly seated in the groove shown in Illustration 17. Illustration
18 and Illustration 19 demonstrate improperly seated seals.

Illustration 20 g03150210
Cutting damage

Illustration 21 g03150211
Pinching damage

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

STOR Assembly
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:

Select the appropriate installation tool.

Verify that the tool is clean and undamaged.

STOR Assembly Procedures


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

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Illustration 22 g03150212
STOR locknut position

(4) Cap

(5) Fitting body

(6) O-ring

(7) Locknut

1. Complete a 1-second inspection of 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. The 1 second inspection is to help identify part issues before assembling the parts to the components.
Note: Ensure that the locknut (7) on adjustable STOR fittings is positioned above the O-ring (6) groove as shown in Illustration 22.

Illustration 23 g03150213
Installation of O-Ring on STOR installation tool

(6) O-ring

(8) Tool

2. Place O-ring (6) over STOR installation tool (8) .

Illustration 24 g03150214
STOR Installation tool on Fitting

(10) Fitting thread

3. Place the tool over the fitting thread (10) .

Illustration 25 g03150215

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Installation of O-ring in fitting

(6) O-ring

4. Place fingers above seal and applying even steady pressure around the seal. Glide seal onto fitting taking care to prevent twisting. If the O-
ring (6) is twisted when seated, the O-ring can fail prematurely due to high strain. If a twist is observed, remove the seal and reinstall
Note: In most cases the O-ring (6) that is to be installed onto a fitting should have polytetrafluoroethylene (PTFE) coating. PTFE is a custom
coating applied to an O-ring to ease assembly installation.

Note: PTFE is more commonly referred to as Teflon from Dupont.

Illustration 26 g03150216
Removal of tool

5. Remove tooling from fitting.

Illustration 27 g03150217
Inspection of seal seating

Illustration 28 g03150218
Seal placement

6. Inspect the placement (seating) of the seal as shown in Illustration 27.


Note: Seal shall be placed over the O-ring groove and resting on washer as shown in Illustration 28.

7. Cap STOR end for contamination prevention where applicable.


Note: 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
reinstall.

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Refer to the Disassembly and Assembly manual for proper tightening specifications of STOR/ORFS into prime product.

Assembly Storage
Assembled product shall be stored in conformance with the Contamination Control Guidelines, PEBJ0002, "Caterpillar Dealer Contamination
Control Compliance Guide".

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 the 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 P-80 or Petro Gel Amber. Both of these products are available in the Caterpillar
aftermarket and should be used sparingly.

Refer to the list of part numbers below.

P-80: CAT P/N (NACD): 207-1601

CAT P/N (EAME): 207-1600

Petro Gel Amber: CAT P/N: 369-9450 (6 lb can) or 369-9451 (10 oz tube)

Captive grooves (for example: 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. Consult the Contamination Control
Guidelines, PEBJ0002, "Caterpillar Dealer Contamination Control Compliance Guide".

Retention Compound Application


Retention compounds are tacky semi-solids that shall 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.

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 shall 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.

Illustration 29 g03150219
Incorrect application of retention compound to O-rings

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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 provides an example of incorrect application of retention compound
after seal installation.

Illustration 30 g03150220
Correct application location for retention compound

Retention compounds (1) shall be applied sparingly (pea-size beads) into the bottom of the O-ring groove as shown in Illustration 30. Use the
minimum amount of compound necessary to retain the O-ring during assembly. 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 31 g03150221
Overfilling of groove with retention compound

Overfilling the groove (Illustration 31) can cause the seal to be displaced, and may result in the compound getting into areas, such as threads,
where the 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 the Contamination Control Guidelines,
PEBJ0002, "Caterpillar Dealer Contamination Control Compliance Guide".

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

Illustration 32 g03150222
Components preworked and stacked

Do not pre-work components or stack assembled parts as this increases the risk of contamination and seal damage (Illustration 32).

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If the retention compound squishes out of a joint or groove, too much has been applied. Use a lint-free wipe to remove excess retention compound
and clean surface thoroughly.

Recommended Cleaning Wipes:


Chemtool CT Clean 15861 Wipe With Cleaner - Cat Part Number 169-5420 .

Chemtool Lint-Free Wipes - Cat Part Number 265-2256 .

Kimtex Lint-Free Polypropylene Towels - Dealer Tools & Supplies: 265-2256 (06179 Kimtech Pure* W5)

New Pig low-lint wipes, Part Number WIP230, or WIP232 from New Pig Corporation.

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

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.

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

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

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

Torque all mating component fasteners immediately.

O-RINGS INSTALLED IN RADIAL SEAL JOINTS


Background

Illustration 33 g03150223
Radial O-ring application on an injector

Illustration 34 g03150224
Seal in bore

(1) Seal

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Illustration 35 g03150225
Seal in groove

(1) Seal

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 33. This document
addresses both Seal-in-Bore (Housing) (Illustration 34), and Seal-in-Piston (Shaft) (Illustration 35) designs.

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 the contact 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 shall be stored in properly identified, clean, closable containers that are kept closed between uses. Consult the Contamination Control
Guidelines, PEBJ0002, "Caterpillar Dealer Contamination Control Compliance Guide".

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

Lubricants shall 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 so P-80 is 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 the following approved lubricant:

Mineral Seal Oil - McMaster Carr Part No. 3190K281

Lubricant Dispensers

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Illustration 36 g03150226
Spray bottle

The recommended method for applying a lubricant is with a small nozzle spray bottle (Illustration 36).

Dispose of lubricant containers that have become internally contaminated.

Lubricant Application
Lubricants are low viscosity fluids that shall be used only on radial seal joints.

Seal lubricant shall 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 shall not introduce debris onto the seal or sealing surface.

Do not apply seal lubricants with brushes or fingers, which can 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, as it
may have an adverse effect on torque. Cover all components that must not be lubricated before lubricating. Follow the Contamination Control
Guidelines, PEBJ0002, "Caterpillar Dealer Contamination Control Compliance Guide".

Over-spray of lubricants can lead to false leaks. Over-spray of lubricants on threads can adversely affect torque on the connection leading to a
loose and leaky joint.

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 mineral oil.

Tooling – Inspection
Inspect tooling before use for contamination and damage that 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 the cone or pusher is damaged, stop using the tool immediately and 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 shall be established at every dealer to report damaged tooling.

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

Assembly

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Illustration 37 g03150227
Cleaning of groove for brake seal

Visually inspect mating parts for contamination or damage (nicks, scratches burrs, and so on). Use a clean lint-free wipe to remove contamination if
present from the groove (Illustration 37). Follow the Contamination Control Guidelines, PEBJ0002, "Caterpillar Dealer Contamination Control
Compliance Guide".

Install the seal into the groove immediately before the joint is assembled to reduce chances of the seal being damaged during transit or handling.

Place 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.

For installation of two-piece seals (example: some brake seals) first install the rubber energizer and then install the cap piece over the rubber
energizer.

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

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

Do NOT install contaminated seals.

Contaminated seals that cannot be removed and reinstalled using the proper assembly techniques must be cleaned thoroughly using a clean lint-
free wipe to reduce 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.

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

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

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.

For larger piston/bore diameters (example: brake seals), 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 diameters (example:
brake seals) applications.

PPI-0002397D

2021/11/29

04:33:40+05:30

i04905677

© 2021 Caterpillar Inc.


Caterpillar:

Confidential Green

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