Lesson 2: Hoses and Seals

Lesson 2: Hoses and Seals

Introduction:
Caterpillar uses many different types of hoses and seals on our
machines and engines. It is important that the technician be familiar
with the different types of equipment used in order to be efficient in
repairing machines.
Objective:
After completing this lesson the student will be able to distinguish
between the different types of seals and hoses used in our industry.
References:
An Introduction to Seals and Gaskets SEBV0511

Materials:
Various Seals, O-rings, and sealant used in the shop
Unit 3 3-2-2 Caterpillar Service Industry
Lesson 2

Fig. 3.2.1 Seal Failure

Seals and Gaskets

For smooth operation with minimal wear, most gears and bearings
require constant lubrication. Since the earliest times engineers have
devised different means to keep lubricant around moving parts and
keep out water, dust and dirt. Given the conditions under which
construction machines typically operate, effective seals are
particularly important. Seal failure (Figure 3.2.1) results in
machinery breakdowns and the resulting lost time and money.
Unit 3 3-2-3 Caterpillar Service Industry
Lesson 2

Fig. 3.2.2 Seal Types

Seal Types
A seal is defined as a piece of material or a method that prevents or
decreases the flow of fluid or air between two surfaces. The sealed
surfaces may be stationary or have movement between them. Some
of the many duties of a seal are to:
- Prevent lubricant leakage

- Keep out dirt and other foreign bodies

- Keep different fluids such as oil and water apart

- Remain flexible enough to allow some movement between

parts without leaking

- Seal rough surfaces

- Wear faster than the more expensive parts with which they
are used.

Seals (Figure 3.2.2) can be classified into two basic types: static
seals and dynamic seals. Static seals are used when there is no
movement between the two sealed surfaces. Dynamic Seals are used
when there is movement of the sealed surfaces in relation to each
other.
Static Seals include O-ring seals, gaskets and liquid gasket material.
Dynamic Seals include O-ring seals, lip seals, Duo Cone seals and
packing rings.
Unit 3 3-2-4 Caterpillar Service Industry
Lesson 2

Fig.3.2.3 Gaskets

Gaskets
Gaskets are one of the most common seals used to seal small
clearances between static machinery parts. They are made of
materials that prevent the passage of air, gas or liquid between
stationary surfaces. Some of the places that gaskets are used are
between the cylinder head and the block and between the block and
the oil pan. Surfaces where gaskets are used must be flat, clean, dry
and free of scratches. The pressure of the fasteners used to join the
surfaces produces an important part of the sealing action of gaskets.
It is essential to tighten fasteners to the specified torque to prevent
leaking.

Fig. 3.2.4 O-ring Seal

O-rings
An O-ring (Figure 3.2.4) is a smooth circular ring made from natural
or synthetic rubber or plastic. In operation the ring is usually
compressed between the two surfaces. The compressed ring provides
the seal. The ring may be used as a static seal in a manner similar to
a gasket.
Unit 3 3-2-5 Caterpillar Service Industry
Lesson 2

Fig. 3.2.5 Backup Ring

In extreme high pressure sealing applications above 5500 kPa
(800 psi), backup rings (Figure 3.2.5) are sometimes used in
conjunction with the O-rings to prevent extrusion of the O-ring into
the clearance space between the sealed parts. The pressure backup
rings are usually made of a plastic material and extend the life of the
O-ring.
While the most commonly used O-rings have a circular cross section
there are other types that are used for specific applications.
Make sure that all surfaces where O-rings are installed are free from
dirt and dust. Inspect the O-ring for dirt, cuts and scratches. Do not
twist or stretch the O-ring during installation. When removing an
O-ring use tools that will not damage the surface of the part.

Fig. 3.2.6 Internal Lip Seals

Lip Seals
Lip seals are some of the most important dynamic seals used in
construction equipment. Lip seals endure operation in all types of
severe conditions and resist breakdown due to heat build-up or
contact with lubrication or hydraulic fluids. They are also resistant to
movement between the two parts they are sealing. Lip seals are
relatively easy to remove for service replacement.
Unit 3 3-2-6 Caterpillar Service Industry
Lesson 2

The two most common types of lip seals are radial lip seals and dirt
excluding lip seals. Dirt excluding lip seals are used as "scrapers" or
"wipers" on hydraulic cylinders. Radial lip seals are used to prevent
leaks on rotating shafts and are manufactured in many different
shapes and sizes to suit specific applications. Internal lip seals have
the seal lip on the inside diameter of the seal. Some of the most
common internal lip seals are shown in Figure 3.2.6.

Fig. 3.2.7 External Lip Seals

External radial lip seals

External radial lip seals (Figure 3.2.7) have the seal lip on the outside
diameter of the seal.

Fig. 3.2.8 Garter Spring

Garter Spring
Radial lip seals are held against the surface of the shaft they seal by
fluid pressure and a garter spring (Figure 3.2.8). The garter spring
provides additional force when fluid pressure is less. The seal
actually operates on a thin film of oil between the seal lip and the
shaft. This permits lubrication of the seal lip without allowing
leakage.
Unit 3 3-2-7 Caterpillar Service Industry
Lesson 2

Make sure that surfaces where lip seals are used are clean and free of
scratches and grooves. do not use lip seals with a broken lip. Do not
use lip seals if the lip is "turned under". Lip seals must be removed
with a special tool.

Fig. 3.2.9 and 3.2.10 Wear Sleeve

Sometimes thin metal cylinders called shaft wear sleeves are used in
conjunction with lip seals to provide a replacement smooth surface
for the seal and avoid replacement of expensive, highly machined
shafts.
One end of the sleeve is tapered to help the installation of the seal
that fits around the outside of the sleeve. Wear sleeves are available
in sizes that range from about .75 to 7.5 inches (1.91 to 19 cm) in
inside diameter. The width is generally determined by the width of
the seal used.
The wear sleeve is pressed on the worn shaft and a new seal of the
correct size is installed over the sleeve. The sleeve makes a smooth
surface for the new seal. This is a common method of repair used on
front or rear crankshaft seal surfaces, accessory drive shafts, and
input and output shafts on transmissions.
Unit 3 3-2-8 Caterpillar Service Industry
Lesson 2

Fig. 3.2.11 Duo-Cone Seal Components

Duo-Cone® Seal
Duo-cone seals are designed to keep large amounts of dirt out and
lubricant in. Because of the harsh conditions where they are used,
duo cone seals must be resistant to corrosion so they last for a long
time with minimum maintenance. They must be resistant to shaft
bends, end play and shock loads.
The Duo-cone seal consists of two rings, usually made of rubber
mounted on two grooved metal retaining rings.
Unit 3 3-2-9 Caterpillar Service Industry
Lesson 2

Fig. 3.2.12 Duo-Cone Seal

In operation, the rubber or toric rings hold the metal rings together to
form a seal. They also provide a cushion for the metal rings and keep
the sealed faces in alignment when the shaft moves during machine
operation. The smooth surfaces of the metal rings combine with the
viscosity of the oil to seal the shaft. Duo-cone seals can be found in
final drives, carrier rollers and other applications where the speeds
are slow and a seal with long life is needed.
Duo cones must be "exercised" to maintain the metal-to-metal seal.
If a machine is idle for a long time, the seals may begin to leak. This
does not mean the seals should be replaced. Use published operation
guidelines to determine whether Duo-Cone seals have failed.
When servicing Duo-Cone seals, thoroughly remove all traces of
protection layers or oil from new duo cone rings. Use a solvent and
make sure all surfaces are dry. Before assembly, wipe clean the seal
faces and using a tissue moistened with light machine oil carefully
apply a layer of oil on the metal seal face. Do not put oil on the
rubber ring. Use an installation tool to install the seal with a correct
and even application of force. Duo-cone seal rings must always be
kept in pairs.
Unit 3 3-2-10 Caterpillar Service Industry
Lesson 2

Fig. 3.2.13 and 3.2.14 V-type and U-cup Packing Rings

V-type and U-cup Packing Rings

The two types of packing rings are the V-type and the U-cup type. A
cross-section of the ring will show that it is shaped live a V or a U.
Several V-type rings are used together to form a seal. Only one
U-cup seal is used to form a seal. Packing rings are usually black in
color and made of synthetic material.
Packing rings are usually used in high-pressure dynamic applications.
Compression of the ring causes the expansion of the inside and
outside lips of the ring. The pressure of the lips against the two
surfaces forms the seal. Packing rings are generally packed in glands
of hydraulic cylinders to seal hydraulic oil between the piston rod and
head.

Fig. 3.2.15 and 3.2.16 Metal-backed Seal

Metal-backed Seal
A metal-backed seal is very similar to an O-ring. A spring steel case
(cover) outside supports the sealing material, which is usually a
synthetic-rubber like material.
Metal-backed seals are used in the same static applications as O-ring
seals especially where high or low temperatures are experienced.
Their primary use is for sealing flanges and hydraulic hose couplings.
Unit 3 3-2-11 Caterpillar Service Industry
Lesson 2

Fig. 3.2.17 and 3.2.18 Radiator Hose

Radiator Hose
Radiator hose is normally made from a flexible, molded soft rubber
compound over cotton braid. It is generally black in color and is
connected by hose clamps. The inside diameter can be from 1 inch
(2.54 cm) to about 5 inches (12.7 cm).
Radiator hose is used to hold coolant and is connected between a
radiator and an engine block.

Fig. 3.2.19 and 3.2.20 Heater Hose

Heater Hose
Heater hose is generally made from a rubber compound. The walls
of the hose are thick and the hose is normally black in color. The
inside diameter of heater hose is about 3/4 inch (1.905 cm). The
hose is flexible.
Heater hose is used on vehicles to transport water or coolant heated
by the engine to a heat exchanger. There is normally a supply hose
and a return hose.
Unit 3 3-2-12 Caterpillar Service Industry
Lesson 2

Fig. 3.2.21 and 3.2.22 Air Brake Hose

Air Brake Hose

Air brake hose is generally made from rubber and reinforced nylon.
It is flexible and lightweight. Air brake hose is normally available in
small diameters.
Air brake hose is used on vehicles such as large tractor-trailer trucks
that have air brakes. The hose directs compressed air from the
compressor to the brakes.

Fig. 3.2.23 and 3.2.24 Hose Clamp

Hose Clamp
Hose clamps are round, metal bands which are tightened around the
end of a hose to attach the hose to a part. There are several different
types, but the "worm drive" type is the most common. The width of
the clamp is usually 1/2 or 5/8 inch (12.7 or 15.875 mm) and the
diameter ranges from about 1/4 to 12 inches (6.35 to 30.48 cm).
Hose clamps are used to prevent large-diameter hose connections
from leaking. They are generally found on radiator hoses, heater
hoses, and other low-pressure hoses which are removed frequently.
Unit 3 3-2-13 Caterpillar Service Industry
Lesson 2

Fig. 3.2.25 and 3.2.26 Collet-type Coupling

Collet-type Coupling
The collet-type coupling is designed to be used more than one time
when resized correctly. The coupling is made up of the following
two components: the stem-collet assembly and a steel sleeve. The
stem-collet assembly is a hollow steel pipe that has a collar on one
end. The other end is installed on the hose. The sleeve is pressed
over the tapered fingers of the stem to hold the coupling on the hose.
Collet-type couplings are available in several sizes for straight or
angled applications.
The collet-type coupling is used with a split flange to bolt the hose
assembly to the part. An O-ring or metal-backed seal is used to seal
the part and the coupling. These couplings are commonly found on
high-pressure, large-diameter hydraulic hose used on implement
systems where the flexibility of a hose is required.

Fig. 3.2.27 and 3.2.28 Hydraulic Hose Armor

Hydraulic Hose Armor

Hydraulic hose armor is a metal band about 1/8 inch (3.175 mm)
thick by 1 inch (25.4 mm) wide and is installed on various hose
sizes. It is wrapped around hydraulic hose to protect it against wear.
The armor is wrapped in a spiral so the hose can still be flexible.
Hydraulic hose armor is used to protect the outer cover of hydraulic
hose from damage. It is generally used on high-pressure hydraulic
hose that is subject to wear such as the hydraulic hoses on the lift
cylinders on wheel loaders.
Unit 3 3-2-14 Caterpillar Service Industry
Lesson 2

Fig. 3.2.29 and 3.2.30 Copper Tubing

Copper Tubing
Generally, copper tubing is rigid but soft and can be bent into
different shapes with the correct tools. It has a copper color unless it
is painted. Copper tubing is generally found in diameters up to
1 inch (2.54 cm).
Copper tubing is generally found in applications in which the fluid to
be handled is at a low temperature and pressure. Copper tubing is
sometimes used for low-pressure fuel injection lines from the tank to
the fuel injection pump.

Fig. 3.2.31 and 3.2.32 Flaring Tool

Flaring Tools
Flaring tools are made from high-quality tool steel. Most models can
flare tubing with an outside diameter of 3/16 inch (4.7625 mm) to
5/8 inch (15.875 mm). The flaring tool is manually operated and
hand held. Two "die bars" pivot on one end and clamp the tube to be
flared. A "yoke" with a handle, screw and flaring cone is placed over
the clamped tube.
Most flaring tools are used on tubing made from soft steel as well as
copper, brass, and aluminum. The angle of the tubing flare is
generally either 45º for automotive applications or 37º for industrial
applications. A flare-type fitting is installed on the flared tube before
flaring.
Unit 3 3-2-15 Caterpillar Service Industry
Lesson 2

Fig. 3.2.33 and 3.2.34 Tubing Cutter

Tubing Cutter
A tubing cutter is a tool used to cut tubing. It may be adjusted for
different sizes of tubing up to 1 1/8 inches (2.875 cm). The tubing is
cut by a round blade that turns around the tubing. The pressure of the
blade against the tubing is adjustable as the cut is made by turning
the knob on the end of the cutter. A reamer and file is located on the
body of the tool.
A tubing cutter is used to cut tubing to the correct length. It makes a
clean cut so a fitting can be installed on the end of the tubing. It is
also used to deburr the end of the tubing after it is cut.

Fig. 3.2.35 and 3.2.36 Tubing Fitting

Tubing Fitting
Small diameter hoses and tubing use threaded couplings called
fittings. There are many different types and sizes for different uses.
Fittings can be made of brass and steel. Brass fittings are used with
copper or plastic tubing. Steel fittings are used with steel or plastic
tubing. The fitting shown is a common "flared type" fitting used on
copper tubing.
Fittings are used to connect small-diameter tubing to parts. There are
many types for different applications.
Unit 3 3-2-16 Caterpillar Service Industry
Lesson 2

Fig. 3.2.37 and 3.2.38 Nylon Tubing

Nylon Tubing
Nylon tubing is made from synthetic material that is usually naturally
black in color. It is flexible, lightweight, easy to install, and has a
high resistance to vibration.
Nylon tubing is generally found in applications in which the fluid to
be handled is at or near ambient temperature and low pressure.
Nylon tubing is sometimes found on hydraulic and fuel testing
equipment, air horns, and some fuel lines and gauge lines.

Fig. 3.2.39 and 3.2.40 Vinyl Tubing

Vinyl Tubing
Vinyl tubing is soft, light, and easy to handle. Vinyl tubing is
generally clear and found in small diameters.
Like nylon tubing, vinyl tubing can only be used in ambient (room)
temperature and low-pressure applications. It is sometimes found on
test equipment and gauges.
Unit 3 3-2-17 Caterpillar Service Industry
Lesson 2

Fig. 3.2.41 and 3.2.42 Non-cog Belt (Vee Belt)

Non-cog Belt
A non-cog vee belt is made from a rubber compound with fiber
reinforcement. It has four flat sides and is flexible. Vee belts are
available in many sizes and are normally black in color.
Non-cog vee belts are used on engines to connect the rotating
crankshaft to a fan, water pump, generator, or compressor. The
rotation of the crankshaft pulley causes the belt to turn that turns the
other pulley.

Fig. 3.2.43 and 3.2.44 Cog Belt (Vee Belt)

Cog Belt
A cog-type vee belt is similar to a non-cog type belt except that the
inside surface of the belt has "cogs" or teeth that contact the pulley.
Cog-type belts are used in many of the same applications as non-cog
type belts.
Unit 3 3-2-18 Caterpillar Service Industry
Lesson 2

Fig. 3.2.45 and 3.2.46 Link Belt

Link Belt
A link-type vee belt is made from many links that can be added or
removed to make a vee belt of the size needed. The width can be
1/2 inch (1.27 cm) to 7/8 inch (2.2225 cm). Lengths can be made to
any size by snapping the links together.
Link-type vee belts are used as a temporary or emergency
replacement for vee belts broken in the field or when there is not a
replacement immediately available.

Fig. 3.2.47 and 3.2.48 Windshield Wiper Blades

Windshield Wiper Blades

A windshield wiper blade is a v-shaped rubber element with a metal
reinforcement. It is available in several lengths and is installed in a
windshield wiper arm. The blade is pressed against the windshield
by the arm and wipes or clears away water.
A windshield wiper blade is used on vehicles to clean the windshield
so the operator can see clearly.