Flexxaire Fan Caterpillar

Preliminary Disassembly Procedure

Note: Refer to the Service Manual Disassembly and Assembly (Engine Supplement), "Reversible Fan - Disassemble" for the Track Feller Buncher machines only on the disassembly procedure.

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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.

Note: Before you proceed, ensure that you know the correct model of the hydraulic actuated fan. Refer to Operation and Maintenance Manual, "Model View Illustrations" to determine the model of the fan.

1. Disconnect the hydraulic lines from the fan. Plug all lines and connectors.

2. Remove the fan from the machine. Refer to Disassembly and Assembly, "Fan - Remove and Install" for your machine for the procedure to remove the fan.
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   Illustration 1	g00905972
   Typical Hydraulic Actuated Fan (1) Hub Assembly (2) Fan Blade (3) Pulley (4) Hydraulic Connector (5) Mounting Bracket (6) Serial Number Plate

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   Illustration 2	g00924361

3. Remove fasteners and fan blades (2) from hub assembly (1). See the above illustration that corresponds to your type of fan.

4. Remove drain plugs from the hub of the fan. Rotate the hub to drain all the oil from the hub. Collect the oil in a suitable container. Lay the fan on the face of the hub to remove any remaining oil.

Pressure Test

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Illustration 3	g00917446

1. Attach air pressure gauge (7) and air chuck (8) into the ports that contained the oil plugs.

2. Pressurize hub (1) with air to 172.37 ± 34.47 kPa (25 ± 5 psi).

   Note: Expect an immediate pressure drop of 6.9 kPa (1.0 psi) to 20.7 kPa (3.0 psi).

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   Illustration 4	g00592775

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   Illustration 5	g00592776

3. If a leak is detected, test all the sealing surfaces, hub inserts, seals, and mating surfaces with soap.

4. Rotate the blade mounting shaft through the full range of motion to ensure that there are no leaks along the internal through shaft as the through shaft moves through the full range of motion past the internal O-ring.

5. Record all possible problem areas for the process of rebuilding.

6. Release the air pressure. Remove the air pressure gauge and the air chuck from the ports on the hub.

7. Loosely install all the oil drain plugs into the hub.

8. Attach a manual hydraulic shutoff valve and a hydraulic pressure gauge between the hydraulic source on the machine and the fan. Repeat this procedure for the other hydraulic line. Ensure that the shutoff valve is between the hydraulic source and the pressure gauge.

9. Pressurize the main shaft with pressure from the hydraulic fluid from the machine, and close the first shutoff valve. Repeat this procedure for the second line. Wait for ten minutes.

   Note: If a leak is present, expect an immediate decline in the hydraulic pressure.

10. If no leaks are detected after ten minutes, release the hydraulic pressure and remove the manual hydraulic shutoff valve and the hydraulic pressure gauge from both of the lines.

11. If leaks are detected, record all possible areas for the purposes of rebuilding .

Hub - Remove

1. Position the fan mounting bracket in a vise that is on a work bench.
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   Illustration 6	g00905911

2. Strike the head of fasteners (9) and the cover plate (10) squarely with the flat end of a ball peen hammer.

3. Remove fasteners (9) with a ratchet. If the fasteners are not loose, repeat step 2.

4. Remove cover plate (10) and O-ring (11) from the hub assembly.

5. Bend the wing of lockwasher (13) away from locknut (12).

6. Remove locknut (12) and lockwasher (13) from through bearing end (14).
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   Illustration 7	g00905921

7. Remove fasteners (18) that hold hub assembly (1) onto flange (17).

8. Remove hub assembly (1) and O-ring (16) from flange (17).

Shifter Block - Disassemble

Illustration 8	g00905927

1. Remove fasteners (20).

   Note: The shifter block assembly is separated by spacers.

2. Remove the shifter block assembly, bearing (19), and spacers (22) from hub assembly (1).

3. Remove pivot blocks (21) from the hub assembly.

Main Bearing - Remove

Illustration 9	g00905933

1. Remove fastener (23) and washer (24) from the through bearing end (14).

2. Remove through bearing end (14) from hex through shaft (26).
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   Illustration 10	g00905948

3. Remove oil dam (25). If your fan is equipped with a spool, remove the spool and the oil dam together. See Illustration 10 to determine if your fan has a spool.

   Note: This step is not applicable to FX 2000 fans.

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   Illustration 11	g00905949

4. If necessary, remove fasteners (29) from bearing carrier (28) .

5. If necessary, remove O-ring (27) and flange (17) from bearing carrier (28).
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   Illustration 12	g00905950
   The shims are not shown in this illustration.

6. Bend the wing of lockwasher (31) away from locknut (30).

7. Remove locknut (30) and lockwasher (31) from main shaft assembly (35).

8. Remove bearing carrier (28), bearing sets (32), bearing spacer (12), and shims from the main shaft assembly.

9. If necessary, remove the pulley from the bearing carrier.
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   Illustration 13	g00905952

10. Remove fasteners (36) from main shaft assembly (35) and from fan mounting bracket (37).

Main Shaft - Disassemble

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Illustration 14	g00905953

1. Remove rear snap ring (40) from main shaft assembly (35).
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   Illustration 15	g00905956

2. Remove end cap (39) from main shaft (35).

   Note: To easily remove the end cap, use air pressure on the hydraulic port. If no source of air is available, place one hand over the end cap. With the other hand, push hex through shaft (38) into the main shaft to force the end cap out of the rear of the main shaft. Do NOT use excessive force on hex through shaft (38) and hex rod shaft (41) to remove the end cap. The hex through shaft will NOT pass through the seal retainer.

3. Remove nut (43) from the threaded end of rod shaft (41).

4. Remove piston (42) from the main shaft (35).

   Note: To remove the piston, use air pressure on the hydraulic port. If no source of air is available, place one hand over the end cap. With the other hand, push the hex through shaft (38) and hex rod shaft (41) into the main shaft to force the end cap out of the rear of the main shaft. Do NOT use excessive force on the hex through shaft or on the hex rod shaft to remove the end cap. The hex through shaft will NOT pass through the seal retainer.

5. Remove hex through shaft (38) and hex rod shaft (41) through the front of main shaft (35).
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   Illustration 16	g00905958

6. Remove seal retainer (45) with Tooling (A).

7. Carefully remove all seals and O-rings (44). Do not damage the seal bores.

8. If necessary, remove hydraulic fittings, but note the orientation of the fittings before removing the fittings.

   Note: Make a note of the orientation of the hydraulic fittings prior to removing the fittings from the main shaft.