VARIABLE SPEED FAN CLUTCH Caterpillar

NOTE: A 122-3188 Seal and 122-3191 Overhaul Kits are available for the 100-8105 and 129-9494 Fan Clutches.

1. Separate the front bearing retainer from the pulley adapter by removing bolts (1) and washers (2). Once separated then remove the O-ring seal (3).

2. Support (6) the front bearing retainer with the clutch hub (5) up. Remove the external snap ring (4) and clutch hub (5). Replace clutch hub (5) if the internal teeth are severely worn or if wear notches made by the facing plates have straight sides.

NOTE: If wear marks have smooth entry and exit marks then the notches will not restrict plate movement and the clutch hub (5) can be re-used.

3. Using FT2464 Plate (7), Press the fan mounting hub from the front bearing retainer.

4. Remove snap ring (8). Drive the seal (9) out with a punch.

5. Use FT2451 Bearing Installer/Remover (12) and FT2465 Plate (10) to press bearing (13) from the front bearing retainer (11).

Inspect:

(11) Bearing retainer.

A. The area must not have any nicks. The surface must seal against the OD of the oil seal.

Diameter (maximum) ... 130.213 mm (5.1265 in)

B. The area should not have any nick that rises above the surface.

C. Snap ring. The sides must be straight. The snap ring must fit freely in the groove.

Width (maximum) ... 1.19 mm (.047 in)

D. The area must have straight sides and no nicks that rise above the surface.

Diameter (maximum) ... 145.004 mm (5.709 in)

E. Any war marks present in the slots must not have straight sides that would restrict the plate movement. If wear marks have smooth entry and exit marks, the notches will not restrict the plate movement and the retainer may be used again.

6. Care must be taken when removing the wear sleeve (14). With a small chisel, make three indentations or grooves 120 degrees apart to loosen wear sleeve (14) from the fan mounting hub. The surface under the sleeve must not be damaged in any way. If the surface is damaged, it will result in seal leaks after rebuild.

7. Inspect the seal retainer assembly (16). If the seal requires replacement, remove the seal retainer assembly (16) with two pry bars from the fan mounting hub (15). If the seal is not damaged or worn then omit this step.

8. Remove the end cap (18) with a 38 mm to 63.50 mm (1.5 to 2.5 in) piece of steel round stock (17) that is 178 mm (7 in) in length.

Inspect:

(19) And (20) Sleeve bearings. If the bearings appear to be satisfactory then do not remove them, refer to the following illustration. Teflon/Bronze ID surface will appear dark bronze in color when new, and will progress to a light bronze color near the end of its useful life. The illustration visually indicates presence of dark teflon on the light bronze surface.

(18) End cap. The area should not have any nicks that rise above the surface.

A. Diameter (maximum) ... 76.149 mm (3.00 in)

9. If the sleeve bearings need replacement use FT2451 Bearing Installer/Remover (12) to remove both bearings (19) and (20) at the same time.

Inspect:

(15) Fan mounting hub.

A. Groove for snap ring (maximum) ... 3.68 mm (0.145 in)

B. Bearing journal diameter (minimum) ... 94.08 mm (3.704 in)

NOTE: If the surface does not indicate the bearing has been spinning and is not less than 95.0 mm (3.74 in) then the shaft may be reused. Install bearing with 7M7456 Bearing Mount Compound.

C. Bore for sleeve bearings (surface must be smooth and without any steps). Diameter (maximum) ... 75.0 mm 2.94 in)

D. Bore for end cap (surface must be smooth). Diameter (maximum) ... 85.8 mm (3.38 in)

10. Remove the seven facing plates (21) and seven clutch plates (22) from the pulley.

Inspect:

(21) Facing plate. Must pass between two plate surfaces 279.4 mm (11 in) by 279.4 mm (11 in) spaced 4.78 mm (.188 in) apart and set at a 45 degree angle. They are considered worn out when they are worn to the bottom of groove. Grooves are 0.13 mm (.005 in) minimum deep when new. Replace when internal teeth are worn a minimum of 0.13 mm (.005 in) per side or if the tooth driving contact surface is worn to a point or to a wedge shape.

(22) Clutch plate. Must pass between two plate surfaces 279.4 mm (11 in) by 279.4 mm (11 in) spaced 3.3 mm (.13 in) apart and set at a 45 degree angle. Replace it when wear on the drive surfaces of the external tangs exceeds 0.13 mm (.005 in) per side.

A. Clutch plate thickness when new ... 3.0734 mm (.121 in)

NOTE: The surface must be smooth and free of grooves, and must not be discolored by heat.

11. Remove the snap ring (23), shim (24), and the spring washer (25) from the pulley and shaft assembly.

12. Turn the pulley and shaft assembly over. The piston (26) will fall out. Remove the piston (26).

13. Remove the seal rings (27) and (28) from the piston (26). The piston (26) should be free of nicks and the sealing grooves must be smooth. The ID must not be elongated from wear.

14. Remove the bolts (1), washers (2) with the pulley supported (6).

15. Loosen the pitot tubes (30) by inserting a screwdriver into the pitot tubes (30). rotate the pitot tubes (30) until the adhesive has broken loose. Remove the pitot tubes (30) by gripping with a pair of pliers and gently tapping the pliers.

16. Remove the seal rings (31) from the shaft.

17. Remove the external snap ring (32) and the internal snap ring (33) from the shaft.

18. Press out the shaft and bracket assembly (34) from the rear bearing retainer (35) using a piece of steel round stock (17). Do not damage the shaft during removal.

19. Drive the seal (36) out of the rear bearing retainer (35) with a punch.

20. Use FT2451 Bearing Installer/Remover (12) and FT2465 Plate (10) to press bearing (37) from the rear bearing retainer (35).

Inspect:

(35) Rear bearing retainer.

A. Seal bore must not have nicks that extend above the bore surface and all adhesives must be removed. Bore for seal (maximum) ... 130.213 mm (5.1265 in)

B. Bearing bore must have straight sides, a square bottom, and not be oval do to wear. Bore for bearing (maximum) ... 145.004 mm (5.7088 in)

NOTE: Surfaces that mate with the pulley and the pitot diameter must be free of nicks that extend above any of the surfaces

21. Care must be taken when removing the wear sleeve (38). With a small chisel, make three indentations or grooves 120 degrees apart to loosen wear sleeve (38) from the fan mounting hub. The surface under the sleeve must not be damaged in any way. If the surface is damaged, it will result in seal leaks after rebuild.

22. Remove the seal assembly (39). Drive the seal assembly (39) of the shaft or wedge a chisel behind the retainer to force it off.

NOTE: The seal assembly (39) does not need to be removed unless it has been damaged or worn.

Inspect:

(34) Shaft. Do not separate from the bracket. Do not remove the tube from the center bore. Pipe plugs must be removed for cleaning. Replace the adhesive on the threads. Snap Ring grooves must have straight sides and square corners.

A. Bore for bearing (minimum) ... 95 mm (3.7 in)

NOTE: If the surface does not indicate the bearing has been spinning and is not less than 95 mm (3.7 in) then the shaft may be reused. Install bearing with 7M7456 Bearing Mount Compound.

B. Bore for sleeve bearings (minimum) ... 70 mm (2.8 in)

C. Groove for internal snap ring (maximum) ... 3.68 mm (.145 in)