This document provides assembly instructions for a Flexxaire fan on a 938G wheel loader. It describes how to assemble the shifter block, hub, actuator bearings/control shaft, install an O-ring on the main shaft, and install main bearing cups. The instructions include illustrations and notes about lubrication, torque specifications, and verifying clearances at various steps.
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2. Shutdown SIS
Previous Screen
Product: WHEEL LOADER
Model: 938G WHEEL LOADER 6WS
Configuration: 938G Wheel Loader 6WS00001-UP (MACHINE) POWERED BY 3126 Engine
Disassembly and Assembly
Flexxaire Fan
Media Number -RENR3699-07 Publication Date -01/02/2012 Date Updated -21/06/2016
i01742847
Mechanical Actuated Fan - Assemble
SMCS - 1356-016
Shifter Block − Assemble
Note: The following procedure should only be performed by persons that have taken the fan
rebuilding training course at FLEXXAIRE Manufacturing Inc. The shifter block assembly is sold
only as an assembly unless you have had the training.
Note: Proceed to “Hub - Assemble” if you have purchased a shifter block assembly.
Illustration 1 g00597621
1. Thread elbow (3) onto pickup tube (2). Then, thread pickup tube (2) into through shaft
bearing end (1).
Note: The orientation of pickup tube (2) in Illustration 2 is shown in the most common
direction. However, other applications may require pickup tube (2) to be rotated 180
degrees. Pickup tube (2) is stationary. Pickup tube (2) does not rotate. The arrows indicate
the direction of oil flow into pickup tube (2).
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3. Illustration 2 g00597622
2. Slide bearing cone (4) onto through shaft bearing end (1). Slide wave washer (5) and spacer
(6) onto through shaft bearing end (1).
Illustration 3 g00597623
3. Slide wave washer (7) onto through shaft bearing end (1).
4. Insert the races into the bores of shifter block plate (8).
5. Slide shifter block plate (8) onto through shaft bearing end (1).
Illustration 4 g00597624
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4. 6. Slide bearing cone (9) onto through shaft bearing end (1).
Illustration 5 g00597625
7. Install locking washer (10) and bearing locknut (11) onto through shaft bearing end (1).
Note: Once proper clearance is obtained, bend the tabs of locking washer (10) into the slots
in bearing locknut (11). Proper clearance is 0.0254 mm to 0.0762 mm
(0.001 inch to 0.003 inch). The shifter block assembly should spin freely.
Hub − Assemble
Illustration 6 g00597501
1. Lubricate O-Ring (1) with a light film of oil and insert O-Ring (1) into the hub insert.
Note: Clean the O-Ring groove thoroughly before installing O-Ring (1) in order to prevent
leakage.
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5. Illustration 7 g00597503
2. Lubricate the shank of blade mounting shaft (2) with oil. Install nylon washer (3) onto blade
mounting shaft (2) and insert blade mounting shaft (2) into the hub insert.
Illustration 8 g00597506
3. Install the race of bearing (4) with the larger inside diameter onto blade mounting shaft (2).
4. Install the cage of bearing (4) onto blade mounting shaft (2).
5. Install the race of bearing (4) with the smaller inside diameter onto blade mounting shaft
(2).
Illustration 9 g00597507
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6. 6. Install collar (5) onto blade mounting shaft (2).
Note: The cut out of collar (5) should be facing upward.
Illustration 10 g00597508
7. Apply 9S-3263 Thread Lock Compound to capscrew (6). Install capscrew (6) into collar (5).
Hold blade mounting shaft (2) as you tighten capscrew (6). Tighten capscrew (6) to a torque
of 54 ± 5 N·m (40 ± 4 lb ft).
Illustration 11 g00597511
8. Repeat Steps 1 through 7 for each remaining blade mounting shaft.
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7. Illustration 12 g00597513
9. Remove capscrews (7) and front plate (8) from the shifter block assembly.
Illustration 13 g00597514
10. Remove two spacers (9).
Illustration 14 g00597515
11. Place pivot blocks (10) onto the pins of collars (5).
Illustration 15 g00597520
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8. 12. Position shifter block assembly (11) in the hub.
Note: Verify that the machined surfaces of pivot blocks (10) are against the flange surface.
Illustration 16 g00597523
13. Put spacers (9) into position over the corresponding holes.
14. Install ring (12) and align the holes with spacers (9).
Illustration 17 g00597526
15. Apply 9S-3263 Thread Lock Compound to capscrews (13A) and (13B) and install the
capscrews. Tighten capscrews (13A) to a torque of 16 ± 4 N·m (12 ± 3 lb ft). Tighten
capscrews (13B) to a torque of 34 ± 4 N·m (25 ± 3 lb ft).
Note: The shifter block assembly should move freely over the pivot blocks. If the shifter
block is binding, it is possible that a pivot block needs to be turned by 90 degrees.
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9. Illustration 18 g00597527
16. Clean the groove in the hub that holds the O-Ring for the cover plate. Install O-Ring (14)
into the groove.
Illustration 19 g00597528
17. Place cover plate (15) onto the hub and align the holes.
18. Install capscrews (16). Do not put any 9S-3263 Thread Lock Compound on capscrews (16).
Tighten capscrews (16) to a torque of 16 ± 4 N·m (12 ± 3 lb ft).
Illustration 20 g00597530
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10. 19. Flip the hub assembly. Clean the groove in the hub that holds the O-Ring for the flange
plate. Install O-Ring (17) into the groove.
Illustration 21 g00597531
20. Place hub flange (18) onto the hub and align the holes.
Note: There is a small capscrew in the flange plate that aligns with a counterbore in the hub.
21. Install capscrews (19). Do not put any 9S-3263 Thread Lock Compound on capscrews (19).
Tighten capscrews (19) to a torque of 54 ± 5 N·m (40 ± 4 lb ft).
Actuator Bearings and Control Shaft Bushings − Install
Illustration 22 g00597972
1. Apply 4C-9507 Retaining Compound to bushing (1) and install bushing (1). The hole in
bushing (1) must line up with the hole in the bushing bore.
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11. Illustration 23 g00597973
2. Install seals (2) and (3) so that the lips face outward.
Note: Some fans do not have seals (2) and (3).
Illustration 24 g00597975
3. Install all grease fittings and hoses.
Illustration 25 g00597977
4. Install spherical bearings (4) into actuator clevis (5).
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12. Illustration 26 g00597979
5. Put actuator collar (6) into position. Apply 9S-3263 Thread Lock Compound to the threads
of shoulder bolts (7) and install bolts (7). Tighten bolts (7) to a torque of 54 ± 5 N·m
(40 ± 4 lb ft).
Note: Actuator collar (6) must be installed so that the four setscrews face outward.
Frost Plug and Main Shaft O-Ring − Install
Illustration 27 g00598467
1. Temporarily install main shaft extension (1) into main shaft (2).
Note: Main shaft extension (1) must be removed during installation of the O-Ring.
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13. Illustration 28 g00598468
2. Use the former bushing as a template in order to create a slot in new bushing (3). Install new
bushing (3) into the rear of the main shaft.
Illustration 29 g00598469
3. Install bushing (4) into main shaft (2) or main shaft extension (1).
Note: Main shaft extension (1) may not be applicable in all cases. If this is true in your case,
bushing (4) will be required in main shaft (2).
Illustration 30 g00598470
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14. 4. Use the existing hole in bracket base (5) as a guide in order to drill a hole through the rear
bushing.
5. Clean the bore of the main shaft thoroughly. Verify that the bore for the internal O-Ring is
free of any foreign material.
Illustration 31 g00598471
6. Verify that through shaft (6) passes freely through both bushings (3) and (4).
Note: If through shaft (6) binds, reaming of bushings (3) and (4) may be required.
Illustration 32 g00598467
7. Remove main shaft extension (1) from main shaft (2).
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15. Illustration 33 g00598472
8. Use through shaft (6) in order to push O-Ring (7) into the groove inside main shaft (2).
Note: You may want to insert through shaft (6) into main shaft (2) from both sides in order
to verify that O-Ring (7) has seated properly.
Main Bearing Cups − Install
Illustration 34 g00598473
1. Install bearing cup (1) into bearing carrier (2).
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16. Illustration 35 g00598474
2. Install bearing cup (3) into the opposite side of bearing carrier (2).
3. Clean the bores of bearing cups (1) and (3). Verify that the grooves for the O-Rings are free
of any foreign material.
Carrier/Spool and Main Bearing − Install
Illustration 36 g00598600
1. Position bracket (1) so that main shaft (2) is vertical.
2. Slide fillet spacer (3) onto main shaft (2). The bevel on fillet spacer (3) must match the
radius on main shaft (2).
Note: Not all fan assemblies have fillet spacer (3).
3. Slide bearing cone (4) onto main shaft (2). Be careful not to damage the threads on main
shaft (2).
Illustration 37 g00598602
4. Set bearing carrier (5) on bearing cone (4).
5. Slide bearing spacer (6) onto main shaft (2).
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17. Illustration 38 g00598603
6. Slide shims (7) and (8) onto main shaft (2).
Illustration 39 g00598604
7. Slide bearing cone (9) onto main shaft (2). Thread bearing locknut (10) onto main shaft (2).
Tighten bearing locknut (10) to the correct torque. Refer to Table 1 for the correct torque.
Note: The use of a torque multiplier is recommended when you tighten bearing locknut
(10).
Table 1
Torque Values for Bearing Locknut (10)
Identification Inside Diameter Torque Value
N09 44.45 mm (1.75 inch) 230 ± 41 N·m (170 ± 30 lb ft)
N14 69.85 mm (2.75 inch) 353 ± 54 N·m (260 ± 40 lb ft)
8. Use a dial indicator to verify bearing clearance. Add or remove shims in order to obtain the
correct bearing clearance. Refer to Table 2 for the correct clearance.
Table 2
Bearing Clearances
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18. Inside Diameter Clearance
44.45 mm (1.75 inch) 0.025 mm to 0.076 mm (0.001 inch to 0.003 inch)
69.85 mm (2.75 inch) 0.076 mm to 0.127 mm (0.003 inch to 0.005 inch)
9. Remove all components except for fillet spacer (3) after the correct bearing clearance has
been obtained. The components will be reinstalled later in the procedure.
Illustration 40 g00598624
10. Place bearing carrier (5) so that the seal end faces upward.
11. Apply 4C-9507 Retaining Compound to the seal bore and the outside diameter of seal (11).
12. Place main bearing cone (12) into the cup. Press seal (11) into the seal bore of bearing
carrier (5) until the face of seal (11) is flush with the edge of bearing carrier (5).
13. Lubricate the double seal with oil.
Illustration 41 g00598607
14. Attach pulley (13) to bearing carrier (5) with capscrews (14). Tighten capscrews (14) to a
torque of 54 ± 5 N·m (40 ± 4 lb ft).
Note: Verify correct orientation of pulley (13).
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20. Illustration 42 g00598608
15. Position pulley (13) and bearing carrier (5) onto main shaft (2). Use care when you slide the
seal over the shoulder of the main shaft in order to not damage the seal. Be careful not to
damage the threads on the main shaft.
Illustration 43 g00598571
16. Install spacer (14) and shim (15). Shim (15) is the thinnest shim.
Illustration 44 g00598569
17. Install remaining shims (16) and bearing cone (17).
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21. Illustration 45 g00598568
18. Thread bearing locknut (18) onto main shaft (2) so that the end with the bevel faces away
from bearing cone (17). Tighten bearing locknut (18) to the correct torque. Refer to Table 3
for the correct torque.
Note: The use of a torque multiplier is recommended when you tighten bearing locknut
(18).
Table 3
Torque Values for Bearing Locknut (18)
Identification Inside Diameter Torque Value
N09 44.45 mm (1.75 inch) 230 ± 41 N·m (170 ± 30 lb ft)
N14 69.85 mm (2.75 inch) 353 ± 54 N·m (260 ± 40 lb ft)
Illustration 46 g00598567
19. Install locking washer (19). Install bearing locknut (20) so that the end with the bevel faces
toward bearing cone (17). Tighten bearing locknut (20) to the correct torque. Refer to Table
4 for the correct torque.
Note: Not all models of fan have two locknuts.
Table 4
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22. Torque Values for Bearing Locknut (20)
Identification Inside Diameter Torque Value
N09 44.45 mm (1.75 inch) 61 ± 11 N·m (45 ± 8 lb ft)
N14 69.85 mm (2.75 inch) 75 ± 11 N·m (55 ± 8 lb ft)
20. Bend the tabs of locking washer (19) into the slots in bearing locknut (20).
Illustration 47 g00598566
21. Apply 7M-7456 Compound to the threads of main shaft extension (21). Thread main shaft
extension (21) into main shaft (2). Tighten main shaft extension (21) to a torque of
136 ± 11 N·m (100 ± 8 lb ft).
Note: Not all fan assemblies have main shaft extension (21).
Illustration 48 g00598564
22. Inspect the groove for O-Ring (22) for any foreign material. Install O-Ring (22) into the
groove in bearing carrier (5). You can use grease in order to hold O-Ring (22) in place.
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23. Illustration 49 g00932665
23. Position spool (23) so that the bolt holes are aligned with the holes in bearing carrier (5).
Install capscrews (14).
Hub Kit − Install
Illustration 50 g00598711
1. Apply 9S-3263 Thread Lock Compound to the threads of through shaft bearing end (1).
Thread through shaft (2) onto through shaft bearing end (1).
2. Lubricate the entire length of through shaft (2) with a film of oil.
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