Tank main shaft seal replacement service guide
Contents
1. Tank disassembly and service guide E520 E720 E820E920 a ie Note to Service Technician This service guide covers complete tank disassembly with special emphasis on main shaft flywheel removal and tank seal replacement Inquiries regarding PC tank adjuster shaft or adjuster plate service can be found in the appropriate service man ual Mainshaft seal spring report From the start of production the FDF Fluid Tank has relied on a spring rein forced seal to prevent leakage along the main shaft This has been extremely reliable over five years of manufacture In 2006 we switched to a new tank back system choosing a fibre reinforced resin material SMC which was more durable than aluminum Extensive testing for 12 months did not produce a single failure We released the S250 S350 models in late 2006 and in about 8 months be gan to experience the occasional failure through the tank main shaft seal The cases were few enough at the time to write it off to manufacturing error although extensive testing of both in house SOP s and parts tolerances turned up nothing unusual The problem was confined to these models However towards the end of 2008 we began to experience occasional main shaft seal failures on other products Again we examined our manufacturing process and found nothing Yet the complaints continued In late March 2009 we swapped what seemed at the time to be the hun dredth tank on2. a soft surface underneath The impeller blades are also sharp use care when handling Removing the flywheel main shaft with the FDF Flywheel shaft puller P N13300 First attach the FDF flywheel shaft puller to the rear of the SMC tank aluminum housing and tighten the four bolts as shown Then with a large open end or crescent wrench slowly turn the main puller bolt clock wise until the flywheel is forced through the hous ing and out of the tank Note Use a towel or other soft surface un derneath to avoid damage when the fly wheel mainshatt assembly drops out of the housing Tank shaft seal Inspection On the left is a healthy tank shaft seal the silicone glue and packing grease main tain their original color The integrity of this tank shaft seal has not been compro mised The bearings will show no sign of water dam age and run smoothly If there are no issues with the tank bearings the bearings and tank shaft seal can be left in place and the tank re assembled The right seal has been compromised Telltale signs are the discolored silicone and the propensity for the tank seal to pop out of posi tion when the main shaft flywheel assembly is re moved The seal part num ber 10025 tank bearings part number 10012 spacer part number 10145 and C clip part number 10186 will be replaced in the tank shaft seal kit 4 Tap out the front bearing and remove 1 Remove C clip from rear of alum
3. 478 3306 ext 45 Slide the cup seal onto the fly wheel mainshaft juts prior to re assembly as shown Reinstalling the flywheel main shaft 1 Apply axle grease to main shaft before installation Note When pressing the main shaft into the SMC tank back make sure the bearing spacer Is aligned 2 Once the Flywheel Main shaft assembly has been completed you may proceed with reinstalling the tank cover O ring PC cover and finally which ever drive system is appli cable for the tank in ques tion Reinstalling the Tank O ring and Polycarbonate cover EE 1 Lay the O ring into the SMC O ring groove making sure it is flat and flush before secur ing the PC cover An improperly laid and prepared O ring will seep water over time If the seal is excessively dry then add a light coat of silicone grease 2 When attaching the PC cover use a cross pattern with the screws If a power tool is used the lightest setting is more than enough to establish a seal Note over tightening the tank screws will readily crack the PC cover Reinstalling the small belt pulley keyway and bolt 1 Reinstall the Small belt pul i ley onto the main shaft Remember to keep the key way positions on the shaft and pulley lined up as you go 2 Apply thread 3 The Keyway small pulley and main shaft as sembly To fin ish reinstall the washer spring washer and tank shaft bolt
4. MC wall with the ex cess silicone paying special attention to the lip area of the hous ing Then clean out any remaining silicone located between the lips of the seal before proceeding Allow a few minutes for the ini tial setup of the silicone glue before moving on to the silicone pack ing grease Silicone Grease Packing Apply a generous amount of Silicone grease standard O ring grease to the inside of the seal and pack the area between the rear of the seal and the front bearing with a liberal amount of O ring grease Above right is an ex ample of a properly prepared tank shaft seal Cup seal addendum Once the bearings mainshaft seal and spacer have been replaced this cup seal slides onto the mainshaft as shown bottom left and right before the flywheel shaft is re installed through the SMC tank back as directed in the service notes Shown upper right without the flywheel mainshaitt for effect is the cup seal It will help direct water away from the mainshaft seal thus reducing wear and tear and greatly extending the longevity of the replacement parts This is especially helpful for the 250 S350 series rowers Note distributors holding existing FDF9E kits without the cup seal can order them Part number 13025 FOC by contacting our Production Manager in Taiwan Note freight charges are the responsibility of the Distributor Michael Botti Email address as follows michaeljbotti gmail com Tel 886 3
5. gh dis tortion of the seal to allow seepage along the main shaft through to the bearings A correct spec Stainless steel mainshaft seal spring after 6 months in wa ter and 4 years after pro duction along side our cur rent stainless spring As pic tured the springs are identical Small belt pulley removal prep see T i p dia Step 2 Flip the tank over to ac cess the main shaft belt pulley Step 3 Using a screwdriver or suit able tool lock the im peller blade in place and remove the rear main shaft bolt Step 1 Remove the ad juster handle grub screws and remove handle from adjuster shaft Small Pulley Removal step 4 Remove Main shaft rear bolt and washer Step 6 With a standard bear ing puller begin threading the pulley off the main shaft Once the pulley has some clearance away from the rear of the alu minum housing reposition the bearing puller to the bottom of the pulley for easer removal as shown below E pi w P w F i Step 5 Screw a M10x at least 7Omm bolt into the main shaft Main shaft shown after small pulley keyway washer and bolt removal Tank main shaft seal replacement service guide Note to Service Technician This service guide is appli cable to all First Degree Products using the Multi level resistance tank which includes the following products manufactured after March of 2006 Fo
6. inum housing 2 With small drift and hammer lightly tap out and remove the rear bearing 5 Lightly tap out the mainshaft seal and re move 3 Remove Rear bearing and spacer Replacing the tank bearings 1 Clean inside of aluminum housing Add thread locker to the outside of the bearing and to the inside of the aluminum housing where the two bear ings will be located Note that the service tech will be required to rig up a tool of some kind to tap the front tank bearing in An example of the set up we use at the factory is shown be low Asimple washer and metal spacer will also work Check that the bearings are ro tating smoothly once seated in the housing 2 Replace Spacer 3 Replace rear bearing 4 Replace C clip Replacing the tank shaft seal 1 Carefully remove any residual matter silicone glue or grease from the SMC seal housing walls be fore pressing in the new seal housing 2 Apply silicone glue to the outside of the NBR tank seal prior to pressing the seal into the SMC tank back Standard fish tank grade silicone is required 3 Tap the seal into place lightly with a rubber mallet until flush with SMC The excess silicone glue will be pushed upward from the sidewall between the seal and SMC seal housing With your finger use this excess silicone to create an extra barrier by covering the an area extending approx 2cm from the outer S
7. locker to the key way before knocking into place Use a drift or heavy bladed screw driver to drive the keyway into place as shown upper right
8. r details regard ing older equipment please consult the service notes re garding the aluminum tank 1 S 500 2 UBE 3 Cycle XT 4 350 S 250 Evolution series 1 E 520 2 E 720 820 920 3 E 316 216 The service guide is for main shaft seal replacement only and assumes the tank has been removed from the machine and pulleys sprockets removed For further de tails regarding specific product tank removal and ser vice please consult the appropriate model specific sec tion of the service manual The seal replacement kit consists of the following parts 1x 10025 NBR tank shaft seal 2x 10012 6005ZZ NSK bearing 1x 10145 Bearing Spacer 1x 10186 C clip Removing the PC tank cover start by removing Polycar bonate shell Once the M3x12mm tank screws 12x have been removed use a rubber mallet and drop cloth and tap gently to break loose the outer tank seal Remove the upper section of the tank and inspect the O ring for any signs of cracking tearing or binding Replace if needed Removing the flywheel main shaft Next flip the tank back over and find a suitable location to drive the flywheel mainshaft through as pictured such as the ends of two tables workbenches or even two chairs Use a rubber mallet to drive the mainshaft through the tank back Screw a M10 bolt into the mainshaft rear to help drive the mainshaft out as shown Note The flywheel mainshaft is heavy Allow the assembly to drop onto
9. to the test machine But this tank was to provide the break through we d been seeking With less than 50 hours of usage this tank had a telltale puddle of rusty water at the rear of our E316 test unit s tank shaft We pulled it apart and discovered a rust colored stain on the inner rim of the main shaft seal Taking out the spring was a revelation Instead of our specified stainless steel spring shown middle lower right we instead dis covered a mild steel spring shown upper right that had failed due to minor corrosion This was the answer we d been seeking The slightly corroded spring could not handle the minute oscillations of the main shaft and allowed water to seep along the main shaft into the bearing housing We immediately con tacted the supplier who confirmed that this was indeed not a stainless steel spring From this date onward we have been using only stainless steel springs as we had for the first 5 years And since this date we ve not received a single warranty claim for tank failure on any product manufactured after this fault was discovered We are completely certain that this is the source of the leaking tanks and now only use stainless steel springs inside our main shaft seals We have procedures in place to prevent this happening again and apologise for the inconvenience it has caused a number of our distributors Corroded non Stainless spring quickly loses abil ity to maintain shape causing just enou
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