EA09-008 PACCAR 10/15/2009 RESPONSE 15 horton TS guide HORTON FAN CLUTCH WITH SYSTEM SENTRY™ FORM NO. L-22459-O-1293 TROUBLESHOOTING GUIDE

PROBLEM PROBABLE CAUSE SOLUTION

I. Air leaking from fan clutch 2

3 1

4 1. Bleed hole. 1. Bad face seal or air cartridge 1. Instal seal kit. 2. Air chamber. 2. Bad O-ring seals 2. Instal seal kit. 3. Come home holes. 3. Bad O-ring seals 3. Instal seal kit. 4. "System Sentry". 4. See Section II. 4. See Section II.

I II. System SentryTM Release: System Sentry will release clutch when clutch slips excessively causing abnormal heat build-up

1. Obstructed Fan 1. Loose shroud, bent fan, torn engine 1. Find and remove obstruction, repair mounts, etc. or replace damaged parts. Install seal kit.

2. Low air pressure to clutch 2. A.Restricted air line. 2. A. Replace air line. B. Restricted Solenoid. B. Replace Solenoid. C. Low system air pressure. C. Determine cause and repair. Install seal kit.

3. Excessive cycling 3. A. A/C freon overcharge. 3. A. Check and adjust to specifications. B. A/C pressure setting too low. B. Check A/C switch. C. Poor ground or wire connection. C. Check electrical connection. D. Improper temperature control setting. D. Check temperature setting of all controls. Thermal Switch setting should engage the Clutch 10 o F higher than the full open temper- ature of the thermostat. E. Faulty Thermal Switch E. Replace Thermal Switch. F. Restriction in front of radiator blocking F. Check for proper shutter opera- air flow. tion, winter front or other restric- tion in or in front of radiator.

III. Fan clutch fails to engage Electrical Problem

1. Broken circuit (Normally Open System). 1. Check electrical connections. 2. Improperly wired. 2. Check wiring according to diagram. 3. Thermal Switch incorrect (for application) 3. Check Thermal Switch (N.O. or N.C.) or defective application. Replace if wrong or defective. 4. Bad Solenoid Valve. 4. Replace Solenoid Valve.

Air Problem

1. Clutch leaking. See Section I. 1. See Section I. 2. Air supply to clutch restricted. 2. Check fittings and air lines for leaks or pinching. 3. Solenoid Valve defective . 3. Replace Solenoid Valve.

CONTINUED ON OTHER SIDE PROBLEM PROBABLE CAUSE SOLUTION

IV. Fan clutch fails to disengage

Electrical Problem

1. Broken current (Normally Closed System). 1. Check electrical connections. 2. Improperly wired. 2. Check wiring according to diagram. 3. Thermal Switch incorrect (for application) 3. Check Thermal Switch (N.O. or N.C.) or defective. application. Replace if wrong or defective.

Air Problem

1. Air line restricted, not allowing air to be 1. Check for pinching or plugging of released from Fan Clutch. air line between clutch and valve. 2. Solenoid Valve not exhausting. 2. Check for plugged exhaust port. Clean port or replace valve.

Piston Friction Disc will not return

1. Possibly seized due to contamination or 1. Clean air supply and install Super Kit. dry o-rings.

V. Fan clutch cycles frequently Electrical Problem

1. Poor ground or wire connection. 1. Check electrical connections. 2. Improper temperature control settings. 2. Check temperature settings of all controls. Thermal Switch setting o should engage Fan Clutch 10 higher than the shutter sensor. 3. A/C Pressure Switch setting too low. 3. Check A/C Pressure Switch. Use higher switch. 4. Restriction in front of radiator, blocking 4. Check shutter operation, winter fronts, air flow. or obstructions in front of radiator. 5. Faulty Thermal Switch. 5. Replace Thermal Switch.

VI. Fan clutch engaged, engine 1. Restriction in front of radiator. 1. Make sure nothing is obstructing running hot. the air flow through radiator. 2. Fan capacity not large enough. 2. Refer to Manufacturer's specs. 3. Problem in cooling system. 3. Refer to engine manual. EA09-008 PACCAR 10/15/2009 RESPONSE 15 horton-22502

Sellos

ación de ación S y HT/S y S Seal Kit

and HT/S Fan Drives and HT/S Fan

Embragues de Ventilador Tipo Ventilador de Embragues Juego de Repar de Juego

Servicing Instructions forType S Servicing Instructions forType Instrucciones de Servicio Para los Para Servicio de Instrucciones

1 English

INTRODUCTION ...... 3 PRE-INSTALLATION ...... 4 FAN CLUTCH & AIR CHAMBER REMOVAL ...6 SEAL KIT ...... 8 O-ring, Face Seal, and System Sentry® ...... 8 Cartridge Assembly...... 12 Clutch Reassembly...... 15

Horton, Inc. 2565 Walnut St. Roseville, MN 55113 1-800-621-1320 www.hortoninc.com

FACTORY/FÁBRICA: Britton, SD 57430-0050

© 2002 Horton, Inc All rights reserved. Printed in U.S.A. Todos los derechos reservados. Impreso en E.U.A. QS9000 Certified

22502-D-0302 2 INTRODUCTION Read this manual carefully, making use of its explanations. This manual describes the correct inspection, service, and repair procedures for Horton Type S and HT/S fan drives. Following the instructions carefully will provide the safest and most trouble-free operation.

Horton uses the following special notices to give warning of possible safety-related problems which could cause serious injury, and provides information to help prevent damage to equipment.

Danger is used to indicate the presence of a hazard which will cause severe personal injury, death, or substantial property damage if the warning is ignored.

Denotes that a potential hazard exists and indicates procedures that must be followed exactly to either eliminate or reduce the hazard, and to avoid serious personal injury, or prevent future safety problems with the vehicle.

Caution is used to indicate the presence of a hazard which will or can cause minor personal injury or property damage if the warning is ignored. NOTE Advises of operation, procedure, or instruction that is inserted for correct service providing greater owner satisfaction. A note can also provide information that will make service quicker and easier. 3 PRE-INSTALLATION You must follow your company safety practices, which should adhere to or be better than Federal or State approved shop safety practices and procedures. Be sure that you understand all the procedures and instructions before you begin work on this unit. NOTE Parts replacement and/or repair of your Horton fan drive should be performed only by the Horton Factory or an authorized Horton Distributor or Dealer to keep your warranty coverage intact during the warranty period.

NOTE In the following sections, an O-Ring is used for the Piston Friction Disc if you have purchased a Minor Seal Kit. The PolarExtremeTM Seal Kit contains a D-Ring for the Piston Friction Disc.

4 5 FAN DRIVE AND AIR CHAMBER REMOVAL

1. Verify the fan drive model and that correct replacement parts fit this model.

2. Remove the fan drive from the engine. Lay the fan drive assembly in a vise and clamp the Journal Bracket tight.

3. Remove the Torx® Socket Head Cap Screws from the Air Chamber.

NOTE Applying a small amount of air pressure to the fan drive air inlet will aid in removal of the Air Chamber Assembly from the fan drive.

Apply air pressure slowly so that the Air Chamber will not pop off quickly, resulting in serious personal injury.

4. Slide the Air Chamber Assembly off the Piston Friction Disc.

5. Examine the inside of the Air Chamber for signs of dirt and foreign material. The Air Chamber should be clean and dry. If not, a problem may exist in the vehicle air system and must be corrected before the fan drive is reinstalled. 6 Torx® Socket Head Air Chamber Cap Screw

Steps 1-5 Piston Friction Disc

7 Minor Seal Kit and Polar Extreme Seal Kit O (D)-Ring, Face Seal and System Sentry® 1. Remove the O-ring from the Air Chamber and clean the O-ring contact surfaces. 2. Inspect the Face Seal for signs of wear that may indicate dirt exists in the air system.

If dirt or oil exists in the air system, the air system must be cleaned and dried before the fan drive is reinstalled. 3. Remove the Piston Friction Disc and clean the splines of both the Piston Friction Disc and the Splined Hub. 4. Check the System Sentry® for visual signs of melting. If your fan drive is not equipped with a System Sentry®, Horton recommends that the Piston Friction Disc is replaced with a System Sentry® PFD for proper, safe operation.

NOTE If for any reason, excessive heat is building up in the fan drive, the System Sentry® will release and create an air open air passage. This shuts down the system to prevent any further damage.

5. When replacing the System Sentry® be sure to loosen it in the correct direction. It is a left hand thread and needs to be turned clockwise for removal. 8 Air Chamber

Face Seal O-Ring

Steps 1-2

Splined Hub

Journal Bracket

Step 3 Piston Friction Disc

Allen Head Torx® Head ® System Sentry System Sentry®

Piston Friction Counter Disc Balance

System Sentry® Steps 4-6 9 NOTE Your System Sentry® may have an Allen head or a Torx® head. The glove box Torx® head tool (part number 994365) was designed with a 30 and 40 Torx® end. The 30 Torx® end will work in the removal and installation of the 3/16 Allen head System Sentry®. The 40 Torx® end will work in the removal and installation of the 40 Torx® System Sentry® or lock-up bolts. The System Sentry® has left hand threads.

Do not replace the System Sentry® with a straight plug. The Piston Friction Disc is balanced and anything other than the Horton System Sentry® will upset the balance and could void warranty. 6. Install the new System Sentry®. 7. Using the small brush supplied in the repair kit, apply an even coating of spline lubricant (also supplied in the repair kit) to both splined areas of the Piston Friction Disc and Hub. 8. Install the Piston Friction Disc. 9. Replace the Face Seal and tighten the Face Seal to 50 In. Lbs. [5.7 N•m] torque. NOTE If the Face Seal is round (NOT HEX. SHAPE) it is considered an obsolete part and a new Air Chamber, with a threaded Face Seal must be used to replace it. 10. Lubricate the new O-ring and O-ring contact surfaces with the fresh O-ring lubricant supplied 10 Piston Friction Lubricate Disk

Brush

Step 7-8 Hub

Air Chamber

O-Ring Face Seal

Apply O-Ring Steps 9-10 Lubricant

11 11. Remove the O-ring from the Piston Friction Disc and clean the O-ring contact surfaces.

12. Lubricate the new D (O)-ring and D (O)-ring contact surfaces with the fresh lubricant supplied in the kit; then, install the new D (O)-ring onto the Piston Friction Disc. NOTE The entire tube of the lubricant should be used when lubricating the new D (O)-rings and D (O)- ring contact surfaces. Extra lubricant may be placed in the bottom of the Air Chamber. A slight amount of lubricant will be needed for the O-rings on the Cartridge Assembly. Cartridge Assembly

Wear safe eye protection when removing Retaining Rings to prevent serious eye injury.

1. Remove the Retaining Ring. 2. Remove the Cartridge Assembly and, if applicable, the U-cup. Clean the Journal Bracket bore if necessary.

The Cartridge Assembly shown in Step 2 is an older style brass Cartridge. The new Cartridge Assembly does not use the U-cup Seal. Make sure you DISCARD the U-cup Seal upon installation of this new style Cartridge. 12 Piston Friction Disc D -(O) D-Ring Ring

Steps 11-12

Retaining Ring

Step 1

Carbon Tip Carbon Tip Brass Cartridge

O-Ring

Retaining Ring Cartridge Assembly U-Cup Step 2 13 3. Apply O-ring lubricant to the outside O-rings of the new Cartridge and install the new Cartridge Assembly into the Journal Bracket; then, reinstall the Retaining Rings to hold the new Cartridge Assembly in tight.

The Retaining Ring must be fully seated in the retaining ring groove to keep the Cartridge Assembly from moving. Also, the Retaining Ring is beveled. The curved side must be installed facing the Cartridge.

4. Clean both the Carbon Tip of the Cartridge Assembly and also the Face Seal of the Air Chamber Assembly to make sure they are free of lubricants and dust. Retaining Ring O-Rings The curve faces the Cartridge Step 3

Retaining Cartridge Ring Assembly

Step 3 Step 4 Carbon Tip 14 Clutch Reassembly

All fan drive components must be cleaned and free of all rust and foreign material prior to reassembly. Extreme care must be exercised when replacing the Air Chamber to avoid damage to the O-rings. 1. Install the Air Chamber onto the Piston Friction Disc. 2. Install the new Torx® Socket Head Cap Screws by alternately and evenly tightening to 180 In. Lbs. [20.3 N•m] torque. 3. Install the Umbrella Check Valve into the Air Chamber bleed hole by pressing it into place with your thumb. 4. Apply 90 to 120 PSI of clean air to the air inlet of the fan drive to check for proper engagement of the Piston Friction Disc and friction material.

If a problem exists, it must be corrected prior to mounting the fan drive onto the vehicle. If the problem is not corrected, the fan drive will fail prematurely.

Umbrella ® Check Valve Torx Socket Air Chamber Head Cap Screw Step 1-4 15 Español

INTRODUCCIÓN ...... 17 INSTALACIÓN PREVIA ...... 18 EXTRACCIÓN DEL EMBRAGUE Y DE LA CÁMARA DEL AIRE ...... 20 JUEGO MENOR DE SELLADO...... 22 O-rings, sello de superficie y fusible térmico System Sentry® ...... 22 Conjunto del cartucho...... 26 Reensamblado del embrague...... 29

Horton, Inc. 2565 Walnut St. Roseville, MN 55113 1-800-621-1320 www.hortoninc.com

FACTORY/FÁBRICA: Britton, SD 57430-0050

© 2002 Horton, Inc All rights reserved. Printed in U.S.A. Todos los derechos reservados. Impreso en E.U.A. QS9000 Certified

22502-D-0302 16 INTRODUCCIÓN Lea detenidamente este manual; asegúrese de aplicar todas las explicaciones. Este manual describe los procedimientos correctos para inspeccionar, mantener y reparar los embragues de ventilador tipo S y HT/S. Seguir cuidadosamente las instrucciones proporcionará un funcionamiento seguro y sin problemas.

Horton utiliza los siguientes avisos especiales para advertir sobre posibles problemas de seguridad que podrían producir heridas de gravedad y para proporcionar información para prevenir daños al equipo.

Se utiliza para indicar la presencia de un peligro que podría producir heridas graves, mortales o daños serios a la propiedad.

Se utiliza para indicar la presencia de un peligro potencial y para indicar exactamente los procedimientos que deben seguirse para eliminar o reducir el peligro y para evitar heridas personales graves, o prevenir futuros problemas de seguridad relacionados con el vehículo. 17 PRECAUCION Se utiliza para indicar la presencia de un peligro que puede o podría producir heridas personales leves o daño a la propiedad. NOTA Se utiliza para dar sugerencias relacionadas con la operación, procedimiento o instrucción para el mantenimiento correcto, lo cual brinda al propietario mayor satisfacción. Una nota también puede proporcionar información que hará más fácil y más rápido el mantenimiento.

INSTALACIÓN PREVIA

Se deben seguir las normas de seguridad de la compañía, las cuales deben ser iguales o mejores que las normas establecidas por el gobierno federal o estatal para talleres de reparación. Asegúrese de entender todas las instrucciones y procedimientos de instalación antes de comenzar a trabajar con esta unidad.

18 NOTA La reparación o cambio de piezas del embrague de ventilador Horton durante el periodo de garantia, debe ser realizada sólo por la Fábrica Horton o por un concesionario o distribuidor Horton, a fin de no anular la garantía. NOTA

En las siguientes secciones un anillo “O” (O ring) se utiliza en el pistón del disco de fricción si usted ha comprado un kit menor de sellado. El PolarExtreme kit de sellado contiene un anillo “D” (D ring) para el pistón del disco de fricción.

19 EXTRACCIÓN DEL EMBRAGUE Y DE LA CÁMARA DEL AIRE 1. Verifique el modelo de embrague y que los repuestos sean adecuados para el mismo.

2. Desmonte el embrague del motor. Póngalo en un tornillo de banco y apriételo por el soporte del muñón.

3. Retire los tornillos Torx® de la cámara del aire.

NOTA Aplicar una pequeña presión de aire a la entrada de aire del embrague ayuda a la extracción de la cámara del aire del embrague.

La presión de aire debe aplicarse lentamente para que la cámara no salte repentinamente y cause heridas graves.

4. Quite la cámara de aire del disco de fricción del pistón.

5. Examine el interior de la cámara para verificar que no haya indicios de suciedad o materias extrañas. La cámara siempre debe estar limpia y seca, si no lo está, puede haber una falla en el sistema del aire del vehículo que debe

20 repararse antes de reinstalar el embrague. Tornillo Torx® Cámara del aire

Disco de fricción del Pasos 1-5 pistón

21 O- ring sello de superficie y fusible térmico System Sentry® 1. Retire el O-ring de la cámara de aire y limpie sus superficies de contacto. 2. Inspeccione el sello de superficie para verificar que no haya indicios de desgaste que pudieran indicar presencia de suciedad en el sistema de aire del vehículo.

Si hay suciedad o aceite en el sistema de aire, limpiar y secar el sistema antes de reinstalar el embrague. 3. Retire el disco de fricción del pistón y limpie las estrías del disco y de la maza estriada. 4. Verifique que el fusible térmico System Sentry® JUEGO MENOR DE SELLADO NOTA Si por alguna razón se está acumulando calor excesivo en el embrague, el fusible térmico System Sentry® se activará y creará una fuga de aire. Esto detiene el sistema para prevenir daños de mayor consideración. 5. Al cambiar el fusible térmico System Sentry®, asegúrese de aflojarlo en la dirección correcta. Tiene rosca izquierda y para sacarlo, hay que girarlo a la derecha.

22 Cámara del aire

Sello de O-Ring superficie

Pasos 1-2

Maza Soporte de estriada muñón

Disco de fricción Paso 3 del pistón

Fusible térmico Fusible térmico System System Sentry® con cabeza Torx® Sentry® con Disco de cabeza Allen fricción del pistón

Contrapesos Fusible térmico System Pasos 4-6 Sentry® 23 NOTA El fusible térmico System Sentry® puede tener una cabeza tipo Allen o Torx®. La herramienta Torx® adjunta, tiene un extremo con Torx® 40 y el otro con 30. El de 30 servirá para montar y desmontar el fusible térmico System Sentry® con cabeza Allen de 3/16. El de 40 servirá para el fusible térmico System Sentry® con cabeza Torx® 40 o sus pernos de ajuste.

No reemplace el fusible térmico por un tapón corriente pues el disco de fricción está balanceado sólo para el fusible térmico System Sentry® de Horton. Cualquier otro alterará el balance del sistema y podría anular la garantía.

6. Instale el fusible térmico System Sentry® nuevo. 7. Use el cepillo pequeño que viene con el juego de reparación para aplicar una capa uniforme de lubricante para estrías (que también viene con el juego) a las superficies estriadas del disco de fricción y de la maza. 8. Instale el disco de fricción del pistón. 9. Cambie el sello de superficie y apriételo a un par de 50 lb- pulg [5.7 Nm].

NOTA Si el sello de superficie es redondo (NO EN FORMA HEXAGONAL) se considera una pieza obsoleta y se debe reemplazar la cámara del aire por una que tenga un sello de superficie con rosca.

10. Lubrique el nuevo O-ring y sus superficies de contacto con el lubricante que viene con el juego, y luego instálelo en la cámara del aire.

24 Disco de fricción Lubricar del pistón

Cepillo

Maza Paso 7

Cámara de aire Sello de superficie O-Ring

Aplique lubricante para O-ring Pasos 9-10

25 11. Retire el O-ring del disco de fricción del pistón y limpie sus superficies de contacto. 12. Aplique lubricante a los O-rings externos del cartucho nuevo e instale el nuevo cartucho en el soporte de muñón; luego, vuelva a instalar los anillos de retención para sujetar el nuevo conjunto. NOTA Se debe utilizar todo el tubo de lubricante para lubricar los D (O)-rings y sus superficies de contacto. Puede aplicar más lubricante al fondo de la cámara de aire. Se necesitará una pequeña cantidad de lubricante para los O-rings del conjunto del cartucho. Conjunto del cartucho

Antes de extraer los anillos de retención, póngase gafas de seguridad para evitar dañarse los ojos ante un posible accidente. 1. Retire el anillo de retención. 2. Retire el conjunto del cartucho y, de ser necesario, la copa en U. Limpie la cavidad del soporte de muñón si es pertinente. El cartucho que se muestra en el Paso 2 es un modelo antiguo de bronce. Los cartuchos modernos no requieren de un sello de copa en U. Asegúrese de DESECHAR la copa en U al instalar este nuevo tipo de cartucho. 26 Disco de fricción del D (O)- pistón Ring D-Ring

Pasos 11-12

Anillo de retención

Paso 1

Punta de carbón Punta de carbón Cartucho de bronce O-Ring

Anillo de retención Conjunto del cartucho Paso 2 Copa 27 3. Aplique lubricante a los O-rings externos del cartucho nuevo e instale el nuevo cartucho en el soporte de muñón; luego, vuelva a instalar los anillos de retención para sujetar el nuevo conjunto. PRECAUCION El anillo de retención debe asentarse correctamente en la ranura para evitar que se mueva el cartucho. Además, el retén es achaflanado y el extremo curvo debe instalarse contra el cartucho. 4. Limpie la punta de carbón del cartucho y el sello de superficie del conjunto de la cámara del aire para asegurarse de que estén libres de polvo o lubricante. Anillo de retención O-Rings La curvatura debe enfrentar al Paso 3 cartucho

Anillo de retención Conjunto del cartucho

Punta de carbón Paso 3 Paso 4 28 Reensamblado del embrague PRECAUCION Todos los componentes del embrague deben estar libres de polvo, de óxido y de materias extrañas antes de su reensamblado.

Se debe tener mucho cuidado al reinstalar la cámara del aire para evitar que se dañen los O-rings. 1. Instale la cámara del aire en el disco de fricción del pistón. 2. Instale los nuevos tornillos Torx® apretándolos en forma alternada y uniforme a un par de 180 lb-pie [20.3 Nm]. 3. Instale la nueva válvula de retención (en “paraguas”) en el agujero de purga de la cámara del aire empujándola con el pulgar. 4. Aplique aire limpio a una presión de 90 a 120 PSI a la entrada de aire del embrague de ventilador, para comprobar el embrague adecuado del disco de fricción del pistón y el material de fricción. PRECAUCION Si existe una falla, ésta debe repararse de inmediato y en forma previa al montaje del embrague en el vehículo. Si no se repara, el embrague fallará prematuramente. ® Válvula de Tornillo Torx retención (en “paraguas”) Cámara del aire

Pasos 1-4 29 n de Sellos ó Menores Minor Seal Kit Servicing Instructions for Type S and HT/S Fan Drives S and HT/S Fan Type Juego de Reparaci de Juego Instrucciones de Servicio Para los Instrucciones de Servicio Para

30 tipo S y HT/S Ventilador de Embragues EA09-008 PACCAR 10/15/2009 RESPONSE 15 horton-22593 HORTON S & HT/S FAN DRIVE REPAIR KIT AND REPAIR KIT INSTALLATION INSTRUCTIONS

INSTRUCCIONES PARA LA INSTALACIÓN DE JUEGOS DE REPARACIÓN HORTON S & HT/S Y JUEGO DE REPARACIÓN

EN EMBRAGUES DE VENTILADOR HORTON TIPO S & HT/S INTRODUCTION ...... 2 General Information ...... 2 PRE-INSTALLATION ...... 3 PREVENTIVE MAINTENANCE ...... 4 Vehicle Preparation ...... 4 Each Week ...... 4 Every 25,000 Miles (40,000 KM) ...... 4 FAN DRIVE AND AIR CHAMBER REMOVAL ...... 5 REPAIR KIT ...... 5 O-Ring and Face Seal ...... 5 Hub Removal ...... 6 Sheave and Sheave Bearing ...... 7 Friction Facing ...... 9 Sheave and Hub Reassembly ...... 9 System Sentry® and Piston Friction Disc Reassembly ...... 10 Air Cartridge and O-Ring Replacement ...... 12 Air Chamber Reassembly ...... 13 FAN DRIVE INSTALLATION ...... 14 TROUBLESHOOTING ...... 15 HT/S FRICTION FACINGS ...... 17 REPAIR KITS FOR SPECIAL SHEAVE BEARING CONFIGURATION ...... 18 PARTS LISTS ...... 19-21 TORQUE SPECIFICATIONS ...... 21

INTRODUCTION General Information

Read this manual carefully, making use of its explanations. This manual describes the correct Inspection, Service, and Repair procedures for Horton Type S and HT/S Fan Drives. Following the instructions carefully will provide the safest and most trouble- free operation. Horton uses the following special notices to give warning of possible safety related problems which could cause serious injury and provide information to help prevent damage to equipment.

Danger is used to indicate the presence of a hazard which will cause severe personal injury, death, or substantial property damage if the warning is ignored.

Warning is used to indicate the presence of a hazard which can cause severe personal injury, death, or substantial property damage if the warning is ignored.

Caution is used to indicate the presence of a hazard which will or can cause minor personal injury or property damage if the warning is ignored.

NOTE Note is used to notify people of installation, operation, or maintenance information which is important but not hazard related. 22593-G-0602 2 PRE-INSTALLATION

You must follow your company safety practices, which should adhere to or be better than Federal or State approved shop safety practices and procedures. Be sure that you English understand all the procedures and instructions before you begin work on this unit.

NOTE Parts replacement and/or repair of your Horton Fan Drive should be performed only by an authorized Horton Distributor or Dealer to keep your warranty coverage intact during the warranty period.

After installation of your Horton Fan Drive, note the Fan Drive Serial No., Service Part No., Date of Installation, and Vehicle Mileage.

Serial No.

Service Part No.

Installation Date

Vehicle Mileage

Drive Type: HT/S S 9'' SP

NOTE One easy way to distinguish an S-type from an HT/S drive or 9'' Single Plate drive is to measure the diameter of the Piston Friction Disc. Another way is to note the first four digits in the Part No.

Part Number and Serial Number is pin-stamped on Air Chamber

7.5” 9.0” 9.5” [191 mm] [229 mm] [241 mm]

S Type 9” Single Plate HT/S Type 5900XX 9908XX 5910XX 7900XX 7910XX 9900XX 9910XX 9901XX 9911XX 9912XX 9913XX 997XXX 22593-G-0602 3 PREVENTIVE MAINTENANCE Vehicle Preparation

Before performing tests on the Fan Drive, be sure to follow good shop safety practices and: • Apply the vehicle’s parking brake. • Block the vehicle’s wheels. Before doing work in the area of the fan: • Start the vehicle’s engine and build air pressure in excess of 90 PSI. • Observe the fan and Fan Drive from a distance, look for vibration, fan blade contact, Fan Drive slippage, and Fan Drive operation. • Turn engine off.

Be sure engine is turned off and fan has stopped turning before approaching Eachfan area Week to prevent serious personal injury. Each Week

Drain Air Filter (if equipped). • If moisture or contamination is detected, the filter must be disassembled and flushed thoroughly with clean parts solvent. • Dry carefully before reassembly. • Determine the cause of the moisture or contamination and correct the condition.

Every 25,000 Miles (40,000 KM)

Air Leaks NOTE Air leaks will cause System Sentry® and/or bearing failure if left unattended. A. Check for air leaks around the Air Chamber and bleed hole. Install a new seal kit if a leak exists.

Fan and Fan Belt Problems NOTE Can cause bearing failure if left unattended. A. Check fan for looseness and damage such as bent, cracked or missing blades, loose rivets or missing weights. Retorque if loose. Replace damaged. B. Check for adequate clearance, according to manufacturer's specifications, between the fan and fan shroud or other engine compartment components. Repair if clearance is inadequate. C. Check fan belt condition, belt tension and belt alignment. Correct if necessary. Friction Facing A. Check for wear condition. Replace when worn to 1/16’’ (1.58 mm) thick, oil spotted, or if burn marks are visible.

22593-G-0602 4 FAN DRIVE AND AIR CHAMBER REMOVAL

When installing a Major Repair Kit, make sure the Fan Drive being rebuilt has ® ® a System Sentry . If the Fan Drive does not have a System Sentry you must English use a Super Kit. 1. Verify the Fan Drive model and that correct replacement parts have been obtained. 2. Remove the Fan Drive from the engine. Lay the Fan Drive assembly in a vise and clamp the Journal Bracket tight. 3. Remove the Torx® Socket Head Cap Screws from the Air Chamber.

NOTE Applying a small amount of air pressure to the air inlet will aid in removal of the Air Chamber Assembly from the Fan Drive.

Apply air pressure SLOWLY so that the Air Chamber will not pop off quickly, resulting in serious personal injury. 4. Slide the Air Chamber Assembly off the Piston Friction Disc. 5. Examine the inside of the Air Chamber for signs of dirt and foreign material. The Air Chamber should be clean and dry. If not, a problem may exist in the vehicle air system and must be corrected before the Fan Drive is reinstalled.

Torx® Socket Head Air Chamber Cap Screw

Piston Steps 1-5 Friction Disc

REPAIR KIT O-Ring and Face Seal

1. Remove the O-Ring from the Air Chamber and clean the O-Ring contact surfaces. 2. Inspect the Face Seal for signs of wear that may indicate dirt exists in the air system.

22593-G-0602 5 If dirt or oil exists in the air system, the air system must be cleaned and dried before the Fan Drive is reinstalled. 3. Replace the Face Seal and tighten the Face Seal to 50 In. Lbs. [5.7 N•m]. NOTE If the Face Seal is round (NOT HEX SHAPE) it is considered an obsolete part and a new Air Chamber with a threaded Face Seal must be used to replace it. 4. Lubricate the new O-Ring and O-Ring contact surfaces with the fresh O-Ring lubricant supplied in the kit. Install the new O-Ring into the Air Chamber. 5. Set aside for reassembly later.

Face Air Chamber Seal

O-Ring

Steps 1-5

Hub Removal

1. Remove and discard Locknut from Journal Bracket. NOTE If the Piston Friction Disc does not have a System Sentry®, a Super Kit must be used to rebuild the Fan Drive.

Locknut

Step 1

2. Remove the Piston Friction Disc from the Splined Hub Assembly. Discard the Piston Friction Disc if rebuilding with a Super Kit or if the Piston Friction Disc is not equipped with a System Sentry®. 3. Remove and discard the Splined Hub Assembly from the Journal Bracket. 22593-G-0602 6 Piston Friction Seal Disc (Advantage only) Journal Bracket English

Spacer (Advantage only)

Splined Hub

Steps 2-3

Sheave and Sheave Bearing

NOTE Some Models of S and HT/S Type Fan Drives have been designed to accept a special sheave bearing arrangement.

In these clutches the two standard sheave bearings and optional spacers have been replaced with one double row angular contact ball bearing.

Standard repair kits will NOT work in these units. Bearing configurations are NOT interchangeable. Ensure that you have the correct repair kit.

See REPAIR KITS FOR SPECIAL SHEAVE BEARING CONFIGURATION section of this manual on Page 18.

1. Remove and save the Journal Spacer.

Journal Spacer

Step 1

2. Slide the Sheave and bearing assembly off the Journal Bracket.

Journal Bracket Sheave

Step 2

22593-G-0602 7 3. Fully support the Sheave and press the Bearing(s) out of the Sheave. NOTE Some Models of S and HT/S Type Fan Drives contain Sheave Bearing Spacers.

Both of these must be positioned BETWEEN the Sheave Bearings when the Sheave Bearings are replaced.

All Bearings are prelubricated and sealed. DO NOT remove the seals to lubricate the Bearings.

Standard Sheave Bearings Double Row SheaveBearing

PRESS TO PRESS TO Sheave REMOVE Sheave REMOVE

SUPPORT SUPPORT

SUPPORT Bearings SUPPORT Double Row Sheave Bearing Step 3

4. Fully supporting the Sheave, press the new Sheave Bearing(s) into place, noting the position of the lip inside the Sheave.

Standard Sheave Bearings Double Row SheaveBearing

Sheave Sheave

Bearings

Bearing Double Row Spacers Bearing

NOTE POSITION NOTE POSITION OF LIP OF LIP

SUPPORT SUPPORT POINTS POINTS

PRESS PRESS

Step 4

22593-G-0602 8 Friction Facing

1. Replace the Friction Facing. 2. Remove the Torx® Button Head Cap Screws (Size T-25) and the old Friction Facing. English 3. Install the new Friction Facing. NOTE Make sure the tapped Lock-Up holes in the Sheave are aligned with the Lock- Up holes in the new Friction Facing.

4. Alternately and evenly tighten the Torx® Button Head Cap Screws (Size T-25) to 35-40 In. Lbs. [4-4.5 N•m].

Friction Facing

Torx® Button Head Cap Screws Steps 1-4

Sheave and Hub Reassembly

NOTE For Advantage Fan Drives or a Fan Drive which has been rebuilt with an Advantage Repair Kit, discard the Spacer (Item 14, Page 20,21) and Front Hub Bearing Seal (Item 25, Page 20,21). The updated hub assembly included with your new kit does not require and will not work with the Spacer or Seal listed above. 1. Slide the Sheave onto the Journal Bracket.

Journal Bracket

Step 1 Sheave NOTE The Journal Spacer Lip must face towards the front of the Fan Drive. 2. Reinstall the Journal Spacer.

Journal Spacer Lip

Journal Spacer

Step 2

22593-G-0602 9 3. Clean the Splined Hub and lubricate the splines with the enclosed anti- seize and brush. 4. Install the Spacer enclosed in the repair kit. 5. Slide the Splined Hub onto the Journal Bracket.

Journal Piston Bracket Friction Disc

Splined Hub

Spacer Steps 3-5

NOTE All Horton Repair Kits come with an enhanced Hub and Bearing Assembly which may appear different from the original configuration. The Spacer in this Kit ensures that the Hub Assembly will be properly aligned when assembled. See the diagram on Page 17 for more information.

System Sentry® and Piston Friction Disc Reassembly

Make sure the Piston Friction Disc is equipped with a System Sentry®. If not, a Super Kit, which contains the System Sentry® style Piston Friction Disc, must be used. Replace the System Sentry® when using a Major Kit.

1. Check the System Sentry® for visual signs of melting.

NOTE If for any reason excessive heat is building up in the Fan Drive, the System Sentry® will release and create an air leak. This shuts down the system to prevent any further damage.

Troubleshooting the Fan Drive and Controls should be done promptly to locate the cause of the System Sentry® release. Refer to the TROUBLESHOOTING section of this manual for possible causes and remedies for system problems.

2. When replacing the System Sentry®, be sure to loosen it in the correct direction. It is a left-hand thread and needs to be turned clockwise for removal.

Do not replace the System Sentry® with a straight plug. The Piston Friction Disc is balanced and anything other than the Horton System Sentry® will upset the balance.

22593-G-0602 10 3. Install the new System Sentry®. Torque to 40-50 inch-lbs (4.5-5.6 N·m)

Allen Torx® Head Head System System English Sentry® Sentry

Counter Piston Balance Friction Disc

Dust Seal System Sentry® Step 3 NOTE PFD supplied with PolarExtreme kits will vary from illustration.

Failure to troubleshoot and correct the failed system component(s) may result in recurring System Sentry® releases. 4. Troubleshoot and correct the failed system component(s) (See Page 15-17). 5. Clean the Piston Friction Disc and lubricate the splines with the enclosed anti-seize and brush. 6. Slide the Piston Friction Disc onto the Splined Hub.

Piston Friction Journal

Splined Hub Spacer Steps 5-6 7. Replace and tighten the Locknut to 150 Ft. Lbs. [203 N•m].

Locknut

Step 7

NOTE PFD supplied with PolarExtreme kit will vary from Illustration.

22593-G-0602 11 Air Cartridge and O-Ring Replacement

Wear safe eye protection when removing Retaining Rings to prevent serious eye injury. 1. Remove the Retaining Ring.

Retaining Ring

Step 1 2. Remove the Cartridge Assembly and, if applicable, the U-cup. Clean the Journal Bracket bore if necessary.

Air Carbon Carbon Cartridge Tip Tip Retaining Assembly Brass Ring Cartridge

O-Ring

U-Cup Step 2

IMPORTANT The Cartridge shown in Step 2 is an older style brass Cartridge. The new Cartridge Assembly does not use the U-cup Seal. Make sure you DISCARD the U-cup Seal upon installation of this new style Cartridge. 3. Apply O-Ring lubricant to the outside O-Rings of the new Cartridge and install the new Cartridge Assembly into the Journal Bracket. Install the Retaining Ring to hold the new Cartridge Assembly in tight.

Air Carbon Cartridge Tip Assembly

Step 3

22593-G-0602 12 The Retaining Ring must be fully seated in the retaining ring groove to keep the Cartridge Assembly from moving. Note that the Retaining Ring is beveled. The curved side must be installed facing the Cartridge. English

Retaining Retaining Ring Ring O-Rings

The curve faces the Cartridge

Caution NOTE A D-Ring will be supplied with PolarExtreme Kits which is used in place of the O- Ring. Piston Friction Disc O-Ring / D-Ring

D-Ring

Step 4 4. Lubricate the new O-Ring and O-Ring contact surfaces with the fresh lubricant supplied in the kit. 5. Install the new O-Ring onto the Piston Friction Disc. If you have a PolarExtreme kit, make sure the D-Ring is placed in the groove as shown to ensure proper operation (see Step 4) NOTE The entire tube of the lubricant should be used when lubricating the new O-Ring and O-Ring contact surfaces of the Air Chamber and Piston Friction Disc. Air Chamber Reassembly

Extreme care must be exercised when replacing the Air Chamber to avoid damage to the O-Ring. 1. Install the Air Chamber onto the Piston Friction Disc carefully to avoid damage to the dust seal. Use a smooth instrument, if required, to aid in A/C installation. 2. Dust Seal only comes in Super Kit format at this time. 3. Install then, alternately and evenly tighten the Torx® Socket Head Cap Screws to 180 In. Lbs. [20.3 N•m]. 4. Install the Umbrella Check Valve into the Air Chamber bleed hole by pressing it into place with your thumb. 22593-G-0602 13 5. Apply 90 to 120 PSI [10.1 - 13.5 Bar] of clean air to the air inlet of the Fan Drive to check for proper engagement of the Piston Friction Disc and friction material.

Umbrella Torx® Socket Head Check Cap Screw Valve

Air Chamber

Dust Seal Steps 1-5

If a problem exists, it must be corrected prior to mounting the Fan Drive onto the vehicle. If the problem is not corrected, the Fan Drive will fail prematurely.

FAN DRIVE INSTALLATION

1. Using SAE Grade 8 bolts, secure the Fan Drive to the vehicle engine. 2. Tighten the SAE Grade 8 mounting bolts to the vehicle manufacturer’s specifications. 3. Check for proper air pressure to the Fan Drive. NOTE To check the air pressure to the Fan Drive, a gauge should be placed at the air inlet of the Fan Drive. Pressure should measure between 90 and 120 PSI [10.1 - 13.5 Bar]. This will assure maximum torque capacity of the Fan Drive and prevent damage to the Fan Drive due to low air pressure. 4. Replace and adjust the belts according to the manufacturer’s specifications.

Correct belt adjustment and alignment is necessary for all belt driven components to assure longevity of component life. Over tightening of belts will shorten Fan Drive bearing life. Loose belts will cause excessive belt wear. Consult vehicle or equipment manufacturer specifications for proper belt adjustment. 5. Mount the fan blade onto the Fan Drive and tighten the nuts to the vehicle manufacturer’s

Maximum metal fan diameter for S and HT/S Type Fan Drive is 28” and 32” respectively. If a larger fan diameter is required, contact Horton.

22593-G-0602 14 6.Check for proper Fan Drive engagement and disengagement.

Insure that all areas around the fan, fan shroud, and pulley are clear, all fasteners are securely tightened, and that the fan can rotate freely. English

TROUBLESHOOTING

PROBLEM PROBABLE CAUSE SOLUTION

I. Air leaking from 3 Fan Drive. 1

2

4 1. Bleed hole. 1. Bad face seal or air 1. Install seal kit. cartridge. 2. Air chamber. 2. Bad O-Ring seals. 2. Install seal kit. 3. Come home holes. 3. Bad O-Ring seals. 3. Install seal kit. 4. System Sentry®. 4. See Section (Below). 4. See Section II (Below).

II. System Sentry® Release

System Sentry® will release Fan Drive when Fan Drive slips excessively causing abnormal heat build-up.

1. Obstructed fan. 1. Loose shroud, bent 1. Find and remove fan, torn engine obstruction, repair or mounts, etc. replace damaged parts. Install seal kit. 2. Low air pressure 2. a.Restricted air line. 2. a.Replace air line. to Fan Drive. b.Restricted b.Replace Solenoid Solenoid Valve. Valve. c.Low system air c.Determine cause and pressure. repair. Install seal kit. 3. Excessive cycling. 3. a.A/C refrigerant 3. a.Check and adjustto overcharge. specifications. b.A/C pressure switch b.Check A/C switch. setting too low. c.Poor ground or wire c.Check electrical connection. connections. d.Improper tempera- d.Check temperature ture control setting. setting of all controls. (Thermal Switch setting should engage the Fan Drive 10o F higher than the full open tempera- ture of the thermostat.)

22593-G-0602 15 PROBLEM PROBABLE CAUSE SOLUTION

II. Continued e. Faulty Thermal e.Replace the Thermal Switch. Switch. 3. Excessive cycling f. Restriction in front of f. Check for proper shutter radiator blocking air operation, winter front or flow. other restriction in or in front of the radiator. Install Seal Kit.

III. Fan Drive fails to Electrical Problem engage 1. Broken circuit (Normally 1. Check electrical Open system). connections. 2. Improperly wired. 2. Check wiring according to diagram. 3. Thermal Switch incorrect 3. Check Thermal Switch for application. (N.O. or N.C.) application. Replace if wrong or defective. 4. Bad Solenoid Valve. 4. Replace the Solenoid Valve.

Air Problem 1. Fan Drive leaking 1. See Problem I. (See Problem I). 2. Air supply to Fan Drive 2. Check fittings and air restricted. linesforleaksor pinching. 3. Solenoid Valve defective. 3. Replace the Solenoid Valve.

IV. Fan Drive fails to Electrical Problem disengage 1. Broken circuit (Normally 1. Check electrical Closed system). connections. 2. Improperly wired. 2. Check wiring according to diagram. 3. Thermal Switch incorrect 3. Check Thermal Switch(N.O. or N.C.)application. Replace if wrong or defective.

Air Problem 1. Air line restricted, not 1. Check for pinching or allowing air to be released plugging of air line from the Fan Drive. between Fan Drive and 2. Solenoid Valve not Solenoid Valve. exhausting. 2. Check for plugged exhaust port on the Solenoid Valve. Clean or replace the Solenoid Valve.

Piston Friction Disc will not return 1. Possiblyseized dueto 1. Clean the air supply and contamination or dry install a Super Kit. O-Ring seals.

22593-G-0602 16 PROBLEM PROBABLE CAUSE SOLUTION

V. Fan Drive cycles Electrical Problem frequently, see Problem II, #3. 1.Poor ground or wire 1. Check electrical connec- English connection. tions. 2. Improper temperature 2. Check temperature control settings. setting of all controls. (Thermal Switch setting should engage the Fan Drive 10o F higher than the full shutter sensor.) 3. A/C Pressure Switch 3. Check A/C Pressure setting too low. Switch. Use higher switch. 4. Restriction in front of 4. Check shutter operation, radiator, blocking air winter fronts, or obstruc- flow. tion in front of radiator. 5. Faulty Thermal Switch. 5. Replace the Thermal Switch. 6. Faulty Air-Temp Switch. 6. Replace the Air-Temp Switch.

VI. Fan Drive engaged, 1. Restriction in front of 1. Make sure nothing is engine running hot. radiator. obstructing the air flow through the radiator. 2. Fan capacity not large 2. Refer to Manufacturer’s enough. specs. 3. Problem in cooling 3. Refer to engine manual. system.

HT/S FRICTION FACINGS

Some Horton HT/S Fan Drives require a special Friction Facing. Below is a diagram of the special Friction Facing (bonded to metal plate) (A) and the standard Friction Facing (B).

(A) Special facing included in (B) Standard facing included in Advantage Super Kit 994306 Advantage Super Kit 994305 Major Kit 994316 Major Kit 994315

22593-G-0602 17 These drives take the special facing

5291003 919103 99112

7491003 979103 99114

9691008 909103 99127

9191016 030104 99127

9191020 99105

These drives take the special facing if built before 2/27/90/(Serial Number 720372 or higher)

9091023 929103 99104

These drives built after 12/6/90 use standard facing.

These drives take the special facing if built before 12/6/88

991021 (Serial Number 991022 (Serial Number 581076 and later) 578968 and later)

These drives built after 12/6/88 use standard facing.

REPAIR KITS FOR SPECIAL SHEAVE BEARING CONFIGURATION

Some models of the HT/S Type Fan Drive have been designed to accept a special sheave bearing arrangement. Below are the Repair Kits for these Fan Drives. • 994333 Super Kit, Sintered Facing • 994334 Major Kit, Sintered Facing • 994335 Major Kit, Standard Facing • 994336 Super Kit, Standard Facing

These drives require the special Repair Kits

9397000 969700 99701

9597001 919700 99705

9697002 949700 99705

22593-G-0602 18 PARTS LIST

HT/S Advantage (with Double Row Hub Bearing) 18

9 8 English 7 6

4 47 44 29 32 3 4

31 30

27 26 20 24 22 23 16

15 19 17

ITEM DESCRIPTION QTY ITEM DESCRIPTION QTY

3 Mounting Bracket 1 231,2,3 Cartridge Assembly 1 42,3 Sheave Bearing 2 241,2,3 Face Seal Assembly 1 6 Sheave 1 (Replace Item 27 if Seal is round) 72,3 Friction Facing 1 261,2,3 O-Ring (Small) 1 8 Journal Spacer 1 27 Air Chamber Assembly 1 92,3 Button Head Cap Screw * 291,2,3 Socket Head Cap Screw 8 152 Piston Friction Disk 1 30 Stud Bolt 6 (includes 46 and 49) 31 Lock Washer 6 161,2,3 O-Ring 1 32 Hex Nut 6 172,3 Splined Hub Assembly 1 444 Bearing Spacers 1 182,3 Bearing Spacer 1 (Inner & Outer) 192,3 Hub Bearing 1 461,2,3 System Sentry® 1 201,2,3 Retaining Ring 1 471,2,3 Umbrella Valve 1 222,3 Lock Nut 1 49 Dust Seal 1

1 Denotes Seal Kit Item 4 Not used on all Fan Drives 2 Denotes Super Kit Item * QTY 6 for S Type 3 Denotes Major Kit Item * QTY 8 for HT/S Type

22593-G-0602 19 PARTS LIST

S and HT/S Standard and Advantage

8 9 18 7 6

4 29 47 44 32

3 4

31 30 27 24 26 23 20 16 22 14 15 25 19 17 10

ITEM DESCRIPTION QTY ITEM DESCRIPTION QTY

3 Mounting Bracket 1 231,2,3 Cartridge Assembly 1 42,3 Sheave Bearing 2 241,2,3 Face Seal Assembly 1 6 Sheave 1 (Replace Item 27 if Seal is round) 72,3 Friction Facing 1 25 Seal, Ring 1 8 Journal Spacer 1 261,2,3 O-Ring (Small) 1 92,3 Button Head Cap Screw * 27 Air Chamber Assembly 1 10 Bearing 1 291,2,3 Socket Head Cap Screw 8 14 Spacer 1 30 Stud Bolt 6 152 Piston Friction Disk 1 31 Lock Washer 6 (includes 46) 32 Hex Nut 6 161,2,3 O-Ring 1 444 Bearing Spacers 1 172,3 Splined Hub Assembly 1 (Inner & Outer) 182,3 Bearing Spacer 1 461,2,3 System Sentry® 1 192,3 Hub Bearing 1 471,2,3 Umbrella Valve 1 201,2,3 Retaining Ring 1 49 Dust Seal 1 222,3 Lock Nut 1

1 Denotes Seal Kit Item 4 Not used on all Fan Drives 2 Denotes Super Kit Item * QTY 6 for S Type 3 Denotes Major Kit Item * QTY 8 for HT/S Type

22593-G-0602 20 PARTS LIST

HT/S Special Case Double Row Sheave Bearing 9 English 6 10 18 47 48 8 29 32 3 7

31 30

27 24 26 20 23 22 16 14 15 25 19 17

ITEM DESCRIPTION QTY ITEM DESCRIPTION QTY

3 Mounting Bracket 1 231,2,3 Cartridge Assembly 1 6 Sheave 1 241,2,3 Face Seal Assembly 1 72,3 Friction Facing 1 (Replace Item 27 if Seal is round) 8 Journal Spacer 1 25 Seal, Ring 1 92,3 Button Head Cap Screw 8 261,2,3 O-Ring (Small) 1 10 Bearing 1 27 Air Chamber Assembly 1 14 Spacer 1 291,2,3 Socket Head Cap Screw 8 152 Piston Friction Disk 1 30 Stud Bolt 6 (includes 46 and 49) 31 Lock Washer 6 161,2,3 O-Ring 1 32 Hex Nut 6 172,3 Splined Hub Assembly 1 461,2,3 System Sentry® 1 182,3 Bearing Spacer 1 47 Umbrella Valve 1 19 Hub Bearing 1 482,3 Double Row Sheave 1 20 Retaining Ring 1 Bearing 222,3 Lock Nut 1 49 Dust Seal 1

1 Denotes Seal Kit Item 2 Denotes Super Kit Item 3 Denotes Major Kit Item

TORQUE SPECIFICATIONS

Intem Deescriptio Tightening Torqu

9wT]orx Button Hd Cap Scre 35-40 In. Lbs. [4-4.5 N•m

2t2 L]ocknu 150 Ft. Lbs. [230 N•m

2l4 F]ace Sea 50 In. Lbs. [5.7 N•m

2w9 T]orx Socket Hd Cap Scre 180 In. Lbs. [20.3 N•m

22593-G-0602 21 INTRODUCCIÓN ...... 22 Información general ...... 22 PREINSTALACIÓN ...... 23 MANTENIMIENTO PREVENTIVO ...... 24 Preparación del vehículo ...... 24 Cada semana ...... 24 Cada 25,000 millas (40,000 Km) ...... 24 REMOCIÓN DEL EMBRAGUE DEL VENTILADOR Y DE LA CÁMARA DE AIRE ... 25 JUEGO DE REPARACIÓN ...... 26 Junta tórica y sello de la cara...... 26 Remoción de la cabeza ...... 26 Polea y balero de la polea ...... 27 Cubierta de fricción ...... 29 Reensamble de la polea y la cabeza ...... 29 Reensamble del System Sentry® y del disco de fricción del pistón ...... 30 Reemplazo del cartucho de aire y junta tórica ...... 32 Reensamble de la cámara de aire ...... 34 INSTALACIÓN DEL EMBRAGUE DEL VENTILADOR ...... 34 SOLUCIÓN DE PROBLEMAS ...... 36 CUBIERTAS DE FRICCIÓN DEL HT/S ...... 39 JUEGOS DE REPARACIÓN PARA CONFIGURACIONES ESPECIALES DE BALEROS DE POLEAS ...... 40 LISTA DE PIEZAS ...... 41-43 ESPECIFICACIONES DE TORQUE ...... 43

INTRODUCCIÓN Información general

Lea cuidadosamente este manual y utilice sus explicaciones. Este manual describe los procedimientos correctos de inspección, servicio y reparación de los embragues de ventiladores Horton Tipo S y HT/S. Si sigue cuidadosamente las instrucciones logrará el funcionamiento más seguro y sin problemas. Horton utiliza las siguientes notificaciones especiales para advertir sobre posibles problemas relacionados con la seguridad que podrían causar serias lesiones, y proporciona información para ayudar a evitar daños al equipo.

Peligro se utiliza para indicar la presencia de un riesgo que causará lesiones personales severas, la muerte o daños importantes a la propiedad si dicha advertencia se ignora.

Advertencia se utiliza para indicar la presencia de un riesgo que puede causar lesiones personales severas, la muerte, o daños importantes a la propiedad si dicha advertencia se ignora.

Cuidado se utiliza para indicar la presencia de un riesgo que puede causar o causará lesiones personales leves o daños menores a la propiedad si dicha advertencia se ignora. NOTA Nota se utiliza para comunicarle información a la gente sobre instalación, operación o mantenimiento que es importante pero que no está relacionada con riesgos.

22593-G-0602 22 PRE-INSTALACIÓN

Debe seguir las prácticas de seguridad de su empresa, las cuales deben cumplir con

las prácticas y procedimientos de seguridad para plantas aprobados a nivel federal o Espa estatal, o ser mejores que éstos. Asegúrese de entender todos los procedimientos e instrucciones antes de comenzar a trabajar en esta unidad. ñ

NOTA ol Para mantener intacta su garantía durante el período de duración de la misma, el reemplazo y/o reparación de las piezas del embrague del ventilador Horton deberá ser efectuado sólo por algún distribuidor o proveedor autorizado por Horton. Después de instalar el embrague de su ventilador Horton tome nota del número de serie del embrague, número de pieza de servicio, fecha de instalación y kilometraje del vehículo.

Núm. de serie

Núm. de pieza de servicio

Fecha de instalación

Kilometraje del vehículo

Tipo de embrague: HT/S S 9'' SP

NOTA Una forma fácil de distinguir el embrague tipo S del HT/S o el de disco simple de 9'’ es medir el diámetro del disco de fricción del pistón. Otra forma es tomar nota de los primeros cuatro dígitos del número de pieza.

El número de pieza y el número de serie están estampados en la cámara de aire

7.5” 9.0” 9.5” [191 mm] [229 mm] [241 mm]

Tipo S Disco simple de 9'’ Tipo HT/S 5900XX 9908XX 5910XX 9912XX 7900XX 7910XX 9913XX 9900XX 9910XX 997XXX 9901XX 9911XX

22593-G-0602 23 MANTENIMIENTO PREVENTIVO Preparación del vehículo

Antes de efectuarle pruebas al embrague del ventilador asegúrese de seguir buenas prácticas de seguridad y: • Aplique el freno de mano del vehículo. • Bloquee las ruedas del vehículo. Antes de realizar algún trabajo en el área del ventilador: • Arranque el motor del vehículo y acumule presión de aire a más de 90 PSI [6.20 bar]. • Observe a distancia el ventilador y su embrague; busque vibración, contacto de las aspas del ventilador, y deslizamiento y funcionamiento del embrague del ventilador. • Apague el motor.

Asegúrese que el motor esté apagado y que el ventilador haya dejado de girar antes de aproximarse al área del ventilador, para evitar lesiones personales serias.

Cada semana Drene el filtro de aire (si es parte del equipo). • Si se detecta humedad y contaminación, el filtro deberá desensamblarse y lavarse cuidadosamente con solvente para piezas limpias. • Séquelo cuidadosamente antes de ensamblarlo de nuevo. • Determine la causa de la humedad o contaminación y corríjala.

Cada 25,000 millas (40,000 KM)

Fugas de aire NOTA Las fugas de aire harán que el System Sentry® y/o el balero fallen si no se les atiende. A. Verifique que no haya fugas de aire alrededor de la cámara de aire y el agujero de purga. Instale un juego de sellos nuevo si existe alguna fuga

Problemas en el ventilador y su banda NOTA Puede causar fallas en el balero si no se atienden. A. Verifique que el ventilador no esté flojo y que no presente daños como dobleces, grietas o aspas faltantes, remaches sueltos o pesos faltantes. Apriételo de nuevo si se encuentra suelto. Reemplácelo si está dañado. B. Verifique que haya una distancia adecuada, de acuerdo con las especifi- caciones del fabricante, entre el ventilador y su cubierta u otros componentes del compartimento del motor. Si la distancia es inadecuada, repárela. C. Verifique las condiciones, tensión y alineación de la banda. Corríjalas de ser necesario.

22593-G-0602 24 Cubierta de fricción A. Verifique que no exista desgaste. Reemplácela cuando se haya desgastado a 1/16" (1.58 mm) de grosor, cuando esté manchada de aceite, o si tiene marcas visibles de quemaduras. Espa

REMOCIÓN DEL EMBRAGUE DEL VENTILADOR Y DE LA CÁMARA ñ

DE AIRE ol

Cuando instale un Major Repair Kit asegúrese que el embrague de ventilador que se está reconstruyendo tenga un System Sentry®. Si el embrague del ventilador no tiene un System Sentry® deberá usar un Super Kit. 1. Verifique el modelo del embrague del ventilador, así como que se hayan obtenido las piezas correctas de reemplazo. 2. Retire el embrague del ventilador del motor. Coloque el ensamble del ventilador en una prensa de tornillo y sujete bien el soporte de la chumacera. 3. Retire los tornillos de cabeza hueca hexagonal Torx® de la cámara de aire.

NOTA Si le aplica una pequeña cantidad de aire a presión a la entrada del aire, esto le ayudará a retirar el ensamble de la cámara de presión del embrague del ventilador.

Aplique el aire a presión LENTAMENTE para que la cámara de aire no se bote rápidamente, ya que esto puede provocar lesiones personales serias. 4. Deslice el ensamble de la cámara de aire para retirarlo del disco de fricción del pistón. 5. Examine el interior de la cámara de aire en busca de señales de suciedad y materiales extraños. La cámara de aire deberá estar limpia y seca. De no ser así, es probable que exista un problema en el sistema de aire del vehículo, el cual deberá corregirse antes de instalar de nuevo el embrague del ventilador.

Tornillo de cabeza hueca Cámara de hexagonal Torx® aire

Disco de fricción Pasos 1 al 5 del pistón

22593-G-0602 25 JUEGO DE REPARACIÓN Junta tórica y sello de la cara

1. Retire la junta tórica de la cámara de aire y limpie sus cubiertas de contacto. 2. Inspeccione el sello de la cara para verificar que no presenta señales de desgaste que puedan indicar la existencia de suciedad en el sistema de aire.

Si existe suciedad o aceite en el sistema de aire, dicho sistema deberá ser limpiado y secado antes de instalar de nuevo el embrague del ventilador. 3. Reemplace el sello de la cara y apriételo a 50 pulg./lbs. [5.7 N•m]. NOTA Si el sello de la cara es redondo (NO HEXAGONAL) se considera una pieza obsoleta y deberá usarse una cámara de aire con un sello roscado para reemplazarlo. 4. Lubrique la junta tórica nueva y sus cubiertas de contacto con el lubricante de juntas tóricas nuevo que se suministra con el juego. Instale la junta tórica nueva en la cámara de aire. 5. Colóquelo a un lado para reensamblarlo posteriormente.

Cámara de aire Sello de la cara

Junta tórica

Pasos 1 al 5

Remoción de la cabeza

1. Retire y deseche la tuerca de seguridad del soporte de la chumacera. NOTA Si el disco de fricción del pistón no tiene un System Sentry®, debe utilizarse un Super Kit para reconstruir el embrague del ventilador. Tuerca de seguridad

Paso 1

22593-G-0602 26 2. Retire el disco de fricción del pistón del ensamble acanalado de la cabeza. Descarte el disco de fricción del pistón si lo está reconstruyendo con un Super Kit, o si dicho disco no está equipado con un System Sentry®. 3. Retire el ensamble acanalado de la cabeza del soporte de la chumacera y

descártelo. Espa

Disco de fricción del pistón

Cabeza ñ Soporte de la acanalada ol chumacera

Espaciador (Advantage solamente) Sello (Advantage solamente) Pasos 2 y 3

Polea y balero de la polea

NOTA Algunos modelos de embragues de ventilador tipo S y HT/S han sido diseñados para aceptar una disposición especial del balero de la polea. En estos embragues, los dos baleros estándar de la polea y los espaciadores opcionales han sido reemplazados con un rodamiento de bolas de contacto angular de doble fila. Los juegos estándar de reparación NO funcionarán en estas unidades. Las configuraciones de los baleros NO son intercambiables. Asegúrese de tener el juego de reparación adecuado. Vea la sección JUEGOS DE REPARACIÓN PARA CONFIGURACIONES ESPECIALES DEL BALERO DE LA POLEA de este manual en la página 39.

1. Retire y guarde el espaciador de la chumacera.

Espaciador de la chumacera

Paso 1

2. Deslice el ensamble de la polea y el balero para retirarlo del soporte de la chumacera.

Soporte de la chumacera Polea

Paso 2

22593-G-0602 27 3. Apoye bien la polea y ejerza presión sobre los baleros para sacarlos de la polea. NOTA Algunos modelos de embragues de ventiladores tipo S y HT/S contienen espaciadores en los baleros de la polea. Ambos deben colocarse ENTRE los baleros de la polea cuando éstos se reemplacen. Todos los baleros vienen previamente lubricados y sellados. NO retire los sellos para lubricar los baleros.

Baleros estándar de la polea Balero de polea de doble fila

PRESIONE PRESIONE Polea PARA EXTRAER Polea PARA EXTRAER

SOPORTE SOPORTE

Baleros de SOPORTE Baleros SOPORTE polea de Paso 3 doble fila

4. Con la polea completamente apoyada, ejerza presión para colocar los nuevos baleros de la polea en su sitio y tome nota de la posición del borde dentro de la polea.

Baleros estándar de la polea Balero de polea de doble fila

Polea Polea

Baleros

Baleros de Espaciadores polea de de baleros doble fila NOTE LA NOTE LA POSICIÓN DEL POSICIÓN DEL BORDE BORDE PUNTOS PUNTOS DE DE SOPORTE SOPORTE

PRESIONE PRESIONE

Paso 4

22593-G-0602 28 Cubierta de fricción

1. Reemplace la cubierta de fricción. 2. Retire los tornillos de cabeza semiesférica Torx® (tamaño T-25) y la antigua cubierta de fricción. Espa 3. Instale la nueva cubierta de fricción.

NOTA ñ

Asegúrese que los agujeros roscados de sujeción de la polea están alineados ol con los agujeros roscados de sujeción de la nueva cubierta de fricción. 4. Apriete los tornillos de cabeza semiesférica Torx® (tamaño T-25) en forma alternada y uniforme de 35 a 40 pulg./lbs. [4 a 4.5 N•m]. Cubierta de fricción

Tornillos de cabeza semiesférica Torx® Pasos 1 al 4

Reensamble de la polea y la cabeza NOTA En los embragues de ventiladores Advantage o cuando el embrague del ventilador se haya reconstruido con un juego de reparación Advantage, descarte el espaciador (artículo 14, páginas 42 y 43) y el sello frontal del balero de la cabeza (artículo 25, páginas 42 y 43). El ensamble actualizado de la cabeza que se incluye con su juego nuevo no requiere el uso del espaciador ni el sello que se mencionan arriba, ni funcionará con ellos.

1. Deslice la polea sobre el soporte de la chumacera.

Soporte de la chumacera

Paso 1 Polea NOTA El borde del espaciador de la chumacera debe estar colocado hacia el frente del embrague del ventilador. 2. Reinstale el espaciador de la chumacera. Borde del espaciador de la chumacera Espaciador de la chumacera Paso 2

22593-G-0602 29 3. Limpie la cabeza acanalada y lubrique los canales con el antiagarrotador y cepillo incluidos. 4. Instale el espaciador que se incluye en el juego de reparación. 5. Deslice la cabeza de la polea sobre el soporte de la chumacera.

Soporte de la Disco de chumacera fricción del pistón

Cabeza acanalada

Espaciador Pasos 3 al 5 NOTA Todos los juegos de reparación Horton vienen con un ensamble de cabeza y balero mejorados que pueden parecer diferentes a los de la configuración original. El espaciador en este juego es para asegurar que el ensamble de la cabeza esté alineado adecuadamente cuando se ensamble. Vea el diagrama de la página 39 para mayor información.

Reensemble del System Sentry® y del disco de fricción del pistón

Asegúrese de que el disco de fricción del pistón esté equipado con un System Sentry®. De no ser así deberá utilizarse un Super Kit, el cual contiene un disco de fricción del pistón estilo System Sentry®. Reemplace el System Sentry® cuando esté utilizando un Major Kit. 1.Verifique que el System Sentry® no presente señales visuales de fusión. NOTA Si por alguna razón se está acumulando un exceso de calor en el embrague del ventilador, el System Sentry® se desconectará y creará una fuga de aire. Esto detiene el sistema para prevenir mayores daños.

Los problemas del embrague del ventilador y sus controles deben solucionarse oportunamente para localizar la causa de la desconexión del System Sentry®. Consulte la sección de SOLUCIÓN DE PROBLEMAS de este manual para analizar las posibles causas y soluciones para los problemas del sistema. 2. Al reemplazar el System Sentry®, asegúrese de aflojarlo en la dirección correcta.

Ésta es una rosca a la izquierda y es necesario darle vuelta en sentido de las manecillas del reloj para retirarla.

No reemplace el System Sentry® con un tapón recto. El disco de fricción del pistón está balanceado y cualquier elemento diferente al System Sentry® de Horton desajustará dicho balance.

22593-G-0602 30 3. Instale el nuevo System Sentry®. Aplique de 40 a 50 pulg./lbs de torque (4.5 a 5.6 N•m)

System System Sentry® con Sentry con Espa cabeza Allen cabeza Torx®

Contrapeso Disco de ñ fricción ol del pistón

Guardapolvo System Sentry® Paso 3 NOTA PFD suministrados con el juego de reparacion PolarExtreme varian a esta ilutraction.

Si no se resuelven y corrigen los componentes del sistema que hayan fallado, esto resultará en desconexiones recurrentes del System Sentry®. 4. Resuelva los problemas y corrija los componentes del sistema que hayan fallado (vea de la página 36 a la 39). 5. Limpie el disco de fricción del pistón y lubrique los canales con el lubricante antiagarrotamiento y cepillo que se incluyen. 6. Deslice el disco de fricción del pistón sobre la cabeza acanalada. Disco de fricción Soporte de la del pistón chumacera

Cabeza acanalada Espaciador Pasos 5 y 6 7. Reemplace y apriete la tuerca de seguridad a 150 pies/lbs. [203 N•m].

Tuerca de seguridad

Paso 7 22593-G-0602 31 Reemplazo del cartucho de aire y junta tórica

Utilice protección de seguridad para los ojos cuando retire los anillos de retención para evitar serias lesiones a los ojos. 1. Retire el anillo de retención.

Anillo de retención

Paso 1

2. Retire el ensamble del cartucho y si es aplicable, la cabeza en forma de U. Limpie la cubierta interior del soporte de la chumacera de ser necesario.

Ensamble Extremo de Extremo de del cartucho carbono carbono Anillo de de aire Cartucho retención de bronce

Junta tórica

Cabeza en U Paso 2

IMPORTANTE El cartucho que se muestra en el paso 2 es un cartucho de bronce de un estilo más antiguo. El nuevo ensamble del cartucho no utiliza el sello de la cabeza en forma de U. Asegúrese de DESCARTAR el sello de la cabeza en forma de U al instalar este nuevo estilo de cartucho.

3. Aplique lubricante para juntas tóricas a las juntas tóricas exteriores del cartucho nuevo, e instale el nuevo ensamble del cartucho en el soporte de la chumacera. Instale el anillo de retención para mantener el ensamble del cartucho nuevo bien sujeto.

Ensamble Extremo del cartucho de de aire carbono

Paso 3

22593-G-0602 32 El anillo de retención debe estar completamente asentado sobre su muesca para evitar que el ensamble del cartucho se mueva. Observe que el anillo de retención está biselado. El lado curvo debe instalarse de cara al cartucho. Espa ñ

Anillo de Anillo de ol retención retención Junta tórica

La curva de cara al cartucho

Cuidado NOTA El Anillo-D sera suministrado con el juego de reparacion PolarExtreme en lugar del Anillo-O.

Disco de fricción del pistón Anillo-O/ Anillo-D AnilloD-Ring - D

Paso 4

4. Lubricar el nuevo Anillo-O/ Anillo-D y superficies de contacto del Anillo-O/ Anillo-D con el lubricante fresco suministrado en el juego.

5. Instale el nuevo Anill- O/Anillo-D en el Piston/Disco de Fricción. Si usted tiene un juego de reparacion PolarExtreme, asegurarse de que el Anillo-D sea colocado dentro de la ranura como se muestra en (paso 4), garantizando asi su correcto functionamiento.

NOTA El total de lubricante suministrado en el tubo debe ser usado al lubricar el nuevo Anillo-O/Anillo-D y las superficies de contacto de este con la Camara de Aire y el Piston/Disco de Fricción.

22593-G-0602 33 Reensamble de la cámara de aire

Tomar extremada precaucion cuando reemplase la Camara de Aire para evitar Daños al Anillo O.

1. Instale cuidadosamente la Cámara de Aire sobre el Piston/Disco de Fricción para evitar dañar el guardapolvo. Si es necesario, use un instrumento liso para ayudar la instalación de la Camara de Aire. 2. Actualmente el guardapolvo sólo viene en el formato del Super Kit. 3. Instale los tornillos de cabeza hueca hexagonal Torx® y apriételos alternada y uniformemente a 180 pulg./lbs. [20.3 N•m]. 4. Instale la válvula de retención de sombrilla en el agujero de purga de la cámara de aire y asegúrela en su sitio presionándola con el pulgar. 5. Aplique de 90 a 120 PSI [10.1 a 13.5 Bar] de aire limpio a la entrada de aire del embrague del ventilador para verificar que el disco de fricción del pistón y el material de fricción estén correctamente conectados.

Válvula de Tornillo de cabeza retención hueca hexagonal Torx® de sombrilla

Cámara de aire

Guardapolvo Pasos 1 al 5

Si existe algún problema, éste debe corregirse antes de montar el embrague del ventilador en el vehículo. Si el problema no se corrige, el embrague del ventilador fallará prematuramente.

INSTALACIÓN DEL EMBRAGUE DEL VENTILADOR

1. Asegure el embrague del ventilador al motor del vehículo usando tornillos SAE grado 8. 2. Apriete los tornillos de montaje SAE grado 8 de acuerdo con las especificaciones del fabricante del vehículo. 3. Verifique que el embrague del ventilador tenga una presión de aire adecuada.

22593-G-0602 34 NOTA Para verificar la presión de aire que entra al embrague del ventilador deberá colocar un calibrador en la entrada de aire del embrague del ventilador. La presión deberá estar entre 90 y 120 PSI [10.1 a 13.5 Bar]. Esto asegurará una capacidad máxima de torque en el embrague del ventilador y evitará daños al mismo debidos a una baja presión de aire.

4. Coloque de nuevo las bandas y ajústelas de acuerdo con las especificaciones del fabricante.

Es necesario tener el ajuste y la alineación correcta de las bandas con todos los componentes accionados por ellas para asegurar la durabilidad de dichos componentes. Las bandas demasiado apretadas reducen la vida de los baleros del embrague del ventilador. Las bandas flojas se desgastarán en forma excesiva. Consulte las especificaciones del fabricante del vehículo o equipo para verificar el ajuste adecuado de las bandas.

5. Coloque la paleta del ventilador en el embrague y apriete las tuercas de acuerdo con las especificaciones del fabricante del vehículo.

El diámetro máximo de ventilador para los embragues de ventiladores tipo S y HT/S es de 28'’ y 32'’ respectivamente. Si requiere un diámetro mayor en el ventilador póngase en contacto con Horton.

6. Verifique que el ventilador embrague y desembrague adecuadamente.

Asegúrese que todas las áreas alrededor del ventilador, su cubierta y la polea estén despejadas, que los sujetadores estén bien apretados y que el abanico pueda girar libremente.

22593-G-0602 35 SOLUCIÓN DE PROBLEMAS

PROBLEMA CAUSA PROBABLE SOLUCIÓN

I. Fuga de aire en el 3 embrague del 1 ventilador 2

4 1. Agujero de purga. 1. Sello de la cara o 1. Instale el juego de sellos. cartucho de aire defectuosos. 2. Cámara de aire. 2. Sellos de la junta tórica 2. Instale el juego de sellos. defectuosos. 3. Orificios guía. 3. Sellos de la junta tórica 3. Instale el juego de sellos. defectuosos. 4. System Sentry®. 4. Vea la Sección II (abajo). 4. Vea la Sección II (abajo).

II. Desconexión del System Sentry®

El System Sentry® desconectará el embrague del ventilador cuando éste patine en forma excesiva provocando acumulamiento anormal de calor.

1. Ventilador obstruido. 1. Cubierta floja, ventilador 1. Encuentre la obstrucción doblado, monturas del y elimínela; repare motor rotas, etc. reemplace las piezas dañadas. Instale el juego de sellos. 2. Baja presión de aire 2. a. Manguera de aire 2. a. Reemplace la al embrague del restringida. manguera de aire. ventilador. b. Válvula solenoide b. Reemplace la válvula restringida. solenoide. c. Baja presión de aire c. Determine la cause y en el sistema. repárela. Instale el juego de sellos. 3. Ciclado excesivo. 3. a. Sobrecarga del 3. a. Verifique y ajuste de refrigerante del aire acuerdo con las acondicionado. especificaciones. b. Ajuste demasiado b. Verifique el interruptor bajo del interruptor del aire acondicionado. de depresión del aire acondicionado. c. Tierra o conexión del c. Verifique lasconexiones cableado deficientes. eléctricas.

22593-G-0602 36 PROBLEMA CAUSA PROBABLE SOLUCIÓN

II. Continuación Espa 3. Ciclado excesivo. d. Ajuste del control de d. Verifique el ajuste de la temperatura temperatura de todos

inadecuado. los controles. (El ajuste ñ

del interruptor térmico ol debe embragar el ventilador a10oF más que a la temperatura totalmente abierta del termostato). e. Interruptor térmico e. Reemplace el defectuoso. interruptor térmico. f. Alguna restricción al f. Verifique que la frente del radiador persiana funcione bien, está bloqueando el así como la funda del flujo de aire. radiador o alguna otra restricción dentro o enfrente del radiador. Instale el juego de sellos.

III. El ventilador no se Problema eléctrico embraga 1. Circuito abierto (sistema 1. Verifique las conexiones Normalmente Abierto). eléctricas. 2. Cableado 2. Verifique el cableado de inadecuadamente. acuerdo con el diagrama. 3. Interruptor térmico 3. Verifique la aplicación del incorrecto para la interruptor térmico (N.A. o aplicación. N.C.). Reemplácelos si son incorrectos o están defectuosos. 4. Válvula solenoide 4. Reemplace la válvula defectuosa. solenoide.

Problema de aire

1. Fuga en el embrague del 1. Vea el problema I. ventilador (vea el problema I). 2. Suministro de aire 2. Verifique que los restringido al embrague conectores y mangueras del ventilador. de aire no tengan fugas o pinchaduras. 3. Válvula solenoide 3. Reemplace la válvula defectuosa. solenoide.

22593-G-0602 37 PROBLEMA CAUSA PROBABLE SOLUCIÓN

IV. El ventilador no se Problema eléctrico desembraga 1. Circuito abierto (sistema 1. Verifique la conexiones Normalmente Cerrado). eléctricas. 2. Cableado 2. Verifique el cableado de inadecuadamente. acuerdo con el diagrama. 3. Interruptor térmico 3. Verifique la aplicación del incorrecto interruptor térmico (N.A. o N.C.). Reemplácelo si es incorrecto o está defectuoso.

Problema de aire

1. Manguera de aire 1. Verifique que no haya restringida, lo cual impide pinchaduras ni que el aire se libere del taponaduras en la embrague del ventilador. manguera de aire entre el embrague del ventilador y la válvula solenoide. 2. La válvula solenoide no 2. Verifique que el puerto de está escapando. escape de la válvula solenoide no esté taponado. Limpie o reemplace la válvula solenoide.

El disco de fricción del pistón no se regresa

1. Es posible que esté 1. Limpie el suministro de atascado debido a aire e instale un Super contaminación o a que Kit. las juntas tóricas están secas.

V. El embrague del Problema eléctrico ventilador se cicla frecuentemente. Vea el 1. Tierra o conexión del 1. Verifique las conexiones problema II, Núm. 3 cableado deficientes. eléctricas. 2. Ajustes inadecuados del 2. Verifique el ajuste de control de temperatura. temperatura de todos los controles. (El ajuste del interruptor térmico debe embragar el ventilador a 10oF más que a la temperatura del sensor de la persiana totalmente abierto).

22593-G-0602 38 PROBLEMA CAUSA PROBABLE SOLUCIÓN

V. Continuación 3. El ajuste del interruptor 3. Verifique el interruptor de de presión del aire presión del aire Espa acondicionado está acondicionado. Utilice un demasiado bajo. interruptor más alto. 4. Alguna restricción al 4. Verifique el ñ

frente del radiador está funcionamiento de la ol bloqueando el flujo de persiana, las fundas del aire. radiador o alguna obstrucción al frente del radiador. 5. Interruptor 5. Reemplace el interruptor térmicodefectuoso. térmico. 6. Interruptor de temperatura 6. Reemplace el interruptor de aire defectuoso. de temperatura del aire.

VI. Ventilador 1. Restricción al frente del 1. Asegúrese que nada embragado, radiador. obstruya el flujo aire por motor funcionando el radiador. caliente 2. La capacidad del 2. Consulte las ventilador no es especificaciones del suficiente. fabricante. 3. Problema en el sistema 3. Consulte el manual del de enfriamiento. motor.

CUBIERTAS DE FRICCIÓN DEL HT/S

Algunos embragues de ventiladores Horton HT/S requieren una cubierta de fricción especial. A continuación encontrará un diagrama sobre la cubierta de fricción especial (soldada al disco de metal) (A) y la cubierta de fricción estándar (B).

(A) La cubierta especial se incluye en (B) La cubierta estándar se incluye en el Super Kit Advantage 994306 el Super Kit Advantage 994305 Major Kit 994316 También en el Major Kit 994315

22593-G-0602 39 Estos embragues requieren la cubierta especial.

5291003 919103 99112

7491003 979103 99114

9691008 909103 99127

9191016 030104 99127

9191020 99105

Estos embragues requieren la cubierta especial si se construyeron antes del 27/2/90 (Núm. de serie 720372 y major).

9091023 929103 99104

(Estos embragues construidos después del 27/2/90 usan la cubierta estándar).

Estos embragues requieren la cubierta especial si se construyeron antes del 6/12/88.

991021 (Núm. de serie 991022 (Núm. de serie 581076 y posterior) 578968 y posterior)

(Estos embragues construidos después del 6/12/88 usan la cubierta estándar).

JUEGOS DE REPARACIÓN PARA BALERO DE POLEA CON CONFIGURACIÓN ESPECIAL

Algunos modelos del embrague del ventilador tipo HT/S han sido diseñados para aceptar una disposición especial del balero de la polea. A continuación se encuentran los juegos de reparación para estos embragues de ventiladores. • 994333 Super Kit, Cubierta sinterizada • 994334 Major Kit, Cubierta sinterizada • 994335 Major Kit, Cubierta estándar • 994336 Super Kit, Cubierta estándar

Estos embragues requieron los juegos especiales de reparación.

9397000 969700 99701

9597001 919700 99705

9697002 949700 99705

22593-G-0602 40 LISTA DE PIEZAS

HT/S Advantage (con balero de la cabeza de doble fila) 18 9 8 Espa 7 6 ñ ol 4 47 44 29 32 3 4

31 30

27 26 20 24 22 23 16

15 19 17

ARTÍ- DESCRIPCIÓN CANT. ARTÍ- DESCRIPCIÓN CANT. CULO CULO 3 Soporte de montaje 1 222,3 Tuerca de seguridad 1 42,3 Balero de la polea 2 231,2,3 Ensamble del cartucho 1 6 Polea 1 241,2,3 Ensamble del sello de la cara 1 72,3 Cubierta de fricción1 (Reemplace el artículo 27 si el sello 8 Espaciador de la chumacera 1 está redondo) 1,2,3 92,3 Tornillo de cabeza * 26 Junta tórica (pequeña) 1 semiesférica 27 Ensamble de la cámara de aire 1 1,2,3 152 Disco de fricción del pistón1 29 Tornillo de cabeza hueca 8 (incluye 46 y 49) hexagonal 161,2,3 Anillo O 1 30 Tornillo prisionero 6 172,3 Ensamble acanalado 1 31 Arandela de presión6 de la cabeza 32 Tuerca hexagonal 6 4 182,3 Espaciador del balero 1 44 Espaciadores del balero 1 192,3 Balero de la cabeza 1 (Internos y externos) 1,2,3 ® 201,2,3 Anillo de retención1 46 System Sentry 1 471,2,3 Válvula de sombrilla 1 49 Guardapolvo 1

1 Indica un artículo del Seal Kit. 4 No se utiliza en todos los embragues de 2 Indica un artículo del Super Kit. ventiladores. 3 Indica un artículo del Major Kit. * CANT. 6 para el tipo S. * CANT. 8 para el tipo HT/S.

22593-G-0602 41 LISTA DE PIEZAS ó

S y HT/S Standard y Advantage 8 9 18 7 6

4 29 47 44 32

3 4

31 30 27 24 26 23 20 16 22 14 15 25 19 17 10

ARTÍ- DESCRIPCIÓN CANT. ARTÍ- DESCRIPCIÓN CANT. CULO CULO 3 Soporte de montaje 1 222,3 Tuerca de seguridad 1 42,3 Balero de la polea 2 231,2,3 Ensamble del cartucho 1 6 Polea 1 241,2,3 Ensamble del sello de la cara 1 72,3 Cubierta de fricción1 (Reemplace el artículo 27 si el sello 8 Espaciador de la chumacera 1 está redondo) 92,3 Tornillo de cabeza * 25 Sello, anillo 1 1,2,3 semiesférica 26 Junta tórica (pequeña) 1 10 Balero 1 27 Ensamble de la cámara de aire 1 1,2,3 14 Espaciador 1 29 Tornillo de cabeza hueca 8 152 Disco de fricción del pistón1 hexagonal (incluye 46 30 Tornillo prisionero 6 161,2,3 Anillo O 1 31 Arandela de presión6 172,3 Ensamble acanalado 1 32 Tuerca hexagonal 6 4 de la cabeza 44 Espaciadores del balero 1 182,3 Espaciador del balero 1 (Internos y externos) 1,2,3 ® 192,3 Balero de la cabeza 1 46 System Sentry 1 1,2,3 201,2,3 Anillo de retención1 47 Válvula de sombrilla 1 49 Guardapolvo 1

1 Indica un artículo del Seal Kit. 4 No se utiliza en todos los embragues de 2 Indica un artículo del Super Kit. ventiladores. 3 Indica un artículo del Major Kit. * CANT. 6 para el tipo S. * CANT. 8 para el tipo HT/S.

22593-G-0602 42 LISTA DE PIEZAS

HT/S Configuración Especial Balero de la Polea Doble Fila 9 Espa 6 10 18 47 48 8 29 32 3 ñ 7 ol

31 30

27 24 26 20 23 22 16 14 15 25 19 17

ARTÍ- DESCRIPCIÓN CANT. ARTÍ- DESCRIPCIÓN CANT. CULO CULO 3 Soporte de montaje 1 222,3 Tuerca de seguridad 1 6 Polea 1 231,2,3 Ensamble del cartucho 1 72,3 Cubierta de fricción1 241,2,3 Ensamble del sello de la cara 1 8 Espaciador de la chumacera 1 (Reemplace el artículo 27 si el sello 92,3 Tornillo de cabeza 8 está redondo) semiesférica 25 Sello, anillo 1 1,2,3 10 Balero 1 26 Junta tórica (pequeña) 1 14 Espaciador 1 27 Ensamble de la cámara de aire 1 1,2,3 152 Disco de fricción del pistón1 29 Tornillo de cabeza hueca 8 (includes 46 and 49) hexagonal 161,2,3 Anillo O 1 30 Tornillo prisionero 6 172,3 Ensamble acanalado 1 31 Arandela de presión6 de la cabeza 32 Tuerca hexagonal 6 1,2,3 ® 182,3 Espaciador del balero 1 46 System Sentry 1 19 Balero de la cabeza 1 47 Válvula de sombrilla 1 2,3 20 Anillo de retención1 48 Balero de polea de doble fila 1 49 Guardapolvo 1

1 Indica un artículo del Seal Kit 2Indica un artículo del Super Kit 3 Indica un artículo del Major Kit ESPECIFICACIONES DE TORQUE

Anrtículo Deescripció Par de Apriet

Tornillos de cabeza 9 35-40 Pulg. Lbs. [4-4.5 N•m] semiesférica Torx

2d2 T]uerca de segurida 150 Pies. Lbs. [230 N•m

2a4 S]ello de la car 50 Pulg. Lbs. [5.7 N•m

Tornillos de cabeza Hexagonal 29 180 Pulg. Lbs. [20.3 N•m] Torx

22593-G-0602 43 Horton, Inc. 2565 Walnut St. Roseville, MN 55113 1-800-621-1320 www.hortoninc.com

Factory: Britton, SD 57430-0050

©2002 Copyright Horton, Inc. All rights reserved. Printed in U.S.A.

Horton, Inc. 2565 Walnut St. Roseville, MN 55113 1-800-621-1320 www.hortoninc.com

Fábrica: Britton, SD 57430-0050

©2002 Copyright Horton, Inc. Todos los derechos reservados. Impreso en U.S.A.

22593-G-0602

22593-G-0602 44 EA09-008 PACCAR 10/15/2009 RESPONSE 15 horton-22656 FAN DRIVE INSTALLATION, OPERATION AND MAINTENANCE INSTRUCTIONS

1 22656-B-0899 ○○○○○○○○○

INTRODUCTION○○○○○○○○○○○○○ 3 ○○○○○○○○○○○○○○ General Information○○○○ 3

PREVENTIVE MAINTENANCE○○○○○○○○○○○○ 4

PRE-INSTALLATION○○○○○○○○○○○○○○○○○○○ 6 ○○○○○○○○ INSTALLATION○○○○○○○○○○○○○○ 7

Vehicle Preparation○○○○○○○○○○○○○○○○○ 7

Fan Drive Installation○○○○○○○○○○○○○○○○ 7 ○○○○○○ ELECTRICAL CONNECTIONS○○○○○○ 10

Electrically Normally Closed (N.C.)○○○○○○○ 10

Electrically Normally Open (N.O.)○○○○○○○ 12

Electronically Controlled Engines○○○○○○○ 14

22656-B-0899 2 INTRODUCTION

General Information

This manual describes the correct Fan Drive Installation procedures. Following the instructions carefully will provide the safest and most trouble-free operation.

Horton uses the following special notices to give warning of possible safety related problems which could cause serious injury and provide information to help prevent damage to equipment.

Danger is used to indicate the presence of a hazard which will cause severe personal injury, death, or substantial property damage if the warning is ignored.

Warning is used to indicate the presence of a hazard which can cause severe personal injury, death, or substantial property damage if the warning is ignored.

Caution is used to indicate the presence of a hazard which will or can cause minor personal injury or property damage if the warning is ignored.

NOTE Note is used to notify people of installation, operation, or maintenance information which is important but not hazard related.

3 22656-B-0899 PREVENTIVE MAINTENANCE

Vehicle Preparation

1. Before performing work on the Fan Drive, be sure to follow good shop safety practices. Turn the vehicle ignition off, apply the vehicle's parking brake, and block the vehicle's wheels.

Be sure engine is turned off and fan has stopped turning before approaching fan area, to prevent serious personal injury.

2. Before doing work in the area of the fan:

• Start the vehicle’s engine and build air pressure in excess of 90 PSI.

• Manually engage and disengage the Fan Drive. Observe the fan and Fan Drive from a distance, look for vibration, fan blade contact, Fan Drive slippage, and Fan Drive operation.

• Turn Engine off.

Each Week

Drain Air Filter (if equipped).

If moisture or contamination is detected, the filter must be disassembled and flushed thoroughly with clean parts solvent. Dry carefully before reassembly. Determine the cause of the moisture or contamination and correct the condition.

22656-B-0899 4 Every 25,000 Miles

Fan and Fan Belt

Fan and Fan Belt problems can cause product failure if left unattended.

1. Check the fan for looseness and damage, such as bent, cracked or missing blades, loose rivets or missing weights. Retorque if loose. Replace if damaged.

2. Check for adequate clearance between the fan and the fan shroud or other engine compartment components in both the engaged mode the and disengaged mode. Repair if the clearance is inadequate.

3. Check the fan belt condition, belt tension, and belt alignment. Correct if necessary.

5 22656-B-0899 PRE-INSTALLATION

You must follow your company safety practices, which should adhere to or be better than Federal or State approved Part No. and shop safety practices and procedures. Serial No. Be sure that you understand all the procedures and instructions before you begin work on this unit.

NOTE Parts replacement and/or repair of your Horton DRIVEMASTER™ Fan Drive should be performed only by the Horton Factory or an authorized Horton Distributor or Dealer to keep your warranty coverage intact during the warranty period.

Before installation of your Horton DRIVEMASTER Fan Drive, note the Fan Drive Serial No., Service Part No., Date of Installation, and Vehicle Mileage.

Serial No.

Service Part No.

Installation Date

Vehicle Mileage

22656-B-0899 6 INSTALLATION

Vehicle Preparation

1. Turn the vehicle ignition off, apply the vehicle's parking brake, and block the vehicle's wheels.

NOTE Protect the radiator from possible damage from the fan during fan removal and fan drive installation.

2. If applicable, remove the existing fan, fan drive, mounting hardware and belts.

Fan Drive Installation

1. Position the Horton Fan Drive on the engine and align the holes for Grade 8 Fan Mounting Drive mounting. Fan NOTE Bolts Most engines have multiple mounting locations. Be sure to use the correct holes for the application.

2. Tighten the SAE Grade 8 mounting bolts and/or nuts to the vehicle manufacturer's specifications.

Correct belt adjustment and alignment is necessary for all belt Grade 8 driven components to assure Steps 1-3 Nuts longevity of component life. Over tightening of belts will shorten bearing life. Loose belts will cause excessive belt wear and shorten bearing life. Consult the equipment manufacturer and/or engine manufacturer specifications for proper belt adjustment.

3. Replace and adjust the belts.

7 22656-B-0899 NOTE Some Horton Fan Drives incorporate Thermal a belt tension feature into the Fan Switch Drive mounting bracket. Use this feature if applicable.

The maximum fan diameter is 32''. If a larger fan diameter is required, contact Horton at 1-800-621-1320.

4. Mount the fan onto the Fan Drive and tighten the bolts and/ or nuts to the vehicle manufac- turer's specifications.

5. Drain the appropriate amount of Step 5 engine coolant from the system before thermal switch installation.

6. Remove the pipe plug from the engine coolant manifold and install the Thermal Switch. (Location of the pipe plug may vary.)

NOTE Locate the Thermal Switch as close to the engine coolant thermostat as possible. The Thermal Switch setting should engage the Fan Clutch at least 10o F higher than the engine thermostat setting.

7. Mount the Solenoid Valve in an upright position on either the vehicle's fire wall or radiator support, in an area where the Solenoid Valve Steps 6-7 will not be subjected to engine heat, vibration, or road dirt.

8. Connect an air hose from the vehicle's air supply to the Solenoid Valve inlet port.

The vehicle's air supply must be clean and free of moisture and oil.

9. Check for proper air pressure to the Fan Drive. This measurement should always be taken at the Fan Clutch air inlet port.

22656-B-0899 8 NOTE To assure maximum performance of the Fan Drive and to prevent damage to the Fan Clutch, there must be a minimum pressure of 90 PSI to the Fan Drive upon disengagement.

9. Affix the WARNING sticker to a highly visible area of the engine compartment. Step 9

9 22656-B-0899 ELECTRICAL CONNECTIONS

Electrically Normally Closed (N.C.)

NOTE The Horton DRIVEMASTER™ Fan Drive is spring engaged, air disengaged. An electrical system wired N.C. will require a normally closed Solenoid Valve.

Also note the N.C. Thermal Switch, N.C. Freon Pressure Switch, and N.C. Solenoid Valve are the only controls absolutely necessary for fan clutch operation. The N.C. manual Switch, Air Pressure Switch, and Indicator Light are all optional controls and may be left out of the circuit.

1. Remove the battery cables from the battery.

2. Install the Air Pressure Switch into the air line between the N.C. Solenoid Valve and the Fan Drive.

3. Mount the optional Indicator Light and Toggle Switch on the dashboard or other convenient location.

NOTE The Manual Toggle Switch is stamped OFF and ON. OFF position is for continuous operation, ON position is for automatic operation. Set the Manual Toggle Switch to ON position and note this position for future reference.

4. Install the N.C. Freon Pressure Switch into the high pressure Freon line of the air conditioning system.

5. Connect the Black lead of the N.C. Solenoid Valve to the vehicle ground. Steps 1-13

6. Connect the Red (12 Volt) or Green

22656-B-0899 10 (24 Volt) lead of the N.C. Solenoid Valve to one lead of the N.C. Freon Pressure Switch.

7. Connect the other lead of the N.C. Freon Pressure Switch to one terminal of the N.C. Thermal Switch.

8. Connect the other terminal of the N.C. Thermal Switch to one terminal of the Manual Toggle Switch.

9. Connect the other terminal of the Manual Toggle Switch to the vehicle accessory or ignition terminal.

10. Connect one terminal of the Air Pressure Switch to the vehicle ground.

11. Connect the other terminal of the Air Pressure Switch to the Indicator Light.

NOTE If using the Air Pressure Switch, it Steps 1-13 must be installed in the air line between the Solenoid Valve and the Fan Drive. Minimize the length of air line between each of these components.

12. Connect the other terminal of the Indicator Light to the vehicle accessory or ignition terminal.

13. Connect the battery cable to the battery.

Electrical System Operation Check

Keep hands and tools clear of the fan blades. The Fan Drive can engage without warning.

1. With the engine temperature below the Thermal Switch setting, turn on the ignition and build up air pressure.

11 22656-B-0899 2. Disconnect one terminal of the N.C. Thermal Switch. This will engage the Fan Drive (air should exhaust from the N.C. Solenoid Valve).

3. Reconnect the terminal of the N.C. Thermal Switch. This will disengage the Fan Drive.

4. Repeat Steps 1-3 for the N.C. Freon Pressure Switch.

5. Set the Manual Toggle Switch to OFF. The Indicator Light will come on when the Fan Drive is engaged. If the Indicator Light does not come on, check the bulb and the Indicator Light's ground connection.

NOTE ON position is for automatic operation, OFF position is for continuous operation.

Electrically Normally Open (N.O.)

NOTE The Horton DRIVEMASTER™ Fan Drive is spring engaged, air disengaged. An electrical system wired N.O. will require a N.O. Solenoid Valve.

Also note the N.O. Thermal Switch, N.O. Freon Pressure Switch, and N.O. Solenoid Valve are the only controls absolutely necessary for fan clutch operation. The N.O. manual Switch, Air Pressure Switch, and Indicator Light are all optional controls and may be left out of the circuit.

1. Remove the battery cables from the battery.

2. Install the Air Pressure Switch into the air line between the N.O. Solenoid Valve and the Fan Drive.

3. Mount the Indicator Light and Toggle Switch on the dashboard or other convenient location. Steps 1-15

22656-B-0899 12 NOTE The Manual Toggle Switch is stamped OFF and ON. ON position is for continuous operation, OFF position is for automatic operation. Set the Manual Toggle Switch to OFF position and note this position for future reference.

4. Install the N.O. Freon Pressure Switch into the high pressure Freon line of the air conditioning system.

5. Connect the Black lead of the N.O. Solenoid Valve to the vehicle ground.

6. Connect the Red (12 Volt) or Green (24 Volt) lead of the N.O. Solenoid Valve to one terminal of the N.O. Thermal Switch. Steps 1-15 7. Connect the other terminal of the N.O. Thermal Switch to the vehicle accessory or ignition terminal.

8. Connect one lead of the Manual Toggle Switch to the Red (12 Volt) or Green (24 Volt) lead connecting the N.O. Solenoid Valve to the terminal of the N.O. Thermal Switch.

9. Connect the other lead of the Manual Toggle Switch to the vehicle accessory or ignition terminal.

10. Connect one lead of the N.O. Freon Pressure Switch to the Red (12 Volt) or Green (24 Volt) lead connecting the N.O. Solenoid Valve to the terminal of the N.O. Thermal Switch.

11. Connect the other lead of the N.O. Freon Pressure Switch to the vehicle accessory or ignition terminal.

12. Connect one lead of the Air Pressure Switch to the vehicle ground.

13 22656-B-0899 13. Connect the other lead of the Air Pressure Switch to one terminal of the Indicator Light.

14. Connect the other terminal of the Indicator Light to the vehicle accessory or ignition terminal.

15. Connect the battery cables to the battery.

Electrical System Operation Check

Keep hands and tools clear of the fan blades. The Fan Drive can engage without warning.

1. With the engine temperature below the Thermal Switch setting, turn on the ignition and build up air pressure.

2. Install a jumper wire between the terminals of the N.O. Thermal Switch, this will engage the Fan Drive (air should exhaust from the N.O. Solenoid Valve).

3. Remove the jumper wire from the N.O. Thermal Switch. This will disengage the Fan Drive.

4. Repeat Steps 1-3 for the N.O. Freon Pressure Switch.

5. Set the Manual Toggle Switch to ON. This will engage the Fan Clutch, the Indicator Light will light when the Fan Drive is engaged. If the Indicator Light fails to light, check the bulb and the Indicator Light’s ground connection.

NOTE OFF position is for automatic operation, ON position is for continuous operation.

Electronically Controlled Engines

Installation of Drivemaster Fan Drives in Electronically Controlled Engines must be performed by a factory authorized service center. Contact your dealer for the location nearest you.

22656-B-0899 14 NOTES

15 22656-B-0899 Horton, Inc. P.O. Box 9455 Minneapolis, MN 55440-9455 (612) 331-5931 1-800-621-1320 FAX: (612) 627-5700 www.hortoninc.com

©1999 Horton, Inc. All rights reserved. Printed in U.S.A. 22656-B-0899 EA09-008 PACCAR 10/15/2009 RESPONSE 15 horton-22748 SPRING-ENGAGED FAN DRIVE

REPAIR KIT INSTALLATION INSTRUCTIONS

INSTRUCCIONES DE INSTALACIÓN KIT DE REPARACION TABLE OF CONTENTS

INTRODUCTION ...... 3 General Information ...... 3 PRIOR TO SERVICING ...... 3 REMOVING THE FAN DRIVE...... 4 DRIVEMASTER PARTS ...... 5 Parts Identification ...... 5 Repair Kits...... 6 DriveMaster Seal Kit (Part #994346) ...... 6 DriveMaster Super Kit...... 7 DriveMaster Friction Disc Kit ...... 8 DriveMaster Friction Liner Kit (Part #994349) ...... 8 DriveMaster Bearing/Cartridge Kit...... 9 DriveMaster Clutch Pack Kit ...... 9 DISASSEMBLING THE FAN DRIVE ...... 10 Tools Required ...... 10 Disassembly ...... 10 Fan Mounting Disc Removal and Inspection ...... 10 Spring Housing/Piston Assembly Removal...... 11 Air Chamber Seals ...... 12 Sheave and Sheave Bearings...... 13 TORQUE SPECIFICATIONS ...... 13 REBUILDING THE FAN DRIVE...... 14 Sheave Bearings ...... 14 Air Cartridge ...... 15 Sheave Replacement ...... 15 Spring Housing/Piston Assembly Reassembly ...... 16 Fan Mounting Disc Reassembly ...... 17 REINSTALLING THE FAN DRIVE ...... 18 TROUBLESHOOTING ...... 19

22748-G-0506 2 English

INTRODUCTION

General Information

Horton uses the following special notices to give warning of possible safety related problems which could cause serious injury and provide information to help prevent damage to equipment.

Danger is used to indicate the presence of a hazard which will cause severe personal injury, death, or substantial property damage if the warning is ignored.

Warning is used to indicate the presence of a hazard which can cause severe personal injury, death, or substantial property damage if the warning is ignored.

Caution is used to indicate the presence of a hazard which will or can cause minor personal injury or property damage if the warning is ignored.

NOTE Note is used to notify people of installation, operation, or maintenance information which is important but not hazard related.

PRIOR TO SERVICING

You must follow your company safety practices, which should adhere to or be better than Federal or State approved shop safety practices and procedures. Be sure that you read and understand all the procedures and instructions before beginning work on this unit. NOTE Parts replacement and/or repair of your Horton DRIVE MASTER Fan Drive should be performed only by the Horton Factory or an authorized Horton Distributor or Dealer to keep your warranty coverage intact during the warranty period.

Before rebuilding your DRIVEMASTER Fan Drive, note the Fan Drive Serial No., Service Part No., Date of Installation, and Vehicle Mileage. Part Number and Serial Number Serial No. ______

Service Part No. ______

Installation Date ______

Vehicle Mileage ______

3 22748-G-0506 REMOVING THE FAN DRIVE

NOTE The procedure for removing the Fan Drive varies from one vehicle to another. Refer to the vehicle’s service manual for a detailed description of this process. In general, proceed as follows:

1. Turn the vehicle ignition off, apply the vehicle's parking brake, and block the vehicle's wheels.

NOTE Protect the radiator from possible damage from the fan during fan removal and fan drive installation.

2. Remove the fan from the Fan Drive.

3. Bleed the air from the vehicle’s reservoir and disconnect the air hose from the Fan Drive.

4. Loosen or remove the drive belts.

NOTE Because of the weight of the Fan Drive (ranging from 35-55 Lbs. [15.88-24.95 Kg]), you may want to use a hoist for support during removal.

5. Remove the Fan Drive mounting bolts and lift the Fan Drive out of the engine compartment.

Grade 8 Mounting Bolts Fan Drive

Grade 8 Nuts

Steps 1-5

22748-G-0506 4 English

DRIVEMASTER PARTS

Parts Identification

ITEM DESCRIPTION QTY ITEM DESCRIPTION QTY 1 Journal Bracket 1 181 Air Chamber Seal 1 21 Ball Bearings 2 201 Face Seal 1 3 Sheave 1 442 Bearing Spacers 1 41 Bearing Nut 1 221 Air Chamber Cap Retaining Ring 1 5 Air Chamber Cap 1 231 Air Cartridge Assembly 1 61 O-Ring Seal 1 241 Air Cartridge Retaining Ring 1 91 Fan Mounting Disc/Studs 1 281 Friction Liner 1 501 Spring Housing/Piston 1 512 Jam Nut 1 171 Button Head Screws 8 551 Cage Nut (Used for repairs only) -

1 Denotes Repair Kit item. 2 Not used on all Fan Drives.

5 22748-G-0506 Repair Kits

Horton offers several different ways to repair or rebuild your DriveMaster Fan Drive.

DriveMaster Seal Kit (Part #994346)

Install a Seal Kit if an air leak has developed inside of the DriveMaster Fan Drive. The Seal Kit consists of the parts listed and described below:

Air Chamber Seal (#18): The air chamber seal forms an air seal between the air chamber and the spring housing/ piston assembly. The air chamber seal goes around the bottom half of the spring housing/piston assembly. O-Ring (#6): The o-ring forms an air seal between the air chamber and the air chamber cap. Air Cartridge (#23): The air cartridge fits inside the Journal shaft. Air pressure comes up through the center of the shaft, into and through the air cartridge, and into the air chamber. The cartridge has a spring loaded carbon tip that presses against the face seal and forms an air tight seal while the fan drive is spinning. Face Seal (#20): The face seal screws into the center of the air cap and forms an air seal with the carbon tip of the air cartridge. Retaining Rings (#22, #24): There are two retaining rings in the seal kit. The smaller retaining ring is used to hold the air cartridge inside the journal shaft. When installing this retaining ring, the beveled side must be facing the air cartridge. The larger retaining ring is used to hold the air cap in place. Button Head Screws (#17): The torx button head screws are used to attach the friction liner and the spring housing to the sheave. Alternately and evenly tighten the screws to 80 in lbs torgue. Cage Nut (#55): The cage nut is used to keep the spring housing/piston assembly together when removing from the sheave. It maintains pressure on internal springs after the button head screws are removed. T55 Torx Plus Bit (not pictured): The T55 torx plus bit is used to help remove the fan mounting disc from the jack bolt. O-Ring Lubricant (not pictured): Apply lubricant to the new air chamber cap o-ring and the air chamber seal before installation.

22748-G-0506 6 English

DriveMaster Super Kit

Install a Super Kit if the bearings are running rough or if the DriveMaster Fan Drive needs to be completely rebuilt due to excessive wear. The Super Kit consists of the parts listed and described below:

Spring Housing/Piston Assembly (#50): The spring housing/piston assembly is the internal mechanism that engages and disengages the DriveMaster fan drive when air pressure is either removed or applied. Fan Mounting Disc (#9): The fan mounting disc is the part that the fan is bolted on to. It is also the part that contacts the friction liner when the fan drive is engaged. The fan mounting disc is screwed onto the jack bolt. Check the fan mounting disc for blistering or damage. Friction Liner (#28): The friction liner is attached to the sheave on top of the spring housing assembly. Sheave Bearings (#2): Use a bearing press to remove old bearings and install new bearings into the center of the sheave. The bearings are prelubricated and sealed. They also contain markings that need to be aligned for proper installation (see sheave illustration Step 2A on page 14). If there are spacers in between the old bearings that were removed, reuse those spacers by positioning them between the new bearings before installation. Do Not remove the seals and attempt to lubricate the old or new bearings. Bearing Nut (#4): The bearing nut is used to hold the sheave onto the journal shaft. Air Chamber Seal (#18) O-Ring (#6) Air Cartridge (#23) Face Seal (#20) Retaining Rings (#22, #24) Button Head Screws (#17) Cage Nut (#55) T55 Torx Plus Bit (not pictured) O-Ring Lubricant (not pictured)

7 22748-G-0506 DriveMaster Friction Disc Kit

Install a Friction Disc kit if the fan mounting disc is damaged from blistering, excessive wear, or failure. The Friction Disc kit consists of the parts listed below (descriptions on previous page):

Fan Mounting Disc (#9) Friction Liner (#28) Button Head Screws (#17) Cage Nut (#55) T55 Torx Plus Bit (not pictured)

DriveMaster Friction Liner Kit (Part #994349)

Install a Friction Liner kit if the friction liner is worn. Check the fan mounting disc to make sure there is no excessive wear. If damage is evident use the DriveMaster Friction Disc kit. The Liner kit consists of the parts listed below (descriptions on previous page):

Friction Liner (#28) Button Head Screws (#17) Cage Nut (#55) T55 Torx Plus Bit (not pictured)

22748-G-0506 8 English

DriveMaster Bearing/Cartridge Kit

Install a Bearing/Cartridge Kit if the sheave bearings are running rough inside of the DriveMaster Fan Drive. The Bearing/Cartridge Kit consists of the parts listed below (descriptions on previous pages):

One Double Row Bearing Two-Single Row Bearings 55 55 17 17 2 2 2 23 23 24 24 4 4 20 20 5 5 6 6 22 22

Sheave Bearings (#2) Bearing Nut (#4) O-Ring (#6) Button Head Screws (#17) Face Seal (#20) Retaining Ring (#22) Air Cartridge (#23) Retaining Ring (#24) Cage Nut (#55) T55 Torx Plus Driver (not pictured) O-Ring Lubricant (not pictured)

DriveMaster Clutch Pack Kit

Install a Clutch Pack Kit if the DriveMaster Fan Drive needs to be completely rebuilt due to excessive wear. The Clutch Pack Kit consists of the parts listed below (descriptions on previous pages):

18

50 17 55

Button head Screws (#17) Air Chamber Seal (#18) Spring Housing/Piston (#50) Cage Nut (Used for Repair Only) (#55) T55 Torx Plus Driver (not pictured) O-Ring Lubricant (not pictured)

9 22748-G-0506 DISASSEMBLING THE FAN DRIVE

Tools Required

• 2” Socket Wrench • T55 Torx Plus Bit (994352) • T27 Torx Bit •Pry Bar • Ring Pliers • Screwdrivers

Disassembly

Fan Mounting Disc Removal and Inspection

1. Place the Fan Drive in a vise and clamp the Journal Bracket tight. Pry Bar

Torx Wrench NOTE Applying 80-120 PSI air pressure to the Fan Drive air inlet. This will aid in removal of the FMFD.

2. Loosen the Jack Bolt (left hand thread) by turning it counter-clockwise using a T55 Torx Plus Bit (Part# 994352). Air Line NOTE Use caution when handling the prybar on the Fan Mounting Disc. Permanent damage may occur if not properly supported. Best results are achieved ® with a flat blade tool like a Wonder Bar or a prybar Pry Bar that has a handle. Placement

NOTE In CCW rotation applications, a jam nut will be installed over the threads of the jack bolt. This nut must be removed (left hand thread) before loosening the jack bolt. Steps 1-2

22748-G-0506 10 English

3. Unscrew the Fan Mounting Disc from the Jack Bolt. Inspect the Fan Mounting Disc for wear or damage. (See examples below)

Fan Mounting Disc

Jack Bolt (left hand thread)

Step 3

Look for signs of damage or blistering

Fan Mounting Disc Fan Mounting Disc Good Condition Bad Condition

Spring Housing/Piston Assembly Removal

4. Hand-tighten the Cage Nut (from the Repair Kit) onto the Jack Bolt (left hand thread) over the Button Spring Housing. The Cage Nut will keep the Head Screws Spring Housing and Piston together as an assembly. It will also maintain pressure on the Friction Liner internal Springs after the Button Head Screws are removed. Cage Nut

Spring Remove air pressure from the unit before Housing/Piston proceeding to Step 5. Assembly

FAILURE TO RELEASE AIR PRESSURE MAY RESULT IN SERIOUS PERSONAL INJURY.

Do not disassemble the Spring Housing. Personal Steps 4-5 injury could occur. 5. Remove the 8 Button Head Screws and the Friction Liner using a T27 Torx Bit.

11 22748-G-0506 NOTE If you are installing either a Friction Liner (Part# 994349), Fan Disc Kit, or Clutch Pack Kit, skip to page 17, step 16.

6. Remove the Spring Housing/Piston Assembly.

7. Examine the inside of the Air Chamber for signs Spring Housing/ Piston Assembly of moisture and/or contaminants.

The Air Chamber should be clean and moisture- free (with the exception of the seal lubricant) . If not, a problem may exist in the vehicle air system Air Chamber and must be corrected before the Fan Drive is reinstalled.

Steps 6-7

Air Chamber Seals

Wear eye safety protection when removing Air Chamber Seal Retaining Ring to avoid serious injury.

8. Remove the Air Chamber Cap Retaining Ring. Retaining Ring

9. Gently and evenly pry the Air Chamber Cap out O-Ring Seal of the Sheave using two small screwdrivers placed 180° apart. Air Chamber Cap

10. Remove the O-Ring Seal and Face Seal from the Air Chamber Cap. Face Seal

11. Inspect the Face Seal for signs of wear. Wear indicates that dirt may exist in the air system.

If dirt or oil exists in the air system, the air system must be cleaned and dried before the Fan Drive is Steps 8-11 reinstalled.

22748-G-0506 12 English

Sheave and Sheave Bearings

12. Remove the Bearing Nut from the Journal Bracket Bearing Nut using a 2” Socket Wrench.

Journal Bracket

Step 12

13. Slide the Sheave and bearing assembly off the Journal Bracket. Sheave

Journal Bracket

Step 13

NOTE If you are only installing a Seal Kit (Part #994346), proceed to page 15, step 3.

TORQUE SPECIFICATIONS

ITEM DESCRIPTION TIGHTENING TORQUE

4 Bearing Nut 130 Ft. Lbs. [176 N•m]

12 Jack Bolt (left hand thread) 100 Ft. Lbs. [136 N•m]

17 Button Head Screws 80 In. Lbs. [9 N•m] 20 Face Seal 75-100 In. Lbs. [8.5-11.5 N•m]

51 Jam Nut 120 Ft-lbs [163 N•m]

13 22748-G-0506 REBUILDING THE FAN DRIVE

Sheave Bearings

1. Fully support the Sheave and press the Bearings out of the Sheave. NOTE Some Models of the DRIVEMASTER Fan Drive SUPPORT contain Bearing Spacers. Both Bearing Spacers PRESS must be positioned BETWEEN the Sheave TO Bearings REMOVE Bearings when the Sheave Bearings are replaced.

All Bearings are prelubricated and sealed. DO NOT SUPPORT remove the seals to lubricate the Bearings. Step 1

2. Fully supporting the Sheave, press the new Align the chevron markings on the bearings to form Sheave Bearings (or single bearing) into place, an arrow. The arrow may point in either direction. noting the position of the lip inside the Sheave. See Figures 2A, 2B, 2C.

NOTE Press on outer Press on Some DRIVEMASTER models utilize a single (one bearing race inner piece) Sheave Bearing. Repair with Kit #994353. when installing bearing new bearings race when NOTE removing When installing new bearings, you must press on old bearing the outer diameter ring of the bearing set to avoid damaging the bearing during installation. Step 2A

NOTE POSITION OF LIP Bearings (or single bearing)

Sheave

Bearings Spacers

Step 2B

SUPPORT

SUPPORT

PRESS

Step 2C

22748-G-0506 14 English

Air Cartridge

Retaining Ring Wear eye safety protection when removing Retaining Ring to avoid serious injury.

3. Remove the Retaining Ring. Step 3

4. Remove the Air Cartridge Assembly. Clean the Journal Bracket bore if necessary. Float Seal Tip 5. Apply O-Ring lubricant to the outside O-Rings of the new Air Cartridge Assembly.

6. Install the new Air Cartridge Assembly into the Journal Bracket.

7. Reinstall the Retaining Ring. Air Cartridge Assembly Step 4

The Retaining Ring must be fully seated in the O-Rings retaining ring groove to keep the Air Cartridge Assembly from moving. Also, the Retaining Ring is beveled. The curved side must be installed facing the Cartridge. The curve faces the Cartridge

Retaining Ring

Step 5

Sheave Replacement

8. Slide the Sheave onto the Journal Bracket.

9. Replace and tighten the Bearing Nut to 130 Ft. Lbs. [170 N•m] torque. Be sure that the Bearing Nut hex is facing up (see detail below).

Sheave Bearing Nut Detail Bearing Nut Journal (Hex faces up) Hex faces up Bracket

Relief points down toward Journal Bracket and Bearings Step 8 Step 9

15 22748-G-0506 Spring Housing/Piston Assembly Reassembly

Use extreme care when reassembling the Air Chamber components to avoid damage to the O-Ring and Air Chamber Seal.

10. Using a clean/dry cloth, clean both the Float Seal Air Chamber Cap Tip (see Air Cartridge illustration, Step 4) of the Air Cartridge Assembly as well as the Face Seal of the Air Chamber Cap. Use care not to scratch Retaining Ring seal surfaces. NOTE The new Face Seal is assembled with an O-ring. If the old Face Seal does not have an O-ring, remove it from the new Face Seal and apply thread sealant ® (Loctite 511 or similar) to the Face Seal threads. Sheave 11. Assemble the Air Chamber Cap and Face Seal. Lubricate the O-ring Seal with the fresh lubricant supplied in the kit and install it on the Air Chamber Steps 11-12 Cap. 12. Carefully set the Air Chamber Cap into the Sheave and install the Retaining Ring.

13. Lubricate the Air Chamber Seal and contact “V” of Seal faces Air Chamber Seal Detail surfaces with the fresh lubricant supplied in the down into kit. Sheave NOTE The entire tube of O-Ring lubricant should be used Do not apply when lubricating the new seals and contact grease beyond these areas. Seat Seal surfaces of the Sheave and Spring Housing/Piston evenly against Assembly. side and Sheave bottom groove (cross-section) surfaces.

Do not apply grease beyond Seal contact surface Steps 13-14 as it will cause improper Fan Drive function. Spring Housing/ 14. Install the Air Chamber Seal into the Sheave as Piston Assembly shown. Be sure the Seal is evenly seated against the side and bottom of the groove surfaces.

15. Carefully set the new Spring Housing/Piston Assembly from the Repair Kit into position. Air Chamber Gently rotate to align the mounting holes in the Seal assembly with the Sheave.

Steps 14-15

22748-G-0506 16 English

16. Set the new Friction Liner (from kit) into place. Handle the Friction Liner by the edges to avoid Button contamination. Head Screws

17. Alternately and evenly tighten the 8 Button Head Friction Liner Screws to 80 In. Lbs. [9 N•m] torque.

Cage Nut

To avoid personal injury, make sure the Button Head Spring Housing/ Screws are properly tightened to the specified torque Piston Assembly before applying air pressure - 80 In. Lbs. [9 N•m].

Fan Mounting Disc Reassembly Steps 16-17 18. Apply a minimum of 80 lbs. PSI of clean air to the air inlet.

NOTE Air must be applied to the air chamber to allow for easy removal of the Cage Nut and to ensure proper torque is applied to the Jack Bolt. Fan Mounting Disc 19. Remove the Cage Nut from the Spring Housing/ Piston Assembly.

20. Install the new Fan Mounting Disc (from kit) if applicable. Jack Bolt (left hand thread) Do not disassemble the Spring Housing. Personal injury could occur.

21. Tighten the Jack Bolt (left hand thread) to 100 Ft. Lbs. [136 N•m] torque. Steps 18-19 22. If a jam nut was present, apply Loctite® 204 (or equivalent) to the threads, reinstall over the jack bolt (left hand thread) and tighten to 120 Ft. lbs [163 N•m] torque.

23. Actuate the DriveMaster and check for proper engagement and disengagement of the Fan Mounting Disc. Check for air leaks at the bleed hole and around the Spring Housing/Piston Assembly.

If a problem exists, it must be corrected prior to mounting the Fan Drive onto the vehicle. If the problem is not corrected, the Fan Drive will fail prematurely. Steps 20-22

17 22748-G-0506 REINSTALLING THE FAN DRIVE

On the workbench, apply 90 psi [6.21 bar] clean air pressure and check the Fan Drive for air leaks. 1. Be sure the vehicle ignition is off, the vehicle's parking brake is applied, and the vehicle's wheels are blocked. NOTE Protect the radiator from possible damage from the fan during fan removal and fan drive installation.

2. Clean the Fan Drive mounting surface on the engine.

NOTE Most engines have multiple mounting locations. Be sure to use the correct holes for the application.

3. Bolt the Fan Drive to the engine. Use flat washers on each manufacturer’s approved bolt or studs - DO NOT use lock washers. Tighten the mounting bolts to the vehicle manufacturer’s specifications.

Correct belt adjustment and alignment is necessary for all belt driven components to assure longevity of component life. Over tightening of belts will shorten bearing life. Loose belts will cause excessive belt wear and shorten bearing life. Consult the equipment manufacturer and/or engine manufacturer specifications for proper belt adjustment.

4. Replace and tighten the belts to manufacturer’s specification.

The maximum fan diameter is 32''. If a larger fan diameter is required, contact Horton at 1-800-621-1320.

5. Check the fan for cracks or missing weights; then, remount the fan on the Fan Drive. Tighten the bolts and/or nuts to the vehicle manufacturer’s specifications.

6. Start the engine and let the air pressure build to at least 90 psi [6.21 bar]. Turn off the engine.

7. Manually engage and disengage the Fan Drive by opening and closing the electrical circuit going to the solenoid valve. For a normally-open electrical system, use a jumper across a sensor. For a normally- closed electrical system, open the circuit by disconnecting a sensor wire. With the Fan Drive engaged, recheck the entire system for air leaks, or activate the manual override switch (if equipped).

22748-G-0506 18 English

TROUBLESHOOTING

PROBLEM PROBABLE CAUSE SOLUTION

I. Air leaking from Fan Drive 1. Bad seals or air cartridge. 1. Install Repair Kit. bleed hole Bleed Hole

Journal Bracket

II. Premature Friction Lining failure 1. Obstructed fan. 1. Loose shroud, bent fan, 1. Find and remove obstruction, torn engine mounts, etc. repair or replace damaged parts. Install Repair Kit.

2. Low air pressure to Fan 2 a. Restricted air line. 2. a. Replace air line. Drive. Install Repair Kit. b. Restricted Solenoid Valve. b. Replace Solenoid Valve. Install Repair Kit. c. Low system air pressure. c. Repair system. Install Repair Kit. d. System air leak. d. Repair leak. Install Repair Kit.

3. Excessive cycling. 3. a. A/C freon overcharge. 3. a. Check and adjust to specifications. b. A/C pressure switch b. Check A/C pressure setting too low. switch. c. Poor ground or wire c. Check electrical connection. connections. d. Improper temperature d. Check temperature control setting. setting of all controls. Thermal Switch setting should engage the Fan Drive 10oF higher than the full open temperature of the thermostat. e. Faulty ECM. e. Check ECM.

19 22748-G-0506 PROBLEM PROBABLE CAUSE SOLUTION

II. Premature Friction Lining failure 3. Excessive cycling (continued) f. Faulty Thermal Switch. f. Replace the Thermal Switch. g. Restriction in front of g. Check for proper shutter radiator blocking air flow. operation, winter front or other restriction in or in front of the radiator. h. Faulty Air-Temp Switch. h. Replace the Air-Temp Switch. Air Problem

1. Solenoid Valve not exhausting 1. Check for plugged exhaust/ or engaging properly. intake port on the Solenoid Valve. Clean or replace the Solenoid Valve.

III. Fan Drive fails to engage/disengage Electrical Problem

1. Open/shorted circuit. 1. Check electrical connections.

2. Improperly wired. 2. Check wiring according to diagram.

3. Thermal Switch incorrect for 3. Check Thermal Switch application. application. Replace if wrong or defective.

4. Failed Solenoid Valve. 4. Replace the Solenoid Valve.

Air Problem

1. Air line restricted. 1. Check air line from solenoid to Fan Drive for kinks or obstructions.

2. Solenoid Valve defective. 2. Replace the Solenoid Valve. Check to see if air exhaust is restricted.

Piston will not actuate

1. Piston seized due to 1. Clean the air supply and contamination or dry seals. install a Rebuild Kit.

22748-G-0506 20 English

PROBLEM PROBABLE CAUSE SOLUTION

IV. Fan Drive cycles frequently Electrical Problem

1. Poor ground wire connection. 1. Check electrical connections.

2. Improper temperature control 2. Check temperature setting of settings. all controls. Thermal Switch should engage the Fan Drive 10o F higher than the full open temperature of the thermostat.

3. A/C Pressure Switch setting 3. Check A/C Pressure Switch. too low. Use higher switch.

4. Restriction in front of radiator, 4. Check shutter operation, blocking air flow. winter fronts, or obstruction in front of radiator.

5. Faulty Thermal Switch. 5. Replace the Thermal Switch.

6. Faulty Air-Temp Switch. 6. Replace the Air-Temp Switch.

7. Vehicle Coolant level too low. 7. Fill to manufacturer's recommended level.

V. Fan Drive engaged, 1. Restriction in front of radiator. 1. Make sure nothing is engine running hot. obstructing the air flow through the radiator.

2. Fan capacity not large 2. Refer to specifications. enough. 3. Problem in cooling system. 3. Refer to engine manual.

21 22748-G-0506 ~

TABLA DE CONTENIDOS

INTRODUCCIÓN ...... 23 Información General ...... 23 INFORMACIÓN PREVIA ...... 23 DESMONTANDO EL IMPULSOR DE VENTILADOR ...... 24 PARTES DEL DRIVEMASTER ...... 25 Identificación de partes ...... 25 Kits de reparación ...... 26 DriveMaster Kit de sellado (N/P 994346) ...... 26 DriveMaster Super Kit...... 27 DriveMaster Disco de Fricción ...... 28 DriveMaster Pastas de Fricción (N/P 994349) ...... 28 Kit de baleros y cartucho de aire del DriveMaster..... 29 Paquete del clutch DriveMaster ...... 29 DESENSAMBLE DEL DRIVEMASTER...... 30 Herramientas requeridas ...... 30 Desensamble ...... 30 Desmontaje del disco de fricción e inspección ...... 30 Desmontaje de la carcaza de resortes...... 31 Sellos de la cámara de aire ...... 32 Polea y sus baleros...... 33 ESPECIFICACIONES DE PAR ...... 33 RECONSTRUCCIÓN DEL DRIVEMASTER ...... 34 Baleros de la polea ...... 34 Cartucho de aire ...... 35 Montaje de la polea ...... 35 Montaje de la Carcaza de resortes ...... 36 Montaje del disco de fricción ...... 37 MONTAJE DEL DRIVEMASTER ...... 38 PROBLEMAS Y SOLUCIONES ...... 39

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INTRODUCCIÓN

Información General

Horton utiliza los siguientes avisos especiales para advertir sobre posibles problemas de seguridad que podrían producir heridas de gravedad y para proporcionar información para prevenir daños al equipo.

PELIGRO Se utiliza para indicar la presencia de un peligro que podría producir heridas graves, mortales ó daños serios a la propiedad.

ADVERTENCIA Se utiliza para indicar la presencia de un peligro que podría producir heridas graves, mortales ó daños serios a la propiedad.

PRECAUCION Se utiliza para indicar la presencia de un peligro que puede ó podría producir heridas leves, ó daños a la propiedad.

NOTA Se utiliza para indicar información importante relativa a la instalación, el funcionamiento ó el mantenimiento, pero que no implica riesgos personales ni a la propiedad.

INFORMACIÓN PREVIA

Se deben seguir las normas de seguridad de la compañía, las cuales deben ser iguales o mejores con respecto a las normas de seguridad establecidas por el gobierno federal y estatal para talleres de reparación. Se debe familiarizar con todas las instrucciones y procedimientos de instalación antes de comenzar a trabajar con esta unidad.

NOTA El cambio de componentes y/o la reparación de su DriveMaster de Horton debe llevarse a cabo en la fabrica de Horton ó con un Distribuidor Autorizado ó Agencia del Fabricante del vehículo para mantener la cobertura de la Garantía durante el período de la misma.

Antes de reparar su DriveMaster, tome nota del número de serie, Número de parte del componente, fecha de instalación y kilometraje del vehículo. Numero De Parte y Numero De Serie

No. De serie ______

No. Parte del componente ______

Fecha de Instalación ______

Kilometraje del vehículo ______

23 22748-G-0506 ~

DEMONTAJE DEL IMPULSOR DE VENTILADOR

NOTA El procedimiento de desmontaje del DriveMaster varía de un vehículo a otro . Refiérase al manual de Servicio para una detallada descripción del proceso. En general proceda como se indica a continuación:

1. Apague el motor, aplique los frenos de estacionamiento y bloquee las ruedas del vehículo.

NOTA Proteja el radiador de posibles daños durante el desmontaje y montaje del DriveMaster.

2. Desmonte el ventilador del DriveMaster

3. Purgue el aire del tanque de almacenamiento del vehículo y desconecte la manguera de aire del DriveMaster.

4. Afloje y desmonte las bandas.

NOTA Debido al peso del DriveMaster 15.88 a 24.95 kg se recomienda el uso de un malacate para la maniobra.

5. Remueva los tornillos del soporte del DriveMaster y levántelo para sacarlo del compartimiento del motor.

Tornillos de montaje grado 8 Impulsor de ventilador

Tuercas grado 8

Pasos 1 - 5

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PARTES DEL DRIVEMASTER

Identificación de Partes

ART DESCRIPCIÓN CANT ART DESCRIPCIÓN CANT 1 Soporte con flecha 1 181 Sello de la cámara de aire 1 21 Baleros de bolas 2 201 Sello Frontal 1 3 Polea 1 442 Espaciador de baleros 1 41 Tuerca de baleros 1 221 Retén del tapón cámara aire 1 5 Tapón de cámara de aire 1 231 Cartucho aire ensamblado 1 61 Aro sello (O-ring) 1 241 Retén del cartucho de aire 1 91 Disco de fricción (birlos) 1 281 Pastas de fricción 1 501 Carcaza de resortes (pistón) 1 512 Contratuerca 1 171 Tornillos Torx 8 551 Tuerca circular (solo para reparaciones) -

1 Artículo del kit de reparación 2 No se utiliza en todos los DriveMaster

25 22748-G-0506 Espanol

Kits de Reparación

Horton ofrece varias maneras de reparar su DriveMaster.

DriveMaster Kit de sellado (N/P 994346)

Instale un kit de sellado, si se ha desarrollado una fuga de aire en el interior del DriveMaster. El kit de sellado contiene los siguientes componentes:

Sello de la cámara de aire (#18): El sello de la cámara de aire forma el sello de aire entre la carcaza de resortes y la cámara de aire. Este sello se coloca alrededor y en la parte inferior de la carcaza de resortes. Aro sello (O-ring #6): El O-ring forma el sello de aire entre la cámara y el tapón de la cámara. Cartucho de aire (# 23): El cartucho de aire se aloja en el barreno de la flecha del soporte. La presión de aire pasa por el centro del cartucho a la cámara de aire. El cartucho tiene una punta flotante de carbón que se presiona contra el sello frontal y forma un sello perfecto de aire mientras el DriveMaster gira. Sello frontal (# 20): El sello frontal se atornilla en el centro del tapón de la cámara de aire y forma el sello de aire con la punta de carbón del cartucho de aire. Anillos retén (#22, # 24): Hay dos anillos retén en el kit. El pequeño se utiliza para detener el cartucho de aire dentro de la flecha. Cuando instale este anillo asegúrese que la parte curva vaya hacia el cartucho de aire. El grande se utiliza para asegurar el tapón de la cámara en su lugar. Tornillos Torx (# 17): Los tornillos Torx se utilizan para fijar las pastas de fricción y la carcaza de resortes a la polea. Apriete estos tornillos siguiendo un patrón de estrella a 80 lbs pulg de par. Tuerca Circular (# 55): La tuerca circular se emplea para mantener la carcaza de resortes ensamblada cuando se desmonta de la polea. Mantiene la presión de los resortes internos después que los tornillos Torx han sido retirados. Herramienta Torx T55 (no se muestra): Se utiliza para desmontar el disco de fricción del tornillo central. Lubricante para O-ring (no se muestra): Aplique el lubricante al nuevo O-ring del tapón de la cámara de aire y al sello de la cámara de aire antes de instalarse.

22748-G-0506 26 Espanol~

DriveMaster Super Kit

Instale un Super Kit si los baleros producen ruido ó si el DriveMaster necesita ser completamente reparado debido a desgaste excesivo. El Super Kit consiste en las partes que se describen a continuación:

Carcaza de resortes/pistón ensamblado (# 50): La carcaza de resortes es un mecanismo interno que embraga y desembraga al DriveMaster cuando la prsion de aire es removida ó aplicada. Disco de Fricción ( # 9): El disco de fricción es la parte donde se fija el ventilador y también la parte donde las pastas de fricción hacen contacto cuando se embraga el DriveMaster. El disco de fricción se atornilla al tornillo central. Revise que el disco de fricción no muestre desprendimiento de material ó daño. Pastas de fricción (# 28): Las pastas de fricción se fijan a la polea encima de la carcaza de resortes. Baleros de la polea (# 2): Utilice una prensa para desmontar los baleros usados e instalar los nuevos en la flecha del soporte. Los baleros son prelubricados y sellados, también están marcados, de manera que necesitan alinearse para instalarse apropiadamente (vea la ilustración 2A, página 34). Si existe un espaciador entre ellos, vuelva a utilizar este entre los nuevos al momento de instalarse. No remueva los sellos e intente lubricar los baleros nuevos ó usados. Tuerca de baleros (# 4): Esta se utiliza para mantener la polea en la flecha del soporte. Sello de la cámara de aire (# 18) Aro sello O-ring (# 6) Cartucho de aire (# 23) Sello frontal (# 20) Anillos retén (# 22, # 24) Tornillos Torx (# 17) Tuerca Circular (# 55) Herramienta Torx T55 (no se muestra) Lubricante para O-ring (no se muestra)

27 22748-G-0506 DriveMaster Kit de Disco de fricción

Instale un kit de Disco de fricción si el disco de fricción está dañado con pérdida de material o desgaste excesivo. El kit de disco de fricción contiene las partes que se describen a continuación:

Disco de fricción (# 9) Pastas de fricción (# 28) Tornillos Torx (# 17) Tuerca Circular (# 55) Herramienta Torx T55 (no se muestra)

DriveMaster Kit de pastas de fricción (N/P 994349)

Instale un kit de pastas de fricción cuando las pastas están gastadas. Revise el disco de fricción y asegúrese que no muestra desgaste excesivo. Si hay daño evidente utilice un kit de disco de fricción. El kit de pastas de fricción contiene los componentes que se describen a continuación:

Pastas de fricción (# 28) Tornillos Torx (# 17) Tuerca Circular (# 55) Herramienta Torx T55 (no se muestra)

22748-G-0506 28 Espanol~

Kit de baleros y cartucho de aire del DriveMaster

Instale un kit de baleros y cartucho de aire, si los baleros de la polea del DriveMaster hacen ruido al girar. El kit de baleros y cartucho de aire contiene las partes listadas abajo (descripciones en páginas anteriores):

Un balero de doble hilera de bolas Dos baleros de una hilera de bolas 55 55 17 17 2 2 2 23 23 24 24 4 4 20 20 5 5 6 6 22 22

Baleros de la polea (#2) Tuerca de baleros (#4) Aro sello (#6) Tornillos cabeza de gota (#17) Sello frontal (#20) Anillo reten (#22) Cartucho de aire (#23) Anillo reten (#24) Tuerca moleteada (#55) Llave Torx T55 (no ilustrada) Lubricante para aro sellos (no ilustrada)

Paquete del clutch DriveMaster

Instale un paquete del clutch DriveMaster, si el DriveMaster requiere ser completamente reconstruido debido a un desgaste excesivo. El paquete del clutch contiene las partes listadas abajo (descripcion en páginas anteriores) 18

50 17 55

Tornillos cabeza de gota (#17) Sello de la cámara de aire (#18) Carcaza de resortes/Pistón (#50) Tuerca moleteada (#55) Llave Torx T55 (no ilustrada) Lubricante para aro sellos (no ilustrada)

29 22748-G-0506 DESENSAMBLE DEL DRIVEMASTER

Herramientas Requeridas

· Dado de 2” · Herramienta Torx T55 (994352) · Herramienta Torx T27 · Barra plana · Pinzas para anillo retén · Desarmadores

Desensamble

Desmontaje e inspección del disco de fricción

1. Coloque el DriveMaster en un tornillo de banco y sujételo por el soporte.

NOTA Barra plana Aplique una presión de aire de 80 – 120 PSI al Herramienta DriveMaster. Esto ayudará al desmontaje del disco Torx de fricción.

2. Afloje el tornillo central (rosca izquierda) girando en el sentido contrario al reloj empleando la herramienta Torx T55 (994352)

NOTA Línea de aire Tenga cuidado cuando maneje la barra plana al desmontar el disco de fricción. Puede producirse daño si no se soporta adecuadamente. Se obtienen mejores resultados si se utiliza una herramienta como la “Wonder bar”® ó una barra con maneral. Colocación de NOTA La barra plana En aplicaciones de rotación en sentido contrario a las manecillas del reloj, se instalará una contratuerca en el tornillo central. Esta tuerca debe removerse (rosca izquierda) antes de aflojar el tornillo central. Pasos 1 - 2

22748-G-0506 30 Espanol~

3. Desatornille el disco de fricción del tornillo central. Revise que el disco de fricción este libre de marcas de desgaste. (Ejemplos se muestran en las fotografías abajo.)

Disco de fricción

Tornillo central (rosca izq.)

Paso 3

Busque signos de desgaste o material desprendido. Disco de fricción en buenas condiciones Disco de fricción en malas condiciones

Desmontaje de la Carcaza de resortes/pistón ensamblado

4. Apriete con la mano la tuerca circular (que viene en el kit) en el tornillo central (rosca izq.) sobre Tornillos Torx la carcaza de resortes. Esta tuerca mantiene a la carcaza de resortes y al pistón juntos como un ensamble. También mantiene la presión de los Pastas de resortes internos después que se han retirado los fricción tornillos Torx. Tuerca circular

ADVERTENCIA La carcaza de Retire la presión de aire antes de proceder con resortes el paso 6.

PELIGRO NO RETIRAR LA PRESION DE AIRE PUEDE OCASIONAR DANOS PERSONALES SEVEROS.

ADVERTENCIA Pasos 4 - 5 No desensamble la carcaza de resortes. Daños personales pueden ocurrir. 5. Retire los 8 tornillos Torx y las pastas de fricción utilizando la herramienta Torx T27.

31 22748-G-0506 NOTA Si usted está instalando ya sea las Pastas de fricción (N/P 994349), el disco de fricción, ó paqueta del clutch DriveMaster, vea la página 37, paso 16.

6. Desmonte la carcaza de resortes/pistón ensamblado. Carcaza de resortes (pistón) 7. Examine el interior de la cámara de aire y busque signos de humedad ó contaminantes.

ADVERTENCIA La cámara de aire debe estar limpia y libre de humedad, solamente debe existir el lubricante del sello. Si no es así existe un problema en el sistema Cámara de aire de aire del vehículo, el cual debe ser corregido antes de volver a montar el DriveMaster.

Pasos 6 - 7

Sellos de la Camara de Aire

ADVERTENCIA Debe utilizar lentes de seguridad cuando remueva Sello de la cámara anillos retén para evitar serios daños. de aire

8. Retire el anillo retén del tapón de la cámara de aire. Anillo retén

9. Suavemente retire de su sitio el tapón de la cámara de Aro sello aire, utilizando para ello dos desarmadores pequeños (O-ring) colocándolos a 180°. Tapón de la cámara de aire Sello frontal 10. Retire el sello frontal y el O-ring del tapón de la cámara de aire.

11. Inspeccione el sello frontal busque signos de desgaste. Si hay desgaste significa que hay contaminantes en el sistema de aire del vehículo.

PRECAUCION Pasos 8 – 11 Si hay contaminante o aceite en el sistema de aire, éste debe limpiarse y secarse antes de instalar nuevamente el DriveMaster.

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Polea y Sus Baleros

12. Quite la tuerca de baleros empleando un dado de 2”.

Tuerca de baleros Soporte

Paso 12

13. Desmonte la polea con sus baleros de la flecha del soporte. Polea

Soporte

Paso 13

NOTA Si está instalando solamente el kit de sellado (Parte #994346), pase a la pág. 35 paso 3.

ESPECIFICACIONES DE PAR

ART DESCRIPCION PAR DE APRIETE

4 Tuerca de baleros 176 N•m (130 ft lbs) 12 Tornillo central(rosca izquierda) 136 N•m (100 ft lbs)

17 Tornillos Torx 9 N•m (80 in lbs)

20 Sello frontal 8.5 – 11.5 N•m (75-100 in lbs)

51 Contratuerca 163 N•m (120 Ft-lbs)

33 22748-G-0506 RECONSTRUCCION DEL DRIVEMASTER

Baleros de la Polea

1. Soporte completamente la polea y extraiga los baleros.

NOTA Algunos modelos del DriveMaster tienen SOPORTE separadores entre los baleros. Estos espaciadores deben colocarse con los baleros nuevos. PRESIONE Baleros PARA EXTRAER Todos los baleros son sellados y prelubricados. No quite los sellos para lubricar los baleros. SOPORTE Paso 1

2. Soporte completamente la polea e introduzca los Alinie las marcas de los baleros formando una flecha, nuevos baleros (ó balero único) en la polea. Ver figuras esta puede apuntar en cualquier dirección. 2A, 2B, 2C. Presione en la NOTA Presione en pista Algunos DriveMaster utilizan solamente un balero. la pista interior Reparelo con el Kit # 994353. exterior para para insertar los extraer NOTA baleros Cuando instale los nuevos baleros, se debe hacer la los presión solo en la pista exterior, para evitar daño a baleros los mismos. usados Paso 2A

NOTE LA POSICION DEL LABIO Baleros (ó un solo balero)

Polea

Separador de baleros

Paso 2B

SOPORTE

SOPORTE

PRESIONE

Paso 2C

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Cartucho de aire

ADVERTENCIA Anillo retén Use lentes de seguridad cuando desmonte anillos retén, para evitar daños personales.

3. Desmonte el anillo retén.

4. Desmonte el cartucho de aire. Limpie el barreno de la flecha si es necesario. Paso 3

5. Aplique lubricante en el exterior de los O-ring del nuevo Punta de cartucho. carbón flotante 6. Inserte el nuevo cartucho en el barreno de la flecha.

7. Reinstale el anillo retén.

PRECAUCION El anillo retén debe asentar en la ranura para Cartucho de aire mantener el cartucho en su posición. Paso 4 También el anillo retén tiene curvatura que va hacia el cartucho. O-Rings

Curva hacia el cartucho

Anillo retén Paso 5

Montaje de la Polea

8. Deslice la polea en la flecha del soporte.

9. Coloque y apriete la tuerca de baleros a 170 N•m (130 ft lbs) de par. Asegúrese que el hexágono de la tuerca está hacia arriba (ver detalle).

Detalle de la tuerca de Polea Tuerca de baleros baleros Hexágono Cara hexagonal Soporte con hacia arriba hacia arriba flecha

Alto relieve hacia abajo, contra los Paso 8 Paso 9 baleros.

35 22748-G-0506 Montaje de Carcaza de Resortes

PRECAUCION Tenga mucho cuidado al ensamblar los componentes de la cámara de aire para evitar dañar el O-ring y el sello de la cámara.

10. Utilizando un trapo limpio y seco, limpie tanto la punta flotante de carbón como el sello frontal, tenga cuidado Tapón de la cámara de de no rayar las superficies de contacto. aire Anillo retén NOTA El nuevo sello frontal tiene un O-ring. Si el anterior no tiene este O-ring, quitelo y aplique sellador a la rosca (Loctite 511 ó similar) del nuevo sello frontal.

11. Ensamble el sello frontal en el tapón de la cámara de Polea aire. Lubrique el O-ring y móntelo en el tapón de la cámara de aire. Pasos 11-12 12. Con mucho cuidado coloque el tapón de la cámara de aire en la polea e instale el anillo retén. Labios V del sello Detalle del sello 13. Lubrique el sello de la cámara de aire y las superficies Van hacia abajo de la cámara de contacto con el lubricante que se surte en el kit.

NOTA No aplique grasa Todo el lubricante que viene en el tubo debe usarse ademas de estas Asiente el para lubricar los sellos y las superficies de areas. sello contra contacto de la polea y la carcaza de resortes. paredes Polea lateral y fondo. PRECAUCION (Sección transversal) No aplique grasa mas alla de los sellos y las superficies de contacto, ya que puede ocasionar Pasos 13-14 un mal funcionamiento.

14. Instale el sello de la cámara de aire en la polea como Carcaza de se muestra. Asegúrese que el sello asienta perfecta- resortes/ Pistón mente tanto en la pared lateral como la del fondo. ensamblado

15. Cuidadosamente asiente la carcaza de resortes en su posición. Gire suavemente para alinearla con los Sello de cámara barrenos de la polea. De aire

Pasos14-15

22748-G-0506 36 Espanol~

16. Coloque las nuevas pastas de fricción en su lugar. Maneje las pastas tomándolas por las aristas para Tornillos Torx evitar contaminación.

17. Apriete los tornillos 8 Torx en patrón de estrella, a 9 Pastas de N•m (80 in lbs) de par. fricción Tuerca ADVERTENCIA circular Para evitar daños personales asegúrese que los Carcaza de tornillos Torx estén apretados al par especificado resortes antes de aplicar la presión de aire.

Pasos 16 - 17

Montaje del disco de fricción

18. Aplique una presión mínima de aire de 80 PSI en la

entrada de aire del DriveMaster Disco de fricción NOTA El aire debe aplicarse a la cámara para facilitar el desmontaje de la tuerca circular y asegurar el par de apriete del tornillo central.

19. Remueva la tuerca circular de la carcaza de resortes. Tornillo central 20. Instale el nuevo disco de fricción (que viene en el (rosca izq.) kit) si aplica.

21. Apriete el tornillo central (rosca izquierda) a 136 N•m (100 ft lbs) de par.

22. Si había una contratuerca, aplique Loctite® 204 (ó Pasos 18 – 19 equivalente)a la rosca y rosquela en el tornillo central (rosca izquierda) apretando a un par de 163 N•m, (120 lbs pie).

23. Active el DriveMaster y verifique que el disco de fricción embrague y desembrague apropiadamente. También verifique que no existan fugas de aire por el barreno de sangrado y alrededor de la carcaza de resortes.

PRECAUCION Si existe algún problema, debe corregirse antes de montar el DriveMaster en el vehículo. Si no se corrige el problema, el DriveMaster fallará prematuramente. Pasos 20-22

37 22748-G-0506 MONTAJE DEL DRIVEMASTER

ADVERTENCIA En el banco de trabajo aplique una presión de aire 6.21 bar (90 PSI) y verifique que no existan fugas en el DriveMaster.

1. Asegúrese que el interruptor de ignición esté en apagado, que los frenos de estacionamiento están aplicados y que las ruedas del vehículo están bloqueadas.

NOTA Proteja el radiador de posibles daños durante la instalación del DriveMaster.

2. Limpie la superficie del motor donde se montará el DriveMaster.

NOTA La mayoría de los motores tienen barrenos multiples para el montaje, asegúrese de usar los correctos para la aplicación.

3. Atornille el DriveMaster al motor, empleando roldanas planas en cada tornillo ó birlo. NO UTILICE ROLDANAS DE PRESION. Apriete los tornillos de acuerdo al par recomendado por el fabricante.

PRECAUCION Es necesario hacer un alineamiento y ajuste correcto de las bandas, para asegurar una larga vida de las mismas. Si se sobretensionan causaran un desgaste prematuro de baleros. Bandas flojas ocasionarán un desgaste excesivo de las mismas y una menor vida de los baleros. Consulte las especificaciones del fabricante de las bandas ó del fabricante del motor para un ajuste apropiado.

4. Coloque y ajuste las bandas de acuerdo a especificaciones.

ADVERTENCIA El máximo diámetro de ventilador es de 32”. Si se requiere uno mayor, contacte a Horton México al (52) 5360 1506 ó a Horton, Inc. Al 1-800-621-1320

5. Revise que el ventilador no muestre rajaduras ó falta de pesos de balance, monte el ventilador en el DriveMaster. Apriete los tornillos y/o tuercas de acuerdo a las especificaciones del fabricante.

6. Ponga en marcha el motor y permita que se eleve la presión de aire a 6.21 bar (90 PSI) apague el motor.

7. Manualmente embrague y desembrague el DriveMaster cerrando y abriendo el circuito eléctrico que va a la válvula solenoide. En un circuito eléctrico normalmente abierto, utilice un puente en las terminales de un sensor. En un circuito eléctrico normalmente cerrado, abra el circuito desconectando una terminal de un sensor. Con el DriveMaster embragado verifique nuevamente que no existan fugas.

22748-G-0506 38 Espanol~

PROBLEMAS Y SOLUCIONES

PROBLEMA PROBABLE CAUSA SOLUCION

I. Fuga de aire por el 1. Mal sellado ó cartucho de 1. Instale un kit de reparación. barreno de sangrado aire.

Barreno de sangrado

Soporte

II. Falla prematura de pastas de fricción 1. Ventilador obstruido. 1. Tolva suelta, ventilador con 1. Localice y elimine la falla, aspas dobladas, motor mal repare ó reemplace las partes montado. dañadas. Instale el kit de reparación.

2. Llega baja presión de aire al 2 a. Línea de aire obstruida. 2. a. Reemplace la línea de aire. DriveMaster. Instale un kit de reparación. b. Válvula obstruida. b. Reemplace válvula. Instale kit de reparación. c. Baja presión en el sistema. c. Repare el sistema. Instale kit de reparación. d. Fuga de aire en el sistema. d. Repare la fuga. Instale kit de reparación.

3. Cicleo excesivo. 3. a. Sobrecarga de freón. 3. a. Revise y ajuste a especificaciones. b. Presión prefijada de freón b. Revise interruptor AC. demasiado baja. c. Tierra falsa ó conexiones c. Revise conexiones. flojas. d. Temperaturas prefijadas d. Revise temperaturas erróneas. prefijadas en todos los controles. La temperatura prefijada en el interruptor térmico debe embragar del DriveMaster 10°F arriba de la temperatura de apertura total del termostato.

e. Falla del ECM. e. Revise ECM.

39 22748-G-0506 PROBLEMA PROBABLE CAUSA SOLUCION

II. Falla prematura de las pastas de fricción 3. Cicleo excesivo (continúa) f. Interruptor térmico f. Reemplace el interruptor defectuoso. térmico.

g. Restricción frente al g. Verifique que las cortinas radiador bloquea flujo de de invierno trabaje aire. apropiadamente, ó localice cualquier otra obstrucción en ó frente al radiador.

h. Interruptor térmico de aire h. Reemplace el interruptor defectuoso. térmico del aire.

Problema de aire

1. Válvula no deja escapar el aire 1. Verifique las conexiones a la ó no embraga apropiadamente. válvula. Limpie ó reemplace la válvula.

III. Falla del DriveMaster al embragar ó desembragar Problema Eléctrico

1. Circuito abierto ó en corto. 1. Revise conexiones eléctricas.

2. Conexiones impropias. 2. Verifique si el alambrado está de acuerdo a diagrama.

3. Interruptor térmico no 3. Revise aplicación del adecuado para la aplicación. interruptor térmico. Cambie si está mal ó defectuoso.

4. Falla de la válvula solenoide. 4. Cambie válvula.

Problema de aire

1. Línea de aire obstruida. 1. Revise obstrucciones de la línea de aire de la válvula al DriveMaster.

2. Válvula solenoide defectuosa. 2. Cambie la válvula. Verifique que el puerto de escape no está obstruido.

El Pistón no actúa

1. Pistón atorado debido a 1. Limpie el abastecedor de aire contaminación ó sellos e instale un kit de reparación. resecos.

22748-G-0506 40 Espanol~

PROBLEMA PROBABLE CAUSA SOLUCION

IV. DriveMaster ciclea frecuentemente Problema eléctrico

1. Tierra falsa. 1. Revise conexiones eléctricas.

2. Temperatura prefijada errónea. 2. Revise las temperaturas prefijadas de todos los controles. El interruptor térmico debe embragar al DriveMaster a 10°F arriba de la temperatura de máxima apertura del termostato.

3. Presión prefijad del freón 3. Revise la presión del demasiado baja. interruptor de AC. Utilice un interruptor de mayor presión.

4. Obstrucción frente al radiador 4. Revise operación de las bloquea flujo de aire. cortinas de invierno, ó alguna obstrucción en el ó frente al radiador.

5. Interruptor térmico defectuoso. 5. Reemplace el interruptor térmico.

6. Interruptor térmico de aire 6. Reemplace el interruptor defectuoso. térmico de aire.

7. Nivel del refrigerante del motor 7. Rellene al nivel recomendado demasiado bajo. por el fabricante.

V. Motor caliente aun con el 1. Obstrucción frente el radiador. 1. Asegúrese que no existe DriveMaster embragado. obstrucción de flujo de aire a través del radiador.

2. La capacidad del ventilador no 2. Revise especificaciones. es suficiente.

3. Problema en el sistema de 3. Revise el manual del motor. enfriamiento.

41 22748-G-0506 Horton, Inc. 2565 Walnut St. Roseville, MN 55113, USA Phone: +1 (651) 361-6400 Toll-free: +1 (800) 621-1320 Fax: +1 (651) 361-6801 Web site: www.hortonww.com e-mail: [email protected]

©2006 Horton, Inc. All rights reserved. Printed in USA Horton Inc. is a Horton Holding, Inc. company. Horton Holding, Inc., Roseville, MN ,USA QS-9000 certified. EA09-008 PACCAR 10/15/2009 RESPONSE 15 horton-dm22742 Fan Drive Maintenance Training Manual

22742M-B-0202 TABLE OF CONTENTS

INTRODUCTION ...... 3 General Information...... 3 LESSON 1: FAN DRIVE SYSTEM ...... 4 1. Operation ...... 4 2. Control System ...... 5 LESSON 2: CONTROL COMPONENTS ...... 6 1. Engine Coolant Thermal Switch...... 6 2. Refrigerant Pressure Switch ...... 6 3. Solenoid Valve...... 7 LESSON 3: ELECTRICAL CONTROL SYSTEMS (ECM) ...... 8 1. Electronic Control Module...... 8 2. Sensors ...... 9 LESSON 4: ELECTRICAL CONTROL SYSTEMS (NON-ECM) ...... 10 1. Types of Electrical Control Systems ...... 10 2. Normally-Open Electrical Controls ...... 11 3. Normally-Closed Electrical Controls...... 12 4. Comparison - Open/Closed Electrical Controls ...... 13 5. Summary ...... 13 LAB ACTIVITY - FAN DRIVE CONTROL COMPONENTS ...... 14 REVIEW QUESTIONS - FAN DRIVE CONTROL SYSTEMS ...... 15 Review Answers - Fan Drive Control Systems ...... 18 PRIOR TO SERVICING ...... 21 LESSON 5: DRIVEMASTER PARTS AND REPAIR KITS...... 22 1. Parts Identification ...... 22 2. Repair Kits ...... 23 1. DriveMaster Seal Kit (Part #994346)...... 23 2. DriveMaster Super Kit (Part #994347) ...... 24 3. DriveMaster Friction Disc Kit (Part #994348) ...... 24 4. DriveMaster Friction Liner Kit (Part #994349) ...... 24 LESSON 6: REMOVING THE FAN DRIVE ...... 26 LESSON 7: DISASSEMBLING THE FAN DRIVE ...... 27 1. Tools Required ...... 27 2. Disassembly ...... 27 Fan Mounting Disc Removal and Inspection...... 27 Spring Housing/Piston Assembly Removal ...... 29 Air Chamber Seals...... 30 Sheave and Sheave Bearings ...... 30 Air Cartridge Removal ...... 31 LESSON 8: REBUILDING THE FAN DRIVE ...... 31 1. Torque Specifications ...... 31 2. Rebuilding ...... 31 Sheave Bearing Replacement ...... 31 Air Cartridge ...... 32 Spring Housing/Piston Assembly Reassembly ...... 33 Fan Mounting Disc Reassembly ...... 34 LESSON 9: REINSTALLING THE FAN DRIVE ...... 35 LESSON 10: PREVENTIVE MAINTENANCE (PM) ...... 36 1. Introduction ...... 36 2. Weekly PM ...... 36 3. 25,000 Mile [40,000 Km] PM ...... 37 LESSON 11: TROUBLESHOOTING ...... 38 REVIEW QUESTIONS - FAN DRIVE SERVICE ...... 41 Review Answers - Fan Drive Service ...... 44 FINAL TEST ...... 47 Final Test Answers ...... 52

2 22742M-A-0901 INTRODUCTION

General Information

Introduction This student manual for the technical course, DriveMaster Heavy Duty Fan Drive Maintenance, is designed to train heavy duty diesel technicians how to perform preventive and corrective maintenance on Horton heavy duty DriveMaster Fan Drives.

The manual, video and CD may be used in the classroom with an instructor or in a self-study mode. After completion of this course, take the Final Test at the end of this student manual. Mail your Final Test to the following address to receive a Certified Horton Technician toolbox sticker and a Horton Certificate of Achievement:

Horton, Inc. 2565 Walnut St. Roseville, MN 55113 651-361-6400 1-800-621-1320 Website: www.hortoninc.com E-mail: [email protected] Horton uses the following special notices to give warning of possible safety related problems which could cause serious injury and provide information to help prevent damage to equipment.

Danger is used to indicate the presence of a hazard which will cause severe personal injury, death, or substantial property damage if the warning is ignored.

Warning is used to indicate the presence of a hazard which can cause severe personal injury, death, or substantial property damage if the warning is ignored.

Caution is used to indicate the presence of a hazard which will or can cause minor personal injury or property damage if the warning is ignored.

NOTE Note is used to notify people of installation, operation, or maintenance information which is important but not hazard related.

In accordance with Horton’s established policy of constant product improvement, the specifications contained in this manual are subject to change without notice and are based on the latest information available at the time of printing.

22742M-B-0202 3 LESSON 1: FAN DRIVE SYSTEM

Learning Objectives 1.1 Operation • Recognize the purpose and advantages of a Fan Drive.

Heavy Duty Fan Drive

Fan Radiator

NOTE: When engaged, the Fan Drive activates the fan to cool the engine by pulling air through An engaged Fan Drive pulls air the radiator. Depending on the size and rotational speed of the fan, as much as 70-75 HP through the radiator to cool the may be needed to run the Fan. The Fan Drive engages only when needed resulting in engine. additional horsepower for drive axles, less noise, and increased fuel economy. Due to these benefits, most new diesel powered vehicles are equipped with a Horton On/Off Fan Drive.

4 22742M-B-0202 1.2 Control System Learning Objectives • Describe the basic operation of the Fan Drive control system.

To Ignition • Identify the components of a Fan Air Filter Drive electrical control system. Manual Override Switch • Describe how air pressure engages/disengages the Thermal Switch DriveMaster Fan Drive.

A/C Refrigerant Pressure Switch

Solenoid Valve Fan Drive

Air Supply

The illustration above depicts an independent Fan Drive control system. The electrically controlled solenoid valve engages and disengages the Fan Drive by regulating its air pres- sure on and off.

The electrical circuit to the solenoid valve contains three switches. Any of these three switches may activate the solenoid and engage the Fan Drive:

•a thermal switch sensing the engine coolant temperature.

•a refrigerant pressure switch in the vehicle’s air conditioning system.

• an optional manual override switch located on the vehicle’s dashboard.

The DriveMaster Fan Drive is spring-engaged and disengages when air pressure is applied.

EXAMPLE. When the engine coolant temperature rises above the thermal switch’s set point, the thermal switch activates the solenoid valve, which shuts off air pressure to the Fan Drive (supplied by the vehicle’s air reservoir) and engages the fan.

Most newer vehicles are equipped with an Electronic Control Module (ECM), which is a small computer that monitors and controls all engine operations, including the Fan Drive. If a vehicle uses an ECM, there is no direct connection between the sensors and the solenoid valve for the Fan Drive. Information from sensors and switches is fed into the ECM which controls the solenoid valve.

22742M-B-0202 5 LESSON 2: CONTROL COMPONENTS

Learning Objectives 2.1 Engine Coolant Thermal Switch • Describe the function of a thermal switch in the Fan Drive control system. Vehicles not using an ECM usually have two sensors to automati- cally turn the fan on and off. First is the engine coolant thermal • State the difference between Normally-Open and Normally- switch and, second, the air conditioning refrigerant pressure Closed components. switch.

The engine coolant thermal switch is mounted in the water jacket on the engine.

NOTE: Thermal switches are either Normally-Open or Normally-Closed depending upon the Thermal switch reset point is electrical control system. usually 7oF [3.9oC] below the set point. Truck designers will typi- • In a Normally-Open thermal switch, the electrical contacts are open when the cally specify a thermal switch with temperature is below the set point and closed when the temperature is above the o o a set point 10-15 F [5.6-8.3 C] set point. higher than the fully open tem- perature of the engine thermostat. • In a Normally-Closed thermal switch, the electrical contacts are closed when the temperature is below the set point and open when the temperature is above the set point.

Learning Objectives 2.2 Refrigerant Pressure Switch • Describe the function of a refrigerant pressure switch in the Fan Drive control system. The refrigerant pressure switch is installed in the high pressure line of the vehicle’s air conditioning system.

NOTE: When the air conditioner is running, heat removed from the air is Air conditioning refrigerant absorbed by the refrigerant (e.g., freon, R-12 and R-134a). As the pressure switches are available refrigerant heats, pressure builds in the air conditioner high pressure as either Normally-Open or line until the refrigerant pressure reaches the switch’s set point. The Normally-Closed. switch then sends a signal to the solenoid valve to engage the Fan Drive. The fan pulls air through the air conditioner condenser coils, which cools the condenser/refrigerant and reduces refrigerant pres- sure.

6 22742M-B-0202 2.3 Solenoid Valve Learning Objectives • Describe the function of a solenoid valve in the Fan Drive The solenoid valve is the heart of the con- N.O. Inlet Port/ control system. trol system, opening and closing to regulate N.C. Exhaust Port • Describe the ideal mounting the air flow to the Fan Drive. location for the solenoid valve.

The solenoid valve is a 3-way valve having NOTE: two inlet and one outlet ports. Air pressure The solenoid valve is controlled from the vehicle’s air system is fed into one by electricity and is available for of the inlet ports and the outlet port is con- 12 and 24 volt electrical systems. nected to the Fan Drive. Turning the sole- noid electric current on and off causes a plunger inside the valve to move up and N.C. Inlet Port/ Air Outlet Port down. The plunger connects the valve out- N.O. Exhaust Port To Fan Drive let port to one of the two inlet ports:

• the Normally-Open port when the electric current is off. • the Normally-Closed port when the electric current is on.

The valve has a 3/64" [1.19 mm] orifice to regulate the volume of air and ensure smooth engagement and disengagement of the Fan Drive.

NOTE: EXAMPLE. Normal can be defined as the state of the solenoid valve if it was Normal (as in Normally-Open or completely disconnected and in your hand — the solenoid would be de- Normally-Closed) refers to the energized, the Normally-Open port would be open to the outlet port, and the state of the solenoid valve, Normally-Closed port would be closed to the outlet port. sensor or switch when it is relaxed or de-energized. The valve outlet port is always connected to the Fan Drive. Depending on the vehicle’s electrical control circuits, the air supply may be connected to either the Normally-Open or the Normally-Closed port. The port not connected to the air supply will exhaust air from the Fan Drive when it disengages.

Various adapters and fittings are available to permit the solenoid valve to be plumbed either Normally-Open or Normally-Closed (i.e., the air supply may be connected to either inlet port). These fittings also permit the solenoid valve to be installed with or without an air filter.

Mount the solenoid valve in a remote location away from the engine to minimize the valve’s exposure to excessive heat, vibration, and contaminants. A solenoid valve mounted off of the engine will prolong the life of the solenoid and ensure proper Fan Drive operation.

Air Supply Air Supply

NO NO

NC NC

OUT OUT Normally-Open Normally-Closed

22742M-B-0202 7 LESSON 3: ELECTRICAL CONTROL SYSTEMS (ECM)

Learning Objectives 3.1 Electronic Control Module • Describe the function of an ECM. The electrical wiring that controls the Fan Drive varies from one vehicle to another, but • State the advantages of an generally will be one of three types of systems: ECM system over an independent hard-wired • ECM controlled control system. • Normally-Open • Normally-Closed

NOTE: Engine manufacturers include Electronic Control Modules (ECMS) in their new designs to An ECM is essentially a digital control the engine, transmission, and other critical operations to improve engine perfor- computer, used to control the mance, reliability, and fuel efficiency. engine, transmission, and other critical operations to improve An ECM is essentially a digital computer, containing a microprocessor, random-access- performance reliability, and memory (RAM), and read-only-memory (ROM). The ROM contains the computer’s pro- efficiency. gram. Design engineers can change a vehicle’s control system and engine performance simply by changing the ECM’s computer program.

Electronic Control Modules are simpler and more reliable than independent hard-wired systems. The decision logic is in the computer program and not the wiring, and all sensors and actuators are wired to the ECM instead of to each other.

Fan Air Override Temperature Switch Sensor Engine Speed Sensor Sensor Common A/C Pressure Coolant Temp. Switch Sensor Air Supply

Foot From other Solenoid Throttle sensors Valve +12 NO Inputs Volts

Electronic NC To indicators Control Module and gauges Fan Outputs Relay +12 OUT Volts To electronic injectors and other actuators Fan Relay: Not in all Systems

8 22742M-B-0202 3.2 Sensors Learning Objectives • Describe the basic operation of an ECM-Controlled System. The diagram on the previous page shows that the sensors are not wired to the solenoid valve or any control actuator as in a conventional system. Instead, each sensor goes to • Describe how ECM sensors an ECM input pin and each actuator is wired to an ECM output pin. The ECM computer operate differently than switches used in independent monitors the data from the sensors and sends the appropriate signals to the controls and hard-wired systems. actuators based on programming logic. The ECM also sends status information to the operator’s warning lights and gauges. • Trace the path of a sensor signal to Fan Drive operation in In an ECM controlled system, one sensor may affect several actuators and one actuator an ECM-controlled system. may be affected by several sensors, depending on how the ECM is programmed. NOTE: The ECM monitors data from the Sensors used in ECM systems are different than those used in independent systems. sensors to send signals to the Instead of the simple open/close type of sensor, ECM systems use thermistors and controls, actuators, and sending units to send signals to the ECM (temperature, pressure, speed, or whatever operator’s warning lights and function is being sensed). gauges.

EXAMPLE. Instead of a thermal switch opening or closing at a preset temperature, ECM’s use a temperature sensor to provide voltage which the logic program converts into an actual temperature measurement. Instead of simply knowing if the coolant temperature is above or below the set point (i.e., hotter that 190o F [88o C]), the program knows the actual temperature (i.e., 196.4o F [91.3o C]).

The Fan Drive solenoid is not wired to the sensors as it is in a conventional system but NOTE: instead wired to a relay controlled by the ECM. The ECM computer program looks at the The ECM program considers data from several sensors and decides when to engage and disengage the Fan Drive. several factors before determin- The program considers engine coolant temperature, air-conditioner’s refrigerant pres- ing Fan Drive engagement. sure, intake-manifold air temperature, engine speed, and the engine brake status.

New troubleshooting techniques may be necessary when working on a truck with an ECM control system. A vehicle’s wiring diagram no longer indicates which sensor af- fects which actuator. The diagram only shows which ECM pin each sensor and actuator is connected. To determine the relationships between the sensors and actuators, refer to the vehicle or engine service manual for descriptions of exact conditions under which each actuator is engaged (i.e. Fault Codes).

22742M-B-0202 9 LESSON 4: ELECTRICAL CONTROL SYSTEMS (NON-ECM)

Learning Objectives 4.1 Types of Electrical Control Systems • Identify the three types of Fan Drive electrical control systems. The electrical wiring that controls the Fan Drive varies from one vehicle to another, but • Describe how solenoid valves generally will be one of three types of systems: should be plumbed in a Normally-Open or Normally- • ECM controlled Closed system. • Normally-Open • Normally-Closed

Most newer engine designs are ECM controlled. Prior to ECM systems, manufacturers that tended to have Normally-Closed electrical controls include:

Blue Bird GMC Mack Ford Navistar / International White GMC

Prior to ECM systems, manufacturers that tended to have Normally-Open electrical controls include:

Freightliner Mack Western Star Kenworth Volvo Peterbilt

The Fan Drive electrical control system may be Normally-Open or Normally-Closed, and the solenoid valve may be plumbed to work in either system.

Horton DriveMaster Fan Drives are plumbed as follows:

• for a Normally-Open electrical system, connect the air supply to the Normally-Open port of the solenoid valve.

• for a Normally-Closed electrical system, connect the air supply to the Normally-Closed port of the solenoid valve.

The commonly-used term “Normally-Open system” refers to an electrical system. The commonly-used term “Normally-Open valve” refers to the pneumatics of the valve.

10 22742M-B-0202 4.2 Normally-Open Electrical Controls Learning Objectives • State how switches are wired in a Normally-Open control In a Normally-Open control system, all switches are below their set points and the system. electrical circuit to the solenoid valve is open. • Describe the operation of the solenoid valve if all switches Manual Override Air Supply are open. Switch (NO) +12 Volts • Describe the operation of the solenoid valve if a switch closes. NO Solenoid A/C Pressure Valve NC Switch (NO)

OUT

Thermal Switch (NO)

In such a system, all electrical switches are wired in parallel. Electricity from the 12 volt NOTE: power supply can take any of the three parallel paths to reach the solenoid valve. A quick, easy way to check if a solenoid is Normally-Open or All three switches are shown in their normal state (open). When all switches are open, no Normally-Closed is to blow in the electricity flows to the solenoid valve and the solenoid remains open. The solenoid valve top. If the air escapes from the outlet port going to the Fan Drive, connects the outlet port to the Normally-Open port and provides air pressure to the Fan the solenoid is Normally-Open. If Drive. The Fan Drive disengages. the air is blocked from the outlet port going to the Fan Drive and When one of the electrical switches closes, electricity flows to energize the solenoid escapes through the exhaust valve. The solenoid valve connects the outlet port to the Normally-Closed inlet port and port, the solenoid is Normally- blocks air pressure going to the Fan Drive, engaging the Fan Drive. Closed.

EXAMPLE. The engine coolant temperature rises above the thermal switch’s set point. The Normally-Open thermal switch closes causing electricity to flow through the thermal switch energizing the solenoid valve. The solenoid valve plunger moves to connect the outlet port to the Normally-Closed inlet port. Air pressure exhausts through the valve to allow engagement of the Fan Drive, turning the fan.

22742M-B-0202 11 Learning Objectives 4.3 Normally-Closed Electrical Controls • State how switches are wired in a Normally-Closed control system. The following schematic diagram is of a Normally-Closed electrical control system. When all switches are below their set points, the electrical circuit to the solenoid valve is • State how to determine if a closed. solenoid valve is Normally-Open or Normally-Closed. Manual Override Air Supply • Describe the operation of the Switch (NC) solenoid valve if a switch +12 Volts opens.

NO A/C Pressure Switch (NC) Solenoid Valve NC

OUT Thermal Switch (NC)

In such a system, all electrical switches are wired in series. Electricity from the 12 volt power supply must flow through all three switches before it reaches the solenoid valve. NOTE: A quick, easy way to check if a All three switches are shown in their normal state (closed). Electricity flows to the sole- solenoid is Normally-Open or noid valve and the solenoid is energized. The solenoid valve connects the outlet port to Normally-Closed is to blow in the the Normally-Closed inlet port and provides air pressure to the Fan Drive. The Fan top. If the air escapes from the Drive disengages. outlet port going to the Fan Drive, the solenoid is Normally-Open. If the air is blocked from the outlet When one of the electrical switches opens, the electrical current is broken and the sole- port going to the Fan Drive and noid valve de-energizes. The solenoid valve connects the outlet port to the Normally- escapes through the exhaust Open inlet port and blocks air pressure to the Fan Drive, engaging the Fan Drive. port, the solenoid is Normally- Closed. EXAMPLE. The engine coolant temperature rises above the thermal switch’s set point. The Normally-Closed thermal switch opens, causing a break in the electrical current and de-energizing the solenoid valve. The solenoid valve plunger moves to connect the outlet port to the Normally-Open inlet port. Air pressure exhausts through the valve and allows engagement of the Fan Drive, turning the fan.

12 22742M-B-0202 4.4 Comparison - Open/Closed Electrical Controls Learning Objectives • For each type of control system Normally-Open Normally-Closed determine: 1) the proper port to plumb the solenoid valve, and Electrical System Electrical System 2) the proper method to test the Normally- Normally- To Fan Fan Drive. Air Supply in Closed Port Drive Open Port Air Supply in

To Fan Drive Exhaust Exhaust

• Electrical switches are wired in • Electrical switches are wired in parallel. series.

• Air supply plumbed to solenoid’s • Air supply plumbed to solenoid’s Normally-Open port (the end port). Normally-Closed port (the side port). • Test Fan Drive by installing a jumper wire across a sensor. • Test Fan Drive by disconnecting a wire from a sensor. • Manual Override Switch (if equipped). • Manual Override Switch (if equipped).

4.5 Summary - Open/Closed Electrical Controls Learning Objectives • (Review Only)

Normally-Open Electrical System with Normally-Open Solenoid Valve

All switches open Any switch closed Solenoid de-energized Solenoid energized Drive disengaged Drive engaged

Normally-Closed Electrical System with Normally-Closed Solenoid Valve All switches closed Any switch open Solenoid energized Solenoid de-energized Drive disengaged Drive engaged

22742M-B-0202 13 Learning Objective LAB ACTIVITY - FAN DRIVE CONTROL COMPONENTS • Locate and identify components of the Fan Drive system. Locate a truck with a Horton DriveMaster Fan Drive, preferably a make and model you • Interpret the vehicle's electrical would work on. diagram for various Fan Drive system components. Locate the components listed below and answer the questions by filling in the corre- sponding blanks and checking the box next to the number when you complete a step. Upon completion, please check this activity with an instructor or supervisor. For your safety, be sure the en- gine is off. 1. Locate the DriveMaster Fan Drive and list the model.

2. Locate the solenoid valve.

3. Locate the Fan Drive air filter (if equipped).

4. Locate the coolant temperature switch or sensor.

5. Locate the air-conditioning refrigerant pressure switch (if equipped).

6. Locate the Fan Drive manual override switch (if equipped).

7. How many belts are on the Fan Drive sheave?

8. What engine components do the belts go around?

9. How many bolts mount the fan drive to the engine?

10. Locate the air hose that supplies air to the solenoid. Where does the hose attach to the air supply?

11. Does the truck have an ECM?

12. In the truck’s service manual, locate the electrical diagram for the fan drive control solenoid and the ECM.

13. Draw the schematic symbol used in your truck’s electrical diagram for each of the following components:

Solenoid valve

Engine-coolant thermal switch/sensor

Air-conditioning refrigerant pressure switch/sensor

Manual override switch

14 22742M-B-0202 REVIEW QUESTIONS - FAN DRIVE CONTROL SYSTEMS

1. Advantages of using a Horton Fan Drive include increased horsepower, consistent coolant temperature, and increased fuel economy. True / False

2. In the operation of most ECM-controlled Fan Drive systems without a relay, the ECM sends a direct signal to the Solenoid Valve to engage or disengage the Friction Disc. True / False

3. Identify this component by circling its name.

COMPONENTS A. Solenoid B. Engine Coolant Thermal Switch C. Refrigerant Pressure Switch

4. Identify this component by circling its name.

COMPONENTS A. Solenoid B. Engine Coolant Thermal Switch C. Refrigerant Pressure Switch

5. Identify this component by circling its name.

COMPONENTS A. Solenoid B. Engine Coolant Thermal Switch C. Refrigerant Pressure Switch

6. The Fan Drive is engaged when air pressure is applied through the Solenoid Valve. True / False

7. The engine coolant Thermal Switch sends a signal to engage the Fan Drive when the engine coolant reaches the switch’s high set point. True / False

8. In a Normally-Closed electrical control system, electrical contacts are closed when engine temperature and air conditioning pressure are below high set points. True / False

9. When air conditioning pressure reaches the low set point, a signal is sent to the Solenoid Valve on ECM by the a) Thermal Switch, b) Solenoid Switch, c) Refrigerant Pressure Switch.

10. The Solenoid Valve functions to regulate air to each of the electrical control components. True / False

11. It is best to locate the Solenoid Valve close to the Fan Drive, and on the engine block if possible. True / False

22742M-B-0202 15 12. An Electronic Control Module is: a) a computer, b) a sensor, c) a sending unit

13. ECM control systems improve engine performance, reliability and fuel efficiency more than non-ECM control systems. True / False

14. ECMs monitor data from sensors and send the appropriate signals to controls and actuators based on: a) operator options, b) programming logic, c) vehicle service periods.

15. In most ECM-controlled systems, sensors and actuators are wired directly to the ECM, not the Solenoid Valve. True / False

16. Draw the path of a sensor signal to Fan Drive operation in an ECM-controlled system.

Fan Air Override Temperature Switch Sensor Engine Speed Sensor Sensor Common A/C Pressure Coolant Temp. Switch Sensor Air Supply

Foot From other Solenoid Throttle sensors Valve +12 NO Inputs Volts Electronic To indicators Control Module and gauges Fan NC Outputs Relay +12 OUT Volts To electronic injectors and other actuators Fan Relay: Not in all Systems

17. To find fault code explanations when troubleshooting ECM-controlled systems, look: a) under the hood, b) inside the door panel, c) in the service manual.

18. The three types of Fan Drive control systems are ECM-controlled, Normally-Open and Normally-Closed. True / False

19. If a vehicle has a Normally-Open control system, the air supply for the Drive Master should be connected to the: a) Normally-Open, or b) Normally-Closed, port of the 3-way Solenoid Valve.

20. In a Normally-Open control system, switches are wired in: a) series, b) parallel.

21. On the diagram, connect the electrical components for a Normally-Open control system and indicate if the air supply is connected to the Solenoid Valve’s Normally-Open or Normally-Closed inlet port.

Manual Override Air Supply Switch (NO) +12 Volts

Solenoid A/C Pressure Valve Switch (NO)

OUT

Thermal Switch (NO)

16 22742M-B-0202 22. When all switches are open In a Normally-Open control system, the solenoid is: a) energized, b) de-energized, and the Fan Drive is: a) engaged, b) disengaged.

23. If a switch closes in a Normally-Open control system, the solenoid is: a) energized, b) de-energized, and the Fan Drive is: a) engaged, b) disengaged.

24. In a Normally-Closed control system, switches are wired in parallel. True / False

25. On the diagram, connect the electrical components for a Normally-Closed control system and indicate if the air supply is connected to the Solenoid Valve’s Normally-Open or Normally-Closed inlet port.

Manual Override Air Supply Switch (NC) +12 Volts

A/C Pressure Switch (NC) Solenoid Valve

OUT Thermal Switch (NC)

26. Air will escape through the outlet port going to the Fan Drive of a Normally-Open Solenoid Valve when air is applied to the top. True / False

27. If a switch opens in a Normally-Closed control system, the solenoid is: a) energized, b) de-energized, and the Fan Drive is: a) engaged, b) disengaged.

28. The Fan Drive can be tested in a Normally-Open control system by disconnecting a wire from a sensor. True / False

22742M-B-0202 17 Review Answers - Fan Drive Control Systems

1. Advantages of using a Horton Fan Drive include increased horsepower, consistent coolant temperature, and increased fuel economy. True / False

2. In the operation of most ECM-controlled Fan Drive systems without a relay, the ECM sends a direct signal to the Solenoid Valve to engage or disengage the Friction Disc. True / False

3. Identify this component by circling its name.

COMPONENTS A. Solenoid B. Engine Coolant Thermal Switch C. Refrigerant Pressure Switch

4. Identify this component by circling its name.

COMPONENTS A. Solenoid B. Engine Coolant Thermal Switch C. Refrigerant Pressure Switch

5. Identify this component by circling its name.

COMPONENTS A. Solenoid B. Engine Coolant Thermal Switch C. Refrigerant Pressure Switch

6. The Fan Drive is engaged when air pressure is applied through the Solenoid Valve. True / False

7. The engine coolant Thermal Switch sends a signal to engage the Fan Drive when the engine coolant reaches the switch’s high set point. True / False

8. In a Normally-Closed electrical control system, electrical contacts are closed when engine temperature and air conditioning pressure are below high set points. True / False

9. When air conditioning pressure reaches the low set point, a signal is sent to the Solenoid Valve on ECM by the a) Thermal Switch, b) Solenoid Switch, c) Refrigerant Pressure Switch.

10. The Solenoid Valve functions to regulate air to each of the electrical control components. True / False

11. It is best to locate the Solenoid Valve close to the Fan Drive, and on the engine block if possible. True / False

18 22742M-B-0202 12. An Electronic Control Module is: a) a computer, b) a sensor, c) a sending unit

13. ECM control systems improve engine performance, reliability and fuel efficiency more than non-ECM control systems. True / False

14. ECMs monitor data from sensors and send the appropriate signals to controls and actuators based on: a) operator options, b) programming logic, c) vehicle service periods.

15. In most ECM-controlled systems, sensors and actuators are wired directly to the ECM, not the Solenoid Valve. True / False

16. Draw the correct path of a sensor signal to Fan Drive operation in an ECM-controlled system.

Fan Air Override Temperature Switch Sensor Engine Speed Sensor Sensor Common A/C Pressure Coolant Temp. Switch Sensor Air Supply

Foot From other Solenoid Throttle sensors Valve +12 NO Inputs Volts

Electronic NC To indicators Control Module and gauges Fan Outputs Relay +12 OUT Volts To electronic injectors and other actuators Fan Relay: Not in all Systems

17. To find fault code explanations when troubleshooting ECM-controlled systems, look: a) under the hood, b) inside the door panel, c) in the service manual.

18. The three types of Fan Drive control systems are ECM-controlled, Normally-Open and Normally-Closed. True / False

19. If a vehicle has a Normally-Open control system, the air supply for the Drive Master should be connected to the: a) Normally-Open, or b) Normally-Closed, port of the 3-way Solenoid Valve.

20. In a Normally-Open control system, switches are wired in: a) series, b) parallel.

21. On the diagram, connect the electrical components for a Normally-Open control system and indicate if the air supply is connected to the Solenoid Valve’s Normally-Open or Normally-Closed inlet port.

Manual Override Air Supply Switch (NO) +12 Volts

NO Solenoid A/C Pressure Valve NC Switch (NO)

OUT

Thermal Switch (NO)

22742M-B-0202 19 22. When all switches are open In a Normally-Open control system, the solenoid is: a) energized, b) de-energized, and the Fan Drive is: a) engaged, b) disengaged.

23. If a switch closes in a Normally-Open control system, the solenoid is: a) energized, b) de-energized, and the Fan Drive is: a) engaged, b) disengaged.

24. In a Normally-Closed control system, switches are wired in parallel. True / False

25. On the diagram, connect the electrical components for a Normally-Closed control system and indicate if the air supply is connected to the Solenoid Valve’s Normally-Open or Normally-Closed inlet port.

Manual Override Air Supply Switch (NC) +12 Volts

NO A/C Pressure Switch (NC) Solenoid Valve NC

OUT Thermal Switch (NC)

26. Air will escape through the outlet port going to the Fan Drive of a Normally-Open Solenoid Valve when air is applied to the top. True / False

27. If a switch opens in a Normally-Closed control system, the solenoid is: a) energized, b) de-energized, and the Fan Drive is: a) engaged, b) disengaged.

28. The Fan Drive can be tested in a Normally-Open control system by disconnecting a wire from a sensor. True / False

20 22742M-B-0202 PRIOR TO SERVICING

You must follow your company safety practices, which should adhere to or be better than Federal or State approved shop safety practices and procedures. Be sure that you read and understand all the procedures and instructions before beginning work on this unit.

NOTE Parts replacement and/or repair of your Horton DRIVE MASTER Fan Drive should be performed only by the Horton Factory or an authorized Horton Distributor or Dealer to keep your warranty coverage intact during the warranty period.

Before rebuilding your DRIVEMASTER Fan Drive, note the Fan Drive Serial No., Service Part No., Date of Installation, and Vehicle Mileage.

Part Number and Serial Number Serial No.

Service Part No.

Installation Date

Vehicle Mileage

22742M-B-0202 21 LESSON 5: DRIVEMASTER PARTS AND REPAIR KITS

Learning Objectives 5.1 Parts Identification • Recognize externally visible parts.

• Identify commonly replaced 6 parts. 5 4 3 2 1

16 17 14 15 14 13 12 11 10 7 8 9

ITEM DESCRIPTION QTY 1 Fan Mounting Disc/Studs 1 2 Button Head Screws 8 3 Friction Liner 1 4 Cage Nut (Used for repairs only) - 5Spring Housing/Piston 1 6 Air Chamber Seal 1 7 Air Chamber Cap Retaining Ring 1 8 O-Ring Seal 1 9 Air Chamber Cap 1 10 Face Seal 1 11 Bearing Nut 1 12 Air Cartridge Retaining Ring 1 13 Air Cartridge Assembly 1 14 Sheave Bearings 2 151 Bearing Spacers 1 162 Sheave 1 172 Journal Bracket 1 1 Not used on all Fan Drives. 2 Denotes item is not included in Repair Kit.

22 22742M-B-0202 5.2 Repair Kits

Horton offers several different ways to repair or rebuild your DriveMaster Fan Drive.

1. DriveMaster Seal Kit (Part #994346) Learning Objectives • Describe when a Seal Kit would be used. Install a Seal Kit if an air leak has developed inside of the DriveMaster Fan Drive. The Seal Kit consists of the parts listed and described below:

Button Head Screws (#2): Used to attach the Friction Liner and the Spring Housing/ Piston Assembly to the Sheave. Cage Nut (#4): Used to keep the Spring Housing/Piston Assembly together when removing from the Sheave. It maintains pressure on internal springs after the Button Head Screws are removed. Air Chamber Seal (#6): Forms an air seal between the Air Chamber and the Spring Housing/ Piston Assembly. It is positioned around the bottom half of the Spring Housing/Piston Assembly. Retaining Rings (#7, #12): There are two Retaining Rings in the Seal Kit. The smaller Retaining Ring is used to hold the air cartridge inside the Journal Bracket shaft. When installing this Retaining ring, the beveled side must be facing the air Cartridge. The larger Retaining Ring is used to hold the Air Chamber Cap in place. O-Ring (#8): Forms an air seal between the Air Chamber and the Air Chamber Cap. Face Seal (#10): Screws into the center of the Air Chamber Cap, forming an air seal with the carbon tip of the Air Cartridge. Air Cartridge (#13): Fits inside the Journal Bracket shaft. Air pressure comes up through the center of the shaft, into and through the Air Cartridge, and into the Air Chamber. The Air Cartridge has a spring loaded carbon tip that presses against the Face Seal, forming an air tight seal while the Fan Drive is spinning. T55 Torx Plus Bit (not pictured): Used to remove the Fan Mounting Disc from the Jack Bolt. O-Ring Lubricant (not pictured): Apply lubricant to the new Air Chamber Cap O-Ring Seal and the Air Chamber Seal before installation.

22742M-B-0202 23 Learning Objectives 2. DriveMaster Super Kit (Part #994347) • Describe when a Super Kit would be used. Install a Super Kit if the bearings are running rough or if the DriveMaster Fan Drive needs to be completely rebuilt due to excessive wear. The Super Kit consists of the parts listed and described below:

6 5 4 3 2 1

14 14 13 12 11 10 9 8 7

Fan Mounting Disc (#1): The part that the fan bolts on to. It is also the part that contacts the Friction Liner when the Fan Drive is engaged. The Fan Mounting Disc is screwed onto the Jack Bolt. Button Head Screws (#2) Friction Liner (#3): Attached to the Sheave on top of the Spring Housing/Piston Assembly. Cage Nut (#4) Spring Housing/Piston Assembly (#5): The internal mechanism that engages and disengages the DriveMaster Fan Drive when air pressure is either removed or applied. Air Chamber Seal (#6) Retaining Rings (#7, #12) O-Ring Seal (#8) Face Seal (#10) Bearing Nut (#11): Used to hold the Sheave onto the Journal Bracket shaft. Air Cartridge (#13) Sheave Bearings (#14): Use a bearing press to remove old bearings and install new bearings into the center of the Sheave. The bearings are prelubricated and sealed. They also have markings that need to be aligned for proper installation. (If there are spacers in between the old bearings that were removed, re-use those spacers by positioning them between the new bearings before installation. DO NOT remove the seals and attempt to lubricate the old or new bearings.) T55 Torx Plus Bit (not pictured) O-Ring Lubricant (not pictured)

24 22742M-B-0202 3. DriveMaster Friction Disc Kit (Part #994348) Learning Objectives • Describe when a Friction Disc Kit would be used. Install a Friction Disc Kit if the Fan Mounting Disc is damaged from blistering, excessive wear, or failure. The Friction Disc kit consists of the parts listed and described below:

Fan Mounting Disc (#1) Button Head Screws (#2) Friction Liner (#3) Cage Nut (#4) T55 Torx Plus Bit (not pictured)

4. DriveMaster Friction Liner Kit (Part #994349) Learning Objectives • Describe when a Friction Liner Kit would be used. Install a Friction Liner Kit if the Friction Liner is worn. Check the Fan Mounting Disc to make sure there is no excessive wear. If damage is evident use the DriveMaster Friction Disc Kit. The Friction Liner Kit consists of the parts listed and described below:

Button Head Screws (#2) Friction Liner (#3) Cage Nut (#4) T55 Torx Plus Bit (not pictured)

22742M-B-0202 25 Learning Objectives LESSON 6: REMOVING THE FAN DRIVE • Describe the safety precautions and order of steps in removing the Fan Drive from the vehicle. 1. Turn the vehicle ignition off and remove the keys from the vehicle.

2. Apply the vehicle's parking brake. NOTE: The procedure for removing the 3. Block the vehicle's wheels. Fan Drive varies from one vehicle to another. Refer to the vehicle’s 4. Bleed the air from the vehicle’s reservoir. service manual for a detailed de- scription of this process. 5. Disconnect the air supply line from the Fan Drive.

NOTE: 6. Loosen the bolts that hold the fan in place. Protect the radiator from possible damage from the fan during fan 7. Remove the fan from the Fan Drive. removal and fan drive installation. 8. Remove any drive belts from the Fan Drive.

NOTE: 9. Remove the Fan Drive mounting bolts. Because of the weight of the Fan Drive (ranging from 35-55 Lbs. 10. Carefully maneuver the Fan Drive out of the engine compartment. [15.88-24.95 Kg]), you may want to use a hoist for support during removal.

Grade 8 Mounting Bolts Fan Drive

Grade 8 Nuts

Steps 1-10

26 22742M-B-0202 LESSON 7: DISASSEMBLING THE FAN DRIVE

7.1 Tools Required

• 2” Socket Wrench • T55 Torx Plus Bit (994352) • T27 Torx Bit • Torque Wrench • Pry Bar • Ring Pliers • Screwdrivers

7.2 Disassembly

Fan Mounting Disc Removal and Inspection Learning Objectives • Describe the steps of safely removing and inspecting the 1. Place the Fan Drive in a vise and clamp the Journal Bracket tight. Fan Mounting Disc. 2. Loosen the Jack Bolt (left hand thread) by turning it counter-clockwise using a • Recognize signs of wear or T55 Torx Plus Bit (Part# 994352). damage to the Fan Mounting Disc.

NOTE: Pry Bar Applying 80-120 PSI [5.44 - 8.16 Placement bar] air pressure to the Fan Drive Pry Bar air inlet will aid in removal of the FMFD. Torx Wrench NOTE: Use caution when handling the prybar on the Fan Mounting Disc. Permanent damage may occur if not properly supported. Use a flat blade tool or a prybar that has a Air Line handle.

Steps 1-2

22742M-B-0202 27 3. Unscrew the Fan Mounting Disc from the Jack Bolt.

Fan Mounting Disc

Jack Bolt (left hand thread)

Step 3

4. Inspect the Fan Mounting Disc for wear or damage.

Step 4

Fan Mounting Disc Good Condition

Look for signs of damage or blistering

Fan Mounting Disc Bad Condition

28 22742M-B-0202 Spring Housing/Piston Assembly Removal Learning Objectives • Describe the steps of safely removing and inspecting the Spring Housing/Piston Assembly. 5. Using the Torx wrench to hold the Jack Bolt, hand-tighten the Cage Button Nut (from the Repair Kit) onto the Head Screws Jack Bolt (left hand thread) Remove air pressure from the unit before proceeding to Step 6. over the Spring Housing. The Friction Liner Cage Nut will keep the Spring Housing and Piston together as Cage Nut Failure to release air pressure an assembly. It will also maintain may result in serious personal in- pressure on the internal Springs Spring jury. after the Button Head Screws are Housing/Piston removed. Assembly Do not disassemble the Spring 6. Remove the 8 Button Head Housing. Personal injury could Screws using a T27 Torx Bit. occur. NOTE: 7. Remove the Friction Liner. If you are installing either a Fric- tion Liner (Part# 994349) or Fan Steps 5-7 Disc Kit (Part# 994348), proceed to page 34, step 20.

8. Remove the Spring Housing/ Spring Housing/ Piston Assembly. Piston Assembly The Air Chamber should be clean 9. Remove the Air Chamber Seal. and moisture-free (with the excep- tion of the seal lubricant) . If not, a problem may exist in the vehicle 10. Examine the inside of the Air air system and must be corrected Chamber for signs of moisture before the Fan Drive is reinstalled. and/or contaminants. Air Chamber

Steps 8-10

22742M-B-0202 29 Learning Objectives Air Chamber Seals • Describe the steps of removing and inspecting the Air Chamber 11. Remove the Air Chamber Cap Retaining Seals. Air Chamber Ring. Seal 12. Gently and evenly pry the Air Chamber Retaining Ring Wear eye safety protection when Cap out of the Sheave using two small removing Retaining Ring to avoid screwdrivers placed 180° apart. O-Ring Seal serious injury. 13. Remove the O-Ring Seal from the Air Face Seal Chamber Cap. Air Chamber If dirt or oil exists in the air sys- 14. Remove the Face Seal. Cap tem, the air system must be cleaned and dried before the Fan 15. Inspect the Face Seal for signs of wear. Drive is reinstalled. Wear indicates that dirt may exist in NOTE: the air system. If you are only installing a Seal Kit Steps 11-15 (Part #994346), proceed to page 31, step 20

Learning Objectives Sheave and Sheave Bearings • Describe the steps of removing the Sheave from the Journal Bracket. 16. Remove the Bearing Nut from the Journal Bracket using a 2” Socket Bearing Nut Wrench. Journal Bracket

Step 16

17. Remove the Sheave from the Journal Sheave Bracket.

Journal Bracket

Step 17

18. Fully support the Sheave and press out the Bearings. SUPPORT PRESS Bearings TO 19. Fully clean and remove any dirt, REMOVE debris, or corrosion that may be present. Step 18-19 SUPPORT

30 22742M-B-0202 Learning Objectives Air Cartridge Removal • Describe the steps of removing the Air Cartridge.

20. Remove the Retaining Ring. Retaining Wear eye safety protection when Ring removing Retaining Ring to avoid serious injury.

Step 20

21. Remove the Air Cartridge Assembly. Air Cartridge Assembly

22. Clean the Journal Bracket bore if necessary. Float Seal Tip Step 21 NOTE If you are installing a Seal Kit (Part# 994346), proceed to page 32, step 5. LESSON 8: REBUILDING THE FAN DRIVE

8.1 Torque Specifications

ITEM DESCRIPTION TIGHTENING TORQUE 3 Button Head Screws 80 In. Lbs. [9 N•m] 10 Face Seal 75-100 In. Lbs. [8.5-11.5 N•m] 11 Bearing Nut 130 Ft. Lbs. [176 N•m] -- Jack Bolt (left hand thread) 100 Ft. Lbs. [136 N•m]

8.2 Rebuilding

Learning Objectives Sheave Bearing Replacement • Describe the steps of removing and replacing the Sheave 1. Fully supporting the Sheave, Bearings. press the new Sheave Bearings (or single bearing) into place, Align the chevron markings on noting the position of the lip the bearings to form an arrow. inside the Sheave. The arrow may point in either See Figures 1A, 1B, 1C. direction.

Step 1A

22742M-B-0202 31 NOTE: Some Models of the LIP INSIDE OF SHEAVE DRIVEMASTER Fan Drive contain Bearing Spacers. Both Bearing Single Bearing Spacers must be positioned BE- (used on TWEEN the Sheave Bearings some models) when the Sheave Bearings are replaced. Bearings and Spacers NOTE: Step 1B All Bearings are prelubricated and sealed. DO NOT remove the seals SUPPORT to lubricate the Bearings.

NOTE: SUPPORT Some DRIVEMASTER models uti- PRESS lize a single (one piece) Sheave Bearing. Repair with Kit #994353. Step 1C

2. Slide the Sheave onto the Journal Bearing Nut Bracket. (Hex faces up)

3. Replace the Bearing Nut. Tighten the Sheave Bearing Nut to 130 Ft. Lbs. [170 N•m] Journal torque. Bracket

Step 2-3 4. Be sure that the Bearing Nut hex is Hex faces up facing up (see detail below). Relief points down toward Journal Bracket and Bearings

Step 4

Learning Objectives Air Cartridge • Describe the steps of replacing the Air Cartridge. 5. Apply O-Ring lubricant to the outside O-Rings of the new Air Cartridge O-Rings Assembly. The Retaining Ring must be fully seated in the retaining ring 6. Install the new Air Cartridge Assembly The curve groove to keep the Air Cartridge into the Journal Bracket. faces the Assembly from moving. Also, Retaining Ring Cartridge the Retaining Ring is beveled. 7. Reinstall the Retaining Ring. The curved side must be in- Step 5 stalled facing the Cartridge.

32 22742M-B-0202 Spring Housing/Piston Assembly Reassembly Learning Objectives • Describe the steps of safely reinstalling the Spring Housing/ 8. Using a clean/dry cloth, clean Piston Assembly. both the Float Seal Tip (see Air • State lubrication requirements and Cartridge illustration, Step 4) of cautions when reassembling the the Air Cartridge Assembly. Spring Housing/ Piston Assembly.

9. Also clean the Face Seal of the Air Chamber Cap. Use extreme care when reas- sembling the Air Chamber com- ponents to avoid damage to the 10. Assemble the Air Chamber Cap O-Ring and Air Chamber Seal. and Face Seal. NOTE: 11. Lubricate the O-ring Seal with The new Face Seal is assembled the fresh lubricant supplied in the Air Chamber with an O-ring. If the old Face Seal kit. Cap does not have an O-ring, do not use an O-ring with the new Face Seal. Remove it from the new 12. Install the O-ring Seal on the Air Retaining Ring Chamber Cap. Face Seal and apply thread seal- ant (Loctite® 511 or similar) to the Face Seal threads. 13. Carefully set the Air Chamber Cap into the Sheave. Steps 13-14 Sheave 14. Install the Retaining Ring. Seat Seal evenly against Air Chamber Seal 15. Install the Air Chamber Seal into side and bottom groove Detail Do not apply grease beyond Seal surfaces. the Sheave. contact surface as it will cause improper Fan Drive function. 16. Be sure the Seal is evenly seated Do not apply grease beyond against the side and bottom of these areas. the groove surfaces. NOTE: The entire tube of O-Ring lubricant 17. Lubricate contact surfaces with should be used when lubricating the fresh lubricant supplied in the Sheave “V” of Seal the new seals and contact sur- kit. faces down faces of the Sheave and Spring (cross-section) Step 15-17 into Sheave Housing/Piston Assembly. 18. Carefully set the new Spring Housing/Piston Assembly from Spring Housing/ the Repair Kit into position. Piston Assembly

19. Gently rotate to align the Piston mounting holes in the assembly with the Sheave. Air Chamber Seal

Steps 18-19

22742M-B-0202 33 20. Set the new Friction Liner (from kit) into place. Handle the Friction Liner by the Button Head Screws edges to avoid contamination. Friction Liner 21. Alternately and evenly tighten the 8 To avoid personal injury, make Button Head Screws to 80 In. Lbs. [9 Cage Nut sure the Button Head Screws are N•m] torque. properly tightened to the specified Spring torque before applying air pres- Housing/ sure - 80 In. Lbs. [9 N•m]. Piston Assembly

Steps 20-21

Learning Objectives Fan Mounting Disc Reassembly • Describe the steps of safely installing the Fan Mounting Disc. 22. Apply a minimum of 80 PSI of clean NOTE: Fan Air must be applied to the air air to the air inlet. Mounting chamber to allow for easy re- Disc moval of the Cage Nut and to en- 23. Remove the Cage Nut from the Spring sure proper torque is applied to Housing/Piston Assembly. the Jack Bolt. 24. Install the new Fan Mounting Disc Jack Bolt (from kit) if applicable. (left hand thread) Do not disassemble the Spring Housing. Personal injury could occur.

Step 24

25. Tighten the Jack Bolt (left hand thread) to 100 Ft. Lbs. [136 N•m] torque.

If a problem exists, it must be cor- 26. Actuate the DRIVEMASTER and check rected prior to mounting the Fan for proper engagement and Drive onto the vehicle. If the prob- disengagement of the Fan Mounting lem is not corrected, the Fan Drive will fail prematurely. Disc. 27. Check for air leaks at the bleed hole.

28. Check for air leaks around the Spring Housing/Piston Assembly.

Step 25

34 22742M-B-0202 LESSON 9: REINSTALLING THE FAN DRIVE Learning Objectives • Describe the steps of safely reinstalling the Fan Drive. • Describe requirements for proper 1. Turn the vehicle ignition off and remove the keys. belt tensioning. • Describe methods to check for 2. Apply the vehicle's parking brake. proper Fan Drive operation.

3. Block the vehicle's wheels. On the workbench, apply 90 PSI [6.21 bar] clean air pressure and 4. Prepare by cleaning all the mounting surfaces of dirt and debris. check the Fan Drive for air leaks. NOTE: 5. Position the Drivemaster into place, aligning the mounting bracket. Protect the radiator from possible damage from the fan during fan removal and fan drive installation. NOTE: 6. Reinstall the mounting bolts and tighten to the vehicle manufacturer’s Most engines have multiple mount- specifications. ing locations. Be sure to use the correct holes for the application. NOTE: Use flat washers on each manufacturer’s approved bolt or studs - DO NOT use lock washers.

7. Replace and adjust the belts. Correct belt adjustment and align- 8. Check the condition of the fan. Look for cracks or missing weights. ment is necessary for all belt driven components to assure longevity of 9. Remount the fan on the Fan Drive and tighten the nuts to the vehicle component life. Over tightening of belts will shorten bearing life. Loose manufacturer’s specifications. belts will cause excessive belt wear and shorten bearing life. Consult the equipment manufacturer and/ or engine manufacturer specifica- tions for proper belt adjustment.

NOTE: The maximum fan diameter is 32''. If a larger fan diameter is required, contact Horton at 1-800-621-1320. 10. Reconnect the air supply line to the Drivemaster. NOTE: 11. Start the engine and let the air pressure build to at least 90 PSI [6.21 bar]. Remove all tools from the work area and visually inspect the area 12. If the vehicle is fitted with a manual override switch, engage and disengage in which you have been working prior to starting the engine. the Fan Drive to observe for proper operation as well as air leaks. NOTE: 13. Turn off the engine. For a Normally-Open electrical system, use a jumper across a sensor. For a Normally-Closed electrical system, open the circuit by disconnecting a sensor wire.

22742M-B-0202 35 LESSON 10: PREVENTIVE MAINTENANCE (PM)

Learning Objectives 10.1 Introduction • Identify general conditions to look for when observing Fan Drive operation. Before performing work on the Fan Drive, be sure to follow good shop safety practices. Turn the vehicle ignition off, apply the vehicle’s parking brake and block the vehicle’s • Describe locations and wheels. methods for checking for air leaks. Start the vehicle’s engine and build air pressure in excess of 90 PSI [6.21 bar].

Manually engage and disengage the Fan Drive. Observe the Fan and Fan Drive from a Be sure the engine is turned off and distance. Look for vibration, Fan blade contact, Fan Drive slippage, and Fan Drive opera- the Fan has stopped turning before tion. approaching Fan area to prevent serious personal injury. Most Fan Drive failures are caused by air leaks. With regular preventive maintenance (PM), the Horton DriveMaster Fan Drive will provide years of reliable service. PM is recommended at the weekly air-filter draining, and 25,000 mile [40,000 Km] PM.

Check for air leaks at these locations

Learning Objectives 10.2 Weekly PM • State weekly preventive maintenance requirements. Each week, drain the air filter at its bleed valve and check for moisture. Filter NOTE: Element Do not pressure wash the Fan 1. If contaminants are present, disassemble the air filter Drive. The Fan Drive needs no as shown. washing or cleaning. Direct spray 2. Clean all parts with parts solvent and dry them thor- Filter from a pressure washer will only oughly. Bowl result in reduced life or damage 3. Check the truck’s air system for the source of the con- to the product. tamination and make the necessary repairs. Bleed Valve

36 22742M-B-0202 10.3 25,000 Mile [40,000 Km] PM Learning Objectives • State 25,000 Mile (40,000Km) preventive maintenance requirements. Every 25,000 miles [40,000 Km] or when Check for performing an oil drain, conduct a quick slipping • Describe how to manually test check of the Fan Drive. between Fan Drive engagement and sheave and disengagement. FMFD Check for air leaks around the Fan Drive while air is applied to the Fan Drive. Check for 1. Listen for leaks at the solenoid discoloration or NOTE: valve and filter assembly, and in other signs of If an air leak is not repaired, the the air hoses and fittings. overheating Fan Drive may slip and overheat. 2. Feel for a leak with a wet finger or by applying soapy water and looking for bubbles.

Check the Fan Drive for discoloration or any other signs of slipping or overheating. The Fan Drive may slip if incoming air pressure is below 90 PSI [6.21 bar] or if an air leak exists inside the Fan Drive. Never let a leak remain unattended.

Check the Fan Drive bearings. 1. Turn the Fan blade in both directions and feel for worn hub bearings. 2. If the Fan belts can be easily removed, remove the belts and check for worn sheave bearings. 3. Turn the sheave in both directions-if either the hub or sheave bearings are worn, remove and replace the Fan Drive.

Check the Fan Drive friction facing for wear by measuring the thickness of the friction material. A new facing is 7/16" [11.11 mm] thick. Replace the friction material if it has worn to less than 3/16" [4.76 mm].

Check the electrical wiring at the thermal switch, air conditioning pressure switch, and solenoid valve. Be certain there are not any loose wires or connections.

Check the Fan Drive for proper engagement and disengagement. Turn on the ignition switch but do not start the engine. 1. Be certain at least 90 PSI [6.21 bar] of air pressure is available in the truck’s reservoir. 2. To manually engage and disengage the Fan Drive, open and close the electrical circuit going to the solenoid valve as follows: a.For a Normally-Open electrical system, use a jumper wire to short out the thermal switch or the air-conditioning refrigerant pressure switch. b.For a Normally-Closed electrical system, open the circuit by disconnecting a wire from one of the sensors or from the solenoid valve.

22742M-B-0202 37 LESSON 11: TROUBLESHOOTING

PROBLEM PROBABLE CAUSE SOLUTION

I. Air leaking from Fan Drive 1. Bad seals or air cartridge. 1. Install Repair Kit. bleed hole Bleed Hole

Journal Bracket

II. Premature Friction Lining failure 1. Obstructed fan. 1. Loose shroud, bent fan, 1. Find and remove obstruction, torn engine mounts, etc. repair or replace damaged parts. Install Repair Kit.

2. Low air pressure to Fan 2 a. Restricted air line. 2. a. Replace air line. Drive. Install Repair Kit. b. Restricted Solenoid Valve. b. Replace Solenoid Valve. Install Repair Kit. c. Low system air pressure. c. Repair system. Install Repair Kit. d. System air leak. d. Repair leak. Install Repair Kit.

3. Excessive cycling. 3. a. A/C freon overcharge. 3. a. Check and adjust to specifications. b. A/C pressure switch b. Check A/C pressure setting too low. switch. c. Poor ground or wire c. Check electrical connection. connections. d. Improper temperature d. Check temperature control setting. setting of all controls. Thermal Switch setting should engage the Fan Drive 10oF higher than the full open temperature of the thermostat. e. Faulty ECM. e. Check ECM.

38 22742M-B-0202 PROBLEM PROBABLE CAUSE SOLUTION

II. Premature Friction Lining failure Excessive cycling (continued) f. Faulty Thermal Switch. f. Replace the Thermal Switch. g. Restriction in front of g. Check for proper shutter radiator blocking air flow. operation, winter front or other restriction in or in front of the radiator. h. Faulty Air-Temp Switch. h. Replace the Air-Temp Switch. Air Problem

1. Solenoid Valve not exhausting 1. Check for plugged exhaust/ or engaging properly. intake port on the Solenoid Valve. Clean or replace the Solenoid Valve.

III. Fan Drive fails to engage/disengage Electrical Problem

1. Open/shorted circuit. 1. Check electrical connections.

2. Improperly wired. 2. Check wiring according to diagram.

3. Thermal Switch incorrect for 3. Check Thermal Switch application. application. Replace if wrong or defective.

4. Failed Solenoid Valve. 4. Replace the Solenoid Valve.

Air Problem

1. Air line restricted. 1. Check air line from solenoid to Fan Drive for kinks or obstructions.

2. Solenoid Valve defective. 2. Replace the Solenoid Valve. Check to see if air exhaust is restricted.

Piston will not actuate

1. Piston seized due to 1. Clean the air supply and install contamination or dry seals. a Rebuild Kit.

22742M-B-0202 39 PROBLEM PROBABLE CAUSE SOLUTION

IV. Fan Drive cycles frequently Electrical Problem

1. Poor ground wire connection. 1. Check electrical connections.

2. Improper temperature control 2. Check temperature setting of settings. all controls. Thermal Switch should engage the Fan Drive 10o F higher than the full open temperature of the thermostat.

3. A/C Pressure Switch setting 3. Check A/C Pressure Switch. too low. Use higher switch.

4. Restriction in front of radiator, 4. Check shutter operation, blocking air flow. winter fronts, or obstruction in front of radiator.

5. Faulty Thermal Switch. 5. Replace the Thermal Switch.

6. Faulty Air-Temp Switch. 6. Replace the Air-Temp Switch.

7. Vehicle Coolant level too low. 7. Fill to manufacturer's recommended level.

V. Fan Drive engaged, 1. Restriction in front of radiator. 1. Make sure nothing is engine running hot. obstructing the air flow through the radiator.

2. Fan capacity not large enough. 2. Refer to specifications.

3. Problem in cooling system. 3. Refer to engine manual.

40 22742M-B-0202 REVIEW QUESTIONS - FAN DRIVE SERVICE

1. DriveMaster Fan Drive parts that are visible externally are the Fan Mounting Disc, Friction Liner, Air Chamber Seal, and Journal Bracket. True / False

2. The two most commonly replaced parts are the Fan Mounting Disc and Friction Liner. True / False

3. A DriveMaster Seal Kit would be the most appropriate choice if: a) an air leak has developed inside the Fan Drive, b) the Bearings are running rough or if the Fan Drive needs to be completely rebuilt, c) the Fan Mounting Disc is damaged, d) the Friction Liner is worn.

4. A DriveMaster Super Kit would be the most appropriate choice if: a) an air leak has developed inside the Fan Drive, b) the Bearings are running rough or if the Fan Drive needs to be completely rebuilt, c) the Fan Mounting Disc is damaged, d) the Friction Liner is worn.

5. A DriveMaster Friction Disc Kit would be the most appropriate choice if: a) an air leak has developed inside the Fan Drive, b) the Bearings are running rough or if the Fan Drive needs to be completely rebuilt, c) the Fan Mounting Disc is damaged, d) the Friction Liner is worn.

6. A DriveMaster Friction Liner Kit would be the most appropriate choice if: a) an air leak has developed inside the Fan Drive, b) the Bearings are running rough or if the Fan Drive needs to be completely rebuilt, c) the Fan Mounting Disc is damaged, d) the Friction Liner is worn.

7. Before removing the Fan Drive from the vehicle, it is important to: a) turn the ignition off, b) apply the parking brake, c) block the wheels, d) bleed the air from the reservoir, e) all the above

8. Applying 80-120 PSI [5.44 - 8.16 bar] air pressure to the Fan Drive air inlet will aid in removing the Fan Mounting Disc. True / False

9. The Jack Bolt is loosened by turning it counter-clockwise using a C55 Torx bit. True / False

10. Pitting or blistering on the inside contact surface of the Fan Mounting Disc is cause for replacement. True / False

11. The Cage Nut from the repair kit keeps the Spring Housing/Piston Assembly together during disassembly. True / False

12. Before removing the Friction Liner, air pressure should be: Off / On

13. The air chamber is located directly underneath the Spring Housing/Piston Assembly. True / False

14. Moisture inside the Air Chamber is normally just routine condensation. True / False

15. When checking the Air Chamber Seals, wear on the Face Seal may indicate dirt exists in the air system. True / False

16. The Air Chamber Cap Retaining Ring must be removed before removing the Air Chamber Cap. True / False

17. First the Bearing Nut is removed, then the Sheave can be removed from the Journal Bracket. True / False

18. The chevron markings on the Bearings must be aligned to form an arrow. True / False.

19. The chevron markings on the Bearings need to be aligned when using Spacers. True / False

22742M-B-0202 41 20. New Bearings must be disassembled and lubricated. True / False

21. When installing the Bearings, only the outer races should be pressed on. True / False

22. When replacing the Air Cartridge, the curved side of the beveled Retaining Ring faces the cartridge. True / False

23. Eye safety protection should be used when removing the Retaining Ring of the Air Cartridge. True / False

24. The O-Rings of a new Air Cartridge Assembly are lubricated: a) before, or b) after, installation.

25. When replacing the Bearing Nut, the hex faces down and the relief of the nut points away from the Journal Bracket and Bearings. True / False

26. The Friction Liner should be properly lubricated before installation. True / False

27. When reinstalling the Spring Housing/Piston Assembly, the “V” of the main Air Chamber Seal faces down in the Sheave. True / False

28. The Button Head Screws should be alternately and evenly tightened when replacing the Friction Liner. True / False

29. When reinstalling the Spring Housing/Piston Assembly, grease should be applied: a) deep into the Air Chamber, b) along the edge of the Friction Liner, c) only in the immediate area of the Air Chamber Seal.

30. When lubricating the Air Chamber Seal, use only the amount that fully covers the seal. True / False

31. When installing the Fan Mounting Disc, air must be blocked from the air chamber to remove the Cage Nut and to ensure proper Jack Bolt torque. True / False

32. When removing or installing the DriveMaster, the best way to protect the radiator is by using cardboard between the fan and radiator. True / False

33. Belts should be tensioned according to: a) Fan Drive specifications, b) industry standards, c) manufacturer or vehicle specifications.

34. A belt tensioner should be used to determine proper belt tightness as listed in the manufacturer or vehicle specifications. True / False

35. Air leaks are the #1 cause of Fan Drive problems. True / False

36. When observing Fan Drive operation, it is a good idea to look for vibration, Fan blade contact, or Fan Drive slippage. True / False

37. The Fan Drive air filter should be drained and inspected for contaminants: a) weekly, b) monthly, c) annually.

38. 25,000 mile (40,000 Km) PM requirements include checking the Fan Drive bearings, Friction Disc facing, wiring, overheating, and proper engagement and disengagement. True / False

39. If an air leak is not fixed the Fan Drive may start to slip and overheat. True / False

42 22742M-B-0202 40. On the illustration below, indicate at least six places you should check for air leaks.

41. For the Fan Drive system below, indicate where a jumper wire would be placed to manually test Fan Drive engagement.

A/C Pressure Air Supply +12 Volts Switch (NO)

NO Solenoid Valve NC

Thermal Switch (NO) OUT

22742M-B-0202 43 Review Answers - Fan Drive Service

1. DriveMaster Fan Drive parts that are visible externally are the Fan Mounting Disc, Friction Liner, Air Chamber Seal, and Journal Bracket. True / False

2. The two most commonly replaced parts are the Fan Mounting Disc and Friction Liner. True / False

3. A DriveMaster Seal Kit would be the most appropriate choice if: a) an air leak has developed inside the Fan Drive, b) the Bearings are running rough or if the Fan Drive needs to be completely rebuilt, c) the Fan Mounting Disc is damaged, d) the Friction Liner is worn.

4. A DriveMaster Super Kit would be the most appropriate choice if: a) an air leak has developed inside the Fan Drive, b) the Bearings are running rough or if the Fan Drive needs to be completely rebuilt, c) the Fan Mounting Disc is damaged, d) the Friction Liner is worn.

5. A DriveMaster Friction Disc Kit would be the most appropriate choice if: a) an air leak has developed inside the Fan Drive, b) the Bearings are running rough or if the Fan Drive needs to be completely rebuilt, c) the Fan Mounting Disc is damaged, d) the Friction Liner is worn.

6. A DriveMaster Friction Liner Kit would be the most appropriate choice if: a) an air leak has developed inside the Fan Drive, b) the Bearings are running rough or if the Fan Drive needs to be completely rebuilt, c) the Fan Mounting Disc is damaged, d) the Friction Liner is worn.

7. Before removing the Fan Drive from the vehicle, it is important to: a) turn the ignition off, b) apply the parking brake, c) block the wheels, d) bleed the air from the reservoir, e) all the above.

8. Applying 80-120 PSI [5.44 - 8.16 bar] air pressure to the Fan Drive air inlet will aid in removing the Fan Mounting Disc. True / False

9. The Jack Bolt is loosened by turning it counter-clockwise using a C55 Torx bit. True / False

10. Pitting or blistering on the inside contact surface of the Fan Mounting Disc is cause for replacement. True / False

11. The Cage Nut from the repair kit keeps the Spring Housing/Piston Assembly together during disassembly. True / False

12. Before removing the Friction Liner, air pressure should be: Off / On

13. The air chamber is located directly underneath the Spring Housing/Piston Assembly. True / False

14. Moisture inside the Air Chamber is normally just routine condensation. True / False

15. When checking the Air Chamber Seals, wear on the Face Seal may indicate dirt exists in the air system. True / False

16. The Air Chamber Cap Retaining Ring must be removed before removing the Air Chamber Cap. True / False

17. First the Bearing Nut is removed, then the Sheave can be removed from the Journal Bracket. True / False

18. The chevron markings on the Bearings must be aligned to form an arrow. True / False

19. The chevron markings on the Bearings need to be aligned when using Spacers. True / False

44 22742M-B-0202 20. New Bearings must be disassembled and lubricated. True / False

21. When installing the Bearings, only the outer races should be pressed on. True / False

22. When replacing the Air Cartridge, the curved side of the beveled Retaining Ring faces the cartridge. True / False

23. Eye safety protection should be used when removing the Retaining Ring of the Air Cartridge. True / False

24. The O-rings of a new Air Cartridge Assembly are lubricated: a) before, or b) after, installation.

25. When replacing the Bearing Nut, the hex faces down and the relief of the nut points away from the Journal Bracket and Bearings. True / False

26. The Friction Liner should be properly lubricated before installation. True / False

27. When reinstalling the Spring Housing/Piston Assembly, the “V” of the main Air Chamber Seal faces down in the Sheave. True / False

28. The Button Head Screws should be alternately and evenly tightened when replacing the Friction Liner. True / False

29. When reinstalling the Spring Housing/Piston Assembly, grease should be applied: a) deep into the Air Chamber, b) along the edge of the Friction Liner, c) only in the immediate area of the Air Chamber Seal.

30. When lubricating the Air Chamber Seal, use only the amount that fully covers the seal. True / False

31. When installing the Fan Mounting Disc, air must be blocked from the air chamber to remove the Cage Nut and to ensure proper Jack Bolt torque. True / False

32. When removing or installing the DriveMaster, the best way to protect the radiator is by using cardboard between the fan and radiator. True / False

33. Belts should be tensioned according to: a) Fan Drive specifications, b) industry standards, c) manufacturer or vehicle specifications.

34. A belt tensioner should be used to determine proper belt tightness as listed in the manufacturer or vehicle specifications. True / False

35. Air leaks are the #1 cause of Fan Drive problems. True / False

36. When observing Fan Drive operation, it is a good idea to look for vibration, Fan blade contact, or Fan Drive slippage. True / False

37. The Fan Drive air filter should be drained and inspected for contaminants: a) weekly, b) monthly, c) annually

38. 25,000 mile (40,000 Km) PM requirements include checking the Fan Drive bearings, Friction Disc facing, wiring, overheating, and proper engagement and disengagement. True / False

39. If an air leak is not fixed the Fan Drive may start to slip and overheat. True / False

22742M-B-0202 45 40. On the illustration below, indicate at least six places you should check for air leaks.

41. For the Fan Drive system below, indicate where a jumper wire would be placed to manually test Fan Drive engagement.

A/C Pressure Air Supply +12 Volts Switch (NO)

NO Solenoid Valve NC

Thermal Switch (NO) OUT

46 22742M-B-0202 FINAL TEST

1. Advantages to using a Horton Fan Drive include: a) additional horsepower, less fan noise, increased fuel economy, b) reduced engine RPM and service, c) reduced water pump repairs.

2. In the Fan Drive control system, the Solenoid Valve: a) acts as a sensor, b) makes sure the air filter is operating properly, c) applies or exhausts air to the Fan Drive.

3. Identify this component by circling its name.

COMPONENTS A. Solenoid B. Engine Coolant Thermal Switch C. Refrigerant Pressure Switch

4. Identify this component by circling its name.

COMPONENTS A. Solenoid B. Engine Coolant Thermal Switch C. Refrigerant Pressure Switch

5. Identify this component by circling its name.

COMPONENTS A. Solenoid B. Engine Coolant Thermal Switch C. Refrigerant Pressure Switch

6. The Fan Drive is engaged when air pressure is blocked by the Solenoid Valve. True / False

7. The engine coolant Thermal Switch sends a signal to dis-engage the Fan Drive when the engine coolant reaches the switch’s high set point. True / False

8. In a Normally-Open electrical control system, electrical contacts are open when engine temperature and air conditioning pressure are below high set points. True / False

9. When air conditioning pressure reaches the low set point the refrigerant pressure switch sends a signal to the: a) air filter, b) Thermal Switch, c) Solenoid Valve to disengage the Fan Drive.

10. The plunger inside the Solenoid Valve moves to connect the valve outlet port to one of the two inlet ports. True / False

11. Solenoid Valves should be mounted: a) near the engine, b) away from vibration and the elements, c) in an easy service location.

22742M-B-0202 47 12. The ECM sends and receives signals from the engine, transmission and other sensors to control how the vehicle operates. True / False

13. In an ECM-controlled system, one sensor may affect several actuators and one actuator may be affected by several sensors. True / False

14. If a vehicle has an ECM-based control system, it will have: a) A/C pressure switch, b) Thermal Switch.

15. Trace the path of a sensor signal to Fan Drive operation in an ECM-controlled system.

Fan Air Override Temperature Switch Sensor Engine Speed Sensor Sensor Common A/C Pressure Coolant Temp. Switch Sensor Air Supply

Foot From other Solenoid Throttle sensors Valve +12 NO Inputs Volts Electronic To indicators Control Module and gauges Fan NC Outputs Relay +12 OUT Volts To electronic injectors and other actuators Fan Relay: Not in all Systems

16. ECM fault code explanations are listed in the vehicle service manual. True / False

17. The three types of Fan Drive control systems are: a) normally-engaged, normally-disengaged, and electrically controlled, b) ECM-controlled, Normally-Open and Normally-Closed, c) electronic, pneumatic and hydraulic.

18. If a vehicle has a Normally-Closed control system, the air supply for the Drive Master should be connected to the: a) Normally-Open, or b) Normally-Closed, port of the 3-way Solenoid Valve.

19. In a Normally-Open control system, switches are wired in parallel. True / False

20. On the diagram, connect the electrical components for a Normally-Open control system and indicate if the air supply is connected to the Solenoid Valve’s Normally-Open or Normally-Closed inlet port.

Manual Override Air Supply Switch (NO) +12 Volts

Solenoid A/C Pressure Valve Switch (NO)

OUT

Thermal Switch (NO)

21. When all switches are open in a Normally-Open control system, the solenoid is: a) energized, b) de-energized, and the Fan Drive is: a) engaged, b) disengaged.

48 22742M-B-0202 22. If a switch closes in a Normally-Open control system, the solenoid is: a) energized, b) de-energized, and the Fan Drive is: a) engaged, b) disengaged.

23. In a Normally-Closed control system, switches are wired in a) series, b) parallel.

24. On the diagram, connect the electrical components for a Normally-Closed control system and indicate if the air supply is connected to the Solenoid Valve’s Normally-Open or Normally-Closed inlet port.

Manual Override Air Supply Switch (NC) +12 Volts

A/C Pressure Switch (NC) Solenoid Valve

OUT Thermal Switch (NC)

25. Air will escape through the outlet port going to the Fan Drive of a Normally-Open Solenoid Valve when air is applied to the top. True / False

26. If a switch opens in a Normally-Closed control system, the solenoid is: a) energized, b) de-energized, and the Fan Drive is: a) engaged, b) disengaged.

27. The Fan Drive can be tested in a Normally-Open control system by disconnecting a wire from a sensor. True / False

28. DriveMaster Fan Drive parts that are visible externally are the Fan Mounting Disc, Friction Liner, Air Chamber Seal, and Journal Bracket. True / False

29. The two most commonly replaced parts are the Fan Mounting Disc and Friction Liner. True / False

30. Match the Repair Kit with the most likely application: ___ DriveMaster Seal Kit A. The Fan Mounting Disc is damaged ___ DriveMaster Super Kit B. The Bearings are running rough or the Fan Drive needs to be completely rebuilt ___ DriveMaster Friction Disc Kit C. The Friction Liner is worn ___ DriveMaster Friction Liner Kit D. An air leak has developed inside the Fan Drive

31. Are the following steps for removing the fan drive in the correct order? 1. Perform safety precautions. 2. Discon- nect the air supply line. 3. Remove the fan. 4. Remove drive belts from the Fan Drive. 5. Remove the Fan Drive. Yes / No

32. Applying 80-120 PSI [5.44 - 8.16 bar] air pressure to the Fan Drive air inlet will aid in removing the Fan Mounting Disc. True / False

33. The best choice for securing the Fan Mounting Disc when loosening the Jack Bolt is a) a screwdriver, b) rebar, c) flat blade tool or small pry bar.

34. Pitting or blistering on the inside contact surface of the Fan Mounting Disc is cause for replacement. True / False

22742M-B-0202 49 35. The purpose of the Cage Nut is to keep the Spring Housing/Piston Assembly together during disassembly of the Fan Drive. True / False

36. Failure to release air pressure before removing the Spring Housing/Piston Assembly could cause the assembly to fly up, causing injury. True / False

37. The Spring Housing is disassembled and routinely serviced. True / False

38. Dirt or moisture problems in the air system must be corrected before the Fan Drive is reinstalled. True / False

39. Air Chamber seals should be inspected for: a) part number and issue date, b) wear, rips and tears, c) hardness, flexibility and grease resistance.

40. The Air Chamber Cap Retaining Ring must be removed before removing the Air Chamber Cap. True / False

41. The Sheave can be pulled off the Journal Bracket once the Bearing Nut is removed. True / False

42. After the chevron markings on the Bearings are aligned to form an arrow, the Bearings must point toward the front of the Fan Drive. True / False

43. The chevron markings on the Bearings need to be aligned when using Spacers. True / False

44. When using Bearing Spacers, the Spacers must be positioned OUTSIDE the Sheave Bearings. True / False

45. When installing the Bearings, pressing on the: a) inner, or b) outer, races will damage the Bearings causing premature wear.

46. When replacing the Air Cartridge, the curved side of the beveled Retaining Ring faces a) toward b) away from the cartridge.

47. The float tip seal on the Air Cartridge should be protected from scratches or damage. True / False

48. The O-Rings of a new Air Cartridge Assembly are lubricated: a) before, or b) after, installation.

49. When replacing the Bearing Nut, the hex faces down and the relief of the nut points away from the Journal Bracket and Bearings. True / False

50. The Friction Liner should be handled on the edges to avoid contamination, and care must be taken to not get grease, liquids or other contaminants on it. True / False

51. When reinstalling the Spring Housing/Piston Assembly, the “V” of the Air Chamber Seal can face either up or down. True / False

52. The Button Head Screws should be alternately and evenly tightened when replacing the Friction Liner. True / False

53. When reinstalling the Spring Housing/Piston Assembly, grease should be applied at, or just below the Air Chamber Seal. True / False

54. The entire tube of O-Ring lubricant is used when lubricating the new seals and contact surfaces. True / False

55. When installing the Fan Mounting Disc, air must be blocked from the air chamber to remove the Cage Nut and to ensure proper Jack Bolt torque. True / False

50 22742M-B-0202 56. When removing or installing the DriveMaster, the best way to protect the radiator is by: a) using cardboard, b) removing the radiator, c) rebuilding the Fan Drive while on the engine.

57. Over- or under-adjusting belt tension could result in: a) premature Bearing failure, b) shortened Friction Liner life, c) both a and b.

58. A belt tensioner should be used to determine proper belt tightness as listed in the manufacturer or vehicle specifications. True / False

59. Fan Drive Operation can be checked by disconnecting/connecting the lead from the ECM to the Solenoid Valve (assuming an “on” signal from the ECM is present). True / False

60. The most frequent thing to check when performing Fan Drive Preventive Maintenance is: a) air leaks, b) Bearing wear, c) PSI to engage.

61. When observing Fan Drive operation, look for: a) vibration, b) Fan blade contact, c) Fan Drive slippage, d) all the above.

62. The Fan Drive filter element should be cleaned using: a) hand cleaner, b) soap and water, c) parts solvent.

63. 25,000 mile (40,000 Km) PM requirements include checking: a) for air leaks, b) for discoloring or signs of overheating, c) Fan Drive Bearings, d) Friction Disc facing, e) electrical wiring, f) proper engagement and disengagement, g) all the above.

64. The recommended methods to check for air leaks in the Fan Drive and control system are: a) listen, b) wet finger, c) soapy water, d) all the above.

65. On the illustration below, indicate at least six places you should check for air leaks.

66. For the Fan Drive system below, indicate where a jumper wire would be placed to manually test Fan Drive engagement.

A/C Pressure Air Supply +12 Volts Switch (NO)

NO Solenoid Valve NC

Thermal Switch (NO) OUT

22742M-B-0202 51 Final Test Answers

1. Advantages to using a Horton Fan Drive include: a) additional horsepower, less fan noise, increased fuel economy, b) reduced engine RPM and service, c) reduced water pump repairs.

2. In the Fan Drive control system, the Solenoid Valve: a) acts as a sensor, b) makes sure the air filter is operating properly, c) applies or exhausts air to the Fan Drive.

3. Identify this component by circling its name.

COMPONENTS A. Solenoid B. Engine Coolant Thermal Switch C. Refrigerant Pressure Switch

4. Identify this component by circling its name.

COMPONENTS A. Solenoid B. Engine Coolant Thermal Switch C. Refrigerant Pressure Switch

5. Identify this component by circling its name.

COMPONENTS A. Solenoid B. Engine Coolant Thermal Switch C. Refrigerant Pressure Switch

6. The Fan Drive is engaged when air pressure is blocked by the Solenoid Valve. True / False

7. The engine coolant Thermal Switch sends a signal to dis-engage the Fan Drive when the engine coolant reaches the switch’s high set point. True / False

8. In a Normally-Open electrical control system, electrical contacts are open when engine temperature and air conditioning pressure are below high set points. True / False

9. When air conditioning pressure reaches the low set point the refrigerant pressure switch sends a signal to the: a) air filter, b) Thermal Switch, c) Solenoid Valve to disengage the Fan Drive.

10. The plunger inside the Solenoid Valve moves to connect the valve outlet port to one of the two inlet ports. True / False

11. Solenoid Valves should be mounted: a) near the engine, b) away from vibration and the elements, c) in an easy service location.

52 22742M-B-0202 12. The ECM sends and receives signals from the engine, transmission and other sensors to control how the vehicle operates. True / False

13. In an ECM-controlled system, one sensor may affect several actuators and one actuator may be affected by several sensors. True / False

14. If a vehicle has an ECM-based control system, it will have: a) A/C pressure switch, b) Thermal Switch.

15. Trace the path of a sensor signal to Fan Drive operation in an ECM-controlled system.

Fan Air Override Temperature Switch Sensor Engine Speed Sensor Sensor Common A/C Pressure Coolant Temp. Switch Sensor Air Supply

Foot From other Solenoid Throttle sensors Valve +12 NO Inputs Volts

Electronic NC To indicators Control Module and gauges Fan Outputs Relay +12 OUT Volts To electronic injectors and other actuators Fan Relay: Not in all Systems

16. ECM fault code explanations are listed in the vehicle service manual. True / False

17. The three types of Fan Drive control systems are: a) normally-engaged, normally-disengaged, and electrically controlled, b) ECM-controlled, Normally-Open and Normally-Closed, c) electronic, pneumatic and hydraulic.

18. If a vehicle has a Normally-Closed control system, the air supply for the Drive Master should be connected to the: a) Normally-Open, or b) Normally-Closed, port of the 3-way Solenoid Valve.

19. In a Normally-Open control system, switches are wired in parallel. True / False

20. On the diagram, connect the electrical components for a Normally-Open control system and indicate if the air supply is connected to the Solenoid Valve’s Normally-Open or Normally-Closed inlet port.

Manual Override Air Supply Switch (NO) +12 Volts

NO Solenoid A/C Pressure Valve NC Switch (NO)

OUT

Thermal Switch (NO)

21. When all switches are open in a Normally-Open control system, the solenoid is: a) energized, b) de-energized, and the Fan Drive is: a) engaged, b) disengaged.

22742M-B-0202 53 22. If a switch closes in a Normally-Open control system, the solenoid is: a) energized, b) de-energized, and the Fan Drive is: a) engaged, b) disengaged.

23. In a Normally-Closed control system, switches are wired in a) series, b) parallel.

24. On the diagram, connect the electrical components for a Normally-Closed control system and indicate if the air supply is connected to the Solenoid Valve’s Normally-Open or Normally-Closed inlet port.

Manual Override Air Supply Switch (NC) +12 Volts

NO A/C Pressure Switch (NC) Solenoid Valve NC

OUT Thermal Switch (NC)

25. Air will escape through the outlet port going to the Fan Drive of a Normally-Open Solenoid Valve when air is applied to the top. True / False

26. If a switch opens in a Normally-Closed control system, the solenoid is: a) energized, b) de-energized, and the Fan Drive is: a) engaged, b) disengaged.

27. The Fan Drive can be tested in a Normally-Open control system by disconnecting a wire from a sensor. True / False

28. DriveMaster Fan Drive parts that are visible externally are the Fan Mounting Disc, Friction Liner, Air Chamber Seal, and Journal Bracket. True / False

29. The two most commonly replaced parts are the a) Cage Nut, b) Fan Mounting Disc, c) Bearing Spacer, d) Friction Liner.

30. Match the Repair Kit with the most likely application: ___D DriveMaster Seal Kit A. The Fan Mounting Disc is damaged ___B DriveMaster Super Kit B. The Bearings are running rough or the Fan Drive needs to be completely rebuilt ___A DriveMaster Friction Disc Kit C. The Friction Liner is worn ___C DriveMaster Friction Liner Kit D. An air leak has developed inside the Fan Drive

31. Are the following steps for removing the fan drive in the correct order? 1. Perform safety precautions. 2. Discon- nect the air supply line. 3. Remove the fan. 4. Remove drive belts from the Fan Drive. 5. Remove the Fan Drive. Yes / No

32. Applying 80-120 PSI [5.44 - 8.16 bar] air pressure to the Fan Drive air inlet will aid in removing the Fan Mounting Disc. True / False

33. The best choice for securing the Fan Mounting Disc when loosening the Jack Bolt is a) a screwdriver, b) rebar, c) flat blade tool or small pry bar.

34. Pitting or blistering on the inside contact surface of the Fan Mounting Disc is cause for replacement. True / False

54 22742M-B-0202 35. The purpose of the Cage Nut is to keep the Spring Housing/Piston Assembly together during disassembly of the Fan Drive. True / False

36. Failure to release air pressure before removing the Spring Housing/Piston Assembly could cause the assembly to fly up, causing injury. True / False

37. The Spring Housing is disassembled and routinely serviced. True / False

38. Dirt or moisture problems in the air system must be corrected before the Fan Drive is reinstalled. True / False

39. Air Chamber seals should be inspected for: a) part number and issue date, b) wear, rips and tears, c) hardness, flexibility and grease resistance.

40. The Air Chamber Cap Retaining Ring must be removed before removing the Air Chamber Cap. True / False

41. The Sheave can be pulled off the Journal Bracket once the Bearing Nut is removed. True / False

42. After the chevron markings on the Bearings are aligned to form an arrow, the Bearings must point toward the front of the Fan Drive. True / False

43. The chevron markings on the Bearings need to be aligned when using Spacers. True / False

44. When using Bearing Spacers, the Spacers must be positioned OUTSIDE the Sheave Bearings. True / False

45. When installing the Bearings, pressing on the: a) inner, or b) outer, races will damage the Bearings causing premature wear.

46. When replacing the Air Cartridge, the curved side of the beveled Retaining Ring faces a) toward, b) away from, the cartridge.

47. The float tip seal on the Air Cartridge should be protected from scratches or damage. True / False

48. The O-Rings of a new Air Cartridge Assembly are lubricated: a) before, or b) after, installation.

49. When replacing the Bearing Nut, the hex faces down and the relief of the nut points away from the Journal Bracket and Bearings. True / False

50. The Friction Liner should be handled on the edges to avoid contamination, and care must be taken to not get grease, liquids or other contaminants on it. True / False

51. When reinstalling the Spring Housing/Piston Assembly, the “V” of the Air Chamber Seal can face either up or down. True / False

52. The Button Head Screws should be alternately and evenly tightened when replacing the Friction Liner. True / False

53. When reinstalling the Spring Housing/Piston Assembly, grease should be applied at, or just below the Air Chamber Seal. True / False

54. The entire tube of O-Ring lubricant is used when lubricating the new seals and contact surfaces. True / False

55. When installing the Fan Mounting Disc, air must be blocked from the air chamber to remove the Cage Nut and to ensure proper Jack Bolt torque. True / False

22742M-B-0202 55 56. When removing or installing the DriveMaster, the best way to protect the radiator is by: a) using cardboard, b) removing the radiator, c) rebuilding the Fan Drive while on the engine.

57. Over- or under-adjusting belt tension could result in: a) premature Bearing failure, b) shortened Friction Liner life, c) both a and b.

58. A belt tensioner should be used to determine proper belt tightness as listed in the manufacturer or vehicle specifications. True / False

59. Fan Drive Operation can be checked by disconnecting/connecting the lead from the ECM to the Solenoid Valve (assuming an “on” signal from the ECM is present). True / False

60. The most frequent thing to check when performing Fan Drive Preventive Maintenance is: a) air leaks, b) Bearing wear, c) PSI to engage.

61. When observing Fan Drive operation, look for: a) vibration, b) Fan blade contact, c) Fan Drive slippage, d) all the above.

62. The Fan Drive filter element should be cleaned using: a) hand cleaner, b) soap and water, c) parts solvent.

63. 25,000 mile (40,000 Km) PM requirements include checking: a) for air leaks, b) for discoloring or signs of over heating, c) Fan Drive Bearings, d) Friction Disc facing, e) electrical wiring, f) proper engagement and disengage- ment, g) all the above.

64. The recommended methods to check for air leaks in the Fan Drive and control system are: a) listen, b) wet finger, c) soapy water, d) all the above.

65. On the illustration below, indicate at least six places you should check for air leaks.

66. For the Fan Drive system below, indicate where a jumper wire would be placed to manually test Fan Drive engagement.

A/C Pressure Air Supply +12 Volts Switch (NO)

NO Solenoid Valve NC

Thermal Switch (NO) OUT

56 22742M-B-0202 Horton, Inc. 2565 Walnut St. Roseville, MN 55113 651-361-6400 Toll-free: 1-800-621-1320 Website: www.hortoninc.com e-mail: [email protected]

© 2002 Horton, Inc. All rights reserved.

22742M-B-0202 EA09-008 PACCAR 10/15/2009 RESPONSE 15 horton-hts22540 Heavy-Duty Fan Drive Maintenance Training Manual

Table of Contents

INTRODUCTION ...... 4

LESSON 1: Fan Drive Operation ...... 5

LESSON 2: Heavy Duty Fan Drives ...... 6

LESSON 3: Fan Drive Control System ...... 10 REVIEW QUESTIONS: Fan Drive Control Systems ...... 19 LAB ACTIVITY: Fan Drive Components ...... 21

LESSON 4: Preventive Maintenance (PM) ...... 23 REVIEW QUESTIONS: Preventive Maintenance ...... 25

LESSON 5: Horton Fan Drive Components ...... 27

LESSON 6: Corrective Maintenance ...... 30 REVIEW QUESTIONS: Corrective Maintenance ...... 34

FINAL TEST: Heavy Duty Fan Drive Maintenance ...... 35

APPENDIX A: Preventive Maintenance Check List 10,000 Miles [16,000 Km] ...... 41

APPENDIX B: Preventive Maintenance Check List 25,000 Miles [40,000 Km] ...... 42

APPENDIX C: Review Question Answers ...... 44

22540 3 Introduction

This student manual for the technical course, Heavy-Duty Fan Drive Maintenance, is designed to train heavy-duty diesel technicians how to perform preventive and corrective maintenance on Horton heavy-duty fan drives.

This guide may be used in the classroom with an instructor or in a self-study mode. After completion of this course, take the Final Test at the end of this student manual. Mail your Final Test to the follow- ing address to receive a Certified Horton Technician toolbox sticker and a Horton Certificate of Achievement:

Horton, Inc. 2565 Walnut St. Roseville, MN 55113, USA Phone: +1 (651) 361-6400 Toll-free: +1 (800)-621-1320 Fax: +1 (651) 361-6801 Web site: www.hortoninc.com e-mail: [email protected]

In accordance with Horton’s established policy of constant product improvement, the specifications contained in this manual are subject to change without notice and are based on the latest information available at the time of printing.

4 22540 LESSON 1: Fan Drive Operation Objectives • Recognize the purpose and advantages of a fan drive.

Heavy-Duty Fan Drive

Radiator

When engaged, the fan drive activates the fan to cool the engine by pulling air An engaged fan drive pulls through the radiator. Depending on the size and rotational speed of the fan air through the radiator to blade, as much as 70-75 HP may be needed to run the fan. The fan drive cool the engine. engages only when needed resulting in additional horsepower for drive axles, less noise, and increased fuel economy. Due to these benefits, most new diesel powered trucks are equipped with a Horton on/off fan drive.

22540 5 Objectives LESSON 2: Heavy-Duty Fan Drives • Recognize the different models of Horton heavy-duty fan drives With more than 50 years of industry experience, Horton is a premier world- • Describe the Horton wide provider of the highest quality truck components. Horton supplies ® System Sentry feature several different models of heavy-duty fan drives.

9 “ [22.86 cm] single 9 “ Single Plate plate fan drives are The 9" [22.86 cm] single plate is an older style painted gray. fan drive (rarely supplied on new trucks) with a larger air chamber than other Horton fan drives.

Original S The S model fan drive has a drive plate that is 7.5 “ [ 19.05 cm] in diameter. An original S model fan drive has a smooth Piston Friction Disc (PFD), whereas the newer model with Sys- S and HT/S fan Drives tem Sentry® has three large bosses on the PFD. are painted blue and may be upgraded by Original HT/S installing an Advantage Super Kit. The HT/S model fan drive has a drive plate that is 9.5" [24.13 cm] in diameter. The origi- S and HT/S Advantage nal HT/S model fan drive has a smooth PFD fan drives are painted while an Advantage model with System Sentry gun-metal blue. has three large bosses on the PFD. Advantage Reman fan drives are painted S and HT/S Advantage maroon. The S and HT/S Advantage are heavy duty fan drives, equipped to handle the frequent on/off cycles common in severe-duty trucking appli- cations. Both fan drives include the System Sentry feature along with a plastic air cartridge and improved hub assembly.

6 22540 System Sentry® Feature The System Sentry In 1994, Horton added the patented feature disengages the fan drive when exces- System Sentry® feature to the S and HT/S sive temperatures occur. designs. System Sentry equipped fan drives have three large bosses on the PFD, one of which contains a System Sentry to protect the fan drive from overheating.

The material in the left-hand threaded System Sentry has a melt- ing point of approximately 600o F [316o C]. If a fan drive should start to slip and overheat, the fuse material will melt and open a passage to release the air pres- System sure, disengaging the fan drive. Sentry

Replacement Fuses are available in all of the Horton fan drive repair kits.

If a fuse has blown, carefully examine the entire cooling system to determine the cause. Replacing a fuse without examining the system may result in a repeated blown fuse and possible damage to the fan drive.

The S and HT/S Advantage fan drives also utilize a new air cartridge design, improving reliability and reducing the possibility of an air leak inside the air chamber.

22540 7 Troubleshooting the fan drive Allen Head Torx Head and controls should be done ® ® promptly to locate the prob- System Sentry System Sentry lem which caused the Sys- tem Sentry® release of the fan drive. First locate and remove anything that may be Piston Friction an obstruction to the fan Counter Disc blade. Check the fan drive Balance for leaks. If no leaks are found, check the solenoid and controls.

Horton fan drives are designed to permit continued operationin the event of a fan drive System Sentry® air source or electrical control system malfunc- tion.

In the event of a malfunction, turn engine off. Visually check the System Sentry for signs of melting.

• If for any reason excessive heat is building up in the fan drive, the System Sentry will release and create an air leak. This shuts down the system to prevent any further damage.

• Your System Sentry may have an Allen head or a Torx head. A Torx wrench will work in the removal and installation of either System Sentry.

When replacing the System Sentry, be sure to loosen it in the correct direction. It is a left-hand thread and needs to be turned clockwise for removal.

WARNING Only use a Horton System Sentry as a replacement. The Piston Friction Disc is balanced and anything other than the Horton System Sentry will upset the balance.

8 22540 Install the new System Sentry®. Troubleshoot and correct the failed system component(s) as soon as possible.

CAUTION Failure to troubleshoot may result in reoccuring System Sentry releases.

Lock Up Bolt Installation

• In the event your System Sentry cannot be replaced or you cannot immediately troubleshoot the cooling system, the lock up bolts can be used as an alternative option.

Horton fan drives are designed to permit continued operation in the event of a fan drive air source or electrical control system malfunction.

In the event of a malfunction, turn engine off. Align two holes in Piston Friction Disc with two holes in sheave. Install grade 8 lockup bolts and tighten to 25 Ft. Lbs. [33.9 N•m] (See diagram).

Cap Screw Specifications

Size Qty

Grade 8, 5/16 - 18NC x 1” 2

CAUTION The lock-up bolt installation procedure is only a temporary Tighten solution. The air source or lockup bolts electrical malfunction must be to corrected as soon as possible. 25 Ft. Lbs. [33.9 N•m] Torque

22540 9 Objectives • describe the LESSON 3: Fan Drive Control System components of a fan drive electrical control system

• determine the correct To ignition air inlet port for a normally Air Filter open and normally closed Manual Override Switch solenoid valve Thermal Switch • describe the basic Air Supply operation of normally A/C Refrigerant Pressure Switch open, normally closed, and the electronic control Solenoid Valve module (ECM) and how they control the electrical control system

• determine if a truck’s fan drive electrical control system is wired normally- open, normally-closed, or connected to an ECM

Depicted is an illustration of an independent fan drive control system. The electrically controlled solenoid valve engages and disengages the fan drive by regulating its air pressure on and off. The electrical circuit to the solenoid valve contains three switches:

•a thermal switch sensing the engine coolant temperature.

•a refrigerant pressure switch in the truck’s air conditioning system.

• an optional manual override switch located on the truck’s dashboard.

Any of these three switches may activate the solenoid and engage the fan drive.

EXAMPLE. When the engine coolant temperature rises above the thermal switch’s set point, the thermal switch will activate the sole- noid valve, which will in turn send air pressure from the truck’s air reservoir to the fan drive and engage the fan.

Most newer trucks have an Electronic Control Module (ECM) – a small computer that monitors and controls all engine operations, including the fan drive. If a truck uses an ECM, there is no direct connection between the sensors and fan drive solenoid valve. Information from sensors and switches is fed into the ECM which in turn controls the solenoid valve.

10 22540 Sensors Trucks not using an ECM usually have two sensors to auto- matically turn the fan on and off. First is the engine coolant thermal switch and second the air conditioning refriger- ant pressure switch.

The engine coolant thermal switch is mounted in the Thermal switch reset water jacket on the engine. point is usually 7oF [3.9oC] below the set point. Truck designers will typically specify a • In a normally-open thermal switch, the electrical contacts are open when thermal switch with a set the temperature is below the set point and closed when the tempera- point 10-15o F [5.6-8.3o ture is above the set point. C] higher than the fully open temperature of the engine thermostat. • In a normally-closed thermal switch, the electrical contacts are closed when the temperature is below the set point and open when the temperature is above the set point.

The refrigerant pressure switch is installed in the high Air conditioning refriger- pressure line of the cab’s air conditioning system. When ant pressure switches the air conditioner is running, heat removed from the are available as either air is absorbed by the refrigerant (e.g., freon, R-12 and normally-open or normally-closed. R-134a). As the refrigerant heats, pressure builds in the air conditioner high pressure line until the refrigerant pressure reaches the switch’s set point. The switch then sends a signal to the solenoid valve to engage the fan drive. The fan pulls air through the air conditioner condenser coils, which cools the condenser/refrigerant and reduces refriger- ant pressure.

Air Filter Some trucks have an air filter Truck Air in To solenoid in the supply line going into valve inlet port the solenoid valve. As shown, the Horton air filter connects directly to the solenoid valve I inlet port. The air filter con- N tains an element to remove dirt from the compressed air before it enters the solenoid valve. A Air Filter drain valve at the bottom of the filter provides a check for excessive contaminants. Drain the truck’s air system prior to air filter removal. The filter is easily removed for cleaning by unscrewing Drain Valve the bowl from the bottom of the assembly, then unscrewing the filter element.

22540 11 Solenoid Valve The solenoid valve is the heart of the N.O. Inlet Port/ fan drive control system, opening and NC Exhaust Port closing to regulate the air flow to the fan drive. The solenoid valve is a 3- way valve having two inlet and one out- let ports. Air pressure from the truck’s air system is fed into one of the inlet ports and the outlet port is connected N.C. Inlet Port/ to the fan drive. The valve has a 3/64" N.O. Exhaust [1.19 mm] orifice to regulate the volume Port of air and ensure smooth engagement Air Outlet Port and disengagement of the fan drive. To Fan Drive

Turning the solenoid electric current on and off causes a plunger inside the valve to move up and down. The plunger connects the valve outlet port to one of the two inlet ports:

• the normally-open port when the electric current is off. • the normally-closed port when the electric current is on.

EXAMPLE. Normal can be expressed as the state the solenoid valve Normal (as in normally- would be in if it was completely disconnected and in your hand - the open or normally-closed) solenoid would be de-energized, the normally-open port would be refers to the state of the solenoid valve when it is open to the outlet port, and the normally-closed port would be closed relaxed or de-energized. to the outlet port.

The valve outlet port is always connected to the fan drive. Depending on the truck’s electrical control circuits, the air supply may be connected to either the normally-open or the normally-closed port. The port not connected to the air supply will exhaust air from the fan drive when it disengages.

Various adapters and fittings are available to permit the solenoid valve to be plumbed either normally-open or normally-closed (i.e., the air supply The solenoid valve is may be connected to either inlet port). These fittings also permit the controlled by electricity solenoid valve to be installed with or without an air filter. and is available for 12 and 24 volt electrical Remote mounting the solenoid valve off of the engine will minimize the valve’s systems. exposure to excessive heat, vibration, and contaminants. The mounting loca- tion of the solenoid should be both functional and free of excessive heat, vibra- tion, and contaminants. A solenoid valve mounted off of the engine will pro- long the life of the solenoid and ensure proper fan drive operation.

12 22540 Electrical Control Systems The electrical wiring that controls the fan drive varies from truck to truck, but generally will be one of three types:

• normally-open

• normally-closed

• ECM controlled

Manufacturers that tend to have normally-closed electrical controls on non-ECM engines include:

Blue Bird GMC Mack Ford Navistar/International White GMC

Manufacturers that tend to have normally-open electrical controls on non-ECM engines include:

Freightliner Mack Western Star Kenworth Volvo Peterbilt

The fan drive electrical control system may be normally-open or normally-closed, and the solenoid valve may be plumbed normally-open or normally-closed. Horton fan drives are plumbed as follows:

• on trucks with a normally-open electrical system, connect the air supply to the solenoid valve’s normally-closed port.

• on trucks with a normally-closed electrical system, connect the air supply to the solenoid valve’s normally-open port.

Also, when referring to normally-open electrical systems, the reference is to electrical; when referring to normally-open valves, reference is to the pneumatics of the valve.

22540 13 Normally-Open Electrical Controls

The following schematic diagram is of a normally-open electrical control system for a fan drive-when all switches are below their set points, the electri- cal circuit to the solenoid valve is open.

Manual Air Supply Override +12 Volts Switch (NO)

A/C NO Pressure Switch (NO) Solenoid Valve NC Thermal Switch OUT (NO)

In a system wired in In such a system, all electrical switches are wired in parallel. Electricity parallel, electricity from from the 12 volt supply can take any one of the three parallel paths to the supply can take any reach the solenoid valve. of the parallel paths to reach the valve. All three switches are shown in their normal state-open. When all switches are open, no electricity flows to the solenoid valve and the solenoid is de- energized. The plunger inside the solenoid valve connects the outlet port to the normally-open port and blocks air pressure from going to the fan drive. The fan drive disengages and the fan is idle.

When one of the electrical switches closes, electricity flows through the switch and energizes the solenoid valve. The plunger inside the solenoid valve moves to connect the outlet port to the normally-closed inlet port. Air pressure flows through the valve to the fan drive, engaging the fan drive and causing the fan blade to turn.

EXAMPLE. The engine coolant temperature rises above the thermal switch’s set point. The normally-open thermal switch closes causing electricity to flow through the thermal switch and energizing the solenoid valve. The solenoid valve plunger moves to connect the outlet port to the normally- closed inlet port. Air pressure flows through the valve to engage the fan drive, turning the fan blade.

14 22540 Normally-Closed Electrical Controls

The following schematic diagram is of a normally-closed electrical con- trol system for a fan drive-when all switches are below their set points, the electrical circuit to the solenoid valve is closed.

Manual Override Air Supply +12 Volts Switch (NC)

A/C Pressure NO Switch (NC) Solenoid NC Valve

Thermal Switch (NC)

In such a system, all electrical switches are wired in series. Electricity In a system wired in from the 12 volt supply must flow through all three switches before it series, electricity from reaches the solenoid valve. the supply must flow through all switches to reach the valve. All three switches are shown in their normal state-closed. When all switches are closed, electricity flows to the solenoid valve and the sole- noid is energized. The plunger inside the solenoid valve connects the outlet port to the normally-closed inlet port and blocks air pressure from going to the fan drive. The fan drive disengages and the fan is idle.

When one of the electrical switches opens, the electrical current is bro- ken. The solenoid valve de-energizes. The plunger inside the solenoid valve moves to connect the outlet port to the normally-open inlet port. Air pressure flows through the valve to the fan drive, engaging the fan drive and causing the fan blade to turn.

EXAMPLE. The engine coolant temperature rises above the thermal switch’s set point. The normally-closed ther- mal switch opens, causing a break in the electrical current and de-energizing the solenoid valve. The solenoid valve plunger moves to connect the outlet port to the normally- open inlet port. Air pressure flows through the valve to engage the fan drive, turning the fan blade.

22540 15 Normally Open Electrical System Normally Closed Electrical System

The following summa- Normally- To Fan rizes the normally-open Drive Closed Port Elbow and normally-closed Air Supply in Air Supply in Normally-

electrical systems for Open Port controlling an air 1 2 engaged fan drive.

2 1

Exhaust To Fan Drive Exhaust

• Electrical switches are wired in parallel. • Electrical switches are wired in series. • Air supply plumbed to solenoid’s normally-closed • Air supply plumbed to port (the side port). solenoid’s normally-open port (the end port). • Test fan drive by installing a jumper wire across a sensor. • Test fan drive by disconnect ing a wire from a sensor. • Manual Override Switch (if equipped). • Manual Override Switch (if equipped).

Normally-Open Electrical System with Normally-Closed Pneumatics All switches open Any switch closed Solenoid de-energized Solenoid energized Drive disengaged Drive engaged

Normally-Closed Electrical System with Normally-Open Pneumatics All switches closed Any switch open Solenoid energized Solenoid de-energized Drive disengaged Drive engaged

16 22540 ELECTRIC CONTROL MODULE (ECM) CONTROL

Engine manufacturers include Electronic Control Modules (ECMS) in their An ECM is essentially a digital new designs to control the engine, transmission, and other critical computer, used to control the operations to improve engine performance, reliability, and fuel efficiency. engine, transmission, and other critical operations to improve performance reliabil- An ECM is essentially a digital computer, containing a microprocessor, ity, and efficiency. random-access-memory (RAM), and read-only-memory (ROM). The ROM contains the computer’s program. Design engineers can change a truck’s control system and engine performance simply by changing the ECM’s computer program.

Air Fan Temperature Override Engine Switch Sensor Speed Sensor Sensor Air Supply Common Foot Coolant Temp. A/C Pressure Throttle Sensor Switch

Solenoid From other sensors Valve +12 NO To indicators Inputs Volts and gauges NC Electronic Control Module Fan Relay OUT Outputs +12 Volts

To electronic injectors and other actuators

As shown, the sensors are not wired to the solenoid valve or any control actuator as previously seen in a conventional system. Instead, each sensor goes to an ECM input pin and each actuator is wired to an ECM output pin. The ECM computer constantly monitors the data from the sensors, and, based on programming logic, sends the appropriate signals to the controls and actuators. The ECM also sends status information to the operator’s waming lights and gauges.

In an ECM controlled system, one sensor may affect several actuators The ECM monitors data from and one actuator may be affected by several sensors, depending on how the sensors to send signals to the ECM is programmed. the controls, actuators, and operator’s warning lights and gauges.

22540 17 The sensors used in ECM systems are different from those used in independent systems. Instead of the simple open/close type of sensor, ECM systems use thermistors and sending units to send signals to the ECM (temperature, pressure, speed, or whatever function is being sensed).

EXAMPLE. Instead of a thermal switch opening or closing at a preset temperature, an ECM will use a temperature sensor to provide a voltage which the logic program converts into an actual temperature measurement. Instead of simply knowing if the coolant temperature is above or below the set point (i.e., hotter that 190o F [88o C]), the program will know the actual temperature (i.e., 196.4o F [91.3o C]).

New troubleshooting techniques may be necessary when working on a truck with an ECM control system. Looking at a truck’s wiring diagram will no longer indicate which sensor affects which actuator. The diagram will only show to which ECM pin each sensor and actuator is connected. To determine the relationships between the sensors and actuators, refer to the truck or engine service manual for descriptions of exact conditions under which each actuator is engaged (i.e. Fault Codes).

The ECM program consid- The fan drive solenoid is not wired to the sensors as it is in a ers several factors before conventional system but instead wired to a relay controlled by the ECM. determining fan drive The ECM computer program looks at the data from several sensors and engagement. decides when to engage and disengage the fan drive. The program consid- ers engine coolant temperature, air-conditioner’s refrigerant pressure, intake-manifold air temperature, engine speed, and the engine brake status.

Electronic Control Modules may seem more complicated than those used in independent hard-wired systems, but they are not. Since the decision logic is in the computer program and not the wiring, and since all sensors and actuators are wired to the ECM instead of to each other. The overall system is much simpler and more reliable.

18 22540 Review Questions: Fan Drive Control Systems

Complete these Review Questions by filling in the blank(s) or circling the appropriate answer(s).

1. When installing a 3-way solenoid valve, connect the air line going to the fan drive to the valve’s ______port.

2. When a fan drive is disengaged, where does air pressure in the fan drive’s air chamber go?

______

3. On the diagram below, connect the electrical components for a normally-open electrical system and indicate if the air supply is connected to the solenoid valve’s normally-open or normally-closed inlet port.

Normally-Open Electrical System

Manual Override Air Supply +12 Volts Switch (NO)

A/C Pressure NO Switch (NO) Solenoid Valve NC Thermal Switch (NO)

4. In a normally-open fan drive electrical system, the switches and sensors are wired in series / parallel.

5. If a truck has a normally-open electrical system, the air supply should be connected to the normally- ______inlet port of the 3-way solenoid valve.

6. In a normally-open electrical system, when all switches are open, the solenoid is energized / de-energized and the fan drive is engaged / disengaged.

22540 19 7. In a normally-open electrical system, if any switch closes, the solenoid will energize / de-energize and the fan drive will engage / disengage.

8. On the diagram below, connect the electrical components for a normally-closed electrical system and indicate if the air supply is connected to the solenoid valve’s normally-open or normally-closed inlet port.

Normally-Closed Electrical System

Manual Air Supply Override +12 Volts Switch (NO)

A/C Pressure NO Switch (NO) Solenoid Valve NC

Thermal Switch (NO)

9. In a normally-closed fan drive electrical system, the switches and sensors are wired in series / parallel.

10. If a truck has a normally-closed electrical system, the air supply should be connected to the normally- ______inlet port of the 3-way solenoid valve.

11. In a normally-closed electrical system, when all switches are closed, the solenoid is energized / de-energized and the fan drive is engaged / disengaged.

12. In a normally-closed electrical system, if any switch opens, the solenoid will energize / de-energize and the fan drive will engage / disengage.

13. ECMs are being added to new truck designs to improve ______, ______, and ______.

14. An ECM is essentially a digital computer, consisting of a ______, ______, and ______.

After completing Review Questions, check answers in Appendix C, Page 43.

20 22540 LAB ACTIVITY: Fan Drive Components

Locate a truck with a Horton heavy duty fan drive, preferably a make and model you would work on.

WARNING: For your safety, be sure the engine is off.

Locate the components listed below and answer the questions by filling in the corresponding blanks and checking the box next to the number when you complete a step. Upon completion, please check this activity with an instructor or supervisor.

‰ 1. Locate the fan drive and list the model.

______

‰ 2. Locate the solenoid valve.

‰ 3. Locate the fan drive air filter (if equipped).

‰ 4. Locate the coolant temperature switch or sensor.

‰ 5. Locate the air-conditioning refrigerant pressure switch (if equipped).

‰ 6. Locate the fan drive manual override switch (if equipped).

‰ 7. How many belts are on the fan drive sheave?

______

‰ 8. What engine components do the belts go around?

______

‰ 9. How many bolts mount the fan drive to the engine?

‰ 10. Locate the air hose that supplies air to the solenoid. Where does the hose attach to the air supply?

______

22540 21 ‰ 11. Is the air supply connected to the solenoid valve’s normally- open or normally-closed inlet port?

______

‰ 12. Does the truck have an ECM?

______

‰ 13. In the truck’s service manual, locate the electrical diagram for the fan drive control solenoid and, if present, the ECM.

‰ 14. Draw the schematic symbol used in your truck’s electrical diagram for each of the following components:

Solenoid valve

Engine-coolant thermal switch/sensor

Air-conditioning refrigerant pressure switch/sensor

Manual override switch

‰ 15. Are the fan drive switches and sensors wired in series, in parallel, or to the ECM?

______

‰ 16. Are the fan drive electrical controls normally-open or normally-closed?

Please remember to review this activity with an instructor or supervisor.

22 22540 LESSON 4: Preventive Maintenance (PM) Objectives • perform weekly, 10,000 mile [16,000 Km], and Most fan drive failures are caused by air leaks. With regular preventive main- 25,000 mile [40,000 Km] fan drive preventive tenance (PM), the Horton heavy duty fan drive will provide years of reliable maintenance service. PM is recommended at the weekly air-filter draining, I0,000 mile [16,000 Km] PM, and 25,000 mile [40,000 Km] PM. • check fan drive system for air leaks

Weekly PM • manually check fan drive operation in either normally-open or normally- Each week, drain the air filter at its bleed valve Filter Element closed systems and check for moisture or con- taminants. If contaminants are present, disassemble the air filter as shown. Clean Filter Bowl all parts with parts solvent and dry them thoroughly. Check the truck’s air system for the source of the contamination and Bleed Valve make the necessary repairs.

10,000 Mile [16,000 Km] PM

Every 10,000 miles [16,000 Km] or when performing Area between air Check for discolora- an oil drain, conduct a chamber and PFD tion or other signs of quick check of the fan drive overheating as described in the Preven- tive Maintenance Check List (See Appendix A). With air applied to the fan drive, check for air Bleed Hole leaks around the fan drive (showing at the points shown. Also Come- Umbrella check for leaks at the home Seal) solenoid valve and filter bolt hole assembly, and in the air System Sentry hoses and fittings. Feel for a leak with a wet finger or by applying soapy water and looking for bubbles. If the leak is in the fan drive itself, repair it by Do not pressure wash installing the appropriate repair kit (See LESSON 6: Corrective the fan drive. The fan Maintenance). drive needs no washing or cleaning.Direct spray from a pressure washer will only result in reduced life or damage to the product.

22540 23 25,000 Mile [40,000 Km] PM

The 25,000 mile [40,000 Km] fan drive PM procedure is defined in Appendix B. The 25,000 mile [40,000 Km] PM is similar to the procedures in the 10,000 mile [ 16,000 Km] PM but is more comprehensive. Inspect the system for leaks at the points indicated in Figure 18. Also, check the fan drive for discol- oration or any other signs of slipping or overheating. The fan drive may slip if incoming air pressure is below 90 psi [6.21 bar] or if an air leak exists inside the fan drive. Never let a leak remain unattended - the appropriate repair kit must be installed for a fan drive with an internal leak.

Check the fan drive bearings. Be certain the engine is off before putting your hands near the fan blades. Turn the fan blade in both directions and feel for worn hub bearings. If the fan belts can be easily removed, remove the belts and check for worn sheave bearings. Turn the sheave in both directions- if either the hub or sheave bearings are worn, install the appropriate repair kit (See LESSON 6: Corrective Maintenance).

Check the fan drive friction facing for wear by measuring the thickness of the friction material. A new facing is 1/4" [6.35 mm] thick. Replace the friction material if it has worn to less than 1/16" [1.59 mm].

Check the electrical wiring at the thermal switch, air conditioning pres- sure switch, and solenoid valve. Be certain there are not any loose wires or connections.

Check the fan drive for proper engagement and disengagement. Turn on the ignition switch but do not start the engine. Be certain at least 90 psi [6.21 bar] of air pressure is available in the truck’s reservoir. To manually engage and disengage the fan drive, open and close the electrical circuit going to the solenoid valve as follows:

• For a normally-open electrical system, use a jumper wire to short out the thermal switch or the air-conditioning refrigerant pressure switch.

• For a normally-closed electrical system, open the circuit by disconnecting a wire from one of the sensors or from the solenoid valve.

24 22540 Review Questions: Preventive Maintenance

Complete these Review Questions by filling in the blank(s) or circling the ap- propriate answer(s).

1. What is the most vital thing to check for when performing fan drive preventive maintenance?

______

2. What will happen to a fan drive if an air leak is not fixed?

______

3. On the illustration below, indicate at least six places you should check for air leaks.

4. What are the recommended methods to check for air leaks in the fan drive and control system? (Check all that apply.)

‰ soapy water ‰ listen for leak ‰ wet finger ‰ chewing gum

5. Whenever you are working around the fan area, the ignition may be on but the engine must be

______.

6. How often should the fan drive air filter be drained? ______

7. With what should the fan drive filter element be cleaned?

______

22540 25 8. When checking fan drive operation and inspecting for air leaks, what condition should each of the following items be in?

ITEM CONDITION Truck ignition On Off Truck engine Running Not Running Truck air reservoir Fully depleted At least 90 psi [6.21 bar] Manual Override Switch On Auto

9. For each of the following fan drive systems, indicate how to manually test fan drive engagement and disengagement. Place an X at points where a wire should be disconnected or draw a jumper wire at points where a component should be shorted out.

A/C Pressure +12 Volts Air Supply Switch (NO)

Solenoid NO Valve

NC

OUT Thermal Switch (NO)

Air Supply Thermal +12 Volts Switch (NC)

Solenoid NO Valve NC

OUT A/C Pressure Switch (NC)

10. How often is fan drive preventive maintenance recommended? ______

After completing Review Questions, check answers in Appendix D, Page 43.

26 22540 LESSON 5: Horton Fan Drive Components Objectives • identify the major components of a Shown below and on the next page are the major components of a Horton fan drive Horton HT/S fan drive. • discuss basic fan drive operation

S and HT/S Advantage 9 47 Split Ring Bearing 7 8 6 29 31 32

4 44 4 3

30 27 26 24 23 22 16 46 15 19 15 18

ITEM DESCRIPTION QTY ITEM DESCRIPTION QTY

3 Mounting Bracket 1 241,2 Face Seal Assembly 1 42 Sheave Bearing 2 (Replace Item 27 if Seal is round) 6 Sheave 1 261,2 O-ring (Small) 1 72 Friction Facing 1 27 Air Chamber Assembly 1 8 Journal Spacer 1 291,2 Socket Head Cap Screw 8 92 Socket Head Cap Screw * 30 Stud Bolt 6 152 Piston Assembly 1 31 Lock Washer 6 (Includes 18, 19, & 46) 32 Hex. Nut 6 161,2 O-ring (Large) 1 443 Bearing Spacers 1 18 Bearing Spacer 1 (Inner & Outer) 19 Hub Bearing (Split Ring) 1 461,2 System Sentry 1 222 Lock Nut 1 47 Umbrella Check Valve 1 231,2 Cartridge Assembly 1 1 Denotes Repair Kit item. * QTY. 8 for HT/S Type. 2 Denotes Super Kit item. * QTY 6 for S Type. 3 Not used on all fan Drives.

22540 27 S and HT/S Standard and Advantage 47 9 7 8 29 31 32 6

4 44 4 3 30 27 26 24 23 22 16 14 25 46 15 19 15 18 10

ITEM DESCRIPTION QTY ITEM DESCRIPTION QTY

3 Mounting Bracket 1 231,2 Cartridge Assembly 1 42 Sheave Bearing 2 241,2 Face Seal Assembly 1 6 Sheave 1 (Replace Item 27 if Seal is round) 72 Friction Facing 1 252,3 Seal 1 8 Journal Spacer 1 (Advantage Drive only) 92 Socket Head Cap Screw * 261,2 O-ring (Small) 1 10 Hub Bearing 1 27 Air Chamber Assembly 1 142 Spacer 1 291,2 Socket Head Cap Screw 8 (Advantage Drive only) 30 Stud Bolt 6 152 Piston Assembly 1 31 Lock Washer 6 (Includes 18, 19, & 46) 32 Hex Nut 6 161,2 O-ring (Large) 1 443 Bearing Spacers 1 18 Bearing Spacer 1 (Inner & Outer) 19 Hub Bearing 1 461,2 System Sentry 1 222 Lock Nut 1 47 Umbrella Check Valve 1 1 Denotes Repair Kit item. * QTY. 8 for HT/S Type. 2 Denotes Super Kit item. * QTY 6 for S Type. 3 Not used on all fan Drives.

28 22540 The mounting bracket and shaft assembly (also called the journal) bolts There are more than a to the front of the engine. hundred different mounting brackets available for different The sheave is essentially a pulley with a large disc on one end. A ring of models of trucks and friction material is bolted to the disc and bearings are pressed into the engines. center of the sheave. The sheave and its bearings slip onto the mounting bracket shaft. Drive belts connect the sheave to the engine’s crankshaft Different sheaves are available for different pulley and whenever the engine is running the sheave is turning. Some trucks and engines. sheaves are designed for only two belts, while other sheaves can accom- modate as many as five belts.

The journal spacer slips onto Journal the mounting bracket shaft Splined Hub Spacer When installing the between the sheave bearings journal spacer, the side and the splined hub. One with the lip must point side of the spacer has a lip. toward the splined hub. The journal spacer must be installed with the lip side pointing toward the splined hub as shown.

Lip Also, due to different sized spacers with different mod- els of fan drives, retain the jour- nal spacer if it is removed dur- ing maintenance for reuse with the same fan drive during re- assembly. Failure to reuse the journal spacer with the same assembly may result in fan drive lock-up.

The splined hub has precision bearing at its center and slips onto the shaft, It is held in place by a large lock nut that screws onto the end of the shaft. The hub is free to spin independently of the sheave. Notice the spring located around the hub. This spring disengages the drive by hold- ing the piston friction disc (PFD) away from the sheave.

The PFD has splines on its inside circumference that mate with the splines on the hub. The PFD simply slips onto the hub; it is not bolted in place.

The air chamber slips over the PFD, but bolts to the splined hub. The PFD, splined hub, and air chamber rotate as one unit when the drive is en- gaged. Since the air chamber is bolted to the hub and not to the PFD, the PFD can move along the splines of the hub to engage and disengage the drive.

To engage the fan drive, 90-120 psi (6.21-8.27 bar] of air pressure goes through the center of the shaft, through the air cartridge, and into the air chamber. This pressure pushes the PFD against the friction material. To disengage the drive, the air pressure is removed and the spring on the hub pushes the PFD away from the friction material.

22540 29 Objectives LESSON 6: Corrective Maintenance • remove and reinstall a fan drive Corrective Maintenance of a Horton heavy duty fan drive will be necessary if • rebuild a fan drive the fan drive develops an air leak, the friction material is worn, or the bearings using the appropriate kit are rough. Several parts replacement kits are available from Horton-the Seal Kit, the Super Kit, and a Major Kit.

• If the fan drive has an air leak, install a Seal Kit.

• If the friction material is worn or the bearings are rough and the fan drive is not equipped with a System Sentry, install the appropriate Advantage Super Kit.

• If the friction material is wom or the bearings are rough and the fan drive has a System Sentry, an Advantage Major Kit may be used.

Before installing any kit, remove the fan drive from the truck.

Removing Fan Drive

The procedure for removing the fan drive varies from truck to truck-refer to the truck’s service manual for a detailed description of this process. In general, proceed as follows:

1. Ensure the truck engine is off.

2. Remove the fan blade from the fan drive.

3. Bleed the air from the truck’s reservoir and disconnect the air hose from the fan drive.

4. Loosen or remove the drive belts.

5. The fan drive is rather heavy, ranging from 35-55 Lbs. [15.88- 24.95 Kg]. Some mechanics like to use a hoist (i.e., cherry picker) to support the drive while they unbolt it. If you use a hoist, be careful not to get the chain hoist tangled with the belts.

6. Remove the fan drive mounting bolts and lift the fan drive out of the engine compartment.

Further information is provided with instructions available with the repair kit.

30 22540 Replacement Kits Horton provides several parts replacement kits for rebuilding various fan drives. The appropriate manual is included in the kit.

IMPORTANT: Use all the parts in the kit. Seal Kit Install a Seal Kit if an air leak has developed inside the fan drive or if the Be careful not to twist O- System Sentry has melted. The Seal Kit consists of the parts as listed and rings as they are installed. described below.

O-rings These O-rings form an air seal between the air chamber and the Piston Friction Disc (PFD). One O-ring goes on Apply O-ring lubricant to the air chamber, the other goes on the PFD. the outside of the air cartridge O-rings. Air The air cartridge fits inside the fan Drive journal shaft. Cartridge Air pressure comes up the center of the shaft, through the cartridge, and into the air chamber. The cartridge has a spring-loaded carbon tip that presses against the face seal and forms a tight air seal while the drive is spinning.

If you have an older style cartridge with a U-cup seal, remove and discard the U-cup seal. Remove the face seal with Face Seal The face seal screws into the center of the air chamber a 5/8” [1.59 cm] socket. and forms an air seal with the carbon tip of the air cartridge.

Retaining The retaining ring holds the air cartridge inside the shaft. Wear safety glasses and Ring When installing the retaining ring, the beveled side use snap-ring pliers to remove and install must point down. retaining rings.

Cap Screws The torx button-head cap screws attach the air chamber to the hub. Tighten screws in a cross sequence to 180 In. Lbs. [20.34 N-m].

System The System Sentry has left-handed threads and screws Sentry® into a boss on the PFD.

O-ring Apply lubricant to new O-rings before their installation. Apply lubricant along Lubricant splines of the hub assembly and the PFD. Anti-Seize Apply as lubricant to hub splines and PFD splines.

Umbrella A one-way valve that prevents moisture and Valve contamination from entering inner drive assembly.

22540 31 Advantage™ Major Kits

Install an Advantage™ Major Kit if the friction material is worn or if the bearings are running rough. This kit can be used to repair any Advan- tage™ fan drive or upgrade an existing fan drive already equipped with a Sys- tem Sentry. The Advantage™ Major Kit includes the contents of the Seal Kit plus the parts as listed and described below.

Friction The friction material mounts to the sheave. Facing

Mounting Hardware to bolt the friction material to the sheave. Screws

Sheave Use a bearing press to remove the old bearings and Bearings press the new bearings into the center of the sheave. The bearings are prelubricated and sealed. Reuse existing two-piece spacer.

DO NOT break the seals or attempt to regrease old bearings.

Hub The splined hub assembly has bearings installed at the Assembly factory. Hub bearings no longer need to be replaced in the field.

Lock Nut The 1-1/2" [3.81 cm] self-locking nut holds the hub onto the shaft. Tighten nut to 150 Ft. Lbs.[203 N•m].

Split Ring Spacer

32 22540 Reinstalling the Fan Drive

After the kit has been installed and the fan drive reassembled, apply 90 psi [6.21 bar] air pressure and check the fan drive for air leaks. If no leaks exist, reinstall the fan drive onto the truck as follows:

1. Clean the fan drive mounting surface on the engine.

2. Using a portable hoist to hold the fan drive, bolt the fan drive to the engine. Use flat washers on each manufacturer’s approved bolt or studs - DO NOT use lock washers. Tighten the mounting bolts to the truck manufacturer’s specifications.

3. Start the truck to recharge the air system. Using an air gauge, check that the air pressure to the fan drive is between 90-120 psi [6.21- 8.27 bar]. Shut the truck off. Reconnect the air hose to the fan drive.

4. Replace and tighten the belts to manufacturer’s specification.

5. Check the fan blade for cracks or missing weights; then, remount the blade to the fan drive. Tighten the lock nuts to 18 Ft.-Lbs. [24•Nm].

6. Start the truck and let the air pressure build to at least 90 psi [6.21 bar]. Shut off the truck.

7. Manually engage and disengage the fan drive by opening and closing the electrical circuit going to the solenoid valve. For a normally-open electrical system, use a jumper across a sensor. For a normally-closed electrical system, open the circuit by disconnecting a sensor wire. With the fan drive engaged, recheck the entire system for air leaks, or flip the manual override switch if so equipped.

22540 33 Review Questions: Corrective Maintenance

Complete these Review Questions by filling in the blank(s) or circling the ap- propriate answer(s).

1. For each of the fan drive situations below that require corrective maintenance, indicate if you would install a Seal, Super, or Major Kit.

PROBLEM KIT Seal Super Major A. Air leak detected at air chamber pilot hole B. System Sentry® is blown C. Rough bearings when fan blade is spinning (without System Sentry) D. Rough bearings when sheave is spinning (with System Sentry) E. Air leak detected between air chamber and PFD F. Friction material worn to less than 1/16" [1.59 mm] (with System Sentry) G. Air leak detected at System Sentry H. Rough bearings and/or friction material worn to less than 1/16" [1.59 mm] (with System Sentry)

2. What should be done with the U-cup when installing a Seal Kit into an HT/S fan drive with an old style cartridge?

A. Remove it and throw it away.

B. Replace it with the new style U-cup from the kit.

C. Leave it inside the shaft beneath the new air cartridge.

3. After removing the cap screws, do the following to help remove the air chamber from the PFD:______.

4. When removing or installing the air cartridge retaining ring, follow proper safety procedures and ______.

5. It is important to install the journal spacer with ______.

6. When installing a new O-ring, be careful not to ______.

7. What is special about the threads on the System Sentry fuse? ______.

After completing Review Questions, check answers in Appendix C, Page 43.

34 22540 Final Test: Heavy Duty Fan Drive Maintenance

Please Print Legibly

Name: Date: Date: Company: Address: Phone: Fax:

Complete the Final Test by filling in the blank(s) or circling the appropriate answer(s).

1. Match the Horton fan drive names listed on the left with the pictures on the right. Grey Gun-metal Blue A. Original S Model

B. Original HT/S Model

C. Reman HT/S Grey

D. 9-inch single plate

E. HT/S Advantage

Maroon Blue F. HT/S with System Sentry®

G. Advantage Reman

Maroon

22540 35 2. Match the components listed on the left with each of the components pictured in both figures.

A. Mounting Bracket B. Sheave Bearing C. Sheave D. Friction Facing E. Journal Spacer F. Piston G. O-ring (Large) H. Bearing Spacer I. Hub Bearing (Split Ring) J. Cartridge Assy. K. Face Seal Assy. L. O-ring (Small) M. Air Chamber Assembly N. Bearing Spacers O. System Sentry® P. Umbrella Check Valve

A. Mounting Bracket B. Sheave Bearing C. Sheave D. Friction Facing E. Journal Spacer F. Hub Bearing G. Spacer (Advatage Drive only) H. Piston I. O-ring (Large) J. Bearing Spacer K. Hub Bearing L. Cartridge Assy. M. Face Seal Assy. N. Seal (Advantage Drive only) O. O-ring (Small) P. Air Chamber Assembly Q. Bearing Spacers R. System Sentry® S. Umbrella Check Valve

36 22540 3. When installing a 3-way solenoid valve, always connect the air line that goes to the fan drive to the valve’s ______port.

4. On the diagram below, connect the electrical components for a normally-open electrical system, and connect the air supply to the correct inlet port on the solenoid valve.

Normally-Open Electrical System Manual Override +12 Volts Switch (NO) Air Supply

A/C Pressure NO Switch (NO) Solenoid Valve NC

Thermal Switch (NO)

5. If a truck has a normally-open electrical system, the air supply should be connected to the normally-______inlet port of the 3-way solenoid valve.

6. In a normally-open electrical system, the fan drive will engage if any switch opens /closes.

7. On the electrical diagram below, connect the electrical components for a normally- closed electrical system and connect the air supply to the correct inlet port on the solenoid valve.

Normally-Closed Electrical System Manual Override +12 Volts Switch (NC) Air Supply

NO A/C Pressure Switch (NC) Solenoid Valve NC

Thermal Switch (NC)

22540 37 8. If a truck has a normally-closed electrical system, the air supply should be connected to the normally-______inlet port of the 3-way solenoid valve.

9. In a normally-closed electrical system, the fan drive will engage if any switch opens /closes.

10. If a truck has an ECM based control system, it will have a (an):

A. A/C Pressure Switch.

B. Thermal Switch.

11. What is the most important thing to check for when performing fan drive PM? ______

12. When working around the fan, the ignition may be on but the engine must be ______.

13. When installing a Seal kit into an HT/S fan drive with an old style cartridge, what should be done with the U-cup?

______

14. When installing the journal spacer, the side with the lip must be facing ______.

15. On the illustration below, indicate at least six places to check for air leaks.

38 22540 16. For the fan drive system below, indicate where a jumper wire would be placed to manually test fan drive engagement.

Air Supply A/C Pressure +12 Volts Switch (NO)

NO

Solenoid Valve NC Thermal Switch (NO)

OUT

17. For the fan drive system below, place an X at the point where a wire would be disconnected to manually test fan drive engagement.

Air Supply

A/C Pressure +12 Volts Switch (NO)

NO

Solenoid NC Valve Thermal Switch (NO) OUT

22540 39 18. How often should PM be performed on a fan drive?

19. Below is a list of fan drive situations requiring corrective maintenance. For each situation, indicate whether to install a Seal, Super, or Major Kit.

PROBLEM KIT Seal Super Major A. Air leak detected at air chamber pilot hole B. System Sentry® is blown C. Rough bearings when fan blade is spinning (without System Sentry) D. Rough bearings when sheave is spinning (with System Sentry) E. Air leak detected between air chamber and PFD F. Friction material worn to less than 1/16" [1.59 mm] (with System Sentry) G. Air leak detected at System Sentry H. Rough bearings and/or friction material worn to less than 1/16" [1.59 mm] (with System Sentry)

40 22540 Appendix A Preventive Maintenance Check List (Every 10,000 Miles [16,000 Km])

Perform the following at every oil drain or every 10,000 miles.

CODES Use these codes to fill 9 = Checked R = Repaired in the boxes as each item is completed: S = Serviced C = Replaced

Fan Drive

Check for air leaks from:

Front bleed hole- if leaking, install seal kit. Area between air chamber and PFD Between PFD and air chamber-if leaking, install Check for discolora- tion or other signs of seal kit. overheating Lock-up bolt holes-if leaking, install seal kit.

Between PFD and friction lining-if leaking, install seal kit. Around the System Sentry- if leaking, isolate the Bleed Hole (showing problem and install appropriate repair kit. Umbrella Come- Seal) Check air line entry at rear of drive: home bolt hole Look for cracked or damaged lines. System Sentry Assure tight connections.

DIAGRAM A Test for air leaks.

Check for rough bearings by spinning fan both ways; look for smooth even flow. Solenoid Check all air connections for tightness and air leaks and examine air lines for damage. Check all electrical connections.

Drain the truck’s air system prior to air filter removal. Drain filter bowl (if equipped).

Thermal Switch & A/C Pressure Switch Check electrical connections.

22540 41 Appendix B Preventive Maintenance Check List (Every 25,000 Miles [40,000 Km]) CODES Normally-Closed 9 = Checked R = Repaired • With engine temperature (Series) Electrical S = Serviced C = Replaced below the thermal switch System setting, start engine and Use the codes as shown above to fill in build up air pressure the boxes as each item is completed:

• Remove either wire from FAN the thermal switch to engage the fan drive, OR Check for bent, cracked, or miss- • Flip the Manual override ing blades, loose rivets, and loose switch to engage drive. or missing weights. Replace fan if defective. • Reconnect the wire to terminal of thermal Tighten fan blade nuts to at least switch to exhaust air and 18 Ft. Lbs. [24 N•m] torque. disengage the fan drive.

Check for adequate clearance DIAGRAM B between fan and fan shroud.

Normally-Open FAN BELTS (Parallel) Electrical • With engine temperature System below the thermal switch Check belt condition. Replace belts setting, start engine and if worn or frayed. build up air pressure.

• Install jumper wire Check for proper belt tension. between terminals of Tighten to manufacturer specifica- thermal switch to engage tions as needed.Check for proper fan drive, OR belt alignment.

• Flip the Manual override DRIVE AND CONTROLS switch to engage drive. Inspect all electrical connections and • Remove jumper wire to wires. Tighten if loose; replace if exhaust air and disen- damaged. Verify drive engagement gage fan drive. and disengagement.

DIAGRAM C

42 22540 Check all air connections for Check for air leaks in fan drive. air leaks. Check bearings in fan drive for smooth and Drain air filter. Clean the bowl • Normally Open even rotation. Engine and filter (if equipped). Electrical System must be off and fan disengaged. Check friction facing for wear. 1. To determine if air is Replace when worn to 1/16 [1.59 mm] leaking from drive, turn • Normally Closed thick. engine off to engage Electrical System drive. 1. Turn key to on position 2. Lightly brush a bubble to disengage Drive (DO Area between air solution on bleed hole NOT START ENGINE). chamber and PFD Check for discol- on fan pilot, between oration or other air chamber and PFD, signs of over- 2. Rotate fan to check for around Come-Home Holes heating front bearing roughness. on PFD, and System Sentry® (see Diagram D). 3. If belts are removed, rotate sheave to check for • Normally Closed for pulley bearing rough- Electrical System ness.

1. To determine if air is leaking from drive, turn Come- If bearing roughness is Bleed Hole key to on position (DO home detected, install the (showing NOT START ENGINE). bolt hole appropriate kit. Umbrella Install jumper wire System Sentry Seal) between thermal switch terminals to engage DIAGRAM D drive.

2. Lightly brush a bubble solution on bleed hole on fan pilot, between air chamber and PFD, around Come-Home Holes on PFD, and Sys tem Sentry (see Diagram D).

3 . Remove jumper wire once leak is found.

22540 43 Appendix C Review Question Answers

Review Questions: Fan Drive Control Systems

Complete these Review Questions by filling in the blank(s) or circling the appropriate answer(s).

1. When installing a 3-way solenoid valve, connect the air line going to the fan drive to the valve’s outlet port.

2. When a fan drive is disengaged, where does air pressure in the fan drive’s air chamber go? It exhausts out the open port of the solenoid valve.

3. On the diagram below, connect the electrical components for a normally-open electrical system and indicate if the air supply is connected to the solenoid valve’s normally-open or normally- closed inlet port.

Normally-Open Electrical System

Manual Override Air Supply +12 Volts Switch (NO)

NO A/C Pressure Switch (NO) Solenoid Valve NC

Thermal Switch (NO)

4. In a normally-open fan drive electrical system, the switches and sensors are wired in series / parallel .

44 22540 5. If a truck has a normally-open electrical system, the air supply should be connected to the normally-closed inlet port of the 3-way solenoid valve.

6. In a normally-open electrical system, when all switches are open, the solenoid is energized / de-energize and the fan drive is engaged / disengaged .

7. In a normally-open electrical system, if any switch closes, the solenoid will energize /de-energize and the fan drive will engage / disengage.

8. On the diagram below, connect the electrical components for a normally-closed electrical system and indicate if the air supply is connected to the solenoid valve’s normally-open or normally-closed inlet port.

Normally-Closed Electrical System

Air Supply Manual Override +12 Volts Switch (NC)

A/C Pressure NO Switch (NC) Solenoid NC Valve

Thermal Switch (NC)

9. In a normally-closed fan drive electrical system, the switches and sensors are wired in series / parallel.

10. If a truck has a normally-closed electrical system, the air supply should be connected to the normally-open inlet port of the 3-way solenoid valve.

11. In a normally-closed electrical system, when all switches are closed, the solenoid is energized / de-energized and the fan drive is engaged /disengaged .

22540 45 12. In a normally-closed electrical system, if any switch opens, the solenoid will energize / de-energize and the fan drive will engage / disengage.

13. ECMs are being added to new truck designs to improve engine performance , reliability , and fuel efficiency .

14. An ECM is essentially a digital computer, consisting of a microprocessor , (RAM) Ready Access Memory , and (ROM) Read Only Memory .

46 22540 Review Questions: Preventive Maintenance

Complete these Review Questions by filling in the blank(s) or circling the appropriate answer(s).

1. What is the most vital thing to check for when performing fan drive preventive maintenance? Air leaks .

2. What will happen to a fan drive if an air leak is not fixed? It will start to slip and overheat.

3. On the illustration below, indicate at least six places you should check for air leaks.

12 locations shown

4. What are the recommended methods to check for air leaks in the fan drive and control system? (Check all that apply.)

; soapy water ; listen for leak ; wet finger ; chewing gum

5. Whenever you are working around the fan area, the ignition may be on but the engine must be off .

6. How often should the fan drive air filter be drained? Weekly .

7. With what should the fan drive filter element be cleaned? Parts solvent or water .

22540 47 8. When checking fan drive operation and inspecting for air leaks, what condition should each of the following items be in?

ITEM CONDITION Truck ignition On Off Truck engine Running Not Running Truck air reservoir Fully depleted At least 90 psi Manual Override Switch On Auto

9. For each of the following fan drive systems, indicate how to manually test fan drive engagement and disengagement. Place an X at points where a wire should be discon- nected or draw a jumper wire at points where a component should be shorted out.

NO

NC

NO NC NO

NC

10. How often should fan drive preventive maintenance be performed? 10,000 mile [16,000 Km] walk around . 25,000 mile [40.000 Km] full PM .

48 22540 Review Questions: Corrective Maintenance

Complete these Review Questions by filling in the blank(s) or circling the appropriate answer(s).

1. For each of the fan drive situations below that require corrective maintenance, indicate if you would install a Seal, Super, or Major Kit.

PROBLEM KIT Seal Super Major A. Air leak detected at air chamber pilot hole 9 B. System Sentry® is released 9 C. Rough bearings when fan blade is spinning (without System Sentry) 9 D. Rough bearings when sheave is spinning (with System Sentry) 9 E. Air leak detected between air chamber and PFD 9 F. Friction material worn to less than 1/16" [1.59 mm] (with System Sentry) 9 G. Air leak detected at System Sentry 9 H. Rough bearings and/or friction material worn to less than 1/16" [1.59 mm] (with System Sentry) 9

2. What should be done with the U-cup when installing a Seal Kit into an HT/S fan drive with an old style cartridge?

A. Remove it and throw it away. B. Replace it with the new style U-cup from the kit. C. Leave it inside the shaft beneath the new air cartridge.

3. After removing the cap screws, do the following to help remove the air chamber from the PFD: Apply air pressure to fan drive .

4. When removing or installing the air cartridge retaining ring, follow proper safety proce- dures and wear safety glasses .

5. It is important to install the journal spacer with lip facing up .

6. When installing a new O-ring, be careful not to twist the o-ring .

7. What is special about the threads on the System Sentry fuse? They are left-handed threads .

22540 49 Notes

50 22540 22540 51 Horton, Inc. 2565 Walnut St. Roseville, MN 55113, USA Phone: +1 (651) 361-6400 Toll-free: +1 (800)-621-1320 Fax: +1 (651) 361-6801 Web site: www.hortoninc.com e-mail: [email protected]

© 2002 Horton, Inc. All rights reserved. Printed in USA. Horton, Inc. is a Horton Holding, Inc. company. QS-9000 certified. Horton Holding, Inc., Roseville, MN USA 22540-E-1002 EA09-008 PACCAR 10/15/2009 RESPONSE 15 horton-l22229d Preventive Maintenance Checklist FIGURE 1 and Emergency Operation Instructions N.C. (Series) Electrical System Preventive Maintenance Checklist* A. Normally Closed (Every 25,000 miles) (Series) Electrical System (See Fig. 1).

*Codes a. With engine tempera- = Checked R = Repaired ture below the thermal S= Serviced C = Replaced switch setting, start engine and build up air pressure. I. Fan b. Remove either wire from 1. Check for bent, the thermal switch. This cracked or missing will engage fan clutch. blades, loose rivets, and loose or missing c. Reconnect wire to weights. Replace de- terminal of thermal fective fans. switch. This will exhaust air and disengage fan 2. Tighten fan blade nuts clutch. to at least 18 ft. lbs. torque. B. Normally Open 3. Check for adequate (Parallel) Electrical clearance between System (See Fig. 2). fan and fan shroud. FIGURE 2 a. With engine tempera- N.O. (Parallel) Electrical System II. Fan Belts ture below the thermal switch setting, start 1. Check belt condition, engine and build up replace if worn or air pressure. frayed. b. Install jumper wire 2. Check for proper belt between terminals of tension and that ten- thermal switch. This sioner is in working will engage fan clutch. order. c. Remove jumper wire 3. Check for proper belt to exhaust air and dis- alignment. engage fan clutch.

III. Clutch and Controls 3. Check all air connec- tions for air leaks. 1. Inspect all electrical connections andwires. 4. Drain air filter. Clean Tighten if loose, the bowl and filter (if replace if damaged. equipped). 5. Check friction facing for 2. Verify clutch engage- wear. Replace when ment and disengage- worn to 1/16" thick ment. (See Fig. 3, part E). L-22229-D-1095WO 6. Check for air leaks in 7. Check bearings in fan FIGURE 3 fan clutch (See proce- clutch for smooth and dures below). even rotation. Engine must be off and fan A. Normally Closed clutch disengaged. Electrical System a. For Normally Closed a. To determine if air is Electrical System, turn leaking from clutch, key to "ON" position turn engine off. This (DO NOT START will engage clutch. ENGINE. This will disengage clutch.) b. Lightly brush a bubble b. Rotate fan to check for solution on bleed hole front bearing roughness. on fan pilot (A), between air chamber c. If belts are removed, and piston friction disc rotate sleave to check for (B), around Come- pulley bearing roughness. Home holes on piston FIGURE 4 friction disc (C), and If bearing wear or roughness System Sentry (D). is detected, install a Super Kit. (See Fig. 3). Emergency Operation

B. Normally Open In the event of a fan clutch Electrical System or control malfunction:

a. To determine if air is 1. Disconnect and plug leaking from clutch, air line to fan clutch. turn key to "ON" position (DO NOT 2. Align two holes in START ENGINE). piston friction disc with Install jumper wire two holes in sheave between thermal (See Fig. 4). switch terminals. This 3. Install two 5/16 NC X will engage clutch. 1" grade 8 socket head cap screws (Horton b. Lightly brush a bubble Part No.994201) and solution on bleed hole tighten to 25 ft. lbs. on fan pilot (A), torque (See Fig. 4). between air chamber and piston friction disc NOTE (B), around Come- Clamping of plates, not Home holes on piston bolts, provides turning friction disc (C), and force. The above proce- System Sentry (D). dure is only a temporary (See Fig. 3). solution. The problem must be corrected as soon c. Remove jumper wire as possible. once leak is found.

If these tests are impractical, For Further Help, Call: listen or feel for air leaks. If an air leak is detected, HORTON HOT LINE install a Minor Repair Seal Kit. 1-800-621-1320 EA09-008 PACCAR 10/15/2009 RESPONSE 15 horton-l22459o HORTON FAN CLUTCH WITH SYSTEM SENTRY™ FORM NO. L-22459-O-1293 TROUBLESHOOTING GUIDE

PROBLEM PROBABLE CAUSE SOLUTION

I. Air leaking from fan clutch 2

3 1

4 1. Bleed hole. 1. Bad face seal or air cartridge 1. Instal seal kit. 2. Air chamber. 2. Bad O-ring seals 2. Instal seal kit. 3. Come home holes. 3. Bad O-ring seals 3. Instal seal kit. 4. "System Sentry". 4. See Section II. 4. See Section II.

I II. System SentryTM Release: System Sentry will release clutch when clutch slips excessively causing abnormal heat build-up

1. Obstructed Fan 1. Loose shroud, bent fan, torn engine 1. Find and remove obstruction, repair mounts, etc. or replace damaged parts. Install seal kit.

2. Low air pressure to clutch 2. A.Restricted air line. 2. A. Replace air line. B. Restricted Solenoid. B. Replace Solenoid. C. Low system air pressure. C. Determine cause and repair. Install seal kit.

3. Excessive cycling 3. A. A/C freon overcharge. 3. A. Check and adjust to specifications. B. A/C pressure setting too low. B. Check A/C switch. C. Poor ground or wire connection. C. Check electrical connection. D. Improper temperature control setting. D. Check temperature setting of all controls. Thermal Switch setting should engage the Clutch 10 o F higher than the full open temper- ature of the thermostat. E. Faulty Thermal Switch E. Replace Thermal Switch. F. Restriction in front of radiator blocking F. Check for proper shutter opera- air flow. tion, winter front or other restric- tion in or in front of radiator.

III. Fan clutch fails to engage Electrical Problem

1. Broken circuit (Normally Open System). 1. Check electrical connections. 2. Improperly wired. 2. Check wiring according to diagram. 3. Thermal Switch incorrect (for application) 3. Check Thermal Switch (N.O. or N.C.) or defective application. Replace if wrong or defective. 4. Bad Solenoid Valve. 4. Replace Solenoid Valve.

Air Problem

1. Clutch leaking. See Section I. 1. See Section I. 2. Air supply to clutch restricted. 2. Check fittings and air lines for leaks or pinching. 3. Solenoid Valve defective . 3. Replace Solenoid Valve.

CONTINUED ON OTHER SIDE PROBLEM PROBABLE CAUSE SOLUTION

IV. Fan clutch fails to disengage

Electrical Problem

1. Broken current (Normally Closed System). 1. Check electrical connections. 2. Improperly wired. 2. Check wiring according to diagram. 3. Thermal Switch incorrect (for application) 3. Check Thermal Switch (N.O. or N.C.) or defective. application. Replace if wrong or defective.

Air Problem

1. Air line restricted, not allowing air to be 1. Check for pinching or plugging of released from Fan Clutch. air line between clutch and valve. 2. Solenoid Valve not exhausting. 2. Check for plugged exhaust port. Clean port or replace valve.

Piston Friction Disc will not return

1. Possibly seized due to contamination or 1. Clean air supply and install Super Kit. dry o-rings.

V. Fan clutch cycles frequently Electrical Problem

1. Poor ground or wire connection. 1. Check electrical connections. 2. Improper temperature control settings. 2. Check temperature settings of all controls. Thermal Switch setting o should engage Fan Clutch 10 higher than the shutter sensor. 3. A/C Pressure Switch setting too low. 3. Check A/C Pressure Switch. Use higher switch. 4. Restriction in front of radiator, blocking 4. Check shutter operation, winter fronts, air flow. or obstructions in front of radiator. 5. Faulty Thermal Switch. 5. Replace Thermal Switch.

VI. Fan clutch engaged, engine 1. Restriction in front of radiator. 1. Make sure nothing is obstructing running hot. the air flow through radiator. 2. Fan capacity not large enough. 2. Refer to Manufacturer's specs. 3. Problem in cooling system. 3. Refer to engine manual. EA09-008 PACCAR 10/15/2009 RESPONSE 15 Peterbilt Owner manual Y53-6004 PM Schedule PART 8: MAINTENANCE AND SERVICE PREVENTIVE MAINTENANCE SCHEDULE

Recommended PM Interval SYSTEM COMPONENT MAINTENANCE TASK I ABCDE Clutch Clutch pedal shaft Check for excessive looseness and lubricate (NLGI #2 grease). X Clutch pedal Check for proper free pedal (see page 180). X Clutch release linkage Check for excessive looseness and lubricate (NLGI #2 grease). X Clutch release bearing Lubricate. X Clutch release shaft Lubricate. X

Cooling Hoses Check the radiator and heater hoses for leaks. X X Extended Life Coolant (ELC) Check the freeze point (see page 181). X Check for contamination using test strips (see page 182). X Replace blank water filter if applicable. X Perform lab analysis (see page 182). X If lab analysis shows coolant is unsuitable for continued use Flush, drain, and refill (see page 183). Add ELC Extender (see page 182). Flush, drain, and refill with new coolant (see page 183). X Fan clutch housing Check for air leaks. (see page 195). X X Surge Tank Fill Cap Check fill cap seal at each oil change. X X X X X X

(08/06) Y53-6004 – 144 – EA09-008 PACCAR 10/15/2009 RESPONSE 15 Peterbilt Owner manual Y53-6004 PM what to do PART 8: MAINTENANCE AND SERVICE ENGINE ACCESSORIES

• Reduce torque by 10% when engine oil is used as a 3. Release the automatic tensioner. lubricant. 4. Check the belt alignment on each pulley. The belt must fall between the flanges of each pulley. • Reduce torque by 20% if new plated capscrews are used. Engine Accessories Accessory Drive Belts

You can extend the reliability and service life of your vehi- cle's drive belts with proper attention to installation, and maintenance. Neglect could cause belt failure. The result could be the loss of the electrical or air system as well as possible engine damage from overheating. So it's a very good idea to check your belts frequently and replace them as soon as you detect trouble. Follow this procedure to install an accessory drive belt: Fan Clutch / Fan 1. Route the new belt around the pulleys, and then WARNING! Engine fans engage suddenly rotate the automatic tensioner so that the idler pulley without warning and can badly hurt you. Stay swings toward the belt routing. Figure 1 shows an away from the fan when the engine is running. example of the rotation direction to release the ten- Your truck may be equipped with an On/Off or Viscous sioner. Fan Drive. Follow these guidelines to check your engine 2. Slip the belt around the idler pulley attached to the fan: automatic tensioner.

(08/06) Y53-6004 – 195 – AIR INTAKE SYSTEM PART 8: MAINTENANCE AND SERVICE

• Check the fan assembly mounting bolts for tightness. elbows. Leaks in the intake system allow abrasive dust to Inspect the fan blades for damage. enter the engine and quickly cause expensive damage. During your daily walk-around inspection, carefully check • On/Off Fan Drives - Check the clutch operation by all tubing, elbows, clamps, supports, and fasteners for starting the engine when it is cold. Idle the engine at condition and tightness. about 800 RPM. Listen for air leaks. Check that the fan is not working while the engine is warming up. Under normal operating conditions, we recommend com- When the clutch engages, note the reading on the plete disassembly and cleaning of the air intake system vehicle's panel-mounted coolant temperature gauge. annually. If the fan clutch engages at low engine temperature or Under severe operating conditions, such as heavy off- cycles on and off more frequently than it should highway use, the disassembly and cleaning should be (receives "false signals"), have the problem corrected more frequent. Replace any defective parts. With the pos- at your dealership. sible exception of mounting brackets, don’t repair defec- • Viscous Fan Drives - Check the clutch operation by tive parts. starting the engine when it is cold. When the truck is Air Cleaners cold the viscous fan clutch will require more time to disengage. This time will depend on the engine RPM. The following service information is basic to all air cleaner Run the engine above idle and you will audibly notice makes and models. the fan turning off. If the fan clutch does not disen- Service the air cleaner filter elements as specified in the gage, have the problem corrected at your dealership. “Preventive Maintenance Schedule” on page 129. If your Air Intake System vehicle is equipped with an optional air inlet restriction indicator, service the filter elements when the air inlet Engine heat, vibration, and age combine to loosen air restriction indicator locks in the extreme Up position. intake connections and cause cracks in the tubing and Paper elements require care and proper handling

– 196 – Y53-6004 (08/06) EA09-008 PACCAR 10/15/2009 RESPONSE 15 Peterbilt service manual pm811001 Fan Clutches Shutters

On-Off Fan Clutches Shutters are mounted to the front of the radiator and are used to shut off air flow to the radiator. They are optional An on-off fan clutch operates either fully on or fully off; on all vehicles except those with a Caterpillar engine and there is no modulation. Typical on-off clutches include air-to-air cooling. Horton (standard), Bendix, Kysor, and Facet. All except Facet are electric-over-air controlled: a thermal switch The power unit to rotate the shutter vanes is usually an senses coolant temperature and operates a solenoid air cylinder. It may also be an air cylinder as an air condi- valve that applies air to the fan clutch. tioning override to a “pill”-type power unit mounted in the radiator bottom tank. If there is no air conditioning con- • Horton requires air pressure to engage the clutch. denser mounted on the front of the radiator, there may • Bendix and Kysor require air pressure to disengage only be the “pill” type unit. the fan clutch. • With the air cylinder, the vanes are either open or If there is an air conditioning condenser in front of the closed. The on-off air operated shutters are con- radiator, the thermal switch is overridden by the tri- trolled with a thermal air valve located near the nary switch (refrigerant pressure switch). The same engine thermostat. The 1270-square-inch radiator solenoid valve supplies air to the clutch. There is also has only an air cylinder. a manual override switch on the dash panel that will • With the “pill” power unit, the vanes are modulated to turn the fan on when all other switches are off. open as much as cooling requires. Shutters operate • Facet is an all-electric clutch that requires voltage to based on coolant temperature for engine demands engage. as well as refrigerant pressure for air conditioner demands. With the modulating-type shutter, the “pill” Modulating Fan Clutches is in the coolant in the bottom tank of the radiator. The temperature of the bottom tank is about 10° F (5.5° C) lower than the top tank. This difference is The Rockford wet clutch is controlled by a thermal air accounted for in the specifications of the “pill”. Refer valve that senses coolant temperature. The amount of to “Operating Temperature Charts” for shutter operat- clutch engagement and the resulting fan speed is con- ing temperatures. trolled by the size of the valve opening. This opening is controlled by expansion of the wax in the thermal unit of the valve. With an air conditioning condenser on the front Winterfronts of the radiator, a solenoid valve overrides the thermal valve. The solenoid valve is controlled by the trinary CAUTION: The use of winterfronts with air- switch that senses refrigerant pressure. In this case the to-air aftercooled engines is strongly dis- fan clutch operates like an on-off fan clutch; i.e., there is couraged by Peterbilt and the engine manu- no modulation. Air pressure is required to disengage the facturer. Use of a winterfront in these fan clutch. situations can result in high intake manifold temperatures, reduced fuel economy, and Viscous Fan Clutches possible engine damage. Operator discre- tion should be exercised to limit winterfront Schwitzer viscous fan clutches have no clutch facing. A usage to extreme conditions where severely fluid transmits torque to the fan. An air-sensing, bi-metal cold ambient temperatures are encountered. strip operates a valve in the fan clutch to control opera- tion. The fan never completely stops while the engine is A winterfront is used to fully or partially block air flow into running, and always operates at a slower speed than the the radiator. It performs the same function a shutters but fan pulley. There are no separate controls. must be manually operated. The winterfront is con- structed of plasticized fabric and mounts on the front of the grill or bugscreen in front of the radiator. It may be Thermostat fastened with zippers, snaps, or a combination of the two. In cold weather, the winterfront helps the radiator to The engine thermostat is a valve that directs coolant rout- retain more heat. ing. It is controlled by the temperature of the coolant; it opens when the engine gets warm enough to require When used with Caterpillar engines with air-to-air cooling cooling. systems, the winterfront must never be completely closed (see Caution statement above). A minimum of 20% of the

(10/99) PM811001 Cooling System 11-21