On/Off and Two-Speed Fan Drive Maintenance Training
Contents
1. 42 On the illustration below indicate at least six places you should check for air leaks HORTON DRAIN WEEKLY 39 HORTON REVIEW ANSWERS FAN DRIVE SERVICE 10 11 12 13 14 15 16 17 18 DM Advantage Fan Drive parts that are visible externally are the fan mounting disc friction liner air chamber seal and the journal bracket True False The two most commonly replaced parts are the fan mounting disc and friction liner True False A DM Advantage Seal Kit would be the most appropriate choice if a an air leak has developed inside the fan drive b the bearing is 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 A DM Advantage Super Kit would be the most appropriate choice if a an air leak has developed inside the fan drive b the bearing is 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 A DM Advantage Fiction Disc Kit would be the most appropriate choice if a an air leak has developed inside the fan drive b the bearing is 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 A DM Advantage Friction Liner Kit would be the most appropriate choice if2. Check for plugged exhaust intake port on the solenoid valve Clean or replace the solenoid valve Check electrical connections Check wiring according to diagram Check thermal switch application Replace if wrong or defective Replace the solenoid valve Check air line from solenoid to fan drive for kinks or obstructions Replace the solenoid valve Check to see if air exhaust is restricted Clean the air supply and install a rebuild kit PROBLEM IV Fan drive cycles frequently V Fan drive engaged engine running hot PROBABLE CAUSE SOLUTION Electrical Problem 1 2 Poor ground wire connection Improper temperature control settings A C pressure switch setting too low Restriction in front of radiator blocking air flow Faulty thermal switch Faulty air temp switch Vehicle coolant level too low Restriction in front of radiator Fan capacity not large enough Problem in cooling system HORTON Check electrical connections Check temperature setting of all controls Thermal switch should engage the fan drive 10 F higher than the full open temperature of the thermostat Check A C pressure switch Use higher switch Check shutter operation winter fronts or obstruction in front of radiator Replace the thermal switch Replace the air temp switch Fill to manufacturer s
3. FMFD IRON PULLEY ALUMINUM FRICTION SPRING HOUSING LINER 33 11 3 25 000 Mile 40 000 Km 3 month PM Every 25 000 miles 40 000 km or 3 months whichever comes first when Area between performing an oil drain conduct a quick sheave and check of the fan drive FMFD Check for air leaks around the fan drive while applying air to the fan drive 1 Listen for leaks at the solenoid valve Check for filter assembly and in the air hoses discoloration or and fittings other signs of 2 Feel for a leak with a wet finger or overheating 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 bearing 1 Turn the fan blade in both directions and feel for worn hub bearing 2 If the fan belts can be easily removed remove the belts and check for worn sheave bearing 3 Turn the sheave in both directions If either the hub or sheave bearing is worn repair or replace the fan drive with a Horton DM Advantage Super Repair Kit a Horton remanufactured DM Advantage Fan Drive or a new DM Advantage Fan Drive Check the fan drive friction facing for wear by measuring the thickness of the friction material A new facing is 8 51 mm 11 32 thick Replace the friction material if it h
4. 12 13 14 15 16 17 18 19 Using a clean dry cloth clean the float seal tip see air cartridge illustration Step 4 of the air cartridge assembly Also clean the face seal of the air chamber cap Assemble the air chamber cap and face seal Lubricate the O ring seal with the fresh lubricant supplied in the kit Install the O ring seal on the air chamber cap Carefully set the air chamber cap into the sheave Install the retaining ring Install the air chamber seal into the sheave Be sure the seal is evenly seated against the side and bottom of the groove surfaces Lubricate contact surfaces with the fresh lubricant supplied in the kit Carefully set the new spring housing piston assembly from the repair kit into position Gently rotate to align the mounting holes in the assembly with the sheave HORTON Air chamber cap Retaining ring Steps 13 and 14 Seat seal evenly against side and bottom groove surfaces Do not apply grease beyond these areas Step 15 to 17 Spring housing piston assembly Steps 18 and 19 Sheave Air Chamber Seal Detail V of Seal faces down into sheave 20 Set the new friction liner from kit into place Handle the friction liner by the edges to avoid contamination 21 Alternately and evenly tighten the 8 button head screws to 80 in Ibs 9 Nem torque Button head screws Friction liner Cage nu
5. 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 When installing the bearing only the outer races should be pressed on True False When installing the bearing the bearing installation tool should not be removed True False The bearing installation tool will be forced out as the sheave is installed on the bracket True False When replacing the air cartridge the curved side of the beveled retaining ring faces the cartridge True False Eye safety protection should be used when removing the retaining ring of the air cartridge True False The O rings of the new air cartridge assembly are lubricated a before or b after installation When replacing the bearing nut the hex faces down and the relief of the nut points away from the journal bracket and bearing True False When installing magnets on a DM Advantage Two Speed Fan Drive place them into the slots in the clutch pack True False The clutch pack assembly and fan mounting disc used on a DM Advantage Two Speed Fan Drive are interchangeable with the DM Advantage On Off Fan Drive True False The friction liner should be properly lubricated before installation True False When reinstalling the spring housing piston assembly the V of the main air chamber seal faces down in the sheave True False The button head screws should be alternately and evenly tightened when replacing the friction
6. 26 27 28 29 Apply a minimum of 80 Ibs psi of clean air to the air inlet spacer et Remove the cage nut from the spring Fan housing piston assembly oe Install the new fan mounting disc from Jack bolt kit if applicable left hand thread Tighten the jack bolt left hand thread to 100 ft Ibs 136 Nem torque Actuate the DM Advantage and check for proper engagement and disengagement of the fan mounting disc Check for air leaks at the bleed hole Check for air leaks around the spring housing piston assembly HORTON J A CAUTION The magnets provided are extremely powerful Do not let them come in contact with each other and do not place near any item that may be damaged Learning Objectives e Describe the steps of safely installing the fan mounting disc NOTE Air must be applied to the air chamber to make easy removal of the cage nut possible and to ensure proper torque is applied to the jack bolt WARNING Do not disassemble the spring housing Personal injury could occur A CAUTION 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 30 LESSON 10 REINSTALLING THE FAN DRIVE Learning Objectives e Describe the steps of safely reinstalling the fan drive e Describe requirements for proper belt tensioning e Describe methods to check for p
7. Fan Drive True False HORTON 35 36 37 38 39 40 41 42 43 44 45 46 47 48 49 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 When reinstalling the spring housing piston assembly the V of the air chamber seal can face either up or down True False The button head screws should be alternately and evenly tightened when replacing the friction liner True False When reinstalling the spring housing piston assembly grease should be applied at or just below the air chamber seal True False The entire tube of O ring lubricant is used when lubricating the new seals and contact surfaces True False 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 When removing or installing the DM Advantage Fan Drive 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 Over or under adjusting belt tension could result in a premature bearing failure b shortened friction liner life c both a and b A belt tensioner should be used to determine proper belt tightness as listed in the manufacturer s or vehicle specifications True False Fan drive operation can be c
8. Instead each sensor goes to an ECM input pin and each actuator is wired to an ECM output pin The ECM computer monitors the data from the sensors and sends the appropriate signals to the controls and actuators based on programming logic The ECM also sends status information to the operator s warning lights and gauges In an ECM controlled system one sensor may affect several actuators and one actuator may be affected by several sensors depending on how the ECM is programmed Sensors used in ECM systems are different than 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 ECMs 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 e g hotter than 190 F 88 C the program knows the actual temperature e g 196 4 F 91 3 C The fan drive solenoid is not wired to the sensors as it is in a conventional system but instead to a relay controlled by the ECM The ECM computer program looks at the data from several sensors and decides when to engage and disengage the fan drive The program considers engine coolant temperature air co
9. as an assembly It will also maintain pressure on the Cage nut internal springs after the button Spring housing head screws are removed piston assembly Remove the 8 button head screws using a T27 Torx bit Remove the friction liner Steps 5 to 7 Remove the spring housing piston assembly Spring housing piston assembly Remove the air chamber seal Examine the inside of the air chamber for signs of moisture and or contaminants Air chamber Steps 8 to 10 HORTON Air Chamber Seals 11 Remove the air chamber cap retaining Airchamber ring seal 12 Gently and evenly pry the air chamber bee tts Ret cap out of the sheave using two small ae screwdrivers placed 180 apart O ring seal 13 Remove the O ring seal from the air chamber cap Air chamber 14 Remove the face seal cap 15 Inspect the face seal for signs of wear Wear indicates that there may be dirt in the air system Sheave and Sheave Bearing 16 Remove the bearing nut from the journal bracket using a 2 inch socket Bearing nut wrench Journal bracket 17 Remove the sheave from the journal bracket 18 Fully support the sheave and press out SUPPORT the bearing PRESS TO REMOVE 19 Fully clean and remove any dirt debris Bearing or corrosion that may be present SUPPORT ef HORTON J Learning Objectives e Describe the steps of removing and ins
10. be completely rebuilt ___ DM Advantage Friction Disc Kit C The friction liner is worn ___ DM Advantage Friction Liner Kit D An air leak has developed inside the fan drive HORTON ii 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 45 Are the following steps for removing the fan drive in the correct order 1 Perform safety precautions 2 Disconnect the air supply line 3 Remove the fan 4 Remove drive belts from the fan drive 5 Remove the fan drive Yes No 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 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 Pitting or blistering on the inside contact surface of the fan mounting disc is cause for replacement True False The purpose of the cage nut is to keep the spring house piston assembly together during disassembly of the fan drive True False Failure to release air pressure before removing the spring housing piston assembly could cause the assembly to fly up causing injury True False The spring housing is disassembled and routinely serviced True False Dirt or moisture problems in the air system must be corrected before the fan drive is reinstalled True False Air chamber seals
11. bolt counterclockwise Steps 1 and 2 HORTON 4 Unscrew the fan mounting disc from the jack bolt Fan mounting disc Jack bolt left hand thread Fan mounting disc good condition Look for signs of damage or blistering Fan mounting disc bad condition HORTON 20 Learning Objectives e Describe the steps of safely removing and inspecting the spring housing piston assembly WARNING Remove air pressure from the unit before proceeding to Step 6 DANGER Failure to release air pressure may result in serious personal injury WARNING Do not disassemble the spring housing Personal injury could occur NOTE If you are installing either a friction liner or fan disc kit proceed to page 26 step 20 AA WARNING 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 and must be corrected before the fan drive is reinstalled NOTE When installing new bearing you must press on the outer diameter ring of the bearing set to avoid damaging the bearing during installation 21 Spring Housing Piston Assembly Removal 10 Using the Torx wrench to hold the jack bolt hand tighten the Button cage nut onto the jack bolt left head screws hand thread over the spring housing The cage nut will keep Friction liner the spring housing and piston together
12. check for air leaks HORTON NOTES HORTON 51 NOTES HORTON NOTES HORTON 53 NOTES HORTON Horton Inc 2565 Walnut St Roseville MN 55113 USA 1 651 361 6400 1 800 621 1320 Fax 1 651 361 6801 www hortonww com info hortonww com 2012 Horton Holding Inc All rights reserved 23000 B 0612
13. liner True False 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 When lubricating the air chamber seal use only the amount that fully covers the seal True False 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 When removing or installing the DM Advantage Fan Drive you should protect the radiator True False Belts should be tensioned according to a fan drive specification b industry standards c manufacturer or vehicle specifications A belt tensioner should be used to determine proper belt tightness as listed in the manufacturer s or vehicle specifications True False Air leaks are the number 1 cause of fan drive problems True False When observing fan drive operations it is a good idea to look for vibration fan blade contact or fan drive slippage True False The fan drive air filter should be drained and inspected for contaminants a weekly b monthly c annually HORTON 38 40 25 000 mile 40 000 km PM requirements include checking the fan drive bearing friction disc facing wiring overheating and proper engagement and disengagement True False 41 Ifan air leak is not fixed the fan drive may start to slip and overheat True False
14. of the cage nut is to keep the spring house piston assembly together during disassembly of the fan drive True False Failure to release air pressure before removing the spring housing piston assembly could cause the assembly to fly up causing injury True False The spring housing is disassembled and routinely serviced True False Dirt or moisture problems in the air system must be corrected before the fan drive is reinstalled True False Air chamber seals should be inspected for a part number and issue date b wear rips and tears c hardness flexibility and grease resistance The air chamber cap retaining ring must be removed before removing the air chamber cap True False The sheave can be pulled off the journal bracket once the bearing nut is removed True False When installing the bearing the bearing installation tool should not be removed True False The bearing installation tool will be forced out as the sheave is installed on the bracket True False When using bearing spacer the spacer must be positioned OUTSIDE the sheave bearing True False When installing the bearing pressing on the a inner or b outer races will damage the bearing causing premature wear When replacing the air cartridge the curved side of the beveled retaining ring faces a toward b away from the cartridge The float tip seal on the air cartridge should be protected from scratches or damage True False The O rings of a new air cartr
15. recommended level Make sure nothing is obstructing the air flow through the radiator Refer to specifications Refer to engine manual 36 10 11 12 13 14 15 16 17 18 37 REVIEW QUESTIONS FAN DRIVE SERVICE DM Advantage Fan Drive parts that are visible externally are the fan mounting disc friction liner air chamber seal and the journal bracket True False The two most commonly replaced parts are the fan mounting disc and friction liner True False A DM Advantage seal kit would be the most appropriate choice if a an air leak has developed inside the fan drive b the bearing is running rough or if the fan drive needs to be completely rebuilt c the fan mount ing disc is damaged d the friction liner is worn A DM Advantage super kit would be the most appropriate choice if a an air leak has developed inside the fan drive b the bearing is 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 A DM Advantage friction disc kit would be the most appropriate choice if a an air leak has developed inside the fan drive b the bearing is 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 A DM Advantage friction liner kit would be the most appropriate choice if a an air leak has developed inside the fan drive b the be
16. should be inspected for a part number and issue date b wear rips and tears c hardness flexibility and grease resistance The air chamber cap retaining ring must be removed before removing the air chamber cap True False The sheave can be pulled off the journal bracket once the bearing nut is removed True False When installing the bearing the bearing installation tool should not be removed True False The bearing installation tool will be forced out as the sheave is installed on the bracket True False When using a bearing spacer the spacer must be positioned OUTSIDE the sheave bearing True False When installing the bearing pressing on the a inner or b outer races will damage the bearing causing premature wear When replacing the air cartridge the curved side of the beveled retaining ring faces a toward b away from the cartridge The float tip seal on the air cartridge should be protected from scratches or damage True False The O rings of a new air cartridge assembly are lubricated a before or b after installation When replacing the bearing nut the hex faces down and the relief of the nut points away from the journal bracket and bearing True False When installing magnets on a DM Advantage Two Speed Fan Drive place them into the slots in the clutch pack True False The clutch pack assembly and fan mounting disc used on a DM Advantage Two Speed Fan Drive are interchangeable with the DM Advantage On Off
17. the journal bracket Bearing installation tool will be forced out as sheave slides onto the journal bracket 3 Replace and tighten the bearing nut to 130 ft Ibs 170 Nem torque 4 Be sure that the bearing nut hex is facing up see detail below Bearing nut Hex faces up Sheave Bearing guide insert Steps 2 and 3 Hex faces up eg Relief points down toward journal bracket and bearing Step 4 Air Cartridge 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 The curve faces the Cartridge Retaining ring Step 5 Spring Housing Piston Assembly Reassembly 8 Using a clean dry cloth clean the float seal tip see air cartridge illustration Step 4 of the air cartridge assembly 9 Also clean the face seal of the air chamber cap 10 Assemble the air chamber cap and face seal 11 Lubricate the O ring seal with the fresh lubricant supplied in the kit 12 Install the O ring seal on the air chamber cap HORTON J Learning Objectives e Describe the steps of removing and replacing the air cartridge A CAUTION The retaining ring must be fully seated in the retaining ring groove to keep the air cartridge assembly from moving Also the retaining ring is beveled The curved
18. the weekly air filter draining and every 25 000 miles 40 000 km or 3 months whichever comes first Check for air leaks at these locations 11 2 Weekly PM Each week drain the air filter at its bleed valve and check for moisture Filter element 1 If contaminants are present disassemble the air filter as shown 2 Clean all parts with parts solvent and dry them thoroughly 3 Check the truck s air system for the source of the contamination and make the necessary repairs HORTON Learning Objectives e Identify general conditions to look for when observing fan drive operation e Describe locations and methods for checking for air leaks WARNING Be sure the engine is turned off and the fan has stopped turning before approaching fan area to prevent serious personal injury Learning Objectives e State weekly preventive maintenance requirements NOTE Do not pressure wash the fan drive The fan drive needs no washing or cleaning Direct spray from a pressure washer will only result in reduced life or damage to the product 32 Learning Objectives State 25 000 mile 40 000 km preventive maintenance requirements Describe how to manually test fan drive engagement and disengagement NOTE If an air leak is not repaired the fan drive may slip and overheat MEASURE THIS DISTANCE TO DETERMINE WEAR Sala
19. 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 airtight seal while the fan drive is spinning O Ring Lubricant not pictured Apply lubricant to the new air chamber cap O ring and the air chamber seal before installation HORTON 3 Friction Disc Kit Learning Objectives e 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 4 Friction Liner Kit Learning Objectives e 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 DM Advantage friction disc kit The liner kit consists of the parts listed and described below Button Head Screws
20. 2 Friction Liner 3 HORTON J 16 Learning Objectives e Describe when a clutch pack kit would be used Ae 5 Clutch Pack Kit Install a clutch pack kit if the DM Advantage 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 Button Head Screws 17 Air Chamber Seal 18 Spring Housing Piston 50 O Ring Lubricant not pictured 6 Bearing Kit Sheave Bearing 2 Bearing Nut 4 Retaining Ring 22 Magnet Assemblies HORTON ei LESSON 6 REMOVING THE FAN DRIVE 1 Turn the vehicle s ignition off 2 Apply the vehicle s parking brake 3 Block the vehicle s wheels 4 Bleed the air from the vehicle s reservoir 5 Disconnect the air supply line from the fan drive 6 Loosen the bolts that hold the fan in place 7 Remove the fan from the fan drive 8 Remove any drive belts from the fan drive 9 Remove the fan drive mounting bolts 10 Carefully maneuver the fan drive out of the engine compartment Grade 8 mounting bolts Grade 8 nuts Steps 1 10 HORTON J Learning Objectives e Describe the safety precautions and order of steps in removing the fan drive from the vehicle NOTE The procedure for removing the fan drive varies from one vehicle to another Refer to the vehicle s service manual for a de
21. DM Advantage On Off and Two Speed Fan Drive Maintenance Training Manual TABLE OF CONTENTS INTRODUCTION WEE 3 General MOMMA EE 3 LESSON 1 FAN DRIVE SYSTEM sissicicisciciciiccvssstvisascestidsedesisecsinserecasnocediaesscansdcunaueddsadertanassddanseessiad denned 4 DEET e EE EE 4 2 COMMON SYSICM EE 4 LESSON 2 CONTROL COMPONENTS ccccseceeeeeeeeseeeeeeecneeeeeeeesceeeeeseaeeeeseeeeaseeaeeseeseeneeesnseeaeeeennensenees 5 T SOIEMOIG EE 5 LESSON 3 ELECTRICAL CONTROL SYSTEMS ECM cccecccsseeseeeeeeeeeeeeesseeeseeecesseneeeenseneessenneeeseaes 6 1 Electronic Contool Module iessen ier aen tices See ED ee C eree E Eee E aae aaa aa Eiei 6 PE A E E E E E sti 7 LESSON 4 ELECTRICAL CONTROL SYSTEMS NON ECM ssssssssseusssnnsrnnnrrnnnnrunnrnnnnnnnnnrennrnnnnrnnnnnnn 8 1 Types of Electrical Control Gvstems siceraria inrer e aae eaei e aaa doao io preian aoaiina aaar SR 8 2 Comparison Open Closed Electrical Control 8 LAB ACTIVITY FAN DRIVE CONTROL COMPONENTS cccceseececeeeeeeeeeeeeesseeeseeeeeeeneeeesseneseeeeneeneees 9 REVIEW QUESTIONS FAN DRIVE CONTROL SYSTEM cccccceeeeeeeteeeeeeeeeeeeeeeeeseeeeeseeeeseseesenseeeenees 10 Review Answers Fan Drive Control System 11 PRIOR TO SERVICING E 12 LESSON 5 DM ADVANTAGE ON OFF AND TWO SPEED PARTS AND REPAIR KITS 2 000 13 1 Parts IGG rtifiCatlom TEE 13 2 Repair KIIS ieres sns irea roei E epee es ddbees Feed EIA wd ede pected da
22. Press outer bearing race to avoid damaging bearing Bearing should be pressed into sheave prior to positioning the bearing spacers outside the bearing Do not remove bearing installation tool insert inside of bearing when pressing bearing into sheave Damage to bearing may occur when installing sheave onto journal bracket See Step 1 on the following page 23 HORTON 2 Slide the sheave onto the journal bracket Bearing installation tool will be forced out as sheave slides onto the journal bracket 3 Replace and tighten the bearing nut to 130 ft Ibs 170 Nem torque A Be sure that the bearing nut hex is facing up see detail at right NOTE POSITION SUPPORT Bearing guide insert SUPPORT A Sheave Bearing Bearing nut Hex faces u p Sheave Bearing guide insert Journal bracket Steps 2 and 3 Hex faces up Ten Relief points down p toward journal bracket and bearing Step 4 Air Cartridge 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 F The curve faces the Cartridge Retaining ring Step 5 HORTON J NOTE Some models of the DM Advantage Fan Drive contain a bearing spacer NOTE Bearing is prelubricated and sealed DO NOT remove the seals to lubricate the
23. Rings 7 12 O Ring 8 Face Seal 10 Bearing Nut 11 Used to hold the sheave onto the journal bracket shaft Air Cartridge 13 Sheave Bearing 14 Use a bearing press to remove old bearing and install new bearing into the center of the sheave The bearing is prelubricated and sealed If there are spacers reuse the spacers DO NOT remove the seals and attempt to lubricate the old or new bearing Check to make sure you have the right kit Bearing Insert Guide not pictured O Ring Lubricant not pictured HORTON Learning Objectives e Describe when a super kit would be used 14 Learning Objectives e Describe when a seal kit would be used 15 2 Seal Kit Install a seal kit if an air leak has developed inside of the DM Advantage 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 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
24. a an air leak has developed inside the fan drive b the bearing is 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 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 of the above Applying 80 120 psi 5 44 8 16 bar air pressure to the fan drive air inlet will aid in removing the fan drive mounting disc True False The jack bolt is loosened by turning it counterclockwise using a T55 Torx bit True False Pitting or blistering on the inside contact surface of the fan mounting disc is cause for replacement True False The cage nut keeps the spring housing piston assembly together during disassembly True False Before removing the friction liner air pressure should be Off On The air chamber is located directly underneath the spring housing piston assembly True False Moisture inside the air chamber is normally just routine condensation True False When checking the air chamber seals wear on the face seal may indicate that there is dirt in the air system True False The air chamber cap retaining ring must be removed before removing the air chamber cap True False First the bearing nut is removed then the sheave can be removed from the journal bracket True False A new bearing must be disassembled an
25. ak is not fixed the fan drive may start to slip and overheat True False 42 On the illustration below indicate at least six places you should check for air leaks HORTON J 42 43 FINAL TEST Complete the following test then submit your answers to Horton Inc 2565 Walnut St Roseville MN 55113 Attn DM Advantage Test Or fax it to 1 651 361 6801 Please fill in the following information so that we can send your test results and training certificate back to you Name Company School Name Address 1 Address 2 City State Zip E mail HORTON 10 11 12 13 FINAL TEST Advantages of using a Horton Fan Drive include a increased horsepower less fan noise increased fuel economy b reduced engine rpm and service c fewer water pump repairs 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 The fan drive is engaged when air pressure is blocked by the solenoid valve True False The plunger inside the solenoid valve moves to connect the valve outlet port to one of the two inlet ports True False Solenoid valves should be mounted a near the engine b away from vibration and the elements c in an easy service location The ECM sends and receives signals from the engine transmission and o
26. all the air chamber seal into the sheave 16 Be sure the seal is evenly seated Steps 13 and 14 against the side and bottom of the groove surfaces Seat seal evenly against side and bottom groove 17 Lubricate contact surfaces with the surfaces fresh lubricant supplied in the kit Do not apply 18 Carefully set the new spring grease beyond housing piston assembly from these areas the repair kit into position NOTE Two Speed and On Off are not interchangeable 19 Gently rotate to align the mounting holes in the assembly with the sheave Using a clean dry cloth clean the float seal Button tip see air cartridge illustration head screws _ Step 4 of the air cartridge Friction liner assembly Magnet holder Sheave Air Chamber Seal Detail VI of seal faces down into sheave Cage nut CA Spring housing GE piston assembly HORTON Magnet Assembly 20 21 22 Button Hold the magnet holder firmly and head screws place the head screws into the corresponding slots in the spring housing Magnet holder Friction liner Set the new friction liner from kit into place Handle the friction liner by the Cage nut edges to avoid contamination Spring housing piston assembly Alternately and evenly tighten the 8 button head screws to 80 in Ibs 9 Nem torque Steps 20 to 22 Fan Mounting Disc Reassembly 23 24 25
27. amage if the warning is ignored NOTE Note is used to notify people of installation operation or maintenance information that 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 3 HORTON LESSON 1 FAN DRIVE SYSTEM 1 1 Operation Heavy duty fan drive Radiator When engaged the fan drive activates the fan to cool the engine by pulling air through the radiator Depending on the size and rotational speed of the fan as much as 70 100 hp may be needed to run the fan The fan drive 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 vehicles are equipped with a Horton on off fan drive 1 2 Control System The DM Advantage Fan Drive is spring engaged and disengages when air pressure is applied An optional manual override switch located on the vehicle s dashboard may engage the fan drive 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 el
28. aring is 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 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 of the above Applying 80 120 psi 5 44 8 16 bar air pressure to the fan drive air inlet will aid in removing the fan drive mount ing disc True False The jack bolt is loosened by turning it counterclockwise using a T55 Torx bit True False Pitting or blistering on the inside contact surface of the fan mounting disc is cause for replacement True False The cage nut keeps the spring housing piston assembly together during disassembly True False Before removing the friction liner air pressure should be Off On The air chamber is located directly underneath the spring housing piston assembly True False Moisture inside the air chamber is normally just routine condensation True False When checking the air chamber seals wear on the face seal may indicate dirt exists in the air system True False The air chamber cap retaining ring must be removed before removing the air chamber cap True False First the bearing nut is removed then the sheave can be removed from the journal bracket True False A new bearing must be disassembled and lubricated True False HORTON 19 20 21
29. as worn to less than 5 76 mm 1 4 Check the electrical wiring at the thermal switch air conditioning pressure switch and solenoid valve Be certain there are no 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 HORTON LESSON 12 TROUBLESHOOTING PROBLEM PROBABLE CAUSE SOLUTION L Air leaking from fan drive 1 Bad seals or air cartridge 1 Install repair kit bleed hole Bleed hole N Journal bracket Premature friction lining failure Obstructed fan Loose shroud bent fan torn engine mounts etc Find and remove obstruction repair or replace damaged parts Install repair kit Low air pressure to fan drive Excessive cycling Restricted air line Restricted solenoid valve Low system air pressure System air leak A C freon overcharge A C p
30. ations when troubleshooting ECM controlled systems look a under the hood b inside the door panel c in the service manual 12 Air will escape through the outlet port going to the fan drive of a normally open solenoid valve when air is applied to the normally open port True False 11 HORTON 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 DM Advantage 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 DM Advantage Fan Drive note the fan drive serial number service part number date of installation and vehicle mileage Part number and serial number Serial Number Service Part Number Installation Date Vehicle Mileage HORTON 12 LESSON 5 DM ADVANTAGE ON OFF AND TWO SPEED PARTS AND REPAIR KITS Learning Objectives 5 1 Parts Identification Recognize externally visible parts e Identify commonly replaced parts DESCRIPTION QTY Fan Mounting Disc Studs Button Head Screws Friction Liner Cage Nut used for repairs only Spring Housing Pi
31. bearing NOTE All DM Advantage models utilize a single one piece sheave bearing Do not remove bearing installation tool when pressing bearing into sheave Damage to bearing may occur when installing sheave onto journal bracket Learning Objectives e Describe the steps of removing and replacing the air cartridge A CAUTION The retaining ring must be fully seated in the 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 24 Learning Objectives Describe the steps of safely reassembling the spring housing piston assembly State lubrication requirements and cautions when reassembling the spring housing piston assembly A CAUTION Use extreme care when reassembling the air chamber components to avoid damage to the O ring and air chamber seal 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 A CAUTION Do not apply grease beyond seal contact surface as it will cause improper fan drive function NOTE The entire tube of O ring lubricant should be used when lubricating the new seals and contact surfaces of the sheave and spring housing piston assembly 25 Spring Housing Piston Assembly Reassembly 10 11
32. d lubricated True False HORTON 40 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 41 When installing the bearing only the outer races should be pressed on True False When installing the bearing the bearing installation tool should not be removed True False The bearing installation tool will be forced out as the sheave is installed on the bracket True False When replacing the air cartridge the curved side of the beveled retaining ring faces the cartridge True False Eye safety protection should be used when removing the retaining ring of the air cartridge True False The O rings of the new air cartridge assembly are lubricated a before or b after installation When replacing the bearing nut the hex faces down and the relief of the nut points away from the journal bracket and bearing True False When installing magnets on a DM Advantage Two Speed Fan Drive place them into the slots in the clutch pack True False The clutch pack assembly and fan mounting disc used on a DM Advantage Two Speed Fan Drive are interchangeable with the DM Advantage On Off Fan Drive True False The friction liner should be properly lubricated before installation True False When reinstalling the spring housing piston assembly the V of the main air chamber seal faces down in the sheave True False The button head scr
33. d neds eee 14 WSSU POR Eeer tess Salas ed dc Sas ae eta ees fess Seene EE 14 25 SOL EE 15 S F Action BIEDEN 16 4 Friction Liner Kit sssini enia Ta h eai E ESATA TAE ESEE AEEA NESE 16 5 Clutch Pack Kit sosceasdariea misiteeen ce aren aba nasser oma EA EANAN 17 is Beanng TEE 17 Fz Two Speed Magnet Kits iscecccccecesence fan vccesebvetsnvssceves ot evana Eda dv eo eecds vetbendaveedanandevebeey easiest 17 LESSON 6 REMOVING THE FAN DRIVE c ccceeeteteeee ee eeene ee eeeee eens eeeceeeeeneeeeneseeeeaceneeaneeesnsneenensenenenes 18 LESSON 7 DISASSEMBLING THE FAN DRIVE cceeeeesete teense eeeeeeeecneeeeseeneneeeesnnseeesaseeeeeeseenneneneees 19 T TOONS REQUIRED EE 19 2 Disassembly erer eege ee eessen eh ees 19 Fan Mounting Disc Removal and Inspection 19 Spring Housing Piston Assembly Removal 21 Alf Chamber Seals a siarane ra a E EEEE devas dani E EEE N 22 Sheave and Sheave Bearing eireto erson eider pes enie as EEU PEE TEELE PELEA Eia Edie 22 Air Cannidge REMOWVAl sr sesiis na a aoe ia aE epo ei aa aoa A eire aaa casks bandacnctavest 23 LESSON 8 REBUILDING THE ON OFF FAN DRIVE sssssssssussensrernrrennrnnnnrnnnnnennrnennrnnnnnennnnennrnnnnrennnnen nne 23 tere UE TTT ER KAN Reb lldiN g EE ER Sheave Bearing Replacement sisisi orsina oi e ie eoeta pdi aiea EEEo Ebie 23 Ait Cartridge eebe ep nce vintdesuded ead sieraad Gude aAa CAS ENNA E STE AEE aA N EE NE ETA 24 Spring Housing Piston Assembly Reassembly ssssiie
34. disengage the friction disc True False 3 The fan drive is engaged when air pressure is applied through the solenoid valve True False 4 The solenoid valve functions to regulate air to each of the electrical control components True False 5 Itis best to locate the solenoid valve close to the fan drive and on the engine block if possible True False 6 An Electronic Control Module is a a computer b a sensor c a sending unit 7 ECM control systems improve engine performance reliability and fuel efficiency more than non ECM control systems True False 8 CMs 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 9 In most ECM controlled systems sensors and actuators are wired directly to the ECM not the solenoid valve True False 10 Draw the path of a sensor signal to fan drive operation in an ECM controlled system Air temperature sensor Fan override switch Sensor Coolant temp AIC pressure sensor switch Air supply T EE g Foot From other Solenoid throttle sensore valve Inputs TH Electronic To indicators Control Module F and gauges z Outputs relay HUNE oe volts To electronic injectors and other actuators Fan relay Not in all systems 11 To find fault code explan
35. e HORTON S LESSON 9 REBUILDING THE TWO SPEED FAN DRIVE Learning Objectives e Describe the steps of removing and replacing the sheave bearing NOTE Some models of the DM Advantage Fan Drive contain a bearing spacer NOTE Bearing is prelubricated and sealed DO NOT remove the seals to lubricate the bearing NOTE All DM Advantage models utilize a single one piece sheave bearing Do not remove bearing installation tool when pressing bearing into sheave Damage to bearing may occur when installing sheave onto journal bracket 27 9 1 Torque Specifications DESCRIPTION TIGHTENING TORQUE Bearing Nut 130 ft Ibs 176 Nem Jack Bolt left hand thread 100 ft Ibs 136 Nem Button Head Screws 80 in lbs 9 Nem Face Seal 75 100 in Ibs 8 5 11 5 Nem 9 2 Rebuilding Sheave Bearing Replacement Fully supporting the sheave press the new sheave bearing into place noting the position of the lip inside the sheave Press outer bearing race to avoid damaging bearing Bearing should be pressed into sheave prior to positioning the bearing spacers outside the bearing Do not remove bearing installation tool insert inside of bearing when pressing bearing into sheave Damage to bearing may occur when installing sheave onto journal bracket NOTE POSITION SUPPORT Bearing guide insert SUPPORT Va Sheave Bearing HORTON 2 Slide the sheave onto
36. e air filter is operating properly c applies or exhausts air to the fan drive The fan drive is engaged when air pressure is blocked by the solenoid valve True False The plunger inside the solenoid valve moves to connect the valve outlet port to one of the two inlet ports True False Solenoid valves should be mounted a near the engine b away from vibration and the elements c in an easy service location The ECM sends and receives signals from the engine transmission and other sensors to control how the vehicle operates True False In an ECM controlled system one sensor may affect several actuators and one actuator may be affected by several sensors True False If a vehicle has an ECM based control system it will have a an A C pressure switch b a thermal switch Trace the path of a sensor signal to fan drive operation in an ECM controlled system Air temperature sensor Fan override switch Engine speed Z sensor Sensor common AIC pressure e Coolant temp switch sensor Air supply 5 e From other Solenoid sensors valve Vy N O Inputs e Jr Electronic To indicators and gauges Control Module Fan C Outputs relay 12 Out EE be To electronic injectors and other actuators Fan relay Not in all systems ECM fault code explanations are listed in the vehicle
37. e fan drive to the engine 8 Locate the air hose that supplies air to the solenoid Where does the hose attach to the air supply 9 Does the truck have an ECM 10 In the truck s service manual locate the electrical diagram for the fan drive control solenoid and the ECM 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 9 HORTON 10 11 12 REVIEW QUESTIONS FAN DRIVE CONTROL SYSTEM Advantages of using a Horton Fan Drive include increased horsepower consistent coolant temperature and increased fuel economy True False 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 The fan drive is engaged when air pressure is applied through the solenoid valve True False The solenoid valve functions to regulate air to each of the electrical control components True False It is best to locate the solenoid valve close to the fan drive and on the engine block if possible True False An Electronic Control Module is a a computer b a sensor c a sending unit ECM control systems improve engine performance reliability and fuel efficiency more than non ECM control systems True False ECMs monitor data from sensors and send the app
38. ectronic control module ECM 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 HORTON Learning Objectives e Recognize the purpose and advantages of a fan drive NOTE An engaged fan drive pulls air through the radiator to cool the engine Learning Objectives e Describe the basic operation of the fan drive control system e Identify the components of a fan drive electrical control system e Describe how air pressure engages disengages the DM Advantage Fan Drive LESSON 2 CONTROL COMPONENTS Learning Objectives Describe the function of a solenoid valve in the fan drive control system Describe the ideal mounting location for the solenoid valve NOTE The solenoid valve is controlled by electricity and is available for 12 and 24 volt electrical systems NOTE Normal as in normally open or normally closed refers to the state of the solenoid valve sensor or switch when it is relaxed or de energized 2 1 Solenoid Valve The solenoid valve is the heart of the control system opening and closing to regulate the airflow to the fan drive N O Inlet Port N C Exhaust Port DN The solenoid valve is a three way valve having two inlet exhau
39. essesrisssiissriresiriiesrinsriresiiiesiinnernnnnrisnnt 25 Fan Mounting Disc hReassembhy ce eeeeeeecee cess ee caaeeeeeeseaeaeeeeseseeaeeeeeeeeeeiaeeeeeneeea 26 LESSON 9 REBUILDING THE TWO SPEED FAN DRIVE c ccseeeeceseeeeeeeeeeeseeeeenecneesesseeeneeeesnesneeeeeee 27 1 TONGUE SPECICATION EE 27 Te a Le EE 27 Sheave Bearing Replacement eeooseneneeeese te neeeten tre sttnsttetttrnsstetntt nette tn tnter tttnsseeeten nesten tnne net 27 ee le EEN 28 Spring Housing Piston Assembly Reassembly ccceecececeeeeeeeeeeeeneeeceeeeeseeeeessneeeeeeneeeeeneeens 28 O le EE 30 Fan Mounting Disc Reassembly 2 cccecc cessteeeseceeneecteesaneeeeneneeneneeenseteesesetneeeeneneenereeteneeers 30 LESSON 10 REINSTALLING THE FAN DRIVE 0 cccseeceete esse reece eeeeeeeeeseeneseneeeaesneeseseeneeeneeneneneneees 31 LESSON 11 PREVENTIVE MAINTENANCE PM 0 c ccceseee esse ee eeeeeeeeeceeeeseeeeeeeeeseesneesesecneeseeenensnenenes 32 TAlntroductOniias ania kasd EE 32 2s Weekly EE 32 3 29 000 Mile 40 000 KM PM EE 33 LESSON 12 TROUBLESHOOTING sisssississssssuunisssnnissadsnnudannndai nesana adiau ranana Esraa adasidan isinaad 34 REVIEW QUESTIONS FAN DRIVE SERVICE sssessssnsenunsunnrrnurennnnrrunnrnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnn ennnen 37 Review Answers Fan Drive Service 0 cc ceeeeeceeeccecenneeeceeneeeseeeeeeeeeeeeeaeeesieeeeesaeeeseeeeeesnneeeeenaeeeneaeens 40 FINAL TEST EE 43 Binal TES
40. ews should be alternately and evenly tightened when replacing the friction liner True False 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 When lubricating the air chamber seal use only the amount that fully covers the seal True False 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 When removing or installing the DM Advantage Fan Drive you should protect the radiator True False Belts should be tensioned according to a fan drive specification b industry standards c manufacturer s or vehicle specifications A belt tensioner should be used to determine proper belt tightness as listed in the manufacturer s or vehicle specifications True False Air leaks are the number 1 cause of fan drive problems True False When observing fan drive operations it is a good idea to look for vibration fan blade contact or fan drive slippage True False The fan drive air filter should be drained and inspected for contaminants a weekly b monthly c annually HORTON 40 25 000 mile 40 000 km PM requirements include checking the fan drive bearing friction disc facing wiring overheating and proper engagement and disengagement True False 41 If an air le
41. hecked by disconnecting connecting the lead from the ECM to the solenoid valve assuming an on signal from the ECM is present True False The most frequent thing to check when performing fan drive preventive maintenance is a air leaks b bearing wear c psi to engage When observing fan drive operation look for a vibration b fan blade contact c fan drive slippage d all of the above The fan drive filter element should be cleaned using a hand cleaner b soap and water c parts solvent 25 000 mile 40 000 km PM requirements include checking a for air leaks b for discoloring or signs of overheating c fan drive bearing d friction disc facing e electrical wiring f proper engagement and disengagement g all of the above 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 of the above On the illustration to the right indicate at least six places you should check for air leaks HORTON J 46 FINAL TEST ANSWERS 1 10 11 12 13 47 Advantages of using a Horton DM Advantage Fan Drive include a increased horsepower less fan noise increased fuel economy b reduced engine rpm and service c fewer water pump repairs In the fan drive control system the solenoid valve a acts as a sensor b makes sure th
42. idge assembly are lubricated a before or b after installation When replacing the bearing nut the hex faces down and the relief of the nut points away from the journal bracket and bearing True False When installing magnets on a DM Advantage Two Speed Fan Drive place them into the slots in the clutch pack True False The clutch pack assembly and fan mounting disc used on a DM Advantage Two Speed Fan Drive are interchangeable with the DM Advantage On Off Fan Drive True False HORTON 48 35 36 37 38 39 40 41 42 43 44 45 46 47 48 49 50 49 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 When reinstalling the spring housing piston assembly the V of the air chamber seal can face either up or down True False The button head screws should be alternately and evenly tightened when replacing the friction liner True False When reinstalling the spring housing piston assembly grease should be applied at or just below the air chamber seal True False The entire tube of O ring lubricant is used when lubricating the new seals and contact surfaces True False 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 When removing or insta
43. ing surfaces of dirt and debris Position the DM Advantage Fan Drive into place aligning the mounting bracket holes with mounting holes on the engine Reinstall the mounting bolts and tighten to the vehicle manufacturer s specifications Replace and adjust the belts Check the condition of the fan Look for cracks or missing weights Remount the fan on the fan drive and tighten the nuts to the vehicle manufacturer s specifications Reconnect the air supply line to the DM Advantage Start the engine and let the air pressure build to at least 90 psi 6 21 bar If the vehicle is fitted with a manual override switch engage and disengage the fan drive to check for proper operation as well as air leaks Turn off the engine HORTON LESSON 11 PREVENTIVE MAINTENANCE PM 11 1 Introduction Before performing work on the fan drive be sure to follow good shop safety practices Turn the vehicle s ignition off apply the vehicle s parking brake and block the vehicle s wheels 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 distance Look for vibration fan blade contact fan drive slippage and fan drive operation Most fan drive failures are caused by air leaks With regular preventive maintenance PM the Horton DM Advantage Fan Drive will provide years of reliable service PM is recommended at
44. lling the DM Advantage Fan Drive 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 Over or under adjusting belt tension could result in a premature bearing failure b shortened friction liner life c both a and b A belt tensioner should be used to determine proper belt tightness as listed in the manufacturer s or vehicle specifications True False 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 The most frequent thing to check when performing fan drive preventive maintenance is a air leaks b bearing wear c psi to engage When observing fan drive operation look for a vibration b fan blade contact c fan drive slippage d all of the above The fan drive filter element should be cleaned using a hand cleaner b soap and water c parts solvent 25 000 mile 40 000 km PM requirements include checking a for air leaks b for discoloring or signs of overheating c fan drive bearing d friction disc facing e electrical wiring f proper engagement and disengagement g all of the above 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 of the above On the illustration to the right indicate at least six places you should
45. lso 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 the engine will prolong the life of the solenoid and ensure proper x Air Supply fan drive operation Air Supply NO NC OUT Normally open Normally closed HORTON LESSON 3 ELECTRICAL CONTROL SYSTEMS ECM 3 1 Electronic Control Module The electrical wiring that controls the fan drive varies from one vehicle to another but generally will be one of three types of systems e ECM controlled e Normally open e Normally closed Engine manufacturers include electronic control modules ECMs in their new designs to control the engine transmission and other critical operations to improve engine performance reliability and fuel efficiency An ECM is essentially a digital computer containing a microprocessor random access memory RAM and read only memory ROM The ROM contains the computer s program 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 i
46. ly Open Electrical System Normally Open Electrical System Normally Air Supply in Open Port To Fan Drive Exhaust e Air supply plumbed to solenoid s normally open port the end port Normally Closed Electrical System Normally Closed Electrical System Normally To Fan Air Supply in Closed Port Drive Exhaust e Air supply plumbed to solenoid s normally closed port the side port HORTON e LAB ACTIVITY FAN DRIVE CONTROL COMPONENTS Learning Objective Locate a truck with a Horton DM Advantage Fan Drive preferably a make and model you would work on Locate and identify components of the fan drive system ie gt Locate the components listed below and answer the questions by filling in the Interpret the vehicle s electrical corresponding blanks and checking the box next to the number when you complete a diagram for various fan drive step Upon completion please check this activity with an instructor or supervisor system components 1 Locate the DM Advantage Fan Drive and list the model AA WARNING S For your safety be sure the engine is off 2 Locate the solenoid valve 3 Locate the fan drive air filter if equipped Locate the fan drive manual override switch if equipped How many belts are on the fan drive sheave D a ss What engine components do the belts go around 7 How many bolts mount th
47. nditioner s refrigerant pressure intake manifold air temperature engine speed and engine brake status and possibly other factors depending on engine configuration 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 affects which actuator The diagram only shows which ECM pin each sensor and actuator is connected to To determine relationships between 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 HORTON LESSON 4 ELECTRICAL CONTROL SYSTEMS NON ECM 4 1 Types of Electrical Control Systems Learning Objectives e Describe the basic operation Horton DM Advantage Fan Drives are plumbed as follows e For a normally open electrical system connect the air supply to the normally open port of the solenoid valve of normally open and normally closed control systems e Describe how solenoid valves should be plumbed in a normally open or normally closed system e 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 4 2 Comparison Open Closed Electrical Controls Normal
48. nstead of to each other Fan Air override temperature switch sensor A Engine sensor Sensor common AIC pressure Coolant temp switch sensor Air supply Foot From other Solenoid throttle sensors valve Inputs Electronic To indicators ntrol M l SE Control Module Fan relay Outputs Wid To electronic injectors and other actuators HORTON Learning Objectives e Describe the function of an ECM State the advantages of an ECM system over an independent hard wired control system NOTE An ECM is essentially a digital computer used to control the engine transmission and other critical operations to improve performance reliability and efficiency Learning Objectives Describe the basic operation of an ECM controlled system Describe how ECM sensors operate differently than switches used in independent hard wired systems Trace the path of a sensor signal to fan drive operation in an ECM controlled system NOTE The ECM monitors data from the sensors to send signals to the controls actuators and operator s warning lights and gauges NOTE The ECM program considers several factors before determining fan drive engagement The diagram on the previous page shows that the sensors are not wired to the solenoid valve or any control actuator as they would be in a conventional system
49. pecting the air chamber seals A WARNING Wear eye safety protection when removing retaining ring to avoid serious injury A CAUTION If dirt or oil is present in the air system the air system must be cleaned and dried before the fan drive is reinstalled NOTE If you are only installing a seal kit proceed to page 26 step 20 Learning Objectives e Describe the steps of removing the sheave from the journal bracket 22 Learning Objectives e Describe the steps of removing the air cartridge Air Cartridge Removal 20 Remove the retaining ring SCH Retaining A WARNING Ring Wear eye safety protection when removing retaining ring to avoid serious injury 21 Remove the air cartridge assembly NOTE If you are installing a seal 22 Clean the journal bracket bore kit part 994346 proceed to if necessary Float seal tip page 24 Step 5 LESSON 8 REBUILDING THE ON OFF FAN DRIVE 8 1 Torque Specifications DESCRIPTION TIGHTENING TORQUE Bearing Nut 130 ft Ibs 176 Nem Jack Bolt left hand thread 100 ft Ibs 136 Nem Button Head Screws 80 in lbs 9 Nem Face Seal 75 100 in Ibs 8 5 11 5 Nem Learning Objectives 8 2 Rebuilding e Describe the steps of removing and replacing the sheave bearing Sheave Bearing Replacement 1 Fully supporting the sheave press the new sheave bearing into place noting the position of the lip inside the sheave
50. ressure switch setting too low Poor ground or wire connection Improper temperature control setting Faulty ECM HORTON J Replace air line Install repair kit Replace solenoid valve Install repair kit Repair system Install repair kit Repair leak Install repair kit Check and adjust to specifications Check A C pressure switch Check electrical connections Check temperature setting of all controls Thermal switch setting should engage the fan drive 10 F higher than the full open temperature of the thermostat Check ECM 34 35 PROBLEM Premature friction lining failure Excessive cycling continued lll Fan drive fails to engage disengage PROBABLE CAUSE SOLUTION Faulty thermal switch Restriction in front of radiator blocking air flow Faulty air temp switch Air Problem 1 Solenoid valve not exhausting or engaging properly Electrical Problem 1 Open shorted circuit 2 Improperly wired 3 Thermal switch incorrect for application 4 Failed solenoid valve Air Problem 1 Air line restricted 2 Solenoid valve defective Piston will not actuate 1 Piston seized due to contamination or dry seals HORTON Replace the thermal switch Check for proper shutter operation winter front or other restriction in or in front of the radiator Replace the air temp switch
51. roper fan drive operation Awarnine On the workbench apply 90 psi 6 21 bar clean air pressure and check the fan drive for air leaks NOTE Protect the radiator from possible damage from the fan during fan removal and fan drive installation NOTE Most engines have multiple mounting 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 A CAUTION Correct belt adjustment and alignment are 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 s and or engine manufacturer s specifications for proper belt adjustment Awarnine The maximum fan diameter is 32 inches If a larger fan diameter is required contact Horton at 1 800 621 1320 NOTE Remove all tools from the work area and visually inspect the area in which you have been working prior to starting the engine NOTE 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 31 10 11 12 13 Turn the vehicle s ignition off Apply the vehicle s parking brake Block the vehicle s wheels Prepare the area by cleaning all the mount
52. ropriate signals to controls and actuators based on a operator options b programming logic c vehicle service periods In most ECM controlled systems sensors and actuators are wired directly to the ECM not the solenoid valve True False Draw the path of a sensor signal to fan drive operation in an ECM controlled system Air temperature sensor ee Fan override switch Sensor Coolant temp AIC pressure sensor switch Air supply Solenoid Foot From other f throttle sensors valve Inputs Vv Electronic i To indicators Control Module oan and gauges Outputs relay 12 USA volts To electronic injectors and other actuators Fan relay Not in all systems 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 Air will escape through the outlet port going to the fan drive of a normally open solenoid valve when air is applied to the normally open port True False HORTON o Review Answers Fan Drive Control System 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
53. service manual True False DM Advantage Fan Drive parts that are visible externally are the fan mounting disc friction liner air chamber seal and the journal bracket True False The two most commonly replaced parts are the fan mounting disc and friction liner True False Match the Repair Kit with the most likely application D DM Advantage Seal Kit A The fan mounting disc is damaged B_ DM Advantage Super Kit B The bearing is running rough or the fan drive needs to be completely rebuilt A DM Advantage Friction Disc Kit C The friction liner is worn CG DM Advantage Friction Liner Kit D An air leak has developed inside the fan drive HORTON 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 Are the following steps for removing the fan drive in the correct order 1 Perform safety precautions 2 Disconnect the air supply line 3 Remove the fan 4 Remove drive belts from the fan drive 5 Remove the fan drive Yes No 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 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 Pitting or blistering on the inside contact surface of the fan mounting disc is cause for replacement True False The purpose
54. side must be installed facing the cartridge Learning Objectives e Describe the steps of safely reassembling the spring housing piston assembly State lubrication requirements and cautions when reassembling the spring housing piston assembly 28 Learning Objectives e Describe the steps of safely reassembling the spring housing piston assembly e State lubrication requirements and cautions when reassembling the spring housing piston assembly A CAUTION Use extreme care when reassembling the air chamber components to avoid damage to the O ring and air chamber seal 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 A CAUTION Do not apply grease beyond seal contact surface as it will cause improper fan drive function NOTE The entire tube of O ring lubricant should be used when lubricating the new seals and contact surfaces of the sheave and spring housing piston assembly WARNING To avoid personal injury make sure the button head screws are properly tightened to the specified torque before applying air pressure 80 in Ibs 9 Nem 29 Spring Housing Piston Assembly Reassembly 13 Carefully set the air chamber cap into the sheave Air chamber cap 14 Install the retaining ring Retaining ring 15 Inst
55. st ports and one outlet port Air pressure from the vehicle s air system is fed into one of the inlet ports and the outlet port is connected to the fan drive Turning the electric current on and off causes a plunger inside the solenoid valve to move up and down The plunger connects the valve outlet port to one of the two inlet ports N C Inlet Port N O Exhaust Port Air Outer POr To Fan Drive e the normally open port when the electric current is off e 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 EXAMPLE Normal can be defined as the state of the solenoid valve if it were completely disconnected and in your hand the solenoid would be de energized the normally open port would be open to the outlet port and the normally closed port would be closed to the outlet port 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 a
56. ston Air Chamber Seal Air Chamber Cap Retaining Ring O Ring Seal Air Chamber Cap Face Seal Bearing Nut Air Cartridge Retaining Ring Air Cartridge Assembly Bearing Spacer Bearing Sheave Journal Bracket ch sch 1 sch sch oe Not used on all fan drives Denotes item is not included in repair kit 13 HORTON 5 2 Repair Kits Horton offers several different ways to repair or rebuild your DM Advantage Fan Drive For specific part numbers visit the online catalog at www hortonww com or call Horton Customer Service at 1 800 621 1320 1 Super Kit Install a super kit if the bearing is running rough or if the DM Advantage Fan Drive needs to be completely rebuilt due to excessive wear The super kit consists of the parts listed and described below Fan Mounting Disc 1 The fan mounting disc is the part that the fan is bolted onto 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 Different DM Advantage Fan Drives have different stud lengths Check this when making repairs Button Head Screws 2 Friction Liner 3 Attached to the sheave on top of the spring housing piston assembly Spring Housing Piston Assembly 5 The internal mechanism that engages and disengages the DM Advantage Fan Drive when air pressure is either removed or applied Air Chamber Seal 6 Retaining
57. t Spring housing piston assembly Steps 20 and 21 A WARNING To avoid personal injury make sure the button head screws are properly tightened to the specified torque before applying air pressure 80 in Ibs 9 Nem Fan Mounting Disc Reassembly Learning Objectives 22 Apply a minimum of 80 Ibs psi of clean air to the air inlet 23 Remove the cage nut from the spring housing piston assembly 24 Install the new fan mounting disc from kit if applicable 25 Tighten the jack bolt left hand thread to 100 ft Ibs 136 Nem torque 26 Actuate the DM Advantage and check for proper engagement and disengagement of the fan mounting disc 27 Check for air leaks at the bleed hole 28 Check for air leaks around the spring housing piston assembly FMFD removal tool Jack bolt Breaker bar Steps 25 Fan Mounting Disc Jack Bolt left hand thread e Describe the steps of safely installing the fan mounting disc NOTE Air must be applied to the air chamber to make easy removal of the cage nut possible and to ensure proper torque is applied to the jack bolt A WARNING Do not disassemble the spring housing Personal injury could occur A CAUTION 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 Rotate jack bolt clockwis
58. tAnSWwersi EE 47 HORTON J INTRODUCTION General Information Introduction This student manual for the technical course DM Advantage On Off and Two Speed Fan Drive Maintenance is designed to train heavy duty diesel technicians how to perform preventive and corrective maintenance on Horton heavy duty DM Advantage Fan Drives The guide 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 or e mail your final test to the following address or e mail address to receive a certified Horton technician toolbox sticker and a Horton certificate of achievement Horton Inc 2565 Walnut St Roseville MN 55113 1 651 361 6400 1 800 621 1320 info hortonww com www hortonww com Horton uses the following special notices to give warning of possible safety related problems that could cause serious injury and to provide information to help prevent damage to equipment A DANGER 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 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 A CAUTION Caution is used to indicate the presence of a hazard which will or can cause minor personal injury or property d
59. tailed description of this process NOTE Protect the radiator from possible damage from the fan during fan removal and fan drive installation NOTE Because of the weight of the fan drive ranging from 35 to 55 Ibs 15 88 to 24 95 kg you may want to use a hoist for support during removal 18 LESSON 7 DISASSEMBLING THE FAN DRIVE Learning Objectives Describe the steps of safely removing and inspecting the fan mounting disc Recognize signs of wear or damage to the fan mounting disc NOTE Applying 80 120 psi 5 44 8 16 bar air pressure to the fan drive air inlet will aid in removal of the FMFD NOTE Use caution when handling the pry bar on the fan mounting disc Permanent damage may occur if not properly supported Use a flat blade tool or a pry bar that has a handle FMFD Removal Tool Part 995098 is available through any Horton dealer or distributor 19 7 1 Tools Required e 2 Socket Wrench T55 Torx Plus Bit e T27 Torx Bit e Torque Wrench e Pry Bar or FMFD Removal Tool Part 995098 e Ring Pliers e Screwdrivers e Cage Nut Part 995508 7 2 Disassembly Fan Mounting Disc Removal and Inspection 1 Place the fan drive in a vise and clamp the journal bracket tight e Loosen the jack bolt left hand thread by turning it counterclockwise using a T55 Torx Plus Bit ue Mirr a G i SAY FMFD removal tool Si i gt Jack bolt Breaker bar t Rotate jack
60. ther sensors to control how the vehicle operates True False In an ECM controlled system one sensor may affect several actuators and one actuator may be affected by several sensors True False If a vehicle has an ECM based control system it will have a an A C pressure switch b a thermal switch Trace the path of a sensor signal to fan drive operation in an ECM controlled system Air temperature sensor Engine SESCH a speed Si sensor Sensor A Fan override switch common Coolant temp i Foot From other Solenoid throttle HG valve AIC pressure switch sensor Air supply Pa Electronic Cc o indicators and gauges Control Module Fan Outputs relay AL Wir volts To electronic injectors and other actuators Out Fan relay Not in all systems ECM fault code explanations are listed in the vehicle service manual True False DM Advantage Fan Drive parts that are visible externally are the fan mounting disc friction liner air chamber seal and the journal bracket True False The two most commonly replaced parts are the fan mounting disc and friction liner True False Match the repair kit with the most likely application ____ DM Advantage Seal Kit A The fan mounting disc is damaged ____ DM Advantage Super Kit B The bearing is running rough or the fan drive needs to
Download Pdf Manuals
Related Search