Technical Service Information

TSI061219
This TSI replaces 001205

Date: October, 2006 Subject File: ENGINE Subject: Air Sensing Viscous Fan Drive Diagnostic Test Procedure
Vendor: BorgWarner

DESCRIPTION
A correctly operating air sensing viscous fan drive may be misdiagnosed as faulty using the procedures previously available. To reduce the number of misdiagnosed viscous fan drives, perform the updated service procedure that follows.

WARNING To avoid property damage, personal injury, or death, read all safety instructions in the S12002Y service manual regarding use, application, or modication of a viscous fan drive and/or the fan it carries.

WARNING To avoid property damage, personal injury, or death, DO NOT operate a vehicle with a fan drive or fan blades that are malfunctioning or damaged.

WARNING To avoid property damage, personal injury, or death, DO NOT attempt to restrict fan blade rotation during engine operation.

Copyright International Truck and Engine Corporation

DESCRIPTION (CONT.)

WARNING To avoid property damage, personal injury, or death, comply with the following before performing tests on the fan drive: Shift transmission to park or neutral, set parking brake, and block wheels. Wear safety glasses with side shields. Do not wear loose clothing that can come into contact with the rotating fan blades. Avoid contact with hot surfaces. Protect test leads from contact with rotating components.

FOR SNAP ACTION BI-METAL OR COIL VISCOUS FAN DRIVE TEST PROCEDURE (AIR SENSING VISCOUS DRIVES ONLY)
NOTE This test is most effective at an ambient air temperature of 80F (26.7C) or higher. Diagnostic Procedure NOTE The engine must be off for Steps 1 through 8. 1. Check the torque of fan blade fasteners. Refer to Table 1, Torque Chart. 2. Check the torque of fan drive-to-pulley, hub and bracket assembly fasteners. 3. Check the torque of pulley, hub and bracket assembly-to-engine fasteners. 4. Check the fan drive, fan blade assembly, shroud, radiator and the immediately adjacent areas for evidence of interference between rotating and non-rotating parts. If damage is present, isolate and repair the problem and replace damaged parts. 5. Rotate the fan, by hand, through at least 360 degrees. It should turn smoothly, but with some internal resistance. Replace fan drive if it binds, jerks, or spins freely. Insure the fan does not contact other objects. NOTE The following step is used to detect looseness in the fan or fan drive mounting; when performing the Step, do not force the blade tip (cause the blade to deect) because this will distort the resulting measurement. 6. Grasp one fan blade tip, and apply fore and aft pressure. At 10 inches (254 mm) radius from the center, the blade tip should not move more than 1/16 inch (1.6 mm). If the blade moves more than specied and the excess cannot be attributed to pulley/water pump bearing wear, fan blade deection, or loose fasteners (fan to fan drive or fan drive to hub/pulley), replace the fan drive. 7. Check for obstructions in the radiator, charge air cooler, air conditioning condenser, and transmission cooler (if equipped). Remove any dirt, bugs, lint, or debris in the air path through the radiator to the engine. Pressure wash if necessary.

TSI061219

FOR SNAP ACTION BI-METAL OR COIL VISCOUS FAN DRIVE TEST PROCEDURE (AIR SENSING VISCOUS DRIVES ONLY) (CONT.)

WARNING To avoid personal injury or death, wear heat protective gloves and safety glasses when working with hot liquids and objects.

CAUTION To avoid property damage, DO NOT direct high-pressure spray onto the fan drive bi-metal. High-pressure sprays must be directed squarely at the front, or rear, of the radiator and other coolers to prevent n damage. Bent n or n damage will negatively affect air ow and/or cooling capacity of the radiator and other coolers.

8. Ensure the cooling system is properly lled with the correct coolant mixtures (not to exceed 60% ethylene glycol). NOTE In the following Step, warming up a cold engine prior to test preparation will shorten the run-time during the test procedure. 9. If engine is cold, start engine and: turn air conditioning OFF, turn heater OFF (NOTE: on buses, turn heater supply valves OFF at the engine), run until thermostat opens; then, turn engine OFF.

WARNING To avoid personal injury or death when working near a hot engine wear protective clothing and heat protective gloves.

NOTE In the following Step, nylon fan blades (yellow in color) may require painting with at black paint in order to measure fan speed. 10. Apply a strip of reective tape to one (1) blade of the fan and another strip to the fan drive shaft so that fan RPM and fan drive shaft RPM can be measured with the digital photo-tachometer (Figure 1).

TSI061219

FOR SNAP ACTION BI-METAL OR COIL VISCOUS FAN DRIVE TEST PROCEDURE (AIR SENSING VISCOUS DRIVES ONLY) (CONT.)

Figure 1

Placement of Reective Tape 1. Reective tape on fan blade 2. Reective tape on fan drive shaft

11. Connect EZ-Tech service tool. If testing a non-electronic engine, measure coolant temperature with an accurate thermometer. 12. Fabricate a cardboard cover that covers the entire frontal area of the radiator. Cut a 5 inch (12.7 cm) hole in the area that aligns directly in front of the fan drive bi-metal switch or coil. Position the cardboard in front of the radiator and tape as necessary to hold in place. 13. Carefully position the temperature probe so that it measures air temperature within 1 inch (2.54 cm) of the fan drive bi-metal or coil. You can safely insert the probe through the A/C condenser, CAC, and radiator core (Figure 2 and Figure 3) .

TSI061219

FOR SNAP ACTION BI-METAL OR COIL VISCOUS FAN DRIVE TEST PROCEDURE (AIR SENSING VISCOUS DRIVES ONLY) (CONT.)

Figure 2

Temperature Probe Inserted through Cardboard and Front of Radiator 1. Temperature probe

TSI061219

FOR SNAP ACTION BI-METAL OR COIL VISCOUS FAN DRIVE TEST PROCEDURE (AIR SENSING VISCOUS DRIVES ONLY) (CONT.)

Figure 3

Positioning of Temperature Probe 1. Temperature probe must be positioned in this area [1 inch (2.54 cm) from bi-metal].

14. Start the engine and: recheck to ensure the air conditioning and heater are still OFF (on buses, turn heater supply valves OFF), turn electrical loads ON (lights, etc.).

NOTE In the following Step the fan drive shaft speed is not the same as engine speed. 15. Raise the engine speed until the fan drive shaft reaches 2500 RPM (measured with digital photo-tach). Do not measure fan speed yet. NOTE Bright sunlight may make it difcult to read RPM measurements using the photo-tachometer. 16. Lock the throttle at this RPM (use PTO/cruise switches if available). This establishes the fan drive shaft TEST RPM. NOTE If engine cannot achieve 2500 RPM fan drive shaft input speed, test at the highest obtainable RPM. 17. Measure fan blade speed with the digital photo-tachometer (Figure 4).

TSI061219

FOR SNAP ACTION BI-METAL OR COIL VISCOUS FAN DRIVE TEST PROCEDURE (AIR SENSING VISCOUS DRIVES ONLY) (CONT.)

Figure 4

Measuring Fan Blade Speed with Digital Photo-Tachometer

NOTE If the vehicle is equipped with shutters, they should open automatically before the fan drive engages. 18. As the engine is warming up: a. The fan RPM should stabilize between 700 and 1100 RPM. Some DD-30 and DD-34 fan drives may stabilize at up to 1300 RPM. b. As engine coolant temperature reaches 200220F (93.3104.4C)(Figure 5), fan speed should increase to 85% or more of the fan shaft RPM. c. The air temperature at the bi-metal or coil should be between 165F (73.9C) and 195F (90.6C) when the fan engages (Figure 5). Refer to the Borg Warner attachment for specic fan drive P/N calibration information.

TSI061219

FOR SNAP ACTION BI-METAL OR COIL VISCOUS FAN DRIVE TEST PROCEDURE (AIR SENSING VISCOUS DRIVES ONLY) (CONT.)

Figure 5

Measuring the Coolant and Air Temperatures

19. With the fan engaged, record fan RPM, coolant temperature, and air temperature at bi-metal or coil. 20. Maintain the TEST RPM, with the fan engaged, by keeping the engine speed constant. Remove the cardboard cover from the cooling module. As temperatures decrease, fan speed should begin to decrease. After 2-3 minutes the fan should slow to the initial fan speed (approximately 700 to 1100 RPM). 21. Allow fan to repeat this cycle several times while recording temperatures and fan RPM, utilizing cardboard cooling module cover as required to force fan drive engagement. Conclusion: 1. If the fan fails to reach 85% of input speed at 200 220F (93.3104.4C) coolant temperature, and the air temperature at the bi-metal exceeds 195F (90.6C), replace the viscous fan drive. 2. If the fan fails to reach 85% of fan input speed, and the coolant temperature exceeds 220F (104.4C), and the air temperature at the bi-metal or coil does not exceed 195F (90.6C); then the fan drive is not faulty. Inspect the vehicle for the following: a. Air ow restrictions (through the CAC and radiator) b. Internal radiator plugging c. Faulty thermostat

TSI061219

FOR SNAP ACTION BI-METAL OR COIL VISCOUS FAN DRIVE TEST PROCEDURE (AIR SENSING VISCOUS DRIVES ONLY) (CONT.)
d. Defective water pump e. Refer to TSI-051234 for additional diagnostic information 3. When the fan drive disengages (with the 2500 TEST RPM maintained), if the fan speed fails to slow to 7001100 RPM; replace the fan drive (except DD-30 and DD-34 which could be in the 1300 RPM range). 4. Remove the air temperature sensing probe from the radiator. 5. Remove the cardboard from the front of the radiator. 6. Return the engine to idle and allow the engine to cool for two (2) minutes before shutting down. NOTES: A. Engagement air temperatures indicate test cell calibration and may vary in the vehicle. B. Bi-metal and coil fan drives will have a gradual engagement speed until the fan is fully in the modulated ON position.

TORQUE CHART
Table 1 Torque Chart Location Fan-to-Drive Hardware (5/16 Inch) Drive-to-Engine Bolt, (5/16 Inch) Drive-to-Engine Bolt, (3/8 Inch Drive-to-Hub Shaft (1 1/416 LH Thread) Ft-Lbs. 13 - 16 20 - 22 34 - 38 120 - 150 Nm 18 - 22 27 - 30 46 - 52 163 - 203

NOTE The fasteners MUST be S.A.E. Grade #8 or better.

SPECIAL TOOLS
Table 2 Tools Required Tool Description EZ-Tech Electronic Service Tool ZTSE-4468 Kit, Viscous Fan Diagnostic (consisting of:) (1) ZTSE-44681, Digital Photo-Tachometer (1) ZTSE-44711, TK80 Temperature Probe (works with Fluke 88 DMM) (1) ZTSE-44712, Thermo-Couple For measuring fan speed For measuring air temperature For measuring air temperature Purpose To measure coolant temperature Tool Part Number

TSI061219

SPECIAL TOOLS (CONT.)

Notice The following information has been furnished by the manufacturer for use with its product. International Truck and Engine Corporation reprints this information based on representations made to the Company. While users are urged to carefully follow the instructions accompanying the product, International cannot accept any responsibility for user errors, or mishaps resulting from such errors, or from any misuse of the product.

TSI061219

10

Viscous Drive Service Part Numbers

All BorgWarner drives have the Part Numbers either etched or printed on the drive
BW Part Number Formats:
Prior to 2000: Since 2004: xxxxxx 0x00xxxxx (6-digit series) (9-digit series) 2000-2003: 1210-091xx-xx (coded series) BorgWarner Part Number International Part Number

MY04-MY06 Applications: MD Truck

Vehicle Stripped Chassis MD Truck43/4400 Conventional Bus MD Truck 73/7400 MD Truck 8500 Bus-Transit: FE Model Bus - Transit: RE Model Blue Diamond Common Chassis (F650/750) Blue Diamond LCF Model Engine V8 - all V8 - 175hp V8 - all I6 - 175hp DT466 I6-2400rpm I6-2600rpm DT466 2400rpm I6 - DT466 V-8 V8 - all ISB CAT V6 - 4.3L Fan Drive 750 750 790 750 805 805 805 805
Visctronic 712

Temp. F 170F 170F 180F 175F 175F 175F 175F 175F n/a 180F 170F 175F 185F

BWE/TS 010019000 1210-09167010019721 010019561 010021526 010021530 010021530 010021526 020003074 010019721 1210-09167010021530 010011239

International Fan 3585866C1 24" MD9 CW 3546534C2 24" MD9 CW 3588739C1 25" MD9 CW 3584452C1 28" CW 8-Blade 3584438C2 28" MD9 CW 30" ECS 83540116C3 Blade 3540116C3 3584438C2 3589802C1 3588739C1 3586345C2 3540116C3 3593589C3 28" CW MD9 28" MD9 CW 24" 9-blade 25" MD9 CW 26" CW MD9 28" MD9 CW 4035-43641-02

BWE/TS 4735-437834735-43783010019754 4735-411344735-43783N/A 4735-4378305 4735-437834735-42622010019754 4735-437834735-43783010020520

International 3539701C1 3539701C1 3588825C1 3554682C1 3541257C1 3588713C1 3541257C1 3541257C1 3602380C1 3588825C1 3546535C1 3541257C1 3593590C1

790 750 805 585

MY'03 Product: MD Truck/Bus

Vehicle Engine V8 - T444E Medium Truck/Bus 3000/4000 Models Viscous Applications (general) V8 - T444E V8- VT365 I6 I6 DT466 I6 I6 I6-I530 I6 - 175hp I6 > 175hp V-8 I6 - DT466 VT365 Cat
E n g in e 12TS V 12TS W 12TS V

Fan Drive 750 750 750 750 750 750 805 805 750 ED-30
Visctronic 712

Temp. F 160F 170F 160F 170F 170F 160F 175F 175F 175F 170F 160F n/a
n/a

BWE/TS 010020791 010020509 010020552 1210-09167010020914 010020755 1210-09167010021530 010021531 010020914 010020755 167852 010003468

International 3540983C3

Transit School Bus FE Model Transit School Bus RE Model Blue Diamond Common Chassis
V e h ic le T444E & S trip C h a ssis PTO H P T w /D T 4 6 6 L o w H P H P T w /D T 4 6 6 D T 4 6 6 L o w H P (S x S ) D T 4 6 6 L o w H P (F T B ) D T466 H i H P

S-750 S-805
F a n D riv e 750 750 750 750 805 750 805

170F 175F
T e m p . F 170 F 160 F 1 6 0 F 170 F 170 F 1 7 5 F 170 F 160 F 1 7 5 F

3547775C3 2587815C1 3546534C2 3522786C3 26" ECS 3522788C3 3533032C3 28" CW 8-Blade 3540116C3 28" CW MD9 3552595C4 26" CW MD9 3522786C3 26" ECS 3522788C3 2036481C91 24" Metal CW 3604368C1 28" Metal CCW 1210-09167-02 3546534C2 25" CW 8-Blade 010021530 3540116C3 28" CW MD9
B W E /T S 01 002 050 9 01 002 055 2 010020791 010020893 1 2 1 0 -0 9 1 6 7 -0 3 010021530 010020914 010020755 010021531 In te rn a tio n a l 3547775C 3 2587815C 1 3540983C 3 3540985C 3 3533032C 3 3540116C 2 3522786C 3 3522788C 3 3552595C 4 Fan

BWE/TS 918889 918693 4735-4378723.23" CCW MD9 02 25" CW 8-Blade 4735-41134NA 4735-411344735-437834735-43783NA 918747 918900
4735-41134-39

Fan 23.23" J7 24" CCW J7

International 3512260C1 2022687C1 3552162C1 3565623C1 1647411C3 3554682C1 3541257C1 3546535C1 1647411C3 2036480C1 3516397C1 3565623C1 3541257C1
In te rn a tio n a l 3547774C 1 2022687C 1 3512260C 1 3548286C 1 3554682C 1 3541257C 1 1647411C 3 3546535C 1

4735-43783B W E /T S

M e m o : P rio r M D P ro d u c t (Q S P -M e d iu m D u ty C o o lin g E n h a n c e m e n t)
2 4 " C C W M D 9 4 7 3 5 -4 3 7 8 7 -0 1 24" C C W J7 2 3 .2 3 " J 7 23" M D 9 2 8 " 8 b la d e 28" M D 9 26" EC S 26" M D 9 918693 918889 4 7 3 5 -4 3 7 8 3 -1 4 4 7 3 5 -4 1 1 3 4 -2 4 4 7 3 5 -4 3 7 8 3 -0 5 NA 4 7 3 5 -4 3 7 8 3 -0 7

12TS V 12TS Y

Confidential/Proprietary

Updated 13-June-2006

NewGen Service Drive Upgrades

Working with International Truck, BorgWarner Thermal Systems is replacing older style viscous fan drives with the NewGen viscous fan drives. The new generation viscous fan drives have a bimetal coil that provides more accurate turn on capability which leads to better engine cooling. The new drives also have improved efficiency, less slippage, less heat, and more torque capacity than the drives they replace. In response to requests from the field BorgWarner has also (in most cases) set the replacement drives cooler than the original equipment drives so the fan comes on sooner. These work better on older vehicles with older cooling systems. The NewGen coil actuated viscous fan drives will provide improved performance for your vehicle application.
Time Period Ends MY03 1995-2001 1995-2001 Ends MY03 1995-2000 1995-2001 1995-2001 1995-2001 Ends MY03 Ends MY03 1995-2000 Ends MY03 1995-2000 1997-2000 ? Vehicle 4700/4900 4700/5000 3000/4700 3800/4700/ 4900 3000/4700 3000/4700 3000/4000 5000 3800/4700 3000/4000? 3000/4700 3800-4700 3000/4700/ 4700LPX 4700LPX ? Engine DT466 Side by Side DT466 DT466 DT466 Front2Back DT466 DT466 DT466 DT466 T444E T444E? T444E T444E T444E T444E T444E BWETS # 1210-09155-01 166283 167046 1210-09157-01 166054 167047 167341 167524 1210-09157-05 1210-09157-02 167981 1210-09156-02 167421 167071 1210-09153-01 International 3522786C2 2004860C1 2021376C1 3522788C2 2001023C1 2021954C1 2027495C1 2029206C1 3547775C2 3540984C2 2038840C1 3540983C2 2033827C1 2022686C1 3522784C1 Temp. O F 170F 170F 170F 180F 180F 180F 190F 190F 170F 750 170F 182F 170F 182F 182F 182F 750 010020791 3540983C1 160F 010020552 or 010020509 2587815C1 or 3547775C3 160F (Rec.) or 170F (OE) 750 010020755 3522788C3 170F Metal CW 23"x7x3.23" MD9 CCW 24"x9x3.6" MD9 CCW 23.25"x9x3.6" Poly9-Bl 24"x9x3.5" Metal CCW 24"x7x2.4" Metal CCW 23.25"x7x2.4" Metal CCW 24"x7x3.2" MD9 CW 24"x9x3.6" Poly 9 BL 24"x9x3.5" MD9 CW 23"x9x3.6" Poly 6 BL 28"x6x2.9" Poly 8 BL 28"x8x3.9" Poly 8 BL 30"x8x3.0" Metal CW 28"x8x3.5" Metal CW 26"x8x2.7" Metal CW 23"x7x3.23" Metal CW 23"x7x3.2" Poly 8 BL 30"x8x3.9" Poly 8 BL 28"x8x3.9" Poly 8 BL 28"x8x3.2" Poly 8 BL 28"x8x3.2" Metal CW 28"x8x3.5" Metal CW 30"x8x3.2" Poly 8 BL 30"x8x3.9" Poly 8 BL 28"x8x3.9" Poly 8 BL 28"x8x3.2" Poly 8 BL 28"x8x3.2" Metal CW 28"x8x3.5" Metal CW 30"x8x3.2" 917809 1650477C1 750 010020914 3522786C3 160F NewGen Drive BWETS # International Temp. O F
Fan

BWETS # ECS 9351 917809

International 1647411C3 1650477C1

Metal CW 26"x8x2.7" Metal CW 23"x7x3.23" Metal CW 26"x8x2.7"

ECS 9351

1647411C3

4735-43787-01 4735-43787-02 4735-42623-44 918694

3547774C1 3552162C1 3541004C1 2022688C1

918889

3512260C1

918693 4735-43783-09 4735-41393-44 4735-43783-14 4035-35480-07 4735-38164-14 4735-42904-19 ECS 412695 ECS 9351 917809 916612 4735-38585-02 4735-38585-07
4735-43439-05 4735-43439-05

2022687C1 3539701C1 3541004C1 3548286C1 1606826C1 1611064C1 1670050C1 2039060C1 1647411C3 1650477C1 492146C1 1666626C1 1611610C1 1607711C1 1607711C1 507018C3 534919C1 1666626C1 1611610C1 1607711C1 1607711C1 507018C3 534919C1

Ends MY03

DT466

1210-09157-03

3540985C2

180F

750 2000/5000/ 8000/8100 DT466/ INT530

010020893

3540985C3

170F

1997-2001

166223

2005257C1

180F

1992-1994 1992-1994 1992-1994 1997-2001

4900 4900 4900 8100

DTA360 DT466 DT466 CAT C10 >335HP CAT 3406 300-375HP

199807 199810 199811 197778

1689479C1 1689481C1 1689480C1 1666056C91

170F 180F 155F 180F 750 010021314 1689481C2 170F

1988-1992

9370/9670

196133

1657425C91

180F

810

010021524

1666056C92

170F

1990-1994

2000/8100

CUMMINS L10

198859

1673889C91

180F

916797 916808 4735-38585-02 4735-38585-07

4735-43439-05 4735-43439-05

1988-1990

9370/9670

CUMMINS N14

194767

1612269C1

150F 810 010021525 1612269C2 150F

1980-88

9300/9670

CUMMINS NTC

187182

507271C2

150F

916797 916808

Confidential/Proprietary

Updated 13-June-2006