DRIVEMASTER TWO-SPEED FAN DRIVE

REPAIR KIT INSTALLATION INSTRUCTIONS

Manufactured under licence by: NORMAN G. CLARK (A/ASIA) PTY. LTD. 44 Kylta Road West Heidelberg, Victoria, 3081, Australia p : +61 3 9450 8200 / f: +61 3 9450 8222 web: www.ngclark.com.au / e: [email protected]

Item # F21675 / IF169 05/10

TABLE OF CoNtENtS

INTRODUCTION 3 General Information PRIOR TO SERVICING 3 DRIVEMASTER Two-Speed Parts 4 Parts Identication 4 DRIVEMASTER Two-Speed Repair Kits 5 Seal Kit 5 Major Kit (FDM prex models) 5 Major Kit (FDMA prex models) 6 REMOVING THE FAN DRIVE 6 DISASSEMBLING THE FAN DRIVE 7 Tools Required 7 Fan Mounting Friction Disc Removal and Inspection 7 Spring Housing / Piston Assembly Removal 8 Air Chamber Seals 8 TORQUE SPECIFICATIONS 9 REBUILDING THE FAN DRIVE 10 Sheave and Sheave Bearings 10 Air Cartridge 11 Journal Bracket & Sheave Reassembly 11 Spring Housing / Piston Assembly, Reassembly 12 Fan Mounting Friction Disc Reassembly 13 Fan Reassembly 13 REINSTALLING THE FAN DRIVE 14 TROUBLESHOOTING 15

INtroductioN

General Information

Horton uses the following special notices to give warning of possible safety related problems which could cause serious injury and provide information to help prevent damage to equipment. DANGER 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. CAUTION Caution is used to indicate the presence of a hazard which will or can cause minor personal injury or property damage if the warning is ignored. NOTE Note is used to notify people of installation, operation, or maintenance information which is important but not hazard related.

Prior To Servicing
You must follow your company safety practices, which should adhere to or be better than Federal or State approved shop safety practices and procedures. Be sure that you read and understand all the procedures and instructions before beginning work on this unit. NOTE Parts replacement and/or repair of your Horton DriveMaster Two-Speed Fan Drive should be performed only by the Horton Factory or an authorized Horton Distributor or Dealer to keep your warranty coverage intact during the warranty period. Before rebuilding your DriveMaster Fan Drive, note the Fan Drive Serial No., Service Part No., Date of Installation, and Vehicle Mileage. Serial Number:_________________________________ Service Part Number:____________________________ Installation Date:_______________________________ Vehicle Mileage:________________________________ Vehicle Make & Model:___________________________

Service Part Number and Serial Number

DRIVEMASTER TWO-SPEED PARTS

Parts Identication

55 9 27 57 17 28

50

18

5 20

54

53 56

2 4 22 23 24 2 44 3 1

ITEM 1 2 3 4 5 6 9 17 18 20 22

DESCRIPTION Journal Bracket Ball Bearings Sheave Bearing Nut Air Chamber Cap O-Ring Seal Fan Mounting Friction Disc Button Head Torx Screws Air Chamber Seal Face Seal Retaining Ring (Air Chamber Cap)

QTY 1 2 1 1 1 1 1 8 1 1 1

ITEM 23 24 27 28 44 50 53 54 55 56 57

DESCRIPTION Air Cartridge Assembly Retaining Ring (Air Cartridge) Fan Mounting Friction Disc Stud Friction Liner Bearing Spacers, pair (where supplied) Spring Housing Socket Flat Head Screws Magnet Plates Cage Nut (used for repairs only) Curved Magnets Jam Nut (Left hand Thread)

QTY 1 1 6 1 1 1 4 2 1 4 1

Denotes Major Kit Item Not used on all fan drives. If present, re-use during repair. Some models manufactured with four (4) sets of magnets. i.e. Model specic. Most models have integrated Air Chamber and Sheave design.

DRIVEMASTER TWO-SPEED REpAir KitS

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

Seal Kit (Suits All DriveMaster Models)

Install a Seal Kit if an air leak has developed inside of the DriveMaster Two-Speed Fan Drive. The Seal Kit consists of the parts listed and described below: ITEM 6 17 18 20 22 23 24 55 DESCRIPTION O-Ring Seal Button Head Torx Screws Air Chamber Seal Face Seal Retaining Ring Air Cartridge Assembly Retaining Ring Cage Nut (Used For Repairs Only) QTY 1 8 1 1 1 1 1 1
6 22 55

# F994346

18 23 24 17 20

Kit Major DriveMaster FDM Prex Models (w/ Match Ground Pair Bearings)
ITEM 2 4 6 17 18 20 22 23 24 28 44 50 55 DESCRIPTION Match Ground Pair Bearings Bearing Nut O-Ring Seal Button Head Torx Screws Air Chamber Seal Face Seal Retaining Ring Air Cartridge Assembly Retaining Ring Friction Liner Bearing Spacer Spring Housing/piston Cage Nut (Used For Repairs Only) QTY 1 1 1 8 1 1 1 1 1 1 1 1 1

# F25009

55

17

28

50

18

20

22

24

23

2 2 44

Kit Major DriveMaster FDMA Prex Models (w/ Double Row Angular Contact Bearing)
ITEM 2 4 6 17 18 20 22 23 24 28 44 50 55 DESCRIPTION Double Row Angular Contact Bearing Bearing Nut O-Ring Seal Button Head Torx Screws Air Chamber Seal Face Seal Retaining Ring Air Cartridge Assembly Retaining Ring Friction Liner Bearing Spacer Spring Housing/piston Cage Nut (Used For Repairs Only) T55 Torx Plus Bit (Not Pictured) O-Ring Lubricant (Not Pictured) QTY 1 1 1 8 1 1 1 1 1 1 1 1 1

# F25010

55

17

28

50

18

20

22

24

23 44

REMOVING THE FAN DRIVE

NOTE The procedure for removing the Fan Drive varies from one vehicle to another. Refer to the vehicles service manual for a detailed description of this process. In general, proceed as follows: 1. Turn the vehicle ignition off, apply the vehicles parking brake, and block the vehicles wheels. NOTE Protect the radiator from possible damage from the fan during fan removal and fan drive installation. 2. Bleed the air from the vehicles reservoir and, if possible, disconnect the air hose from the Fan Drive. 3. Loosen or remove the drive belts. 4. Remove the Fan Drive/Fan sub assembly from the Vehicle.

DISASSEMBLING THE FAN DRIVE

Tools Required
1 - 1/16 27mm Hex Socket 2 Socket Wrench T55 Torx Plus Bit (F994352) T27 Torx Bit Pry Bar/Fan Retaining Ring Pliers Screwdrivers 2.5mm Allen Wrench

DiSASSEmBLy Fan Mounting Friction Disc Removal and Inspection

1. Place the Fan Drive in a vice and clamp the Journal Bracket tight. NOTE Applying 80-120 PSI air pressure to the Fan Drive air inlet. This will aid in removal of the Fan Mounting Friction Disc (FMFD). 2. Use a fan blade for leverage to remove Fan Mounting Friction Disc by rst removing the Jam Nut (left-hand thread), then loosening the Jack Bolt (left-hand thread) by turning the jack bolt counter-clockwise using a T55 Torx Plus Bit (Part #F994352). It is recommended that another person hold the fan blade to aid in removing the fan mounting friction disc due to awkward layout of the FMFD/fan assembly. 3. Unscrew the Fan Mounting Friction Disc from the Jack Bolt. Inspect the FMFD for wear or damage. (See examples below)
Fan
Fan Mounting Friction Disc Jack Bolt (left hand thread)

Step 2

Jack Bolt

Step 3

Fan Mounting Friction Disc Good Condition

Look for signs of damage or blistering.

Spring Housing / Piston Assembly Removal

4. Hand tighten the Cage Nut (from the Repair Kit) onto the Jack Bolt (left hand thread) over the Spring Housing. The Cage Nut will keep the Spring Housing and Piston together as an assembly. It will also maintain pressure on the internal Springs after the Button Head Screws are removed. WARNING Remove air pressure from the unit before proceeding to step 5. DANGER Failure to release air pressure may result in serious personal injury. WARNING Do not disassemble the spring housing. Personal injury could occur. This item is non-repairable. 5. Remove the 8 Button Head Screws and the friction Liner using a T27 Torx Bit. NOTE If you are installing either a Friction Liner Kit (Part#F994349) , or a Fan Mounting Friction Disc Kit, skip to page 14, step 16. 6. Remove the Spring Housing/Piston Assembly. 7. Examine the inside of the Air Chamber for signs of moisture and/or contaminants. 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.
Steps 6-7 Spring Housing/ Piston Assembly

Button Head Screws Friction Liner Cage Nut Spring Housing/Piston Assembly

Steps 4-5

Air Chamber

Air Chamber Seals

WARNING
Air Chamber Seal

Wear eye safety protection when removing Retaining Ring to avoid serious injury. 8. Remove the Air Chamber Cap Retaining Ring. 9. Gently and evenly pry the Air Chamber Cap out of the Sheave using two small screwdrivers placed 180 apart. 10. Remove the O-Ring Seal and Face Seal from the Air Chamber Cap. 11. Inspect the Face Seal for signs of wear. Wear indicates that dirt may exist in the air system. CAUTION If dirt, moisture or oil exists in the air system, the air system must be cleaned and dried before the Fan Drive is reinstalled.

Retaining Ring O-Ring Seal Face Seal Air Chamber Cap

Steps 8-11

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

Bearing Nut Journal Bracket

Step 12

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

Step 13

TorquE SpEciFicAtioNS
ITEM 4 50 57 17 20 53 27 DESCRIPTION TIGHTENING TORQUE 130 ft-lbs [176 Nm] 100 ft-lbs [136 Nm] 100 ft-lbs [136Nm] 80 in-lbs [9 Nm] 75-100 in-lbs [8.5-11.5 Nm] 32-39 in-lbs [3.6-4.4 Nm] 95-105 in-lbs [10.7-11.9 Nm

Bearing Nut Jack Bolt (left hand thread) Jam Nut (left hand thread) Button Head Torx Screws Face Seal Socket Flat Head Screws Fan Mounting Friction Disc Studs 5/16 UNC

REBuiLdiNg thE FAN drivE

Sheave & Sheave Bearings

1. Fully support the Sheave and press the Bearings out of the Sheave. NOTE Some Models of the DRIVEMASTER Fan Drive contain Bearing Spacers. Both Bearing Spacers must be positioned BETWEEN the Sheave Bearings when the Matched Ground Bearings are replaced. When replacing the single DRAC Bearing, the pair of Bearing Spacers are to be positioned on top of the Bearing when re-installing the Bearing Nut (4). Refer to Step 9. All Bearings are prelubricated and sealed. DO NOT remove the seals to lubricate the Bearings. 2. Fully supporting the Sheave, press the new Sheave Bearings (or single bearing) into place, noting the position of the lip inside the Sheave. See Figures 2A, 2B, 2C. NOTE Some DRIVEMASTER models utilize a single (one piece) Sheave Bearing. Repair with model specic Kit. NOTE When installing new bearings, you must press on the outer diameter ring of the bearing set to avoid damaging the bearing during installation.
SUPPORT

Bearings

PRESS TO REMOVE

SUPPORT Step 1

Align the chevron markings on the matched ground bearings to form an arrow. The arrow may point in either direction.

Press on outer bearing race when installing new bearings

Press on inner bearing race when removing old bearings.

Step 2A

NOTE POSITION OF LIP

Bearings (or single bearing) Sheave Bearings Spacers

Step 2B

SUPPORT

SUPPORT PRESS Step 2C

10

Air Cartridge
WARNING Wear eye safety protection when removing Retaining Ring to avoid serious injury. 1. Remove the Retaining Ring. 2. Remove the Air Cartridge Assembly. Clean the Journal Bracket bore if necessary. 3. Apply O-Ring lubricant to the outside O-Rings of the new Air Cartridge Assembly. 4. Install the new Air Cartridge Assembly into the Journal Bracket. 5. Reinstall the Retaining Ring. 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. Refer to Step 5.
Step 3

Retaining Ring

Floating Seal Tip

Air Cartridge Assembly Step 4

O-Rings

The curve faces the Cartridge Retaining Ring Step 5

Journal Bracket & Sheave Reassembly

8. Slide the Sheave onto the Journal Bracket. 9. Replace and tighten the Bearing Nut to 130 ft. lbs. [170 Nm] torque. Be sure that the Bearing Nut hex is facing up (see detail below). On DriveMaster Advantage models with the single DRAC Bearing, the inner Bearing Spacer must locate on the relief diameter of the bearing nut.

Sheave Journal Bracket

Bearing Nut (Hex faces up)

Bearing Nut Detail Hex faces up

Step 8

Step 9

Relief points down toward Journal Bracket and Bearings Step 9

11

Spring Housing / Piston Assembly, Reassembly

CAUTION Use extreme care when reassembling the Air Chamber components to avoid damage to the O-Ring and Air Chamber Seal. 10. Using a clean/dry cloth, clean both the Floating Seal Tip (see Air Cartridge illustration, Step 4) of the Air Cartridge Assembly as well as the Face Seal of the Air Chamber Cap. Use care not to scratch seal surfaces. NOTE The new Face Seal is assembled with an O-ring. If the old Face Seal does not have an O-ring, remove it from the new Face Seal and apply thread sealant (Loctite 511 or similar) to the Face Seal threads. 11. Assemble the Air Chamber Cap and Face Seal. Lubricate the O-ring Seal with the fresh lubricant supplied in the kit and install it on the Air Chamber Cap. 12. Carefully set the Air Chamber Cap into the Sheave and install the Retaining Ring. 13. Lubricate the Air Chamber Seal and contact surfaces with the fresh lubricant supplied in the kit. 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. CAUTION Do not apply grease beyond Seal contact surface as it will cause improper Fan Drive function. 14. Install the Air Chamber Seal into the Sheave as shown. Be sure the Seal is evenly seated against the side and bottom of the groove surfaces. 15. Carefully set the new Spring Housing/Piston Assembly from the Repair Kit into position. Gently rotate to align the mounting holes in the assembly with the tapped holes in the Sheave. 16. Set the new Friction Liner (from kit) into place. Handle the Friction Liner by the edges to avoid contamination.
Steps 14-15 Air Chamber Seal Sheave Steps 11-12

Air Chamber Cap

Retaining Ring

V of Seal faces down into Sheave Do not apply grease beyond these areas. Sheave (cross-section) Steps 13-14

Air Chamber Seal Detail

Seat Seal evenly against side and bottom groove surfaces.

Spring Housing/ Piston Assembly

17. Alternately and evenly tighten the 8 Button Head Screws to 80 In. Lbs. [9 Nm] torque. WARNING To avoid personal injury, make sure the Button Head Screws are properly tightened to the specied torque before applying air pressure - 80 In. Lbs. [9 Nm].
Button Head Screws Friction Liner Cage Nut Spring Housing/ Piston Assembly

Steps 16-17

12

Fan Mounting Friction Disc Reassembly

18. Apply a minimum of 80 PSI of clean air to the air inlet. CAUTION Air must be applied to the air chamber to allow for easy removal of the Cage Nut. 19. Remove the Cage Nut from the Spring Housing/ Piston Assembly. 20. Install the new Fan Mounting Friction Disc (from kit) if applicable. (left hand thread) CAUTION Air must be applied to the air chamber to ensure proper torque is applied to the Jack Bolt. 21. Tighten the Jack Bolt (left hand thread) to 100 Ft. Lbs. [136 Nm] torque. 22. Apply Loctite 262 Threadlocker (or equivalent) to the threads of the Jam Nut, reinstall over the jack bolt (left hand thread) and also tighten to 100 Ft. lbs [136 Nm] torque. 23. Actuate the DriveMaster and check for proper engagement and disengagement of the Fan Mounting Friction Disc. Check for air leaks at the bleed hole and around the Spring Housing / Piston Assembly. 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.
Steps 20-22 Jack Bolt Fan Fan Mounting Friction Disc Jam Nut (left hand thread)

Jack Bolt (left hand thread)

Steps 18-19

Fan Reassembly
24. Reinstall the fan onto the Fan Mounting Friction Disc using 6 spring washers and 6 nyloc nuts. NOTE: Refer to Page 10 for recommended Torque Specications. Do not overtighten or damage to FMFD will result.

Fan Drive

Step 24

5/16 Spring washers & nyloc nuts

13

REiNStALLiNg thE FAN DrivE

WARNING On the workbench, apply 90 psi [6.21 bar] clean air pressure and check the Fan Drive for air leaks. 1. Be sure the vehicle ignition is off, the vehicles parking brake is applied, and the vehicles wheels are blocked. NOTE Protect the radiator from possible damage from the fan during fan and fan drive installation. 2. Clean the Fan Drive mounting surface on the engine. NOTE Most engines have multiple mounting locations. Be sure to use the correct holes for the application. 3. Bolt the Fan Drive to the engine. Use at washers on each manufacturers approved bolt or studs - do not use lock washers. Tighten the mounting bolts to the vehicle manufacturers specications. CAUTION Correct belt adjustment and alignment is necessary for all belt driven components to assure longevity of component life. Over tightening of belts will shorten bearing life. Loose belts will cause excessive belt wear and shorten bearing life. Consult the equipment manufacturer and/or engine manufacturer for specications of proper belt adjustment. 4. Replace and tighten the belts to manufacturers specication. WARNING The maximum recommended fan diameter is 32. If a larger fan diameter is required, contact Norman G. Clark Engineering. 5. Reinstall air inlet hose and ttings. 6. Check the fan for cracks or missing weights; then if re-usable, remount the fan on the Fan Drive. Tighten the bolts and/or nuts to the vehicle manufacturers specications. If cracking or incidental damage has occurred to any of the blades, replace the fan. 7. Start the engine and let the air pressure build to at least 90 psi [6.21 bar]. Turn off the engine. 8. Manually engage and disengage the Fan Drive by opening and closing the electrical circuit to the solenoid valve. For a normally-open electrical system, use a jumper across a sensor. For a normally-closed electrical system, open the circuit by disconnecting a sensor wire. With the Fan Drive disengaged, re-check the entire system for air leaks, or activate the manual override switch (if equipped). NOTE For DriveMaster applications, air pressure needs to be applied to disengage the drive.

14

TrouBLEShootiNg
PROBLEM I. Air leaking from Fan Drive bleed hole PROBABLE CAUSE 1. Bad seals or air cartridge.
Bleed Hole

SOLUTION 1. Install Repair Kit.

Journal Bracket

II. Premature Friction Lining ailure 1. Obstructed fan.

Slipping Problem 1. Bad seals or air cartridge. torn engine mounts, etc. 2a. Restricted air line. b. Restricted Solenoid Valve. c. Low system air pressure. d. System air leak. 1. Find and remove obstruction, repair or replace damaged parts. Install Repair Kit. 2.a. Replace air line. Install Repair Kit. b. Replace Solenoid Valve. Install Repair Kit. c. Repair system. Install Repair Kit. d. Repair leak. Install Repair Kit. 3.a. Check and adjust to specications. b. Check A/C pressure switch. c. Check electrical connections. d. Check temperature setting of all controls. ECM / Thermal Switch setting should engage the Fan Drive 10 F higher than the full open temperature of the thermostat. e. Check ECM. f. Replace the Thermal Switch. g. Check for proper shutter operation, winter front or other restriction in, or in front of, the radiator. h. Replace the Air-Temp Switch.

2. Low air pressure to Fan Drive

3. Excessive cycling.

3.a. A/C freon overcharge. b. A/C pressure switch setting too low. c. Poor ground or wire connection. d. Improper temperature control setting. e. Faulty ECM. f. Faulty Thermal Switch. g. Restriction in front of radiator blocking air ow. h. Faulty Air-Temp Switch. Air Problem 1. Solenoid Valve not exhausting or engaging properly..

1. Check for plugged exhaust/intake port on the Solenoid Valve. Clean or replace the Solenoid Valve.

15

TrouBLEShootiNg
PROBLEM III. Fan Drive fails to engage / disengage PROBABLE CAUSE Electrical Problem 1. Open / short 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. IV. Fan Drive cycles frequency Electrical Problem 1. Poor Ground Wire Connection. 2. Improper Temperature Control settings. 3. Faulty A/C Pressure Switch 4. Restriction In Front Of Radiator, blocking Air Flow. 5. Faulty Thermal Switch. 6. Faulty Air-temp Switch. 7. Vehicle Coolant 1. Check electrical connections. 2. Check temperature setting of all controls. EMC / Thermal Switch should engage the Fan Drive 10 F higher than the full open temperature of the thermostat. 3. Replace the A/C Pressure Switch 4. Check shutter operation, winter fronts, (where tted) or obstruction in front of radiator. 5. Replace the Thermal Switch. 6. Replace the Air-Temp Switch. 7. Fill to manufacturers recommended level. Level Too Low. 1. Make sure nothing is obstructing the air ow through the radiator. 2. Refer to vehicle manufacturers specications. 3. Refer to engine manual. 4. Establish and correct the problem causing the excessive cycling. Install appropriate Repair Kit. 1. Clean the air supply and install a Repair Kit. 1. Check air line from Solenoid to Fan Drive for kinks or obstructions. 2. Replace the Solenoid Valve. Check to see if air exhaust is restricted. 1. Check electrical connections. 2. Check wiring according to vehicle manufacturers specications. 3. Check Thermal Switch. Replace if wrong temperature setting or defective. 4. Replace the Solenoid Valve. SOLUTION

V. Fan Drive engaged, engine running hot.

1. Restriction in front of radiator. 2. Fan capacity not large enough. 3. Problem in cooling system. 4. Friction Lining worn out due to excessive cycling. 16

Manufactured under licence by: NORMAN G. CLARK (A/ASIA) PTY. LTD. 44 Kylta Road West Heidelberg, Victoria, 3081, Australia p : +61 3 9450 8200 / f: +61 3 9450 8222 web: www.ngclark.com.au / e: [email protected]

Item # F21675 / IF169 05/10