Drivemaster 2speed Installation Instructions

DRIVEMASTER TWO-SPEED FAN DRIVE

REPAIR KITINSTALLATION INSTRUCTIONS

Manufactured under licence by:NORMAN G. CLARK (A/ASIA) PTY. LTD.

44 Kylta Road West Heidelberg, Victoria, 3081, Australiap : +61 3 9450 8200 / f: +61 3 9450 8222web: www.ngclark.com.au / e: [email protected] Item # F21675 / IF169 05/10

�

Table Of COnTenTs

InTRODUCTIOn 3 GeneralInformationPRIOR TO seRVICInG 3DRIVeMasTeR Two-speed Parts 4 PartsIdentification 4DRIVeMasTeR Two-speed Repair Kits 5 SealKit 5 MajorKit(FDMprefixmodels) 5 MajorKit(FDMAprefixmodels) 6ReMOVInG THe fan DRIVe 6DIsasseMblInG THe fan DRIVe 7 ToolsRequired 7 FanMountingFrictionDiscRemovalandInspection 7 SpringHousing/PistonAssemblyRemoval 8 AirChamberSeals 8TORQUe sPeCIfICaTIOns 9RebUIlDInG THe fan DRIVe �0 SheaveandSheaveBearings 10 AirCartridge 11 JournalBracket&SheaveReassembly 11 SpringHousing/PistonAssembly,Reassembly 12 FanMountingFrictionDiscReassembly 13 FanReassembly 13ReInsTallInG THe fan DRIVe �4TROUblesHOOTInG �5

3

InTRODUCTIOn

General Information

Hortonusesthefollowingspecialnoticestogivewarningofpossiblesafetyrelatedproblemswhichcouldcauseseriousinjuryandprovideinformationtohelppreventdamagetoequipment.

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

Youmustfollowyourcompanysafetypractices,whichshouldadheretoorbebetterthanFederalorStateapprovedshopsafetypracticesandprocedures.Besurethatyoureadandunderstandalltheproceduresandinstructionsbeforebeginningworkonthisunit.

nOTeParts 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.

BeforerebuildingyourDriveMasterFanDrive,notetheFanDriveSerialNo.,ServicePartNo.,DateofInstallation,andVehicleMileage.

SerialNumber:_________________________________ServicePartNumber:____________________________InstallationDate:_______________________________VehicleMileage:________________________________VehicleMake&Model:___________________________

ServicePartNumberandSerialNumber

4

DRIVeMasTeR TWO-sPeeD PaRTs

Parts Identification

ITeM DesCRIPTIOn QTY

1 JournalBracket 12º BallBearings 23³ Sheave 14º BearingNut 1

5 AirChamberCap 16º O-RingSeal 19 FanMountingFrictionDisc 1

17 ButtonHeadTorxScrews 818 AirChamberSeal 120º FaceSeal 122º RetainingRing(AirChamberCap) 1


23º AirCartridgeAssembly 124º RetainingRing(AirCartridge) 127 FanMountingFrictionDiscStud 628º FrictionLiner 1

44¹ BearingSpacers,pair(wheresupplied) 150º SpringHousing 153 SocketFlatHeadScrews 4²

54 MagnetPlates 2²55 CageNut(usedforrepairsonly) 156 CurvedMagnets 4²57 JamNut(LefthandThread) 1

1243

4 44

2

23222

2757

9 1728

50 18 5

5356

54

20

556

ºDenotesMajorKitItem¹Notusedonallfandrives.Ifpresent,re-useduringrepair.²Somemodelsmanufacturedwithfour(4)setsofmagnets.i.e.Modelspecific.³MostmodelshaveintegratedAirChamberandSheavedesign.

5

DRIVeMasTeR TWO-sPeeD RePaIR KITs

seal Kit (suits all DriveMaster Models)

HortonoffersseveraldifferentwaystorepairorrebuildyourDriveMasterTwo-SpeedFanDrive.

InstallaSealKitifanairleakhasdevelopedinsideoftheDriveMasterTwo-SpeedFanDrive.TheSealKitconsistsofthepartslistedanddescribedbelow:


6 O-RingSeal 117 ButtonHeadTorxScrews 818 AirChamberSeal 120 FaceSeal 122 RetainingRing 123 AirCartridgeAssembly 124 RetainingRing 155 CageNut(UsedForRepairsOnly) 1

55

22

6

1720

24

23

18

# f994346

Kit Major DriveMaster fDM Prefix Models (w/ Match Ground Pair bearings)


2 MatchGroundPairBearings 14 BearingNut 16 O-RingSeal 117 ButtonHeadTorxScrews 818 AirChamberSeal 120 FaceSeal 122 RetainingRing 123 AirCartridgeAssembly 124 RetainingRing 128 FrictionLiner 144 BearingSpacer 150 SpringHousing/piston 155 CageNut(UsedForRepairsOnly) 1

# f�5009

1728 50 18

55

244206

223 4422 2

6

Kit Major DriveMaster fDMa Prefix Models (w/ Double Row angular Contact bearing)


2 DoubleRowAngularContactBearing 14 BearingNut 16 O-RingSeal 117 ButtonHeadTorxScrews 818 AirChamberSeal 120 FaceSeal 122 RetainingRing 123 AirCartridgeAssembly 124 RetainingRing 128 FrictionLiner 144 BearingSpacer 150 SpringHousing/piston 155 CageNut(UsedForRepairsOnly) 1 T55TorxPlusBit(NotPictured)

O-RingLubricant(NotPictured)

# f�50�0

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

1.Turnthevehicleignitionoff,applythevehicle’sparkingbrake,andblockthevehicle’swheels.

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

2.Bleedtheairfromthevehicle’sreservoirand,ifpossible,disconnecttheairhosefromtheFanDrive.3.Loosenorremovethedrivebelts.4.RemovetheFanDrive/FansubassemblyfromtheVehicle.

ReMOVInG THe fan DRIVe

1728 50 18

55

244 2442322206

7

DIsasseMblInG THe fan DRIVe

Tools Required

• � - �/�6” �7mm Hex socket • �” socket Wrench• T55 Torx Plus bit (f99435�)• T�7 Torx bit

DIsasseMblYfan Mounting friction Disc Removal and Inspection

1.PlacetheFanDriveinaviceandclamptheJournalBrackettight.

nOTeapplying 80-��0 PsI air pressure to the fan Drive air inlet. This will aid in removal of the fan Mounting friction Disc (fMfD).

2.UseafanbladeforleveragetoremoveFanMountingFrictionDiscbyfirstremovingtheJamNut(left-handthread),thenlooseningtheJackBolt(left-handthread)byturningthejackboltcounter-clockwiseusingaT55TorxPlusBit(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.UnscrewtheFanMountingFrictionDiscfromtheJackBolt.InspecttheFMFDforwearordamage.(Seeexamplesbelow)

Step 2

Fan

Jack Bolt

• Pry bar/fan• Retaining Ring Pliers• screwdrivers• �.5mm allen Wrench

Jack Bolt(left handthread)

FanMountingFrictionDisc

Fan Mounting Friction Disc Good Condition Look for signs of damage or blistering.

Step 3

8

spring Housing / Piston assembly Removal

4.HandtightentheCageNut(fromtheRepairKit)ontotheJackBolt(lefthandthread)overtheSpringHousing.TheCageNutwillkeeptheSpringHousingandPistontogetherasanassembly.ItwillalsomaintainpressureontheinternalSpringsaftertheButtonHeadScrewsareremoved.

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.Removethe8ButtonHeadScrewsandthefrictionLinerusingaT27TorxBit.

nOTeIf you are installing either a friction liner Kit (Part#f994349) , or a fan Mounting friction Disc Kit, skip to page �4, step �6.

6.RemovetheSpringHousing/PistonAssembly.7.ExaminetheinsideoftheAirChamberforsignsofmoistureand/orcontaminants.

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 4-5

ButtonHead Screws

Cage Nut

Friction Liner

SpringHousing/Piston

Assembly

air Chamber seals

WaRnInG

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

8.RemovetheAirChamberCapRetainingRing.9.GentlyandevenlyprytheAirChamberCapoutoftheSheaveusingtwosmallscrewdriversplaced180°apart.10.RemovetheO-RingSealandFaceSealfromtheAirChamberCap.11.InspecttheFaceSealforsignsofwear.Wearindicatesthatdirtmayexistintheairsystem.

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.

Steps 6-7

Spring Housing/Piston Assembly

Air Chamber

Face Seal

Steps 8-11

Air Chamber Seal

Retaining Ring

Air Chamber Cap

O-Ring Seal

9

TORQUe sPeCIfICaTIOns

Bearing Nut

Step 12

Journal Bracket

Sheave

Journal Bracket

Step 13

12.RemovetheBearingNutfromtheJournalBracketusinga2”SocketWrench.

13.SlidetheSheaveandbearingassemblyofftheJournalBracket.

ITeM DesCRIPTIOn TIGHTenInG TORQUe

4 BearingNut 130ft-lbs[176Nm]50 JackBolt(lefthandthread) 100ft-lbs[136Nm]57 JamNut(lefthandthread) 100ft-lbs[136Nm]17 ButtonHeadTorxScrews 80in-lbs[9Nm]20 FaceSeal 75-100in-lbs[8.5-11.5Nm]53 SocketFlatHeadScrews 32-39in-lbs[3.6-4.4Nm]27 FanMountingFrictionDiscStuds5/16”UNC 95-105in-lbs[10.7-11.9Nm

�0

Step 2C

PRESS

SUPPORT

SUPPORT

Sheave

Bearings(or single bearing)

Step 2B

NOTE POSITION OF LIP

Bearings Spacers

PRESSTOREMOVE

SUPPORT

SUPPORT

Bearings

Step 1

1.FullysupporttheSheaveandpresstheBearingsoutoftheSheave.

nOTesome 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.FullysupportingtheSheave,pressthenewSheaveBearings(orsinglebearing)intoplace,notingthepositionofthelipinsidetheSheave.SeeFigures2A,2B,2C.

nOTesome DRIVeMasTeR models utilize a single (one piece) sheave bearing. Repair with model specific Kit.

nOTeWhen installing new bearings, you must press on the outer diameter ring of the bearing set to avoid damaging the bearing during installation.

RebUIlDInG THe fan DRIVe

sheave & sheave bearings

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

Step 2A

Press on outerbearing racewhen installingnew bearings

Press oninnerbearingrace whenremovingold bearings.

��

air Cartridge

RetainingRing

Step 3

WaRnInG

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

1.RemovetheRetainingRing.

2.RemovetheAirCartridgeAssembly.CleantheJournalBracketboreifnecessary.

3.ApplyO-RinglubricanttotheoutsideO-RingsofthenewAirCartridgeAssembly.

4.InstallthenewAirCartridgeAssemblyintotheJournalBracket.

5.ReinstalltheRetainingRing.

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 5

Retaining Ring

O-Rings

The curve facesthe Cartridge

Journal bracket & sheave Reassembly

8.SlidetheSheaveontotheJournalBracket.

9.ReplaceandtightentheBearingNutto130ft.lbs.[170Nm]torque.BesurethattheBearingNuthexisfacingup(seedetailbelow).OnDriveMasterAdvantagemodelswiththesingleDRACBearing,theinnerBearingSpacermustlocateonthereliefdiameterofthebearingnut.

Step 4Air Cartridge Assembly

Floating SealTip

Bearing Nut(Hex faces up)

Step 9

Hex faces up

Bearing Nut Detail

Relief points downtoward Journal

Bracket and Bearings Step 9Step 8

Sheave

JournalBracket

��

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.Usingaclean/drycloth,cleanboththeFloatingSealTip(seeAirCartridgeillustration,Step4)oftheAirCartridgeAssemblyaswellastheFaceSealoftheAirChamberCap.Usecarenottoscratchsealsurfaces.

nOTeThe 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 ® 5�� or similar) to the face seal threads.

11.AssembletheAirChamberCapandFaceSeal.LubricatetheO-ringSealwiththefreshlubricantsuppliedinthekitandinstallitontheAirChamberCap.

12.CarefullysettheAirChamberCapintotheSheaveandinstalltheRetainingRing.

13.LubricatetheAirChamberSealandcontactsurfaceswiththefreshlubricantsuppliedinthekit.

nOTeThe 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.InstalltheAirChamberSealintotheSheaveasshown.BesuretheSealisevenlyseatedagainstthesideandbottomofthegroovesurfaces.

15.CarefullysetthenewSpringHousing/PistonAssemblyfromtheRepairKitintoposition.GentlyrotatetoalignthemountingholesintheassemblywiththetappedholesintheSheave.

16.SetthenewFrictionLiner(fromkit)intoplace.HandletheFrictionLinerbytheedgestoavoidcontamination.

17.Alternatelyandevenlytightenthe8ButtonHeadScrewsto80In.Lbs.[9Nm]torque.

WaRnInG

To avoid personal injury, make sure the button Head screws are properly tightened to the specified torque before applying air pressure - 80 In. lbs. [9 nm].

“V” of Seal facesdown intoSheave

Sheave(cross-section)

Do not applygrease beyondthese areas.

Air Chamber Seal Detail

Steps 13-14

Seat Sealevenly against

side andbottom groove

surfaces.

Retaining Ring

Steps 11-12

Air Chamber Cap

Sheave

Air Chamber

Seal


Steps 14-15

Steps 16-17

ButtonHead Screws

Cage Nut

Friction Liner


�3

�8. 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.RemovetheCageNutfromtheSpringHousing/PistonAssembly.

20.InstallthenewFanMountingFrictionDisc(fromkit)ifapplicable.(lefthandthread)

CaUTIOn

air must be applied to the air chamber to ensure proper torque is applied to the Jack bolt.

21.TightentheJackBolt(lefthandthread)to100Ft.Lbs.[136Nm]torque.

22.ApplyLoctite®262Threadlocker(orequivalent)tothethreadsoftheJamNut,reinstalloverthejackbolt(lefthandthread)andalsotightento100Ft.lbs[136Nm]torque.

23.ActuatetheDriveMasterandcheckforproperengagementanddisengagementoftheFanMountingFrictionDisc.CheckforairleaksatthebleedholeandaroundtheSpringHousing/PistonAssembly.

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.

fan Mounting friction Disc Reassembly

Steps 20-22

Fan

Jack Bolt

Steps 18-19

FanMountingFriction Disc

Jam Nut(left handthread)

Jack Bolt(left handthread)

24.ReinstallthefanontotheFanMountingFrictionDiscusing6springwashersand6nylocnuts.

nOTe: Refer to Page �0 for recommended Torque specifications. Do not overtighten or damage to fMfD will result.

fan Reassembly

Fan Drive

5/16” Spring washers & nyloc nutsStep 24

�4

WaRnInG

On the workbench, apply 90 psi [6.�� bar] clean air pressure and check the fan Drive for air leaks.

1.Besurethevehicleignitionisoff,thevehicle’sparkingbrakeisapplied,andthevehicle’swheelsareblocked.

nOTeProtect the radiator from possible damage from the fan during fan and fan drive installation.

2.CleantheFanDrivemountingsurfaceontheengine.

nOTeMost engines have multiple mounting locations. be sure to use the correct holes for the application.

3.BolttheFanDrivetotheengine.Useflatwashersoneachmanufacturer’sapprovedboltorstuds-donotuselockwashers.Tightenthemountingboltstothevehiclemanufacturer’sspecifications.

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 specifications of proper belt adjustment.

4.Replaceandtightenthebeltstomanufacturer’sspecification.

WaRnInG

The maximum recommended fan diameter is 3�’’. If a larger fan diameter is required, contact norman G. Clark engineering.

5.Reinstallairinlethoseandfittings.

6.Checkthefanforcracksormissingweights;thenifre-usable,remountthefanontheFanDrive.Tightentheboltsand/ornutstothevehiclemanufacturer’sspecifications.Ifcrackingorincidentaldamagehasoccurredtoanyoftheblades,replacethefan.

7.Starttheengineandlettheairpressurebuildtoatleast90psi[6.21bar].Turnofftheengine.

8.ManuallyengageanddisengagetheFanDrivebyopeningandclosingtheelectricalcircuittothesolenoidvalve.Foranormally-openelectricalsystem,useajumperacrossasensor.Foranormally-closedelectricalsystem,openthecircuitbydisconnectingasensorwire.WiththeFanDrivedisengaged,re-checktheentiresystemforairleaks,oractivatethemanualoverrideswitch(ifequipped).

nOTefor DriveMaster applications, air pressure needs to be applied to disengage the drive.

ReInsTallInG THe fan DRIVe

�5

TROUblesHOOTInG

PRObleM

I. air leaking from fan Drive bleed hole

PRObable CaUse

1.Badsealsoraircartridge.

sOlUTIOn

1.InstallRepairKit.

Journal Bracket

Bleed Hole

II. Premature friction lining ailure

1.Obstructedfan.

2.LowairpressuretoFanDrive

3.Excessivecycling.

slipping Problem

1.Badsealsoraircartridge.tornenginemounts,etc.

2a.Restrictedairline.

b.RestrictedSolenoidValve.

c.Lowsystemairpressure.

d.Systemairleak.

3.a.A/Cfreonovercharge.

b.A/Cpressureswitchsettingtoolow.

c.Poorgroundorwireconnection.

d.Impropertemperaturecontrolsetting.

e.FaultyECM.

f.FaultyThermalSwitch.

g.Restrictioninfrontofradiatorblockingairflow.

h.FaultyAir-TempSwitch.

air Problem

1.SolenoidValvenotexhaustingorengagingproperly..

1.Findandremoveobstruction,repairorreplacedamagedparts.InstallRepairKit.

2.a.Replaceairline.InstallRepairKit.

b.ReplaceSolenoidValve.InstallRepairKit.

c.Repairsystem.InstallRepairKit.

d.Repairleak.InstallRepairKit.

3.a.Checkandadjusttospecifications.

b.CheckA/Cpressureswitch.

c.Checkelectricalconnections.

d.Checktemperaturesettingofallcontrols.ECM/ThermalSwitchsettingshouldengagetheFanDrive10°Fhigherthanthefullopentemperatureofthethermostat.

e.CheckECM.

f.ReplacetheThermalSwitch.

g.Checkforpropershutteroperation,winterfrontorotherrestrictionin,orinfrontof,theradiator.

h.ReplacetheAir-TempSwitch.

1.Checkforpluggedexhaust/intakeportontheSolenoidValve.CleanorreplacetheSolenoidValve.

�6

TROUblesHOOTInG

PRObleM

III. fan Drive fails to engage / disengage

IV. fan Drive cycles frequency

V. fan Drive engaged, engine running hot.

PRObable CaUse

electrical Problem

1.Open/shortcircuit.

2.Improperlywired.

3.ThermalSwitchincorrectforapplication.

4.FailedSolenoidValve.

air Problem

1.Airlinerestricted.

2.SolenoidValvedefective.

Piston will not actuate

1.Pistonseizedduetocontaminationordryseals.

electrical Problem

1.PoorGroundWireConnection.

2.ImproperTemperatureControlsettings.

3.FaultyA/CPressureSwitch

4.RestrictionInFrontOfRadiator,blockingAirFlow.

5.FaultyThermalSwitch.

6.FaultyAir-tempSwitch.

7.VehicleCoolant

1.Restrictioninfrontofradiator.

2.Fancapacitynotlargeenough.

3.Problemincoolingsystem.

4.FrictionLiningwornoutduetoexcessivecycling.

sOlUTIOn

1.Checkelectricalconnections.

2.Checkwiringaccordingtovehiclemanufacturersspecifications.

3.CheckThermalSwitch.Replaceifwrongtemperaturesettingordefective.

4.ReplacetheSolenoidValve.

1.CheckairlinefromSolenoidtoFanDriveforkinksorobstructions.

2.ReplacetheSolenoidValve.Checktoseeifairexhaustisrestricted.

1.CleantheairsupplyandinstallaRepairKit.

1.Checkelectricalconnections.

2.Checktemperaturesettingofallcontrols.EMC/ThermalSwitchshouldengagetheFanDrive10°Fhigherthanthefullopentemperatureofthethermostat.

3.ReplacetheA/CPressureSwitch

4.Checkshutteroperation,winterfronts,(wherefitted)orobstructioninfrontofradiator.

5.ReplacetheThermalSwitch.

6.ReplacetheAir-TempSwitch.

7.Filltomanufacturer’srecommendedlevel.LevelTooLow.

1.Makesurenothingisobstructingtheairflowthroughtheradiator.

2.Refertovehiclemanufacturer’sspecifications.

3.Refertoenginemanual.

4.Establishandcorrecttheproblemcausingtheexcessivecycling.InstallappropriateRepairKit.

Manufactured under licence by:NORMAN G. CLARK (A/ASIA) PTY. LTD.

44 Kylta Road West Heidelberg, Victoria, 3081, Australiap : +61 3 9450 8200 / f: +61 3 9450 8222web: www.ngclark.com.au / e: [email protected] Item # F21675 / IF169 05/10

Documents

Drivemaster 2speed Installation Instructions