Borg Warner Kysor On/Off Rear Air Fan Drive
Contents
1. EE Lining Replacement The Rear Air Fan Clutch is easy to reline without removing it from the vehicle Tools amp Parts Required e Inch pound or Newton Meter torque wrench s 1 4 drive ratchet s 1 4 drive 5 16 socket s Clutch lining kit 1033 08250 01 for K22 or 1033 09340 01 for K26 Step 1a Caution The fan clutch must have air pressure 90 120 psi 6 2 8 2 bar during this procedure Step 1b X 1 Remove the six lining plate screws and the three lining retainer plates 2 Remove the old lining If the lining sticks use a hammer and a screwdriver to free it by tapping on the dividing cut in the lining 3 Inspect clutch shaft If lining residue is present or if surface appears glazed over non metallic temporarily release air pressure from the clutch to allow shaft to protrude and use ScotchBrite to break the glaze 4 Re apply air pressure to the clutch and install the new lining as shown Some applications may be too tight to spread the lining and slip over the pulley If necessary the lining can be cut in half with a hacksaw for instal lation 5 Replace the plates and screws using the new screws supplied in the kit and torque screws to 30lbs in 3 4 Newton Meters Step 5a Step 5b Step 5c Note Front to rear play at the fan blade tip with the clutch disengaged is normal and does not indicate a problem with the clutch o 2 Kysor On Off Rear Air Fan Drive INSTALLATION SERVI2. ma Fan Control Systems 3 If the vehicle is used in any kind of stationary operation involving a PTO or turbo unloader there Control System Specifications MUST be a provision in the control system to auto 1 As a minimum control systems must be thermal matically lock the fan clutch ON whenever the PTO switches controlling solenoid valves Mechanical or unloader is being operated Failure to provide thermal valves such as the old Shutterstat are this will void all warranties BRT 4 If the vehicle is a sleeper cab and the engine is 2 Air conditioning override pressure switches must fast idled with the AC on then a timed AC override have a built in hysteresis of 50psi 3 4 bar mini circuit MUST be provided so that the fan clutch will mum not be over cycled The Medallion TTM system is an example of a timed control system Normally Closed Fan Clutch Control Circuit KEY SWITCH EE Ee SOLENOID VALVE AIR 1056 07994 01 SUPPLY FAN CONTROL ALARMSTAT 1002 05825 33 205 F Screw Terminals 1002 07625 33 205 F Metripack NOTE The ALARMSTAT and the freon switch are normally closed and the solenoid valve plumbed normally closed When the key switch is turned off the fan clutch will engag Kysor On Off Rear Air Fan Drive _ INSTALLATION SERVICE X BorgWarner Normally Closed System With 3 Minute Timer L MEDALLION 4 venice an pill WIRE TIMER MODULE E ENGAGES FAN CL
3. Electronic Engine Control System ENGINE ECM EE Installation Hub Series 1077 HUB ASSEMBLY SOCKET HEAD CAPSCREW 3042 01223 16 COUPLING Ss 27 S S 4 4038 40903 01 28 P AIR LINE Warning Due care and caution must be exercised when installing a fan hub Failure to follow these instructions may cause vehicle damage fan breakage and possible serious personal injury 1 Attach the hub to the engine 2 Check for proper belt tension engine manufacturers recommendation 3 If the fan clutch is attached the fan may have to be put into position on the fan clutch or set into the shroud before the fan drive assembly is put into position on the engine Kysor On Off K22RA Rear Air Fan Clutch Series 1090 09500 Hub Series 1077 S INSTALLATION SERVICE TROUBLSHOOTING X BorgWarner EE Preventive Maintenance Hub Series 1077 Periodic Checks already have preventative maintenance sheets with The Items below are to be inspected as part of fan acceptable intervals If preventative maintenance hub preventative maintenance We do not specify sheets are not available refer to the engine intervals as many fleets manufacturers recommendations Maintenance Item Action Refer to engine manufacturer s Inspect for loose or E f R i Replace adjust as neccessary belt tension specs and adjustment frayed drive belts procedures Verify with dial indicator if Check fan hub endplay necessary R amp R and overhaul if play i
4. 10 9 0 231 779 7500 phone 231 775 5749 fax 800 927 7811 Customer Service 231 779 7528 Tech Service amp Troubleshooting 1100 Wright Street Cadillac MI 49601 www ets borgwarner com Lit 21120 9 05
5. CE RS Clutch Repair Tools amp Parts Required s Inch pound or Newton Meter torque wrench 5 16 and 1 2 sockets with driver 5 8 open end wrench Step 6a 1 Remove the fan then remove fan clutch with a flex head ratchet and 5 16 hex bit Pressurize clutch to disengage so that holes can be lined up with 3 8 allen screws inside clutch 2 Two Carriage bolts with washers are necessary for compressing the fan clutch slightly They should be about four inches long 3 Alternately tighten the wing nuts until the fan clutch compresses 1 16 Caution Do not over compress or clutch can be damaged Step 2 4 Remove the cylinder nut and cylinder It will be necessary to hold the opposite end of the piston rod from turning with a 5 8 open end wrench 5 Remove the seal washer from the front of the piston rod below the cylinder cap 6 Remove the lip seal from the large groove in Step 3 the piston Remove the dust seal from the small i groove 7 Remove the 6 lining plate screws and the 3 lining retainer plates Remove the lining See lining replacement images 1 2 8 Inspect the two surfaces where the lining makes contact Lining surfaces may be cleaned with ScotchBrite Do this before removing the housing from the shaft or abrasives may contaminate the needle bearings and result in early clutch failure Step 4a 9 Equally remove the carriage bolts and lift the Step 9b housin
6. UTCH FOR 3 5 MINUTES WHEN TRIGGERED BY A C SWITCH TRANSMISSION AIR SOLENOID VALVE 23 TEMPERATURE SWITCH NORMALLY CLOSED 921 ENGINE OIL TEMPERATURE NO CURRENT NO AIR R SWITCH ETC VENTS CLUTCH AIR WHEN E IT CLOSES QO BORGWARNER ON OFF FAN CLUTCH A C HIGH PRESSURE SWITCH SPRING ENGAGED NORMALLY CLOSED l POSSIBLE SERIES OF AIR DISENGAGED VARIOUS PRESSURE SETTINGS AVAILABLE NORMALLY CLOSED SWITCHES I E ENGINE i OIL TEMPERATURE COOLANT TEMPERATURE SWITCH SWITCH ETC NORMALLY CLOSED OPENS AT 200 F 93 3 C RESETS AT 192 F 88 9 C VARIOUS TEMPERATURE SETTINGS AVAILABLE TTM Timed Control System KEYSWITGHI TEMP TRANSDUCER GROUND NEG F TRANSDUCER E TRANSDUCER 0 GAUGE GROUND OVERRIDE B IGNITION A Temperature Transducer Module FREON 1039 07710 Tot SYOVERRIDE NC ny 06 SWITCH v GAUGE SENDER C ALARM B FAN A a 1039 07710 TF05 HARNESS 5507 10149 10 RED BLACK FAN CLUTCH SOLENOID VALVE TO FAN DRIVE RED Notes PTO Turbo Unloader Switch Use a pressure switch in the control circuit that will open the pink wire when the PTO or Unloader is engaged If required by engine manufacturer install a normally closed charge air temperature override ALARMSTAT 1002 04880 22 a Kysor On Off Rear Air Fan Drive INSTALLATION SERVICE X BorgWarner Typical
7. ear of piston rod and lubricate with grease from kit 18 Before installing the clutch loosen the fan belts and check for roughness or play in the hub bearings If problems are found perform fan hub maintenance Tighten the drive belts to manufactures specifications 19 Reinstall fan clutch to fan hub using a new coupling and new nylon patch allen bolts supplied in kit Apply air to clutch and check for normal operation Step 19b Step 17a Kysor On Off Rear Air Fan Drive S INSTALLATION SERVICE X BorgWarner RS Components 21 Part Item Part Item clutch housing 1 cylinder 13 clutch shaft 2 seal washer 14 clutch lining 3 3 8 24 hex nut 15 lining plates 4 lock washer 16 front spring cap 5 washer 17 spring 6 3 8 wheel bolt 18 spring carrier 7 U cup 19 O ring 8 dust seal 20 O ring 9 rotary seal 21 snap ring 10 10 32 X 50 HHCS 22 coupling 11 piston rod 23 5 16 24 locknut 12 nylon patch SHCS 24 24 gt Service Kit Lining Kit Cylinder Seal Kit x an Sa LU Ne 18 Part Number Description Item Qty Part Number Description Item Qty 1033 05435 03 clutch lining 3 tea f 1033 09339 01 clutch lining 3 lea coupling 11 lea coupling 11 lea 5 16 24 locknut 12 lea 5 16 24 locknut 12 lea seal washer 14 lea seal washer 14 lea U cup 19 lea U cup 19 lea rotary seal 21 lea rotary seal 21
8. epair as required 5 Check exhaust port on solenoid for restrictions and debris Remove any obstructions to insure positive engagement Clutch Lining Maintenance It is very important to check fan clutch lining condition on a regular basis First Check 100 000 miles 160 930KM Subsequent Checks Every 50 000 miles 80 465KM System Alert Tool This tool is a go no go gauge that will indicate whether the lining is close to wear ing out and needs replacing Start with the fan clutch engaged No air to the clutch If neces sary disconnect the air line from the fan clutch k e The clutch in the top image has a brand new lining Notice how the tool sits down in the pocket below the surface of the lining retention plate e The clutch in the bottom image has a lining that is worn to the point where it should be replaced Note how the tool protrudes above surface of the lining plate 2 Order a new lining when the tool is exactly flush with the plate and change it at the next scheduled service Instructions for changing the lining are included in the lining kit part 1033 08250 01 for K22 and 1033 09340 01 for K26 Note Rapid lining wear indicates a problem in the fan drive control system See page 6 8 for control system specifications and types Call Technical Service for troubleshooting assistance 800 927 7811 Kysor On Off Rear Air Fan Drive INSTALLATION SERVICE X BorgWarner
9. g from the shaft Inspect needle bearing inner race on shaft It is acceptable to have some discoloration If cracking or scoring is found replace the clutch Shaft may be cleaned with a Scotch Brite pad to make inspection easier Step 4b Install new front O ring on piston rod assembly Step 1 0 ans Kysor On Off Rear Air Fan Drive a o p INSTALLATION SERVICE x BorgWarner Step 11 Step 12a Step 12b Kysor On Off Rear Air Fan Drive INSTALLATION 12 SERVICE 11 Inspect the needle bearings in housing If any are Place rear spring cap small onto piston rod Place the housing on the shaft assembly During EE Clutch Repair continued Torque Specs Clutch to Hub 45lbs ft 61 Newton Meters Fan to Clutch 26lbs ft 35 3 Newton Meters Front Piston Nut 84lbs in 9 5 Newton Meters Lining Plate Screws 30lbs in 3 4 Newton Meters cracked or missing replace the clutch Remove grease seal from the bearing housing Use a rag to thoroughly clean needle bearings and bearing housing Use a flat plate to press in new grease seal lip down Press in until flush with edge of hole Apply grease from kit to the needle bearings and fill the spaces between the needle bearings Push the shaft into the housing Rotate it a few times to work the grease into the needles Then remove the shaft and remove any excess grease If there is no excess grease the first time you try this then you have not
10. lea 10 32 X 50 HHCS 22 6ea 10 32 X 50 HHCS 22 6ea dust seal 20 lea dust seal 20 lea O ring 9 lea O ring 9 lea cylinder 13 lea cylinder 13 lea nylon patch SHCS 24 6ea nylon patch SHCS 24 6ea grease packet grease packet lea 1033 08250 01 1033 08233 01 O rin clutch lining 10 32 x 50 HHCS dust seal grease packet O ring 9 lea cylinder 13 lea U cup 19 lea seal washer 14 lea 5 16 24 locknut 12 lea coupling 11 lea lea 1033 09340 01 1033 08233 01 O rin clutch lining lea 10 32 x 50 HHCS dust seal O ring 9 lea cylinder 13 lea U cup 19 lea seal washer 14 lea 5 16 24 locknut 12 lea coupling 11 lea grease packet lea INSTALLATION Kysor On Off Rear Air Fan Drive SERVICE X BorgWarner m Fan Mounting Kit for Crank Mounted Applications Ford Detroit Diesel ISO Mount Crank Mount Kit 1097 09115 01 FAN MOUNTING SCREW TORQUE PATTERN Cross Torque fan mounting screws to 15 lbs ft Repeat process to 25 Ibs ft MOUNTING SCREWS INCLUDED WITH CLUTCH MOUNTING RUBBER La SUPPORT PLATE 4082 43892 01 2 pcs 4038 37641 01 iaae 4038 43893 01 MUST BE REPLACED IF SYSTEM IS Note Written engineering approval is required for all crankshaft applications
11. s present Check for lube leaks R amp R and overhaul if found Check for loose attaching Torque to specs if loose hardware Check pulley grooves for R amp R overhaul replace damage from belt slippage pulley if damaged Periodic teardown Per fleet PM interval or engine inspection overhaul manufacturers recommendations Kysor On Off Rear Air Fan Drive INSTALLATION SERVICE RS Repair Kits Idler Pulley Idler Part Number N14 1077 07756 01 L10 1077 07756 02 3116 1077 07756 03 3306 1077 07756 04 3306 1077 07756 05 Repair Kit 1033 07783 01 One Piece Bearing Design Two Piece Bearing Design X BorgWarner Tools amp Material Required Overhaul kit see product catalog Nut 3029 01317 03 hub Washer 3058 01603 01 hub Pulley installer tool for two bearing design 4038 42192 01 Bearing driver that contacts outer race of bearing Rear Air Fan Hubs amp Idler Pulleys One Piece Bearing Design Overhaul is a matter of replacing the single piece bearing Use LocTite 271 on the nut and torque it to 170 Ibs ft 230 5 Newton Meters Rear Air Fan Hubs Two Bearing Design During overhaul it is extremely important to use the pulley installer tool to press the pulley back onto the base Failure to use this tool may result in damage to the bearings Use LocTite 271 on the nut and torque it to 170 Ibs ft 230 5 Newton Meters Kysor On Off Rear Air Fan Drive aoo INSTALLATION SERVICE S 1 05
12. used enough grease Repeat this process a few times until there are no signs of excess grease The goal is to have a layer of grease packed within the needle bearings Make sure no grease is present on the grease seal where it could get into the lining Step 13b Place spring onto piston rod Liberally lubricate inside of rear of front spring cap and place on piston rod Wipe any grease or fingerprints from shaft where lining touches final assembly use the carriage bolts again to compress the engagement spring Place new lining into pocket Equally compress clutch while flush with outer edge of clutch Install lining plates sharp edge down Tighten screw to 30 lbs in Step 14b X BorgWarner EE Clutch Repair continued 15 Install the white dust seal and place the new lip seal in the piston groove with the lip facing towards the front of the fan clutch Up in this picture Liberally grease the lip seal and the white dust seal with the grease that came with the kit 16 Lubricate the new seal washer and place it on the piston rod 17 Install the cylinder and torque the new nut to 84 Ibs in while holding opposite end of piston rod from turning with a 5 8 open end wrench Release the clutch from the carriage bolts and pressurize it several times with 120 psi shop air to check for leaks and proper operation While clutch Step 17c is disengaged line up access holes in front with bolt holes in rear Install O ring on r
13. x BorgWarner Kysor On Off Rear Air Fan Drive INSTALLATION SERVICE Proper precautions must be taken to prevent personal injury from contact with moving parts unintended engine start or other hazards present when working with powered equipment Refer to the vehicle owners manual and or appropriate service manual for proper safety precautions before beginning any diagnostic or repair procedures CONTENTS Clutch Maintenance Lining Replacement Clutch Repair Components Fan Mounting Kit Fan Control Systems Hub Installation Preventative Maintenance Repair Kits Idler Pulley This fan clutch requires 90 120 PSI air pressure to DISENGAGE 6 2 8 2 bar The air pressure is vented to ENGAGE the fan Any interruption of the air supply will allow the fan to run keeping it in fail safe mode RS Maintenance Clutch Series Fan clutch maintenance should be performed at every A PM schedule at every oil drain or every 25 000 miles 40 225 KM which ever comes first 1 Verify clutch operation Turn key or jump the con trol system so that 90 120 psi air is supplied to the clutch It should disengage and turn freely Remove air supply Clutch should lock up and be difficult to turn by hand 2 With engine stopped and clutch disengaged check for air leaks at front of clutch and between the clutch and drive hub 3 Check electrical and air connections at solenoid 4 Examine wire and airline routing for damage and chafing R
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