Usage:
Introduction
This Special Instruction will provide the necessary information to retrofit a tractor or truck with a variable speed fan clutch. This clutch is an oil pressure actuated, oil cooled and lubricated, multi plated clutch designed for infinite fan to engine pulley speed. The fan is also controlled by the engine coolant and air-conditioner pressure. This clutch will keep the engine at proper temperature using minimum horsepower.
Do not perform any procedure outlined in this publication, or order any parts, until you read and understand the information contained within.
NOTE: Make sure to purchase the parts for your tractor or truck only. Carefully read the NOTES following the parts list.
Reference: Service Manual and Parts Manual
Removals
1. Partially drain the engine coolant.
2. Partially drain the engine oil.
3. Disconnect any harnesses fastened to the spreader bar.
4. Remove the left and right cooling tube located above the thermostat housing.
5. Remove the spreader bar between the right and left beam.
6. Refer to the service manual for removal of the fan guard, fan belts, spacer and fan drive.
7. Remove the bracket assembly and belt tightener from the engine.
Installation
1. 6I-4427 Drive Group. 2. 100-8533 Pulley. 3. Four 5M-1932 Stud. 4. Four 1F-7958 Nut. 5. Eight 5P-8245 Washer. 6. 100-8532 Bracket. 7. 1S-9209 Shaft. 8. 4N-0955 Pin. 9. Two 0S-1587 Bolt. 10. Six 5S-7382 Bolt. 11. Six 8T-4896 Washer. 12. 101-1929 Adapter. 13. Two 1A-1460 Bolt. 14. Six 5P-2424 Bolt. 15. Six 8C-4436 Bolt. 16. Six 8T-4223 Washer. 17. 5N-4751 V-Belt Set.
1. Press 1S-9209 Shaft (7) in 100-8532 Bracket (6) as shown in the illustration. Drill a 6.342 ± 0.02 mm (.2497 ± .001 in) Ø hole 45 mm (1.8 in) deep in the bracket to the dimensions shown in the illustration at location (A). Install 4N-0955 Pin (8) into the hole to the dimensions shown. This will hold the shaft in place.
Install the bracket assembly with two 0S-1587 Bolts (9), two 1A-1460 Bolts (13) and four 5P-8245 Washers (5).
NOTE: Install the fittings, before installing the drive group on the engine. The fittings are called out in the Hose Installation Section, Steps 1 thru 3.
2. Install 100-8533 Pulley (2) to 6I-4427 Drive Group (1) with six 5S-7382 Bolts (10) and six 8T-4896 Washers (11).
3. Install the drive group to the bracket with four 5M-1932 Studs (3), four 1F-7958 Nuts (4) and 5P-8245 Washers (5).
Refer to the service manual for some of the following Steps.
4. Install the belt tightener and 5N4751 V-Belt Set (17).
(768C, 769C and 771C only for Step 5.)
5. Install 101-1929 Adapter (12) to the pulley group.
6. Install the existing fan to the drive group with the following hardware.
- * The 768C, 769C and 771C requires six 5P-2424 Bolts (14) and six 8T-4223 Washers (16).
- * The 772B, 773B and 775B requires six 8C-4436 Bolts (15) and six 8T-4223 Washers (16).
7. Install the appropriate tube assembly to the engine and radiator
- * 768C, 769C and 771C uses 101-2723 Tube Assembly
- * 772B, 773B and 775B uses 101-2722 Tube Assembly.
Hose Installation
1. 8N-9394 Hose Assembly. 2. 8W-5426 Hose Assembly. 3. Two 8C-6865 Connector. 4. 3Y-2888 Connector. 5. 7X-2459 Tee. 6. 101-1927 Plug. 7. 8M-2773 Clip. 8. 4L-6454 Bolt. 9. Three 8T-4896 Washer. 10. 6V-8628 Elbow. 11. 6V-8723 Elbow. 12. 6V-8636 Connector. 13. 6V-8715 Connector. 14. 6V-9836 Tee. 15. Two 8T-9364 Bolt. 16. Two 8T-4205 Washer. 17. 101-0329 Valve Assembly. 18. 3J-7354 Seal. 19. Four 4J-5477 Seal. 20. 3K-0360 Seal. 21. Six 6V-8397 Seal. 22. Three 3J-1907 Seal. 23. 2M-9708 Seal. 24. 9M-9647 Seal. 25. 5P-9085 Clip. 26. 3B-6552 Elbow. 27. 6V-8934 Reducer. 28. 101-0328 Bracket. 29. 9C-7335 Hose Assembly. 30. 6R-7451 Hose Assembly. 31. 101-9556 Hose Assembly. 32. 101-9567 Hose Assembly. 33. 091-0843 Hose Assembly. 34. 101-9568 Hose Assembly. 35. Three 098-5708 Cable Tie. 36. Two 7X-0293 Bolt. 37. Two 1U-2812 Spacer. 38. 5P-1075 Washer. 39. 9B-7237 Bolt.
1. Install 6V-8723 Elbow (11), 3K-0360 Seal (20) and 6V-8397 Seal (21) in the top of the drive group.
2. Install 6V-8628 Elbow (10), 3J-7354 Seal (18) and 4J-5477 Seal (19) in the right side of the drive group.
3. Install 6V-8636 Connector (12), 3J-1907 Seal (22) and 6V-8397 Seal (21) in the left side of the drive group.
4. Remove 3J-5389 Plug from the block at location (A).
8. Connect one end of 8W-5426 Hose (2) to tee (14) and the other end to the left side of the drive group.
9. Install 101-0328 Bracket (28) to the filter housing with two 7X-0293 Bolts (36), two 1U-2812 Spacers (37) and two 8T-4896 Washers (9).
NOTE: When connecting the fittings to the valve be careful not to break the strap holding the valve to the engine. It may be necessary to install the fittings on the bench.
12. Install 3B-6552 Elbow (26) to the bottom of the valve assembly.
13. Install 101-0329 Valve Assembly (17) to the bracket with two 8T-9364 Bolts (15) and two 8T-4205 Washers (16).
14. 768C, 769C and 771C
* Fasten one end of 101-9568 Hose Assembly (34) to the top of valve assembly (14) and the other end to the right side of the drive group.
15. 772B, 773B and 775B
* Fasten one end of 101-9566 Hose Assembly (31) to the top of valve assembly (17) and the other end to the right side of the drive group.
16. 768C, 769C and 771C
* Connect one end of 091-0843 Hose Assembly (33) to valve assembly (17) and the other end to tee (14).
17. 772B, 773B and 775B
* Connect one end of 6R-7451 Hose Assembly (30) to valve assembly (17) and the other end to tee (14).
18. Remove the old plug and replace it with 101-1927 Plug (6) and 9M-9647 Seal (24). Fasten it to the pan with existing bolt.
21. Connect one end of 8N-9394 Hose Assembly (1) to the bottom of valve assembly (17) and the other end to connector (4).
23. 768C, 769C and 771C
* Fasten one end of 101-9567 Hose Assembly (32) to tee (5) and the other end to the top of the drive group.
24. 772B, 773B and 775B
* Fasten one end of 9C-7335 Hose Assembly (29) to tee (5) and the other end to the top of the drive group.
26. Secure the hoses with 098-5708 Cable Ties (35) where necessary.
Trucks With Air-Conditioner
1. Discharge the air-conditioner as shown in air-conditioner service manual.
2. Remove the high pressure tube assembly from the back of the air compressor.
3. 768C, 769C and 771C
- * Remove 9D-7994 Fitting Assembly.
- * Install 7X-1402 Fitting for R-12 and 3E-4060 Fitting Assembly for R-134A on the back of the compressor.
4. 772B, 773B and 775B
- * Remove 6V-0879 Fitting Assembly.
- * Install 7X-1402 Fitting for R-12 and 3E-4060 Fitting Assembly for R-134A on the back of the compressor.
5. Install 101-0912 Switch in the A/C fitting assembly.
Electrical
1. Install 101-0911 Sensor in the left tube assembly.
Turn sensor in finger tight plus one turn.
101-1670 Retrofit Harness Assembly
NOTE: Before the following Product Identification Number (PIN); (02X371, 01X6001, 3BJ71, 64W190, 63W3733 and 7XJ76) use 101-1670 Retrofit Harness Assembly.
4. Connect the four pin breakout from 101-1670 Harness Assembly to the four pin breakout on the 102-8644 Harness Assembly.
5. Run the two pin breakout and ground through the cab wall and connect the two pin breakout to a two pin breakout on the Main Cab Harness (which has a 138-GR wire). Connect the ground to the ground terminal on the back of the cab wall.
102-8644 Air Condition Harness Assembly
6. Connect one end of 102-8644 Harness Assembly to 101-1670 Harness Assembly and the other end of 102-8644 Harness Assembly to the air conditioner switch.
NOTE: After the following PIN; (02X370, 01X6000, 3BJ70, 64W189, 63W3732 and 7XJ75) 101-1670 Retrofit Harness Assembly is not needed.
There are breakouts on the existing engine harness that can be connected to the temperature sensor, valve assembly and 102-8644 Harness Assembly (air-conditioner).
NOTE: If the 138-GN is already connected to a fuse disregard Steps 7, 8 and 9.
7. Install 4K-5122 Fuse Holder Assembly in an extra fuse slot in the front of the cab.
8. Install a 3K-8782 Fuse in the fuse holder.
9. Connect 112-PU to one side of the fuse holder and a 138-GN wire to the other side.
10. Paint all necessary area's.
11. Start the truck or tractor and check for leaks.
Checkout Procedure 1
Start the cold engine and watch the fan. The fan should be much slower than the engine (just turning). The fan speed will increase as the clutch fills with oil.
| NOTICE |
|---|
Do not make any adjustments while the engine is running or the fan is in motion |
Disconnect 101-0911 Temperature Sensor from the wiring harness. This will engage the clutch and the fan will run at full speed. Start the engine and observe the difference in air flow from low idle to high idle. This difference should be clearly evident.
Connect 101-0911 Temperature Sensor and run the engine from low idle to high idle. You should observe very little difference in air flow between the two speeds.
Stop the engine, the fan should continue to rotate for five to ten seconds. This verifies that the clutch is not pressurized and the electrical system is working.
If the air flow test doesn't work, test the wiring harness at the sensor to see if the sensor is getting power.
Checkout Procedure 2.
Disconnect the temperature sensor and start the engine, leave at low idle.
The fan should pick-up speed and push some air.
Stop engine, the fan should stop the same time the engine does.
Connect the temperature sensor and start engine at low idle. The fan should slow down slightly after three to five seconds.
Stop the engine. The fan should continue to rotate after the engine is shut off.
Repeat the above steps disconnecting the air-conditioner sensor and shorting the circuit. This will cause the fan to be fully engaged. Short pins 3 and 4 on 102-8644 Air Conditioner Harness Assembly.
With the engine at 700 rpm and the clutch disengaged, the fan should turn from 50 to 200 rpm. With the clutch fully engaged, the fan will turn at 385 rpm.
Operation
The temperature control will cause the clutch to begin actuating at coolant temperature of 93 ± 2°C (200 ± 5°F). The control will cause the fan to modulate to hold the coolant temperature within a 5°C (10°F) range.
The air-conditioner pressure switch will cause the clutch to become fully engaged at a pressure above 1585 ± 140 kPa (230 ± 20 psi). It will stay fully engaged until the pressure drops below 1276 ± 100 kPa (185 ± 15 psi).