SERVICE MANUAL

SERVICE MANUAL SECTION

VISCOUS FAN DRIVES

Unit Code: 12TSA

Unit Code: 12TSB
Unit Code: 12TSG
Unit Code: 12TSJ
Unit Code: 12TSL
Unit Code: 12TSS
Unit Code: 12TST
Unit Code: 12TSU
Unit Code: 12TSV
Unit Code: 12TSW

S12002Y, Formerly CTS-5055T

08/07/2000

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Copyright © 08/07/2000 International Truck and Engine Corporation
 VISCOUS FAN DRIVES i

Table of Contents

DESCRIPTION.. .. . .. .. .. . .. .. . .. .. .. . .. .. . .. .. .. . .. .. . .. .. . .. .. .. . .. .. . .. .. .. . .. .. . .. .. . .. .. .. . .. .. . .. .. .. . .. .. . .. .. .. . .. 1

OPERATION.. . . .. . .. . . .. . . .. . . .. . . .. . . .. . .. . . .. . . .. . . .. . . .. . . .. . .. . . .. . . .. . . .. . . .. . .. . . .. . . .. . . .. . . .. . . .. . .. . . .. . . .. . . .. . 2

MAINTENANCE CHECK. . .. . . .. . . .. . .. . . .. . . .. . .. . . .. . .. . . .. . . .. . .. . . .. . . .. . .. . . .. . .. . . .. . . .. . .. . . .. . . .. . .. . . .. . .. . . .. . 3

REMOVE. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . 4

INSTALL.. . .. . .. .. . .. .. . .. .. . .. .. . .. . .. .. . .. .. . .. .. . .. .. . .. .. . .. . .. .. . .. .. . .. .. . .. .. . .. . .. .. . .. .. . .. .. . .. .. . .. . .. .. . .. .. . .. 4

TROUBLESHOOTING. . .. . .. . .. . .. . .. .. . .. . .. . .. . .. . .. . .. .. . .. . .. . .. . .. . .. . .. .. . .. . .. . .. . .. . .. . .. . .. .. . .. . .. . .. . .. . .. . .. 4
SOLENOID ACTIVATED VISCOUS FAN DRIVES (RE BUS ONLY). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
VISCOUS FAN DRIVE TEST PROCEDURE (BI-METAL DRIVES ONLY). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Diagnostic Procedure. . . .. . . . . . .. . . . . . .. . . . . . .. . . . . . .. . . . . . .. . . . . . .. . . . . . .. . . . . . .. . . . . . . .. . . . . . .. . . . 6
Conclusion:. . . .. . . . . .. . . . . .. . . . . .. . . . . .. . . . . .. . . . . .. . . . . .. . . . . .. . . . . .. . . . . .. . . . . .. . . . . .. . . . . .. . . . .. . . .10

TORQUE CHART.. .. . .. .. .. .. .. .. .. . .. .. .. .. .. .. .. . .. .. .. .. .. .. .. . .. .. .. .. .. .. .. . .. .. .. .. .. .. .. . .. .. .. .. .. .. .. .. . .. .. .. ..12

SPECIAL TOOLS. .. .. .. .. .. .. .. . .. .. .. .. .. .. .. . .. .. .. .. .. .. .. .. . .. .. .. .. .. .. .. . .. .. .. .. .. .. .. .. . .. .. .. .. .. .. .. . .. .. .. .. ..12

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ii VISCOUS FAN DRIVES

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 VISCOUS FAN DRIVES 1

DESCRIPTION
The Viscous Fan drive is completely self-contained. It is filled with silicone fluid, and operates as a fluid
coupling. It is matched to a nylon or metal fan.

On bi-metal fan drives, a bi-metal disk senses air temperature from the radiator to engage and disengage
the fan. The only service for a bi-metal fan drive is to replace the unit.

Refer to Figure 1.

Figure 1 Viscous Fan Drive (Bi-Metal Types)

1. BI-METAL DISK
2. DRIVE PART NUMBER

On the Solenoid Activated Viscous Fan Drives, a solenoid controlled by a coolant temperature sensing system
or engine ECM, replaces the bi-metal (Figure 2). The fan drive is disengaged when power is applied to the
solenoid. The Solenoid Activated Drives can be serviced by replacing a defective solenoid (using Kit Number
2501200C91); or the entire unit can be replaced.

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2 VISCOUS FAN DRIVES

Figure 2 Viscous Fan Drive (Solenoid Activated Type)

1. SOLENOID
2. CONNECTION FOR TEMPERATURE SENSING SYSTEM OR ENGINE ECM

OPERATION
The fan drive operates on the viscous fluid shear principle. The drive is attached to the engine jackshaft or
water pump. The input and output ends are coupled by silicone fluid, which must be driven at a certain
speed before it will turn the fan blades.

Fan speed is controlled by the amount of coupling between the input and output shafts. When the fan drive
is disengaged, fluid is evacuated from the drive chamber into a storage reservoir. This condition provides
minimum coupling and minimum or reduced fan speed. When the fan drive is engaged, a valve is opened
allowing fluid into the drive chamber. This condition provides maximum coupling and maximum fan speed.
Valve opening and closing is controlled by the bi-metal disk on bi-metal drives. On solenoid-activated drives a
solenoid on the front of the fan drive unit controls valve opening and closing.

With the viscous fan drive engaged, as the input r.p.m. increases, the difference between input speed and
output speed ("slip") becomes greater until a predetermined peak speed is reached. At peak speed, fluid shear
prevents the fan from turning faster regardless of further increases in input speed.

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 VISCOUS FAN DRIVES 3

MAINTENANCE CHECK

WARNING – Improper use or application, or modification of a viscous fan drive or the fan that
it carries can result in property damage or personal injury.

WARNING – DO NOT operate a vehicle with a drive or fan blades that are malfunctioning or
are externally damaged. Continued operation could result in property damage or personal injury.

WARNING – DO NOT attempt to restrict fan blade rotation during engine operation. Damage
to the fan drive, property damage or personal injury could result.

WARNING – Before performing tests on the fan drive with the engine running, insure that the
wheels are properly chocked and the parking brake is engaged, wear eye protection, prevent loose
clothing from contact with the rotating fan blades, stay clear of hot surfaces and insure that any
test leads are protected from rotating components. Failure to follow these warnings could result
in property damage, personal injury or death.

At 25,000 miles, perform the following:

1. Check the torque of fan blade fasteners.

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 or replace
defective parts.

5. Rotate the fan through at least 360 degrees. It should turn smoothly, but with some resistance. Replace
fan drive if the fan binds, jerks, or spins freely.

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 deflect) because this will distort the resulting
measurement.

6. Grasp one fan blade tip, and move it back and forth from the radiator. 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
specified and the excess cannot be attributed to pulley/water pump bearing wear, blade deflection, or
loose fasteners (fan to fan drive or fan drive to hub/pulley), replace the fan drive.

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4 VISCOUS FAN DRIVES

REMOVE
NOTE – On bi-metal fan drives, DO NOT remove (or tamper with) the bi-metal, the bracket, or the pin at
the front of the drive. The locations of these mechanisms are critical, and preset for the life of the unit.
Any tampering can cause loss of calibration and/or loss of viscous fluid from the housing.

NOTE – DO NOT steam clean or use high pressure jets to clean the fan drive. This could force foreign
material past the external seals, contaminating the viscous fluid, and causing the drive to malfunction.

NOTE – Some spin-on fan drives are left hand thread.

1. Remove the old fan drive from the engine shaft/water pump shaft.

2. Remove and retain the fan blades.

3. To remove the solenoid from a solenoid activated fan drive, refer to the procedures supplied with the
solenoid replacement kit.

INSTALL
1. On model SD-65, and all SA series fan drives, install fan on drive using capscrews. On all other models,
install fan on drive with lockwashers and hexnuts. Lubricate the threads, and tighten fasteners to the
values found in the TORQUE CHART (See TORQUE CHART, page 12).

NOTE – On Model DD-34 drives, DO NOT allow the cover-to-housing bolts to rotate while attaching the
fan to the fan drive. If the screws are loosened, the viscous fluid will leak, and the unit will be out of
calibration and have a short service life.

2. If the solenoid was replaced on a solenoid activated fan drive, install the new solenoid on the fan drive by
referring to the procedures supplied with the solenoid replacement kit.

NOTE – Some spin-on fan drives are left hand thread.

3. Install the fan drive on the engine. Lubricate the threads, then tighten to the values found in the TORQUE
CHART (See TORQUE CHART, page 12).

TROUBLESHOOTING
This section provides the information needed to troubleshoot a faulty or suspected faulty viscous fan drive.
To troubleshoot a solenoid activated fan drive, refer to SOLENOID ACTIVATED VISCOUS FAN DRIVES. To
troubleshoot a bi-metal viscous fan drive, refer to VISCOUS FAN DRIVE TEST PROCEDURE (See VISCOUS
FAN DRIVE TEST PROCEDURE (BI-METAL DRIVES ONLY), page 6 ).

SOLENOID ACTIVATED VISCOUS FAN DRIVES (RE BUS ONLY)

NOTE – Engine at ambient temperature while performing the steps in the following table.

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 VISCOUS FAN DRIVES 5

Table 1 Symptom — Fan Drive Runs Fully Engaged at All Times.

Step Key Action Spec. Yes-In Spec. No-Out Of Spec.
1. OFF Spin fan blade by hand Fan should Go to Step 2. Fan drive is locked up
several times. rotate smoothly or binding internally.
with consistent Replace fan drive.
drag. No
binding or
roughness
allowed.
2. ON Disconnect electrical 9 to 12 VDC. Go to Step 3. Locate and repair
connector that feeds fan electrical fault.
drive solenoid.
3. ON [(Coolant temperature Solenoid Go to Step 5. Go to Step 4.
less than 190°F (87.8°C).] operates.
Disconnect electrical
connector (at end of solenoid
harness) that feeds solenoid.
Reconnect solenoid and
listen for solenoid operation.
4. ON Check electrical connector at Solenoid Go to Step 5. Tether/wiring damaged
base of solenoid to be sure operates. or solenoid inoperative.
it is securely connected. Replace solenoid with
Disconnect electrical Solenoid Replacement
connector that feeds solenoid Kit – OR – replace fan
(at end of solenoid harness). drive.
Reconnect solenoid and
listen for solenoid operation.
5. OFF Check gap between rotating 0.045 inch Go to Step 6. Solenoid bearing
mounting plate and the (1.143 mm) or dislodged. Replace
solenoid body. less. solenoid with Solenoid
Replacement Kit – OR –
replace fan drive.
6. OFF Disconnect electrical Solenoid Fan drive Solenoid bearing failure.
connector at solenoid base. should rotate checks good. Replace solenoid with
Rotate solenoid 360° on completely and Solenoid Replacement
mounting plate. smoothly. Kit – OR – replace fan
drive.

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6 VISCOUS FAN DRIVES

NOTE – Engine at ambient temperature while performing the steps in the following table.

Table 2 Symptom — Fan Drive Will not Fully Engage

Step Key Action Spec. Yes-In Spec. No-Out of Spec.
1. ON Disconnect electrical Solenoid Go to Step 2. Locate/ repair fault in
connector that feeds engages. vehicle temperature
solenoid. sensing system or
electrical system.
2. OFF Disconnect electrical Solenoid should Fan drive checks Solenoid bearing failure.
connector at solenoid rotate completely good. Replace solenoid with
base. Rotate solenoid and smoothly. Solenoid Replacement Kit
360° on mounting – OR – replace fan drive.
plate.

VISCOUS FAN DRIVE TEST PROCEDURE (BI-METAL DRIVES ONLY)

NOTE – This test is most effective at an ambient air temperature of 80°F (26.7°C) or higher.

Diagnostic Procedure

1. Perform all of the steps in MAINTENANCE CHECK (See MAINTENANCE CHECK, page 3 ).

2. 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.

NOTE – To prevent damage, do not direct high-pressure spray onto the fan drive bi-metal. Also, the
high-pressure wash must be directed squarely at the front, or rear, of the radiator to prevent radiator fin
damage.

3. Ensure the cooling system is properly filled 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.

4. 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.

NOTE – In the following step, nylon fan blades (yellow in color) may require painting with flat black paint
in order to measure fan speed.

5. Apply a strip of reflective 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 3).

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 VISCOUS FAN DRIVES 7

Figure 3 Placement of Reflective Tape

1. REFLECTIVE TAPE ON FAN BLADE
2. REFLECTIVE TAPE ON FAN DRIVE SHAFT

6. Connect EZ-Tech service tool. If testing a non-electronic engine, measure coolant temperature with a
suitable thermometer.

7. 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 with the fan drive bi-metal. Position the cardboard in front of the radiator and tape as
necessary to hold in place.

8. Carefully position the temperature probe so that it measures air temperature within 1 inch (2.54 cm) of
the fan drive bi-metal. You can safely insert the probe through the A/C condenser, CAC, and radiator
core (Figure 4 and Figure 5) .

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8 VISCOUS FAN DRIVES

Figure 4 Temperature Probe Inserted through Cardboard and Front of Radiator

1. TEMPERATURE PROBE

Figure 5 Positioning of Temperature Probe

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

9. Start the engine and:

• turn the air conditioning OFF,

• turn electrical loads ON (lights, etc.),

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• turn heater OFF (on buses, turn heater supply valves OFF).

NOTE – In the following step the fan drive shaft speed is not the same as engine speed.

10. 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 difficult to take RPM measurements using the photo-tachometer.

11. 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.

12. Measure fan blade speed with the digital photo-tachometer (Figure 6).

Figure 6 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.

13. As the engine is warming up:

a. The fan RPM should stabilize between 800 and 1000 RPM. Some DD-30 and DD-34 fan drives may
stabilize at up to 1300 RPM. Refer to Table 3 for fan drive information (See Table 3, page 11) .

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10 VISCOUS FAN DRIVES

b. As engine coolant temperature reaches 200–220°F (93.3–104.4°C), (refer to Figure 7), fan speed
should increase to 2125 RPM or higher (85% of the test RPM).
c. The air temperature at the bi-metal should be between 165°F (73.9°C) and 195°F (90.6°C) when
the fan engages (Figure 7). Refer to Table 3 for specific fan drive P/N calibration information (See
Table 3, page 11).

Figure 7 Measuring the Coolant and Air Temperatures

14. With the fan engaged, record fan RPM, coolant temperature, and air temperature at bi-metal.

15. Maintain the TEST RPM, with the fan engaged, by keeping the engine speed constant. As temperatures
decrease, fan speed should begin to decrease. After 2-3 minutes the fan should slow to the initial fan
speed (approximately 40% of the TEST RPM).

16. Allow fan to repeat this cycle several times while recording temperatures and fan RPM.

Conclusion:

1. If the fan fails to reach 2125 RPM or higher (or 85% of input speed) at 200 – 220°F (93.3–104.4°C) coolant
temperature, and the air temperature at the bi-metal exceeds 195°F (90.6°C), replace the viscous fan drive.

2. If the fan fails to reach 2125 RPM or higher (or 85% of input speed), and the coolant temperature exceeds
220°F (104.4°C), and the air temperature at the bi-metal does not exceed 195°F (90.6°C); then the fan
drive is not faulty. Inspect the vehicle for the following:
a. Air flow restrictions (through the CAC and radiator)
b. Internal radiator plugging

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c. Faulty thermostat
d. Defective water pump

3. When the fan drive disengages (with the 2500 TEST RPM maintained), if the fan speed fails to slow to
800–1000 RPM; replace the fan drive (except DD-30 and DD-34, see step 13a of the VISCOUS FAN
DRIVE TEST PROCEDURE (See VISCOUS FAN DRIVE TEST PROCEDURE (BI-METAL DRIVES
ONLY), page 6 )).

4. Remove the temperature 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.

Table 3 Fan Drive Identification and Calibration Information

Engine Model Part Number Temperature (Air) for Fan
Drive Engagement
165-175°F
DD26 2022685C1 (73.9-79.4°C)
177-187°F
DD26 2033827C1 (80.6-86.1°C)
177-187°F
DD30 2022686C1 (80.6-86.1°C)
177-187°F
T444E
SA65 3540983C1 (80.6-86.1°C)
185-195°F
SA75 3540985C1 (85-90.6°C)
3540984C1, 177-187°F
SA75 3547775C1 (80.6-86.1°C)
177-187°F
SD65 2038840C1 (80.6-86.1°C)
175-185°F
DD26 2001023C1 (79.4-85°C)
165-175°F
DD26 2004860C1 (73.9-79.4°C)
185-195°F
DT466E
DD26 2027495C1 (85-90.6°C)
1657424C91,
and 2005257C1, 175-185°F
DD30 2021954C1 (79.4-85°C)
165-175°F
Intl. 530E
DD30 2021376C1 (73.9-79.4°C)
185-195°F
DD30 2029206C1 (85-90.6°C)

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Table 3 Fan Drive Identification and Calibration Information (cont.)

Engine Model Part Number Temperature (Air) for Fan
Drive Engagement
DT 466E and 1666056C91,
1673889C91, 175-185°F
DD34 2009769C1 (79.4-85°C)
Intl. 530E 175-185°F
SA75 3522786C1 (79.4-85°C)
cont. 3522788C1, 185-195°F
SA75 3540985C1 (85-90.6°C)

NOTES:

A. Engagement air temperatures indicate test cell calibration and may vary in the vehicle.
B. * Bi-metal coil fan drives will have a gradual engagement speed and may not obtain the 2125
fan RPM.

TORQUE CHART
Table 4 Torque Chart
Location Ft-Lbs. N•m
Fan-to-Drive Hardware 13 - 16 18 - 22
Drive-to-Engine Bolt, 5/16 Inch 20 - 22 27 - 30
Drive-to-Engine Bolt, 3/8 Inch 34 - 38 46 - 52
Drive-to-Hub Shaft 120 - 150 163 - 203

NOTE – The fasteners MUST be S.A.E. Grade #5 or better.

SPECIAL TOOLS
Table 5 Tools Required
Tool Part Number Tool Description Purpose
EZ-Tech Electronic Service Tool To measure coolant temperature
ZTSE-4468 Kit, Viscous Fan Diagnostic
(consisting of:)
(1) ZTSE-4468–1, Digital Photo-Tachometer For measuring fan speed
(1) ZTSE-4471–1, TK80 Temperature Probe For measuring air temperature
(works with Fluke 88 DMM)
(1) ZTSE-4471–2, Thermo-Couple For measuring air temperature

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