BENDIX FD-3 User Manual

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®
Bendix® FD-3™ TorqueMaster Fan Clutch
SD-09-8504
BRACKET
PULLEY
SHAFT
BRACKET
FAN PLATE
DUST
CAP
BEARINGS
PRESSURE PLATE
RETURN SPRINGS (8)
FAN HUB
PISTON
BEARINGS
LOCK NUT
DUST
CAP
PILOT DIAMETER
2.560
PISTON HOUSING
BEARINGS
LOCK
NUT
AIR INLET
PULLEY
FIGURE 1
DESCRIPTION
The Bendix® FD-3™ T orqueMaster fan clutch is an air operated thermostat controlled clutch for the engine cooling fan. Its purpose is to maintain engine temperature by engaging or
O-RINGS
DUST
STANDARD PILOT
DIAMETER 1.998
DRIVE PIN (2)
CAP
disengaging the cooling fan, thereby providing better fuel economy , greater engine efficiency , faster warm-ups and a quieter vehicle.
The FD-3™ fan clutch is produced in several different models to accommodate the variety of installation requirements
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resulting from the many engine, vehicle and accessory combinations. Its fail-safe design prevents overheating in the event of air loss for any cause.
FAN ENGAGED
OPERATION
GENERAL
The FD-3™ TorqueMaster fan clutch replaces the standard fan hubs on the engine and interchanges with other Bendix and competitive fan clutches. It is controlled by a temperature sensitive air valve. (See Figure 4). The same valves used to control radiator shutters are used to control the FD-3 control valve directly senses coolant temperature. Provided coolant temperature remains below the setting of the valve, air passes through it to disengage the fan clutch. When coolant temperature rises to the valve setting, the valve closes and exhausts air pressure from the fan clutch which engages the fan.
Depending upon optional equipment installed on the vehicle such as radiator shutters and radiator mounted air conditioning condenser, dif ferent piping arrangements are necessary. These will be explained in the paragraph on control systems.
T orqueMaster. Installed in the engine block, the
DISENGAGED
When the vehicle is started with a cold engine the thermo-pneumatic control valve is open. As brake system air pressure is built up, air passes through the control valve to the fan clutch. Air enters the inlet port in the bracket of the fan clutch and travels through the drilled passage in the shaft to fill the piston cavity. When air in the piston cavity reaches a pressure of 70-75 psi, the piston slides on the shaft moving the pressure plate assembly to the disengaged position. In this position the clutch lining is out of contact with the fan plate and the fan is no longer driven by the engine (see Fig. 2).
FAN DISENGAGED
PISTON SHOULD
MOVE FORWARD AS
AIR IS EXHAUSTED
FIGURE 3
ENGAGED
As the engine coolant rises in temperature, the engine thermostat opens to circulate radiator coolant through the engine. When the engine coolant temperature reaches the setting of the control valve, the valve exhausts air from the piston cavity. The fan clutch springs force the piston and pressure plate forward on the shaft. When the lining contacts the fan plate, the fan is engaged and is driven by the engine (see Figure 3).
CONTROL SYSTEMS
The fan clutch, in addition to its primary function of operating the fan as needed to maintain the cooling liquid within a certain temperature range, must be coordinated with other devices when installed on the vehicle.
These are radiator shutters and radiator mounted condenser for air conditioning. Four basic configurations are possible as follows:
FIGURE 4. F AN CLUTCH ONL Y FIGURE 5. F AN CLUTCH WITH SHUTTERS FIGURE 6. FAN CLUTCH WITH RADIATOR MOUNTED
CONDITIONING CONDENSER
FIGURE 7. F AN CLUTCH, SHUTTERS AND CONDENSER
The objective in the case of Figure 5 is to not engage the fan until the engine thermostat is fully open. The thermo­pneumatic control valve should therefore be calibrated to release the air from the fan clutch when the coolant temperature is at least 10°F higher than the shutter opening point. If the shutters are the modulating type, the fan engagement should be at least 10°F higher than the full­open temperature of the shutter.
FIGURE 2
2
In the case of Figure 6 the fan must be controlled to perform the supplementary function of pulling cooling air through the air conditioning condenser when required, although the engine coolant may be below the fan cut-in temperature. This is most likely to occur at high ambient temperatures
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and low road speed or idling. If the condenser is inadequately cooled, the air conditioning system will start to build up a higher than normal pressure. Therefore, a pressure switch is connected into the air conditioning compressor discharge line, as shown in Figure 6. When this pressure switch senses a higher than normal pressure in the air conditioning system (approximately 250 psi), it closes an electrical circuit which in turn energizes a solenoid operated air supply valve which exhausts the air supply for the fan control, causing the fan to engage.
THERMO-PNEUMATIC
VALVE
AIR
CONDITIONING
SIGNAL
SOLENOID VALVES (NORMALLY OPEN)
IGNITION
THERMO-PNEUMATIC
VALVE
BLOCK
AIR COND. COMPRESSOR
OVERRIDE
SWITCH
FAN
CLUTCH
FAN
AIR
CONDITIONER
OVERRIDE
SWITCH
RECEIVER
DRYER
FIGURE 4
FIGURE 5
AIR
CONDITIONING
SIGNAL
THERMO-PNEUMATIC
BLOCK
THERMO-PNEUMATIC
VALVES
BLOCK
FAN
CLUTCH
RADIATOR
VALVE
FAN
CLUTCH
RADIATOR
FAN
OVERRIDE
SWITCH
SHUTTER
AIR
CONDITIONING
OVERRIDE
SWITCH
RECEIVER
DRYER
SHUTTER
FIGURE 7
RADIATOR
CONDENSER
Most vehicles also have an additional dual function pressure switch connected in series with the air conditioner clutch. This switch is normally open, closes at approximately 30 psi and opens again at approximately 400 psi. Its purpose is to prevent operation of the air conditioning compressor if the refrigerant is lost or to shut off the compressor if the system pressure reaches a dangerously high pressure (approximately 400 psi). This switch does not normally have anything to do with fan operation; however, it is sometimes combined with the previously mentioned override switch.
Figure 7 depicts a combination of shutters, fan clutch and air conditioning. This combination requires the two thermo­pneumatic controls for fan and shutters, as well as the electro-pneumatic override for the air conditioning. With this combination the same requirements for fan control apply as in Figure 5 and 6 with the additional requirement that the shutters should be controlled in such a manner that they always open whenever the air conditioning compressor operates.
A variation of this combination consists of a two section shutter with one section in front of the condenser and the other in front of the remaining portion of the radiator. In this combination only the section in front of the condenser needs to open when the air conditioner engages.
PREVENTIVE MAINTENANCE
SOLENOID VALVE
BLOCK
AIR COND.
COMPRESSOR
FAN
CLUTCH
RADIATOR
FIGURE 6
CONDENSER
There is no need for periodic maintenance; however, the following service checks should be made to ensure proper function of the fan clutch.
GENERAL
The condition of the two fan plate ball bearings should be checked at regular intervals to ensure proper operation of the FD-3™ fan clutch. The procedure presented here is intended to check excessive bearing play by measuring
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lateral movement of the fan plate relative to the edge of the pulley or a scribed line in the dust shield.
CHECKING PROCEDURE
1. Park the vehicle on a level surface and block the wheels.
2. Shut off the engine and apply a minimum of 85 p.s.i. to the fan clutch to disengage it. NOTE: If air brake system
pressure is above 85 p.s.i. and the engine is cool, the FD-3™ fan clutch will be disengaged. Disengagement is
confirmed by noting that the fan can be rotated freely by hand. DO NOT PERFORM THIS CHECK WITH THE ENGINE RUNNING .
3. With the engine off and the FD-3™ fan clutch disengaged, grasp the tip of one fan blade using only the thumb and index finger. (Refer to Figure 8.) Using a moderate force, rock the fan blade back and forth toward the radiator and measure the total movement of the fan plate relative to the edge of the pulley .
Replace or repair the fan clutch if the total movement of the fan plate is 1/16" or greater.
AL TERNA TE METHOD - using thumb and index finger, pull the fan blade toward the engine with a moderate force and scribe a line on the dust shield along the edge of the fan plate. After scribing the lines, push the fan blade toward the radiator and measure the distance between the scribed line and the edge of the fan plate. (Alternate method not illustrated.)
Replace or repair the fan clutch if the total movement of the fan plate is 1/16" or greater.
LINE HAUL VEHICLES
Every 50,000 miles; 1,800 hours, or every six months, whichever occurs first, perform the service checks outlined in this manual.
CITY DELIVERY
Every 15,000 miles, 300 hours or two months whichever occurs first, perform the service checks outlined in this manual.
SERVICE CHECKS
Before performing the operational and leakage checks, apply the vehicle parking brakes or chock the wheels.
OPERATIONAL
1. With the engine cold, the ignition off and at least 75 psi air pressure in the brake system, note that the fan is disengaged from the pulley and can be turned by hand. If the fan can be turned, proceed to Step #2. If it cannot be turned;
A. Drain all reservoirs and disconnect the air control
line leading to the fan clutch and apply at least 75 psi shop air pressure to the fan clutch.
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FAN PLATE
DUST SHIELD
PULLEY
THE TOTAL CHANGE IN THIS
DIMENSION FROM ITS NARROWEST TO WIDEST MEASUREMENT SHOULD
NOT BE 1/16” OR GREATER
FIGURE 8
B. If the fan cannot be turned, the clutch is defective
and must be repaired or replaced (see appropriate section of this manual).
C. If the fan can now be turned; check the air lines
leading to and from the thermostatic control valve for ‘kinks’ or obstructions, and check the control valve itself according to the manufacturer’s instructions.
2. After performing check #1, drain all air pressure from the brake system. Note that the fan is now engaged and cannot be turned by hand. If it cannot be turned, proceed to test #3. If it can be turned, the clutch is defective and must be repaired or replaced.
3. Check the operation of the thermostatic control valve by running the engine up to operating temperature. Note that the fan clutch engages when engine temperature rises to normal or above and disengages after fan cooling is accomplished. Normal engagement time should not exceed two minutes. If engagement time does not exceed two minutes, proceed to check #4. If engagement time does exceed two minutes:
A. If this test is being performed for the first time after
installation of the fan clutch, recheck the setting of the thermostatic control valve and compare it with the setting of the engine coolant thermostat or in the case of vehicles with radiator shutters, with the setting of the shutter control. The fan clutch control should always be 10°F higher than the highest setting.
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B. If the fan clutch installation has successfully passed
this test before, but does not do so now, the thermostatic control valve is defective and should be replaced.
4. With the clutch in the engaged position (control air vented), check the condition of the drive pins and mating holes in the pressure plate by attempting to rotate the fan clockwise and counterclockwise. If free play exceeds 5/16” (8 MM), fan clutch must be repaired or replaced.
LEAKAGE CHECKS
In order to check for air leakage past the only two sliding o-rings in the FD-3™ T orqueMaster fan clutch it is necessary to disconnect the single air control line.
Check for leakage by connecting a 90 cu. in. reservoir (Bendix part number 225000) with a gauge installed to the control port of the fan clutch. Af ter filling the 90 cu. in. reservoir with 100 psi, allow the pressure to stabilized and observe the time required for the reservoir pressure to drop to 90 psi. If the time required is less than 1 minute, leakage is excessive and repair or replacement is necessary .
WARNING! PLEASE READ AND FOLLOW THESE INSTRUCTIONS TO AVOID PERSONAL INJURY OR DEATH:
When working on or around a vehicle, the following general precautions should be observed at all times.
1. Park the vehicle on a level surface, apply the
parking brakes, and always block the wheels. Always wear safety glasses.
2. Stop the engine and remove ignition key when
working under or around the vehicle. When working in the engine compartment, the engine should be shut off and the ignition key should be removed. Where circumstances require that the engine be in operation, EXTREME CAUTION should be used to prevent personal injury resulting from contact with moving, rotating, leaking, heated or electrically charged components.
3. Do not attempt to install, remove, disassemble or
assemble a component until you have read and thoroughly understand the recommended procedures. Use only the proper tools and observe all precautions pertaining to use of those tools.
4. If the work is being performed on the vehicle’s air
brake system, or any auxiliary pressurized air systems, make certain to drain the air pressure from all reservoirs before beginning ANY work on the vehicle. If the vehicle is equipped with an AD-IS air dryer system or a dryer reservoir module, be sure to drain the purge reservoir.
5. Following the vehicle manufacturer’s
recommended procedures, deactivate the electrical system in a manner that safely removes all electrical power from the vehicle.
6. Never exceed manufacturer’s recommended
pressures.
7. Never connect or disconnect a hose or line
containing pressure; it may whip. Never remove a
component or plug unless you are certain all system pressure has been depleted.
8. Use only genuine Bendix
®
replacement parts, components and kits. Replacement hardware, tubing, hose, fittings, etc. must be of equivalent size, type and strength as original equipment and be designed specifically for such applications and systems.
9. Components with stripped threads or damaged parts should be replaced rather than repaired. Do not attempt repairs requiring machining or welding unless specifically stated and approved by the vehicle and component manufacturer.
10. Prior to returning the vehicle to service, make certain all components and systems are restored
to their proper operating condition.
REMOVAL
It is recommended that the FD-3™ T orqueMaster fan clutch be removed from the vehicle for service even though it is possible on some installations to install kits 104937 and 104938 without clutch removal.
1. Secure the vehicle on a level surface by means other
than the brakes.
2. Drain ALL reservoirs to 0 psi (0 kPa) air pressure.
3. Disconnect the air line from the fan clutch.
4. Remove the six cap screws and lockwashers that attach
the vehicle’s fan to the fan plate of the FD-3
T orqueMaster.
5. Remove the fan. NOTE: Remove and retain any spacers
that may be installed between fan and fan plate assembly.
6. Loosen, remove and retain the vehicle’s fan belts.
7. Remove the attaching hardware from the fan clutch
mounting bracket and remove the fan clutch from the vehicle.
DISASSEMBLY (Refer to Figure 9)
1. Remove the dust cap(1) by pulling it off of the end of the
shaft.
2. Remove the cotter pin(2) from the lock nut (10).
3. Remove the locknut(10).
4. Remove the fan plate assembly and set aside.
5. Slide the piston housing(15) and piston(16) off the shaft.
6. Separate the piston(16) from the piston housing (15) and
remove the o-rings(4 & 5) from the piston.
7. Remove o-ring(3) from the shaft.
8. Remove pressure plate(7) from the shaft. Remove the
four o-rings(6) from the drive pin holes in the pressure plate.
9. Remove the two 1/4”x20 Phillips head screws that secure
the spring pack(9) to the pulley . Remove the spring pack.
10. Remove the anti-rotation spring(17).
11. Using a drift punch, disengage the locktab of the
lockwasher(23) from the notch of the locknut(18).
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PILOT DIAMETER
1.998
7
16
5
15
13
14
3
4
12 11
10 1
22
Key
No. Qty. Description
1 1 Cap 2 1 Cotter Pin 3 1 O-ring 4 1 O-ring 5 1 O-ring 6 1 O-ring 7 1 Pressure Plate Complete 8 2 1/4" Sems Screw 9 1 Spring Pack
FIGURE 9
6
21
19
PILOT DIAMETER
2.560
20
18
23
17
8
9
PILOT DIAMETER 1.998
Key
No. Qty. Description
10 1 Flange Nut 1 1 1 Ball Bearing 12 1 Spacer 13 1 Ball Bearing 14 1 Retaining Ring 15 1 Piston Housing 16 1 Piston Complete 17 1 Anti-rotation Spring 18 1 Locknut 19 2 Ball Bearing 20 1 Spacer 21 1 Retaining Ring 22 1 Retaining Ring 23 1 Lockwasher
2
7
5
16
15
3
4
14
13
12
1
11
10
2
PILOT DIAMETER 2.560
Key
No. Qty. Description
10 1 Flange Nut 1 1 1 Ball Bearing 12 1 Spacer 13 2 Ball Bearing 14 1 Retaining Ring 15 1 Piston Housing 16 1 Piston Complete 17 1 Anti-rotation Spring 18 1 Locknut 19 2 Ball Bearing 20 1 Spacer 21 1 Retaining Ring 22 1 Retaining Ring 23 1 Lockwasher
12.Using a Spanner wrench, remove the locknut(18) and the lockwasher(23). NOTE: See Figure 10 for
instructions to fabricate a Spanner wrench.
13. Support the pulley so that the shaft and bracket assembly can be pressed out of the pulley assembly. Since the bearings(19) are originally installed with Loctite between the shaft and the bearing race, a force as high as 5000 lbs. may be required to separate these parts. Press the shaft and bracket assembly out of the pulley assembly .
PULLEY DISASSEMBLY (see Figure 11)
1. Support the pulley so that the tapered retaining ring(22) is visible. Displace the bearing spacer(20) so that it is eccentric to the bearing bore as far as possible. Insert
6
a round pressing tool through the I.D. of the bearing(19) until it contacts the spacer. Press out the lower bearing(19) and bearing spacer(20). Discard the bearing.
2. Remove the tapered retaining ring(22).
3. Turn the pulley over and press the remaining bearing(19) out of the pulley . Discard the bearing.
4. Remove the retaining ring(21) from the pulley .
FAN PLATE DISASSEMBLY WITH PILOT DIAMETER OF 1.998
1. Support the fan mounting surface of the fan plate assembly making certain sufficient space is left beneath to permit the ball bearings(11) to be pressed out.
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27/32” DRILL THRU (2 HOLES FOR 3/4”
BAR”
2.125 + .010
FIGURE 10
PULLEY
2-3/4”
MATERIAL O.H.T.S. TUBING
HDN. & DRAW. RC 40-45
.235 + - .002 CENTERED
(4 LUGS)
1/32” FLAT
REASSEMBLY
ASSEMBL Y OF PULLEY (Refer to Figure 11)
1. Install snap ring(21) using Waldes tool #6500 or equivalent.
2. Support the pulley on the drive pin end and press one of the bearings(19) (seal side up) into the pulley until it contacts the snap ring(21). Use a pressing tool that contacts the outer race of the bearing.
3. Turn the pulley over and position the spacer(20) concentric with the inner race of the previously installed bearing. Pack grease (Exxon Unirex N-2 or equivalent) around the spacer making certain not to overfill the volume. Support both the inner and outer race of the previously installed bearing. Press in second bearing(19) (seal side up) using a tool that contacts both the inner and outer race until the inner race of the bearing contacts the spacer(20).
4. Turn the pulley over and install the tapered snap ring(22) (flat side towards the bearing) making sure the snap ring is fully seated in its groove.
DRIVE PINS
19
20
22
SEAL
21
FIGURE 1 1
19
SEAL
Displace the bearing spacer(12) so that it is eccentric to the bearing bore as far as possible. Insert a round pressing tool through the I.D. of the ball bearing(13) until it contacts the spacer(12). Press the ball bearing(11) and the bearing spacer(12) out of the fan plate. Discard the bearing because it will be damaged by disassembly .
2. Remove retaining ring(14) using Waldes tool #6500. Turn fan plate over and press out remaining bearing(13). Discard the bearing.
FAN PLATE DISASSEMBLY WITH PILOT DIAMETER OF 2.560
1. Remove the retaining ring(14) from the fan plate. Place the fan plate on a firm surface and utilizing a round pressing tool, press out the two ball bearings(13) and the spacer(12). Discard the bearings.
ASSEMBL Y OF PULLEY ONTO THE BRACKET AND SHAFT
1. Support the bracket with the shaft pointing up. Apply one bank of Loctite RC609 around the shaft at the location of inner races of the bearings(19) in the pulley . Also put a band of the Loctite on the inner races of the bearings(19). NOTE: Parts must BE free of oil and
grease for Loctite to properly bond.
2. Slide the pulley onto the shaft, making sure the bottom bearings inner race(19) contacts the bracket. Allow 24 hours for complete curing of the Loctite to take affect.
3. Place locking ring(23) on the shaft and install locknut(18) using the same tool as Step 12 of ‘Disassembly’. T orque locknut to 100-150 ft. lbs. until one of the tangs of the lockring(23) can be bent up into one of the slots of the locknut. Never back the torque off to align parts.
ASSEMBL Y OF F AN PLATE WITH 1.998 PILOT DIAMETER
1. Support the fan plate on the fan mounting surface (nose down) and press bearing (13) into the housing until it bottoms against the shoulder of the fan plate. NOTE:
Use a pressing tool that contacts the outer race of the bearing, do not use a load greater than 1100 lbs. to press bearing into bore.
2. Turn fan plate over and fully support the previously installed bearing (13) both inner and outer race. Install spacer (12) concentric with the inner race of bearing (13). Press in bearing (11) with a tool that contacts both the inner and outer race and with a force no greater than 1 100 lbs. until the inner race cont acts the sp acer.
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The spacer (12) should be tight against both bearing inner races, yet be able to be moved by a finger load.
3. Turn the fan plate over and install snap ring (14) with the flat side towards the bearing, making certain the snap ring is fully seated in its groove.
ASSEMBL Y OF F AN PLATE WITH 2.560 PILOT DIAMETER
1. Support the fan plate on the fan mounting surface (nose down). Using a pressing tool that contacts the outer bearing race only, press ball bearing (13) into the fan plate using a force no greater than 1100 lbs. Until it contacts the fan plate shoulder. Install the bearing spacer(12) (as illustrated in Figure 1) concentric with the inner race of the ball bearing previously installed.
2. Continue to support the fan plate (nose down) and press bearing (1 1) using a pressing tool that contacts the outer race of the bearing only. Carefully press the bearing with a force no greater than 1100 lbs. until the inner bearing race contacts spacer (12). Do not continue pressing the bearing once the inner race has touched the spacer; severe damage to the bearings may result. As a check after assembly, the bearing spacer should be tight against each bearing race yet able to be moved by a finger load.
3. Turn the fan plate over and install snap ring (14) with the flat side towards the bearing, making certain the snap ring is fully seated in its groove.
8. Install fan plate assembly onto the shaft and retain with the locknut(10). NOTE: On unit with 2.560 diameter hub, washer(11) to be inst alled before the locknut. T orque to 90 to 100 ft.lbs.
9. Install cotter pin(2) and bend to hold in place. Replace cap(1).
INSTALLATION
1. Attach fan clutch unit to vehicle by installing cap nuts and lockwashers through mounting bracket holes into mating holes in engine bracket.
2. Reconnect air line to unit.
3. Adjust fan belts per vehicle manufacturer’s recommendation.
4. Replace fan on pressure plate with six cap screws and lockwashers. T orque to 300-360 inch pounds. (Be sure to install any spacers that were removed during disassembly .)
5. Perform service checks as previously outlined.
TEST
1. With no air pressure applied, the torque required to rotate the clutch must not exceed 150 in. oz.
2. With 70-75 psi applied, the fan plate must separate from the pulley and rotate freely .
3. Perform the leakage checks outlined in the manual.
ANTI-ROTATIONAL
SPRING
ONE END OF SPRING
INSTALLED IN NOTCH
IN SPRING COLLAR
FINAL ASSEMBL Y
1. Support the bracket, shaft, and pulley assembly with the shaft pointing up.
2. Install spring pack (9) onto the pulley assembly and retain with the two 1/4"x20 Phillips screws. Torque to 50-75 inch pounds.
3. Install the anti-rotational spring(17) making sure one end of the spring is engaged in the notch of the shaft. (See Figure 12)
4. Apply a thin film of silicone lubricant BW-655M to the four o-rings(6). Position the o-rings into the grooves located in the drive pin holes of the pressure plate(7). Apply the same lubricant to the drive pins on the pulley .
5. Install the pressure plate(7) onto the pulley assembly making sure the end of the antirotational spring(17) is engaged in the notch of the spring collar on the I.D. of the pressure plate. Holes in the pressure plate must slide over the drive pins.
6. Lubricate the I.D. of the piston housing(15) and the three o-rings (3,4, & 5) with lubricant used in Step 4. Install o-rings (4&5) onto the piston and o-ring (3) onto the shaft.
7. Install piston(16) into the piston housing(15) and install unit onto the shaft.
8
BW1452 © 2004 Bendix Commercial Vehicle Systems LLC All rights reserved. 4/2004 Printed in U.S.A.
ONE END OF SPRING INSTALLED
IN NOTCH OF THE SHAFT
FIGURE 12
RETROFIT INSTALLATION INFORMATION
To determine which fan clutch piece number should be purchased when retrofitting existing equipment, consult the nearest authorized Bendix distributor for assistance. Complete installation instructions and piping diagrams are packed with each FD-3™ T orqueMaster fan clutch. It is recommended that only cooling fans approved by the vehicle or fan manufacturer be installed on the FD-3™ T orqueMaster . Maximum weight of fan blade assembly is 30 lbs. Maximum R.P.M. of 28 inch fan is 2700. Maximum R.P.M. of 34 inch fan is 2100. Maximum thickness of spacers between fan and hub plate is 1-1/2".
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