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Kysor-Style Fan Clutch

Installation and Repair Kit Instructions

Horton, Inc.
2565 Walnut Street
Roseville, MN 55113, USA
Phone: (651) 361-6400
Toll-free: (800) 621-1320
Fax: (651) 361-6801
Web site: www.hortonww.com
e-mail: info@hortonww.com
22815-B-0304 Klondike is a Horton, Inc. brand.

36 1
Table of Contents
10. On Rear-Air Units: Lubricate new shaft O-ring with
grease* and reinstall clutch to hub using new coupler
Introduction and Safety Precautions 3 from kit.

Pre-Installation 4 *NOTE
Use a high temperature rated wheel bearing grease,
Fan Clutch Installation 6 preferably a synthetic. DO NOT USE CHASSIS
GREASE AND DO NOT USE GREASES THAT YOU
Liner Kit Installation (Front Air or Rear Air) 9 ARE NOT SURE OF.

Rear-Air Seal Kit Installation 11

Rear-Air Major Kit Installation 15

Front-Air Seal Kit Installation 23

Front-Air Major Kit Installation 26

Hub Bearing Kit Installation 34

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KLONDIKE Kysor-Style Fan Clutch: Introduction
Hub Bearing Kit Instructions
Horton uses the following special notices to give warning of
Tools Required
possible safety related problems which could cause serious
injury and provide information to help prevent damage to
Foot pound or Newton Meter torque wrench
3/8” drive flex head ratchet equipment.
3/8” drive 5/16” hex bit socket
1 5/8” socket Danger is used to indicate the presence of a hazard
Loctite 271 which will cause severe personal injury, death, or
substantial property damage if the warning is
NOTE ignored.
Protect the radiator from possible damage from the fan
during fan removal and fan and clutch installation.
Warning is used to indicate the presence of a hazard
which can cause severe personal injury, death, or
1. Remove clutch from hub. On Rear-Air Units: Remove
substantial property damage if the warning is
and discard rear shaft O-ring and replace it with new
ignored.
one from kit.
2. Remove hub from engine.
3. Remove nut and washer from front of hub. Caution is used to indicate the presence of a hazard
4. Remove pulley from hub shaft. which will or can cause minor personal injury or
5. Remove bearing(s) and retaining ring(s) from pulley property damage if the warning is ignored.
and discard.
6. Install new bearing(s) and retaining ring(s). NOTE
7. Press pulley back onto hub and reinstall washer. Note is used to notify people of installation,
8. Apply Loctite 271 to nut and torque to 170 ft.-lbs. operation, or maintenance information which is
9. Reinstall hub to engine. important but not hazard related.

34 3
Pre-Installation
You must follow your company safety practices, which the shaft and push the cylinder onto
should adhere to or be better than Federal or State clutch. Grasp the cylinder while
approved shop safety practices and procedures. Be sure tightening the new cylinder nut to
you have all the required parts and have read and prevent the shaft from turning. Torque
understand all the procedures and instructions before the cylinder nut to 84 in.-lbs. (9.5 N-
beginning work on the unit. m).

Torque Specifications
Clutch to Hub 45 ft.-lbs. (61.0 Newton Meters) 21. Remove clutch from press and turn Step 20
Fan to Clutch 26 ft.-lbs. (35.3 Newton Meters) cylinder. It may have a slight gritty feel
Cylinder Nut 84 in.-lbs. (9.5 Newton Meters) due to the additives in the grease, but if
Retaining Plate Screws 30 in.-lbs. (3.4 Newton Meters) it feels notched, or turns hard, you most
likely lost the small O-ring. Disassemble
Optional Tools and correct.
In addition to the required tools listed in the kit
instructions, the following tools will be helpful in 22. Apply 90-120 psi (6.2-8.2 bar) air to
expediting the repair of your fan drive: the clutch several times to test for free
movement and leaks. With clutch
disengaged, align the six access
• Foot pound or Newton Meter torque wrench
holes on the front of the clutch with
• Hydraulic or hand-operated press the mounting holes on the back.
• Scotchbrite® pad Reinstall clutch to hub using the
• Brake Cleaner mounting screws included in the kit.
• Fan clutch support tool and Step 22
compressor
Support Tool
& Compressor

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spring retainer and then place it on (for use with hydraulic or hand-operated presses)*
the shaft. Use Brake Cleaner to • A selection of screwdrivers
remove any grease or fingerprints that
may be on the disc where the lining
• Lubricant (included in the repair kit)**
touches.
* The support tool and compressor can be made from
pieces of pipe and flat steel.
17. Insert disc assembly into clutch
housing. Place unit studs down into Step 16 ** NOTE
support tool. Place new lining into clutch. Use If greases are substituted, you must insure that you use
compressor tool to compress clutch slowly while a high temperature rated wheel bearing grease, preferably
pushing down on lining. When lining gets flush with a synthetic. DO NOT USE CHASSIS GREASE AND DO
outer edge of clutch, stop. NOT USE GREASES THAT YOU ARE NOT SURE OF.

18. Install lining plates, sharp edge down.


Tighten screws to 30 in.-lbs. Take Emergency Lock-Up Procedures
clutch out of press and set on bench,
studs up. If the lining wears to the point where the
fan clutch will not engage, the fan clutch
19. Lubricate the new small O-ring with can be locked up, by doing the following:
Step 18
grease from the kit and place it on the
shoulder of the cylinder. Apply grease 1. Remove air supply from fan clutch (In
to the rest of the shoulder in front of most cases, disconnecting solenoid
the O-ring. electric plug will work).
2. For Rear-Air: Remove the cylinder nut,
cylinder, and seal washer. Step 1-2
20. Place new tab washer in the cavity of Step 19
the cylinder. Align tab with key way on For Front-Air: Remove the cylinder nut,
tab washer, and cylinder.
32 5
Klondike Rear-Air Kysor-Style
Fan Clutch Installation Instructions the groove between the needle bearings and the
For some situations it will be necessary to tilt the radia- rotary seal.
tor away from the engine in order to gain enough room
to remove and repair the fan clutch. A few applications 13. Use crocus cloth, sandpaper, or a Scotchbrite→ pad
require removing the entire fan drive assembly. We to break the glaze on the disc and retaining plates.
recommend whenever possible to remove only the Wash the parts with Brake Cleaner and dry.
clutch, doing so will save substantial time and work.
14. Take the cleaned up disc (inner part) and push it into
NOTE the clutch housing. Turn it a few times to work the
Protect the radiator from possible damage from the fan grease into the needles. Remove it and wipe off any
during fan removal and fan and clutch installation. grease that comes out with it on the front. Do this a
couple of times until no more excess grease comes
1. Remove the fan and place it inside the out. However if no grease came out, there wasn’t
radiator shroud. Apply 90-120 psi (6.2- enough grease in there to start with. The optimum
8.2 bar) air to the clutch to disengage it. grease application is to end up with a layer of grease
Rotate the front of the clutch until the from front to rear, even with the needles, and with
six access holes are aligned with the plenty of grease worked in behind the needles, but no
six 5/16" socket head cap screws. If more than that.
the clutch won’t disengage, put the fan
back on the fan-mounting studs and try 15. Use Brake Cleaner, to clean any grease or greasy
to force the clutch to slip by pulling on a fingerprints from the inside of the clutch housing
blade. If this doesn’t work, remove the where lining touches. Also, make sure no grease is
entire fan drive assembly. on the outside of the grease seal where it could get
Step 1 slung into the lining. Set clutch housing aside.

16. Place rear spring retainer onto the shaft. Place


spring on shaft. Liberally lubricate inside rear of front

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which are removed one at a time. Discard the wiper. 2. A long handled, 3/8" drive flex head
ratchet and a short 5/16" hex bit
10. Set clutch housing nose down in support tool, and socket works best for removing the six
place in press. Use compressor tool to hold the clutch mounting cap screws.
clutch in the press while you pry out the rotary seal
with a very large screwdriver. Use a rag, wet with 3. The short length of the socket keeps
Brake Cleaner, to thoroughly wash needle bearings the ratchet close to the clutch, so you
and clutch housing. Do not let Brake Cleaner get into can easily get at the mounting screws
piston bearing. from behind the fan

NOTE 4. Remove the old coupler and install a Step 2


Do not use safety solvent to clean needle bearings. new one on the hub shaft.

11. With clutch in support tool, use a flat 5. Reinstallation: Lubricate rear shaft O-
plate to press the new rotary seal in, ring with grease*. Stick one of the
lip down. Press until flush with edge of mounting screws into the clutch and
Step 3
the housing bore. hold it in place with the socket. Get
the shaft of the clutch into the cavity
Step 11
12. Lubricate the big O-ring, wiper, and of the coupler and start the one
the nose of the clutch housing where mounting screw so the clutch will
they are located with grease from the hang. It is not necessary to get the
kit. Install big O-ring and wiper on flats of the shaft aligned with the Step 4
clutch housing. Apply grease to the coupler at this time.
needle bearings, and pack the groove
in front of the needle bearings (down * NOTE
in the bottom near the snap ring) and If greases are substituted, you must
Step 12 insure that you use a high temperature
Step 5
rated wheel bearing grease, preferably a
30 7
synthetic. DO NOT USE CHASSIS 5. Inspect needle bearing race on disc. It may be
GREASE AND DO NOT USE GREASES discolored and streaked, but as long as you can feel
THAT YOU ARE NOT SURE OF. no damage with a fingernail, it’s acceptable. It may
be cleaned up with a Scotchbrite→ pad to make
6. Grab the front of the clutch and push it inspection easier. If damaged, discard clutch.
towards the hub. Now, slowly turn the
Step 6
cylinder until the flats of the shaft align 6. Inspect the fan studs on the clutch housing (outer
with the coupler. The clutch should now part). If any are loose or missing, discard clutch. If
pop into place on the hub. Install the any are damaged and cannot be repaired with a
other mounting screws and torque all thread die, discard clutch.
six to 45 ft.-lbs. (61 N-m).
7. Inspect piston bearing by turning piston. If bearing
feels rough or spins freely, indicating
no grease, discard clutch. If needle
bearing inner race, studs and piston
are acceptable, proceed with rebuild.

8. Remove O-ring from piston and


Step 8
discard.

9. Remove wiper from front groove of


housing. It may be the steel type, which
has to be spiraled out like a piston ring.
It may be the Teflon type, which is cut
and comes out easily. It may be the two-
piece; O-ring and square cut seal type,
Step 9

8 29
Liner Replacement For Klondike Front-Air /
Remove the retaining plate screws, retaining plates, Rear-Air Kysor-Style Fan Clutches
and friction liner. Discard the old screws and friction
liner. Tools Required

Inch pound or Newton Meter torque


Do not over compress clutch or damage can occur. wrench
1/4” drive ratchet
3. Remove the cylinder nut. Grasp the cylinder while 1/4” drive T25 Torx® socket
loosening the cylinder nut to prevent
the shaft from turning. Carefully Step 1
release pressure from clutch. 1. Apply 90-120 psi (6.2-8.2 bar) air to the
clutch to disengage it.
4. Remove cylinder and tab washer.
Remove the small O-ring from the 2. Remove the six retaining plate screws
cylinder and discard. Separate the and the three retaining plates. Discard
disc assembly (inner part) from the Step 3 the old screws. Step 2
clutch housing (outer part), then
remove front spring retainer and 3. Remove the old friction liner. If the liner
spring. Inspect front spring retainer for sticks to the clutch housing, free it by
signs of rubbing (it will be shiny). If tapping on the dividing cut of the liner
found, stop and replace clutch. with a hammer and screwdriver. Step 3
NOTE Step 4 4. Inspect clutch disc. If liner residue is
A new cylinder is not included in the kit. If present or if surface appears glazed,
the old one is damaged, replace temporarily release air pressure to the
clutch.
Step 4

28 9
clutch to get a little more access to Tools Required
the clutch disc, and use crocus cloth,
sandpaper, or a Scotchbrite® pad to Inch pound or Newton Meter torque wrench
break the glaze. 3/8” drive flex head ratchet
Step 5 3/8” drive 5/16” hex bit socket
5. Reapply air pressure to the clutch, and 3/8” drive 1/2” socket
install the new liner as shown. 1/4” drive ratchet
1/4” drive T25 Torx® socket
6. Reinstall the retaining plates with the
screws supplied in the kit and torque NOTE
them to 30 in.-lbs. (3.4 N-m). Protect the radiator from possible damage from the fan
Step 6
during fan removal and fan and clutch installation.

1. Disconnect air line from front of fan clutch. Remove


the fan and place it inside the radiator
shroud. Apply 90-120 psi (6.2-8.2 bar)
air to the clutch to disengage it.
Rotate the front of the clutch until the
six access holes are aligned with the
six 5/16” socket head cap screws and
remove them with the flex head
ratchet and 5/16” hex bit socket.

2. Using either a hydraulic press or two


4” long bolts with washers and wing
nuts, compress clutch slightly.
Step 1

10 27
KLONDIKE Front-Air Kysor-Style Fan Klondike Rear-Air Kysor-Style Fan Clutch:
Clutch: Major Kit Instructions Seal Kit Instructions
Exploded View of Front-Air Fan Clutch Tools Required

7 Inch pound or Newton Meter torque wrench


9 3
3/8" drive flex head ratchet
5 6
3/8" drive 5/16" hex bit socket
8 3/8" drive 1/2” socket
1 2 5/8" open-end wrench

NOTE
Protect the radiator from possible damage
from the fan during fan removal and fan
and clutch installation.

4 1. Remove the fan and place it inside the


radiator shroud. Apply 90-120 psi (6.2-
8.2 bar) air to the clutch to disengage Step 1
it. Rotate the front of the clutch until
Item Description the six access holes are aligned with
1 Cylinder Nut the six 5/16" socket head cap screws
2 Tab Washer and remove them with the flex head
3 Rotary Seal ratchet and 5/16" hex bit socket.
5 2 pc. Lining 2. Using either a hydraulic press or two
6 Screw 4” long bolts with washers and wing
7 Wiper nuts, compress clutch slightly.
8, 9 O-Rings
Step 2

26 11
5. Install the new white Teflon→ wiper,
regardless of current wiper type. Place
Do not over compress clutch or the new large O-ring on the piston.
damage can occur. Liberally grease the new large O-ring,
wiper and area around the outside of
3. Remove the cylinder and cylinder nut. the piston and wiper with grease from
Put the 5/8" open-end wrench on the the kit.
flats of the shaft to prevent it from
turning while loosening the cylinder Step 3 6. Lubricate the new small O-ring with Step 6
nut. grease from the kit and place it on the
shoulder of the cylinder. Apply grease
4. Remove the seal washer from the front to the rest of the shoulder in front of
of the shaft. the O-ring.
Step 4
5. Remove the U-cup seal from the 7. Place new tab washer in the cavity of
piston, the O-ring from the front of the the cylinder. Align tab with key way on
shaft, and the wiper from the housing. the shaft and push the cylinder onto
The wiper may be one of the three clutch. Torque the new cylinder nut to
styles shown in the photo. 84 in.-lbs. (9.5 N-m). Remove the wing
nuts, washers, and bolts from the
Step 7
6. Install the new white Teflon® wiper, Step 5 clutch. Apply 90-120 psi (6.2-8.2 bar)
regardless of current wiper type. air to the clutch several times to test for free
Place the new U-cup seal on the movement and leaks. With clutch disengaged, align
piston. Make sure the lip faces the six access holes on the front of the clutch with
towards the front of the clutch. Install the mounting holes on the back.
big O-ring on front of shaft. Liberally
Step 6

12 25
2. Using either a hydraulic press or two grease the U-cup seal, O-ring, and
4” long bolts with washers and wing wiper with the grease from the kit.
nuts, compress clutch slightly.
7. Lubricate the new seal washer with
grease from the kit and place it on the Step 7
shaft.

Do not over compress clutch or 8. Align tab on cylinder with key way on
damage can occur. the shaft and push the cylinder onto
Step 3 clutch. Place a 5/8” wrench on the
3. Remove the cylinder nut, tab washer flats of the shaft to prevent the
and cylinder. Grasp the cylinder while cylinder from turning while tightening
loosening the cylinder nut to prevent the new cylinder nut. Torque the
the shaft from turning. Remove the cylinder nut to 84 in-lbs. (9.5 N-m).
small O-ring from the cylinder and
discard. 9. Remove the wing nuts, washers, and
bolts from the clutch. Apply 90-120
NOTE Step 4 Step 8
psi (6.2-8.2 bar) air to the clutch
A new cylinder is not included in the kit. If several times to test for free
the old one is damaged, replace movement and leaks. With clutch
clutch. disengaged, align the six access
holes on the front of the clutch with
4. Remove the large O-ring from the the mounting holes on the back.
piston and the wiper from the
housing. The wiper may be one of the
three styles shown in the photo.
Step 5
Step 9
24 13
KLONDIKE Front-Air Kysor-Style Fan Clutch:
10. Remove old O-ring from rear of shaft and replace it Seal Kit Instructions
with new one from kit. Lubricate O-ring with grease
from the kit and reinstall clutch to hub using new Tools Required
coupler.
Inch pound or Newton Meter torque wrench
3/8” drive flex head ratchet
3/8” drive 5/16” hex bit socket
3/8” drive 1/2” socket

NOTE
Protect the radiator from possible damage
from the fan during fan removal and fan
and clutch installation.

1. Disconnect air line from front of fan


clutch. Remove the fan and place it Step 1
inside the radiator shroud. Apply 90-
120 psi (6.2-8.2 bar) air to the clutch
to disengage it. Rotate the front of
the clutch until the six access holes
are aligned with the six 5/16” socket
head cap screws and remove them
with the flex head ratchet and 5/16”
hex bit socket.

Step 2

14 23
Klondike Rear-Air Kysor-Style Fan
the new cylinder nut. Torque the cylinder Clutch - Major Kit Instructions
nut to 84 in.-lbs. (9.5 N-m).
Exploded View of the Rear-Air Fan Clutch
22. Apply 90-120 psi (6.2-8.2 bar) air to the
clutch several times to test for free
movement and leaks. With clutch 6 9 7
disengaged, align the six access holes
on the front of the clutch with the 1
5 1 8
mounting holes on the back.
4
23. Lubricate rear shaft O-ring (small one) Step 22
with grease from the kit and install on
shaft. Reinstall clutch to hub using the
new coupler and mounting screws
included in the kit. 2

Step 23
10 11 3

Item Description Item Description


1 2-Piece Lining 6 U-cup
2 Spring 7 Rotary Seal
3 Coupler 8 Screw
4 Cylinder Nut 9 Wiper
5 Seal Washer 10,11 O-rings

22 15
Tools Required retainer and then place it on the shaft.
Use Brake Cleaner to remove any
Inch pound or Newton Meter torque wrench grease or fingerprints that may be on
3/8” drive flex head ratchet the disc where the lining touches.
3/8” drive 5/16” hex bit socket
3/8” drive 1/2” socket 18. Insert disc assembly into clutch Step 19
5/8” open-end wrench housing. Place unit studs down into
1/4” drive ratchet support tool. Place new lining into
1/4” drive T25 Torx® socket clutch. Use compressor tool to
compress clutch slowly while pushing
NOTE down on lining. When lining gets flush Step 20
Protect the radiator from possible damage from the fan with outer edge of clutch, stop.
during fan removal and fan and clutch installation.
19. Install lining plates, sharp edge down.
1. Remove the fan and place it inside the radiator Tighten screws to 30 in.-lbs. (3.4 N-
shroud. Apply 90-120 psi (6.2-8.2 bar) air to the m).
clutch to disengage it. Rotate the front of the clutch
until the six access holes are aligned with the six 20. Lubricate the new seal washer with
5/16” socket head cap screws and grease from the kit and place it on the
remove them with the flex head shaft.
ratchet and 5/16” hex bit socket.
21. Align tab on cylinder with keyway on
2. Using either a hydraulic press or two the shaft and push the cylinder onto
4” long bolts with washers and wing clutch. Place a 5/83 wrench on the
nuts, compress clutch slightly. flats of the shaft to prevent the
Remove the retaining plate screws, cylinder from turning while tightening Step 21
Step 2

16 21
14. Use crocus cloth, sandpaper, or a Scotchbrite→ pad retaining plates, and friction liner. Discard the old
to break the glaze on the disc and retaining plates. screws and friction liner.
Wash the parts with Brake Cleaner and dry.

15. Take the cleaned up disc (inner part) and push it into Do not over compress clutch or damage can occur.
the clutch housing. Turn it a few times to work the
grease into the needles. Remove it and wipe off any 3. Remove the cylinder nut. Use a 5/8” wrench on the
grease that comes out with it on the front. Do this a flats of the shaft to prevent the cylinder from turning.
couple of times until no more excess grease comes Carefully release pressure from clutch.
out. However if no grease came out, there wasn’t
enough grease in there to start with. The optimum 4. Remove cylinder and seal washer.
grease application is to end up with a layer of grease Separate the disc assembly (inner
from front to rear, even with the needles, and with part) from the clutch housing (outer
plenty of grease worked in behind the needles, but no part), then remove front spring retainer
more than that. and spring. Inspect front spring
retainer for signs of rubbing (it will be
16. Use Brake Cleaner, to clean any shiny). If found, stop and replace
grease or greasy fingerprints from the clutch. Step 3
inside of the clutch housing where
lining touches. Also, make sure no 5. Inspect needle bearing race on disc. It
grease is on the outside of the grease may be discolored and streaked, but
seal where it could get slung into the as long as you can feel no damage
lining. Set clutch housing aside. with a fingernail, it’s acceptable. It
may be cleaned up with a
17. Place rear spring retainer onto the Scotchbrite→ pad to make inspection
shaft. Place spring on shaft. Liberally easier. If damaged, discard clutch.
lubricate inside rear of front spring Step 17 Step 4

20 17
6. Inspect the fan studs on the clutch housing (outer you pry out the grease seal with a very large
part). If any are loose or missing, discard clutch. If screwdriver. Use a rag, wet with Brake Cleaner, to
any are damaged and cannot be repaired with a thoroughly wash needle bearings and clutch housing.
thread die, discard clutch. Do not let Brake Cleaner get into piston bearing.

7. Inspect piston bearing by turning piston. If bearing NOTE


feels rough or spins freely, indicating no grease, Do not use safety solvent to clean needle bearings.
discard clutch. If needle bearing inner
race, studs and piston are acceptable, 11. With clutch in support tool, use a flat
proceed with rebuild. plate to press the new rotary seal in,
lip down. Press until flush with edge of
8. Remove all O-rings from shaft. the housing bore.
Discard. Step 11
12. Using specified grease, lubricate and
9. Remove wiper from front groove of install the wiper.
clutch housing. It may be the steel
type, which has to be spiraled out like 13. Install and liberally lubricate the U-cup
Step 8 Step 12
a piston ring. It may be the Teflon seal, the front shaft O-ring (big one)
type, which is cut and comes out and the nose of the clutch housing
easily. It may be the two-piece; O-ring where they are located with grease
and square cut seal type, which are from the kit. Apply grease to the
removed one at a time. Discard the needle bearings, and pack the groove
wiper. in front of the needle bearings (down
in the bottom near the snap ring) and
10. Set clutch housing nose down in the groove between the needle Step 13
Step 9
support tool, and place in press. Use bearings and the rotary seal.
compressor tool to hold the clutch in the press while

18 19