793F OFF-Highway Truck Engine Fan Hydraulic System

Jose L. Rodriguez
Instructor Tec.
joseoyk@gmail.com
 Jose Luis Rodriguez
It is necessary for technicians to properly
locate and identify machine components
and service points to efficiently maintain
the machine, which will ensure customers
experience quick and proper maintenance
services.

Jose L. Rodriguez
Instructor Tec.
joseoyk@gmail.com
 Jose Luis Rodriguez
Shown is the 793F engine fan hydraulic schematic. Oil flows from the fan drive
pump (1) through a makeup valve (2) to the fan drive motor (3). Oil flows from
the motor through the makeup valve, the steering and fan oil cooler (4), and the
return oil filter (5) to the steering / fan tank section (6).

If supply oil to the fan stops suddenly, the fan and motor may continue to rotate
because of the mass of the fan.

The makeup valve allows oil to flow from the return side of the circuit to the
supply side to prevent a vacuum in the supply line. The fan drive motor is a fixed
displacement motor; therefore, the fan speed is determined by the amount of
flow from the fan drive pump. The fan drive pump is a variable displacement
piston type pump that is controlled by the Brake ECM. Case drain oil flows from
the fan drive motor and pump through a case drain oil filter (7) to the steering /
fan tank section.

Jose L. Rodriguez
Instructor Tec.
joseoyk@gmail.com
 Jose Luis Rodriguez
Engine Fan Components

These illustrations show the location of the engine fan system main components.
Oil flows from the fan drive pump (1) through a makeup valve (2) to the fan drive
motor (3).
The makeup valve is located behind the lower right section of the radiator.
Return oil also flows from the fan drive motor through the makeup valve,
steering / fan oil cooler (4), and return oil filter (5) to the steering / fan tank
section. The fan drive pressure tap (6) is used to measure fan drive pump
pressure. Pump pressure should be between approximately 0 to 22,750 kPa (0 to
3300 psi) at sea level.

Case drain oil from the fan pump and motor flows through the case drain oil filter
(7) to the tank. The case drain filter includes a bypass switch (8) which informs
the Chassis ECM if the filter is restricted.
The fan speed sensor (9), located on the bottom of the fan motor, provides an
input signal to the Brake ECM. The Brake ECM uses this input to maintain the fan
speed between 0 and 817 rpm . Jose L. Rodriguez
Instructor Tec.
joseoyk@gmail.com
 Jose Luis Rodriguez
Shown is a sectional view of the fixed displacement, bent-axis fan drive motor.
The motor is rotated by flow from the fan drive pump. Oil flows through the
supply port (1) and the port plate (2) and pushes the pistons (3) out of the barrel
(4). The pistons force the barrel and the output shaft (5) to rotate. The output
shaft turns the planetary drive group and the fan. As the barrel rotates and the
pistons return, oil lows from the pistons through the port plate, the return port
(6), and a makeup valve to the steering / fan drive tank.

Oil that leaks past the pistons into the motor housing provides lubrication for
the rotating motor components. This oil leakage is referred to as case drain oil.
Case drain oil flows through the case drain port (7) and a case drain oil filter to
the steering / fan drive tank.

Jose L. Rodriguez
Instructor Tec.
joseoyk@gmail.com
 Jose Luis Rodriguez

The fan drive pump (1) is part of a double piston pump group that includes the
steering pump (2). The pump group is mounted to the pump drive. The pump
drive is located on the inside of the right frame rail. A charging pump is located
between the fan pump and the steering pump and is used to keep the pumps
supplied with oil. The fan drive pump is a variable displacement piston-type
pump. The Brake ECM controls the flow of oil from the fan drive pump by
Jose L. Rodriguez
energizing the displacement solenoid (3). Instructor Tec.
joseoyk@gmail.com
The Brake ECM analyzes the temperatures, brake status, and ground speed inputs
and sends between a 0 and 640 milliampere signal to the solenoid.

At 0 to 200 milliampere, the pump is at maximum displacement and the fan is at

maximum speed. At 600 to 640 milliampere, the pump is at the minimum
displacement and the fan is at minimum speed.

The coil resistance through the solenoid is approximately 24 ohms. The

displacement solenoid moves a spool in the pressure and flow compensator valve
(not visible), inside the pump control valve (4), to control the flow of pump output
pressure to the minimum angle actuator piston. The minimum angle actuator
piston moves the swashplate to the minimum flow position.

Jose Luis Rodriguez

The current adjustment screw (5) controls the minimum current required to start
destroking the pump.

NOTE: Do not adjust the current adjustment screw in chassis. This adjustment
should only be done on a hydraulic test stand

Jose L. Rodriguez
Instructor Tec.
joseoyk@gmail.com
The high pressure cut-off valve (6) controls the maximum pressure in the fan drive
system. The high pressure cut-off valve controls maximum pressure by controlling
the flow of pump output pressure to the minimum angle actuator piston. When
system pressure is at maximum, the high pressure cut-off valve sends oil to the
minimum angle actuator piston and moves the swashplate to the minimum flow
position. The high pressure cut-off valve for the pump should be set at a minimum
of 2070 kPa (300 psi) above the pressure that is required to maintain the
maximum fan speed of 817 rpm [approximately 32,400 kPa (4700 psi) at sea level].

When accelerating from LOW IDLE to HIGH IDLE, the fan drive pressure will spike
to start the fan rotation. The spike pressure may be the pump high pressure cut-
off setting. To adjust the pump high pressure cut-off setting, install a blocker plate
in the pump outlet port and disconnect the fan drive pump solenoid. Start the

Jose Luis Rodriguez

engine and run at LOW IDLE.

The pump will destroke and operate at minimum flow and maximum pressure
(High Pressure Cut-off). Adjust the high pressure cut-off to the specification.

The minimum angle stop screw (7) is located near the pressure and flow
compensator valve. The maximum angle stop screw is located on the other side of
the pump.

NOTE: Do not adjust the minimum or maximum angle stop screws in the chassis.
This adjustment should only be done on a hydraulic test stand.

Jose L. Rodriguez
Instructor Tec.
joseoyk@gmail.com
 Jose Luis Rodriguez
Shown is a sectional view of the double piston pump group, which includes the
hydraulic fan pump (1) and the steering pump (2). Both pumps are variable
displacement piston type pumps. The steering pump will be covered in the
“Steering System” module of this training course.
Oil from the steering tank enters the pump group in the port below the charge
pump impeller (3). The charge pump keeps the pump full of oil. The large spring
around the maximum angle actuator piston (4) holds the swashplate (5) at
maximum angle. Pump output pressure is always present on the right side of
the maximum angle actuator piston and also helps to hold the swashplate at
maximum angle. When the swashplate is at maximum angle, pump output is at
maximum flow and fan speed is at maximum. This is the position of the pump
when the displacement solenoid receives 0 milliamps from the Brake ECM.
When the displacement solenoid is receiving between 0 and 1 amp from the
ECM, a spool in the pressure and flow compensator valve directs pump output
flow to the minimum angle actuator piston (6).

Jose L. Rodriguez
Instructor Tec.
joseoyk@gmail.com
The minimum angle actuator piston has a larger diameter than the maximum
angle actuator piston. The minimum angle actuator piston moves the swashplate
toward the minimum flow position.

The swashplate angle, pump flow, and fan speed will modulate with the amount of
current at the displacement solenoid. When the swashplate is at minimum angle,
pump output is at minimum flow and fan speed is at minimum. This is the position
of the pump when the displacement solenoid receives 1 amp from the Brake ECM.

Before the swashplate contacts the minimum angle stop (7), the minimum angle
actuator piston (8) will open a small drain port to tank and stop the movement of
the swashplate. Draining the minimum angle actuator piston oil will prevent the
swashplate from contacting the minimum angle stop repeatedly which can be

Jose Luis Rodriguez

noisy and may cause damage to the pump.

Oil that leaks past the pistons into the pump housing provides lubrication for the
rotating components. This oil leakage is referred to as case drain oil. Case drain oil
flows through the case drain port and a case drain oil filter to the steering / fan
section of the hydraulic tank

Jose L. Rodriguez
Instructor Tec.
joseoyk@gmail.com
 Jose Luis Rodriguez
Fan Pump Operation

This illustration shows the hydraulic fan pump control valve (18) with the fan at
high speed.

During normal fan speed operations, the pump output oil and the spring around
the maximum angle actuator piston (1) holds the swashplate at maximum
angle. Maximum angle is the position of the swashplate when the displacement
solenoid (2) receives approximately 0 milliamps from the Brake ECM and pump
output pressure is not at high pressure cut-off.

Fan pump oil flows to the pressure compensator (cut-off) valve (3), the
displacement solenoid, and the maximum angle actuator piston. When the fan
system pressure is higher than the steering system pressure, the shuttle valve
(4) moves up and blocks steering pump oil from flowing to the fan pump control
valve. The pump output oil and the spring around the maximum angle actuator
piston holds the swashplate at maximum angle. Maximum angle is the pump
position when the displacement solenoid receives 0 amp from the Brake ECM
and pump output pressure is low. Jose L. Rodriguez
Instructor Tec.
joseoyk@gmail.com
The pressure compensator valve controls the maximum pressure in the fan system
by controlling the pump flow to the minimum angle actuator piston (5). When
system pressure is at maximum, the pressure compensator valve moves to the left
and directs oil to the minimum angle actuator piston which moves the swashplate
to the minimum flow position.

The pressure compensator valve for the pump should be set at a minimum of 2070
kPa (300 psi) above the pressure that is required to maintain the maximum fan
speed of 817 rpm. When the steering system pressure is higher than the fan
system pressure, the shuttle valve moves down and allows steering pump oil to
flow into the fan pump control valve.

Jose Luis Rodriguez

The steering pump oil flows to the pressure compensator valve, the displacement
solenoid, and the maximum angle actuator piston. In trucks with the high altitude
arrangement, a pressure reducing valve (14) is installed, which reduces the
steering system oil pressure for the fan system.

NOTE: To adjust the pressure compensator, refer to the Service Manual for the
correct procedure.

Jose L. Rodriguez
Instructor Tec.
joseoyk@gmail.com
 Jose Luis Rodriguez
This illustration shows the hydraulic fan pump control valve (18) with
the fan at low speed.
When the displacement solenoid (2) receives between 0 and 680
milliamps from the Brake ECM, the flow compensator moves the valve
spool to the right.

The spool directs pump discharge oil to the minimum angle actuator
piston (5). The minimum angle actuator piston has a larger diameter
than the maximum angle actuator piston (1). The minimum angle
actuator piston moves the swashplate toward the minimum flow
position.

At low fan speed, the flow compensator valve spool meters the oil to
the minimum angle actuator piston to control the swash plate angle at
low flow.

Jose L. Rodriguez
Instructor Tec.
joseoyk@gmail.com
Engine Fan Speeds

Jose Luis Rodriguez

Fan speed varies depending on the sensor inputs to the Brake ECM. The
maximum fan speeds are:
Hoisting: 200 rpm
Standard retarding: 725 rpm
Additional retarding: 817 rpm
Hauling: 650 rpm

As shown in the illustration above, if the fluid and air temperatures are
all below the lower limits, the hydraulic fan is OFF and fan speed could
be as low as 0 rpm.

If the fluid and air temperatures are between the lower and upper
limits, the fan pump will modulate fan speed by sensor priority to a fan
speed curve that has been pre-set for each sensor.

If the brake oil outlet temperatures are above the top limit but the
engine coolant, engine oil, and intake air temperature are between the
sensor lower and upper limits,

the fan speed will be approximately 725-817 rpm. If the engine coolant,
engine oil, or intake air temperatures are above the top limit, the fan
speed will be approximately 650 rpm. Jose L. Rodriguez
Instructor Tec.
joseoyk@gmail.com
THE END

Jose L. Rodriguez
Instructor Tec.
joseoyk@gmail.com