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Mine doesn't come on at all when empty, and only on help hill pulls with my trailer on (8000lbs.) and only a short time then. Need to check your temps for sure.
There was a thread on this and I tried to find it but the search engine can't find any matches for "fan", "cooling fan" clutch fan, fan clutch etc. Stupid thing. Anyways, blocked airflow can cause it, mine kicks on at 212, didn't know that until I got guages, it will vary from 180-215 without the oem guage even moving.
Mine is just at random times. Comes on at seemingly odd times. More so when towing....it comes on enough for me to think that it is on too often. With the fan coming on links to the oil cooler going out, links the new egr cooler i just got about a month ago, which some how links to the several egr valves i have had and the intake soaked???? Does this make sense guys?
Maybe one of the more knowledgable people can give better advice then me. Out of curiosity, who has been working on it for you? Im originally from the Morganton/Hickory area.
The fan is turned on based on oil and water temps. You need to know what those are to really know anything. It is possible for you to have a plugged oil cooler even though it's just been replaced. It has been reported here before.
A good set of gauges should tell you what you are looking for. There are a number of reasons why the fan can kick in. A/C, oil etc... Mine does the same. I talked to one service manager and he stated that it's also more common on trucks with automatic climate control - like mine.