INSTALLATION AND SERVICE MANUAL FOR THE
Contents
1. be applied every time the hose is attached or de tached from the rotary union 5 2 HYDRAULIC LINE SPECIFICATIONS Series 2000 1 The connection on the rotary union is a 1 8NPT female thread 2 The fitting on the end of the default hose is a male 1 8NPT An adapter is used to mate to the 6 ORB port on the manifold 3 If supplying your own hose it is recommended to use a hose that is as small as possible The poten tial exists that a large heavy hose with bulky fit tings could create a side load on the rotary union just due to the weight of the hose Side loads can drastically reduce the life of the rotary union 4 Series 3000 1 The connection on the rotary union is a 1 8NPT female thread 2 The fitting on the end of the default hose is a flare 37 deg 4 An adapter is used to mate to the 6 ORB port on the manifold 3 If supplying your own hose it is recommended to use a hose that is minimum 1 4 inside diameter Smaller hoses can cause a problem with the fan performance as the small hose will slow down the actuation speed of the fan blades while changing pitch or purging 4 6 0 SERVICE AND MAINTENANCE Flexxaire s Series 2000 Series 3000 fan hub is fully sealed with o rings and contains a small amount of oil As a re sult the fan should not require any maintenance 6 1 VISUAL INSPECTIONS Under normal operating conditions Series 2000 Series 3000 fans do not require any scheduled maintenance and2. are built to provide thousands of hours of trouble free ser vice In moderate to extreme operating conditions a visu al inspection of the moving parts is recommended Flexxaire com 01900r1 from time to time to safeguard against fan blade damage which could lead to equipment downtime and or other damages 6 2 MECHANICAL REVIEW 1 Ensure that the fan fully reverses pitch 2 Check for leaks in the rotary union 3 Check that the rotary union bearings rotate smoothly 4 Verify that you have the correct blade clearance as per Figure 7 on page 6 6 3 INSTALL CHECK LIST Does fan rotate in default and full reverse pitches without obstruction Are blades installed in the correct orientation blower sucker See Fig 5 page 5 Has the side load on the pressure line been mini mized Has the pressure line been constrained to prevent contact with the blades Is the pressure line flexible enough to accommodate relative movement be tween the radiator and engine Are any of the blades damaged Does the rotary union ro tate freely Are there any pressure leaks in the system Are all screens and guards secured Have you recorded the fan S N for future reference S N Page 8 of 10 6 4 ROTARY UNION The rotary union used in the fan hub is lubricated for life and requires no additional maintenance other than periodic inspection to determine if normal wear has caused the un ion to leak A locking ring i
3. 5 Refer to Figure 3 Set up dial gauge to measure radial deviation of the mounting adapter on the 1 pilot hole surface Devi ation should not exceed 0 005 Refer to Figure 3 Remove the shipping plug from the rear of the fan Place the Series 2000 Series 3000 fan onto the mounting adapter and torque the 3 8 bolts to 30 Ft Lbs 41 N m Do not use loctite Refer to Figure 4 3 8 16NC TOROUE 40 FT LBS Figure 4 3 0 ATTACHING THE BLADES Your Flexxaire fan shipped with the fan blades unat tached Care must be taken to ensure the blades are attached correctly If the primary operation of the fan is to pull air to wards the engine the blades must be mounted with the concave surface towards the engine assuming the fan rotates counter clockwise as viewed from the en gine towards the fan If the primary operation of the fan is to push air away from the engine the blades must be mounted with the concave surface away from the engine Refer to Figure 5 Some fans are shipped from Flexxaire with the blades already attached by special order Page 4 of 10 Blades Mounted for Sucker Fan Pull Blades Mounted for Blower Fan Push Airflow Direction Direction Figure 5 1 Series 2000 Series 3000 fans are supplied with either 1 or 2 counterweights per blade If two counter weights per blade are supplied install one weight on each side If only one counterweight is s
4. FLEXXAIRE INSTALLATION AND SERVICE MANUAL FOR THE SERIES 2000 amp SERIES 3000 FAN SERIES GEN 2 PNEUMATIC CONTROL AND HYDRAULIC CONTROL PUBLICATION No 01900 Revision 1 Printed in Canada 1 1 INTRODUCTION Thank you for purchasing a Flexxaire Fan System Flexxaire takes great pride in designing manufacturing and assembling its products for many years of use This manual P N 01900 is produced to assist in the in Sstallation operation and maintenance of the GEN 2 Flexx aire Series 2000 and Series 3000 Fan Systems using Pneumatic or Hydraulic actuation Flexxaire has made every effort to ensure that the infor mation contained in this manual is correct and complete at the time of printing Flexxaire will assume no responsibility for any errors or omissions If you have any questions regarding this manual any other document provided with your fan system or any questions not answered by this manual please contact Flexxaire Inc Product Support Department 10430 180 Street Edmonton Alberta Canada T5S 1C3 Phone 780 483 3267 Fax 780 483 6099 Monday to Friday 7 00 am to 3 30 pm MST 1 2 IMPORTANT SAFETY INFORMATION The safety information in this publication is to be used in conjunction with the safety information supplied from the original machine manufacturer Please refer to all safety information supplied prior to doing any work on the fan assembly or any other component to assure safety Improper op
5. ations Full Pitch default position O psi Neutral Pitch Stop air position 190 psi Reverse Pitch Purge position 300 psi Maximum continuous pressure 500 psi 5 1 HYDRAULIC LINE INSTALL Drill a hole in your fan shroud to allow the flexible hose to be routed into the engine compartment Secure the hose using hose clamps 2 No exterior bracing should be used to prevent the rotary union from rotating It is imperative that a flexible connection be used DO NOT PIPE SOLID 3 Ensure that the hose clears all parts of the fan If possible secure the hose away from the fan Common ways to do this are zip tie the hose to the radiator core or to attach it to the radiator frame or the bolted flanges between the radiator cores WARNING Do not secure the hydraulic hose so tight as to cause a side load on the rotary union Failure of the bearings could result Page 7 of 10 WARNING Do not secure the hydraulic hose so loose that the hose could contact the blades due to sudden air reversal vibration etc WARNING Ensure that you have the minimum clearance between the rotary union and closest obstruction as per Figure 7 on page 6 4 The fan is shipped with a default hose assembly attached to the hub assembly Contact Flexxaire if you want a different hose length of different fit tings for future orders The hose is attached at the Flexxaire factory to avoid unnecessary side loads to the bearings of the rotary union that can
6. ave just been stopped and have hot fluid in lines tubes and compartments 1 3 FAN SPECIFICATIONS The following needs to be considered prior to the installa tion of the Flexxaire Fan System If your situation is listed in this section DO NOT INSTALL THE FAN Damage and or injury may occur 1 3 1 MOUNTING WARNING This fan is not designed to be mounted onto a crank shaft or crank shaft pulley Torsional vibration from crankshafts will damage the fan and could result in machine damage and serious injury 1 3 2 FAN BLADE TIP SPEED WARNING The fan system must not exceed a blade tip speed of 20 000 feet minute Exceeding this speed may cause damage to and or failure of the fan which in turn may cause injury or death or damage to the radiator and surrounding equipment To calculate the blade tip speed use the following formu la Fan Diameter Inches X 3 14 X Fan RPM 12 If your calculated tip speed exceeds 20 000 ft min con tact Flexxaire directly prior to installation It Is im portant to use Fan RPM and NOT engine RPM Page 1 of 10 1 4 FAN OVERVIEW The Series 2000 Series 3000 fan has a number of im Flexxaire s Series 2000 3000 fan systems are designed portant features to minimize overheating caused by debris plugged radia tors screens and guards and reduce overcooling in low Fail Safe Operation The blades are spring loaded ambient temperatures The blades of the Series 2000 into the default full pitch pos
7. e fan blades 2 Attach the incoming air line to the push in fitting on the front of the fan If you did not purchase one of Flexxaire s control kits you will need to source flexible hose and fittings that will attach to the 1 8 NPT female fitting on the front of the fan The hose should be robust enough to withstand abrasion from air flow and temperature and vibra tion inherent from engines Failure of the hose could lead to fan damage if the hose comes in contact with the blades WARNING Do not secure the air lines in any way that will cause leverage to be applied to the rotary union Failure of the rotary union could result Flexxaire com 01900r1 5 0 HYDRAULIC SPECIFICATIONS Flexxaire supplies a number of hydraulic control options but the Series 2000 Series 3000 Hydraulic versions can be operated using any hydraulic source that meets the gen eral specifications listed below If your machine has hy draulics on board then this source should be available Series 2000 Hydraulic General Specifications Full Pitch default position O psi Neutral Pitch Stop air position 100 psi Reverse Pitch Purge position 180psi Maximum continuous pressure 500 psi Series 2000 High Pressure Hydraulic General Spec ifications Full Pitch default position O psi Neutral Pitch Stop air position 310 psi Reverse Pitch Purge position 460 psi Maximum continuous pressure 950 psi Series 3000 Hydraulic General Specific
8. eration maintenance or repair of this product can be dangerous and could result in injury or death Always use Genuine Flexxaire parts and components or Flexxaire approved parts and components The use of un approved parts and or components will void the 1 year warranty Do not operate or perform any maintenance on this product until you have read and understand the op eration and maintenance information Please con tact Flexxaire or an approved dealer for any infor mation that you may require The person s servicing the product may be unfa miliar with many of the systems or components on the product It is important to use caution when performing any type of service work Knowledge of the product and or its components is important be fore the removal or disassembly of any component Flexxaire com 01900r1 1 2 1 PROTECTIVE EQUIPMENT Always wear protective glasses protective shoes and any other protective equipment as required by law and or your company safety program 1 2 2 PRESSURIZED FAN HUB The hub assembly is spring loaded If disassembly of the hub is required take caution that you are well protected from the hub s release which may be sudden and pose an impact related injury Also make sure that the internal pressure is released Consult the pneumatic or hydraulic control instructions in this manual 1 2 3 HOT FLUIDS AND PARTS To avoid burns be alert for hot parts on the assembly or the machine that h
9. eries 3000 hub assembly See Figures 8 and 9 1 4 20 NC x 1 2 Long Blue Loctite 9 ft lb 12 2 N Figure 8 Figure 9 Flexxaire com 01900r1 Page 6 of 10 4 0 PNEUMATIC SPECIFICATIONS Flexxaire supplies a number of pneumatic control options but the Series 2000 Series 3000 Pneumatic versions can be operated using any air source that meets the general specifications listed below If your machine has air on board then this source will be available If not then a compressor kit will be required Series 2000 Pneumatic General Specifications Full Pitch default position O psi Neutral Pitch Stop air position 75 psi Reverse Pitch Purge position 98 psi Max continuous pressure 120 psi extended operation at higher pressure will reduce the life of the rotary union seal Series 3000 Pneumatic General Specifications Full Pitch default position O psi Neutral Pitch Stop air position 45 psi Reverse Pitch Purge position 57 psi Max continuous pressure 120psi Recommended minimum flow rate 35cfm 70 psi The lower the flow rate the longer it takes to purge the fan at 35cfm 70psi it takes approximately 7 seconds to fully reverse pitch 4 1 PNEUMATIC LINE INSTALL 1 Drill a hole in your fan shroud to allow the flexible hose to be routed into the engine compartment Secure the hose using hose clamps or tie wraps Be sure that the air line is properly secured so it cannot interfere with th
10. he blade pitch reversed and check for ob structions 5 Ensure you have the correct blade clearance See Figure 7 on the next page or a list of recom mended minimum clearances based on fan diam ter 6 Tighten the fan belts and replace all the fan guards and safety equipment 7 Attach the WARNING label to the machine on a housing guard or any location near the fan where it can be easily seen WARNING Failure to have the correct blade clear ance could result in blade contact that can cause ex tensive damage to people and equipment Page 5 of 10 Fan Minimum Diameter 18 00 30 00 30 01 48 00 48 01 54 00 54 01 72 00 re 457mm 762mm Hh o 763mm 1219mm ae Miili 1220mm 1372mm IER 1373mm 1829mm 0 5 13mm minimum ih clearance required A between the Rotary O N Y Union and the nearest Please refer to chart above for object proper clearance required for fan blades to nearest object Proper clearance is needed on both sides of the blade Failure to have the proper clearance could allow for blade contact to occur Figure 7 3 1 Series 3000 AIR DAM Series 3000 fans above 54 in diameter have extended blade shafts and an aluminum air dam air seal is mounted to the front of the hub This air dam is necessary to prevent reverse airflow between the bottom of the blades and the hub diameter The air dam is mounted with 5 bolts on the front shoulder of the S
11. ition If the fan loses Series 3000 vary pitch not speed to control air flow pressure the fan will default to full pitch and act volume and direction like a fixed pitch fan giving maximum cooling Depending on the control kit ordered see Section How your Series 2000 Series 3000 works 2 0 the fan can be run in a neutral pitch or any The Series 2000 Series 3000 can be purchased as a pneu pitch in between to solve overcooling problems matically actuated variable pitch fan or hydraulically actu and save horsepower and fuel ated variable pitch fan The blades are held in full pitch by l l When purging there are no horsepower spikes in a heavy spring As pneumatic or hydraulic pressure is applied to the control line the pitch of the blade is reduced fact the horsepower drops off as you pass and then reversed When the pressure is released the fan through neutral pitch then slowly builds as pitch blades return to their default position increases J amp y fy TT pon Oa be Dorie a lt NORMAL OPERATION NEUTRAL PITCH PUTRO E EFFICIENT COOLING STOF AIR FLOW CLEAN RADIATOR PREVENT OVERCOOLING CAVE HORSEPOWER PREVENT OVERHEATING 2 0 CONTROL KITS HYDRAULIC CONTROL Due to the variability of machines that the Series 2000 2 Position kit Manual Purge Series 3000 fan may be installed on the fan does not in clude any control components Flexxai
12. plied with a pre Series 3000 Fan i machined mounting adapter plate Pre machined mount ing adapters are machined for your pilot and bolt circle Remove fan guards and safety equipment to gain For some applications a wider 2 piece adapter may be access to the existing fan used and the necessary hardware for assembling the 2 Loosen belt s and remove existing fan hardware parts together will be included This 2 piece adapter may as required be pre assembled Clean mounting surface of the fan drive Flexxaire com 01900r1 Page 3 of 10 2 3 2 Fan Position Ideally the fan should be centered in the shroud 30 70 immersion is acceptable This may require modification or removal of the fan spacer or modification of the shroud See Figure 2 fo SHROUD pu MODIFIED A FAN SPACER ORIGINAL FAN FLEXXAIRE FAN Figure 2 1 Install the Flexxaire supplied mounting adapter using bolts from the original fan If the bolt length needs to be changed use an equivalent or better grade of bolt Follow original equipment manufacturer s torque and thread locking specifications when in Stalling the mounting adapter to the fan drive Refer to Figure 3 FAN DRIVE PULLEY SPACER MOUNT PLATE 1 PILOT HOLE FOR FLEXXAIRE FAN HUB Le PIZZA A Figure 3 Flexxaire com 01900r1 Set up dial gauge to measure axial deviation of the mounting adapter on the fan mounting surface Deviation should not exceed 0 00
13. re has a number of different control kits available to suit a wide range of appli Infinitely Variable Pitch Controller IVP fan control cations PNEUMATIC CONTROL 2 Position kit Manual Purge 2 Position kit with timer Manual and Auto Purge Available in 12V and 24V configurations Contact Flexxaire or your dealer for details and 2 Position kit with timer Manual and Auto Purge availability Infinitely Variable Pitch Controller IVP fan control Each kit is available with or without an air compressor Available in 12V and 24V configurations Flexxaire com 01900r1 Page 2 of 10 2 1 MAJOR COMPONENTS The Series 2000 Series 3000 Fan Assembly can be identified by several external components as shown in Figure 1 Use this diagram for terminology and major component identification This figure is of a Series 2000 Hydraulic but all the major components are the same between the Series 2000 and Series 3000 fans ATTACH TO INCOMING HYDRAULIC LINE FRONT VIEW SIDE VIEW REAR VIEW Figure 1 MAJOR COMPONENTS 1 Blade Assembly 4 Mounting Adapter Bolts 7 Blade Counter Weight 2 Rotary Union 5 Mounting Adapter 8 Blade Mounting Shaft 3 Hub Assembly 6 Hub Mounting Bolts 9 Fan Pilot 2 2 EXISTING FAN REMOVAL 2 3 INSTALLATION The following is a general description for the removal of an 2 3 1 Mounting Adapters existing fan and the installation of a Flexxaire Series 2000 The Series 2000 Series 3000 fan is sup
14. s used to lock the rotary union into the fan system In addition some fans are supplied with a Pitch Sensor or are Pitch Sensor Ready These fans have a pin installed internally in the piston that travels through rotary union when installed A jig is supplied with rotary union to verify pin center for applicable models If your design does have the internal pin please refer to Section 6 4 3 for proper use of jig 6 4 1 ROTARY UNION REPLACEMENT Figure 12 8 32 NC 0 38 Long Torx Rotary Union 1 Push in straight Refer to Section 6 4 3 if Pitch Sensor Pin is visible inside the fan prior to installing Rotary Figure 11 Figure 14 Flexxaire com 01900r1 Page 9 of 10 Install Screws 1 Apply Blue Loctite to screw threads 2 Torque to 21 in Ib 2 4 Nm Figure 15 6 4 3 INTERNAL PIN VERIFICATION FOR PITCH SENSOR ENABLED PITCH SENSOR READY FANS For Pitch Sensor Fans 1 Install Pin Center Jig EE Internal Pin Use Caution Do not bend the pin Figure 16 Pin should be centered in the jig If not remove jig and adjust with length of finger and recheck Figure 17 Flexxaire com 01900r1 Page 10 of 10
15. upplied then the counterweight can be installed on either side as long as they are all on the same side Insert the supplied 4 NC long hex bolt through the counterweight then the lower hole in the blade or cap The head of the bolt should be on the side with the counterweight when only one counter weight is being used Tighten the assembly with the supplied NC lock nut See Figure 6 Concave Side 1 4 Self Locking Nut 1 4 Bolts ate Short Torque 9 ft lb 2Nm Blade Cap 1 4 Bolt Long Bolt 1 4 Bolt Long ea aii ER i Fay i E a A Y AD SQ F Wy Counterweight Figure 6 Flexxaire com 01900r1 2 Insert the 1 4 NC short bolts through the upper holes in the blade caps and blades Tighten the assembly to the blade shaft and the blade Regu lar hex head bolts with washers may be substitu ted for the flange headed bolts id Carefully torque the blade bolts with a certified torque wrench to the following specification 14 20NC to 9 ft Ibs WARNING DO NOT OVER TORQUE NOTE If any of the supplied flanged lock nuts are lost they may be replaced with grade 8 flanged lock nuts Loctite 242 or equivalent must be applied to the bolt if lock nuts are not used 4 Rotate the fan by hand and check for obstruct tions A final check will be required once the pneumatic or hydraulic hose has been connected to the fan See Page 7 for a list of required pres sures for each fan model Spin the fan by hand with t
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