FLEXXAIRE ENGINE TEMPERATURE CONTROL SYSTEM AX1000 FAN SERIES

(PNEUMATIC PITCH CONTROL)

PUBLICATION No. 01553 Revision 1

Printed in Canada

1.1.

INTRODUCTION

This manual (P/N 01553) is produced to assist in the installation, operation and maintenance of Flexxaire AX1000 Series Fan Systems. Flexxaire Manufacturing Inc. has made every effort to ensure that the information 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 or any other document provided with your fan system, please contact:

any type of service work. A knowledge of the product and/or its components is important before the removal or disassembly of any component.

1.2.1.

Protective Equipment

Always wear protective glasses, protective shoes and any other protective equipment as required by job conditions when working around this product.

1.2.2.

Spring Loaded Fan Hub

Flexxaire Manufacturing Product Support Department 10430-180 Street Edmonton, Alberta, Canada T5S-1C3 Phone: 780-483-3267 Fax: 780-483-6099

The hub assembly is spring loaded. If disassembly of the hub is required, take caution that you are well protected from the hubs release which may be sudden and pose an impact related injury. See section 5.0. for hub disassembly procedure.

1.2.3.

Hot Fluids and Parts

1.2.

IMPORTANT SAFETY INFORMATION

To avoid burns, be alert for hot parts on the assembly or the machine that have just been stopped and have hot fluid in lines, tubes and compartments.

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 operation, maintenance or repair of this product can be dangerous and could result in injury or death. Always use Flexxaire parts and components or Flexxaire approved parts and components. The use of unapproved parts and/or components may void the 1-year warranty. Do not operate or perform any maintenance on this product until you have read and understand the operation and maintenance information. Please contact Flexxaire or an approved dealer for any information that you may require. The person(s) servicing the product may be unfamiliar with many of the systems or components on the product. This makes it important to use caution when performing

1.3.

PRODUCT SUPPORT

The Product Support Department provides technical support, information on fan installation and maintenance, parts, instruction manuals, and ins responsible for warranty administration. Contact the Product Support Department for any problems that this technical manual does not address. Phone: 780-483-3267 or 780-930-6836 Monday to Friday 8:00 a.m to 4:00 p.m. MST

1.4.

FAN SPECIFICATIONS

The following needs to be considered prior to the installation of the Flexxaire Fan System. If your situation is listed in this section, DO NOT INSTALL THE FAN. Damage and/or injury may occur.

1.4.1.

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.

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1.4.2.

FAN BLADE TIP SPEED

2.0.

AX1000 CONTROL KITS

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 less importantly, damage to the radiator and surrounding equipment. To calculate the blade tip speed, use the following formula: Fan Diameter (Inches) X 3.14 X Fan RPM 12 If your calculated tip speed exceeds 20,000 ft/min, contact Flexxaire Manufacturing Inc. directly, prior to installation. It is important to use Fan RPM and NOT engine RPM.

Due to the variability of machines that the AX1000 may be installed on, the AX1000 fan does not include any control components. Flexxaire has a number of different control kits available to suit a wide range of applications: Machines with an on board air supply: -2 Position kit (Manual Purge) -2 Position kit with timer (Manual and Auto Purge) -3 Position kit (Manual Purge with neutral capability) -3 Position kit with timer (Manual and Auto. Purge with neutral capability) -Full Variable Pitch Controller (Full fan control) Machines without an on board air The same 5 kits offered above, except with an added compressor kit. All of these kits are available in 12V and 24V configurations. Contact Flexxaire or your dealer for availability.

1.5.

FAN OVERVIEW

Flexxaires AX1000 fan system is designed to minimize overheating caused by debris plugged radiators, screens and guards, and reduce overcooling in low ambient temperatures. The blades of the AX1000 vary pitch, not speed, to control air flow and direction. How your AX1000 works: The AX1000 is a pneumatically actuated variable pitch fan. The blades are held in full pitch by a heavy spring. As air pressure is applied to the control line, the pitch of the blade is reduced and then reversed. When the pressure is released, the fan blades return to their default position. The AX1000 has a number of inherent features: 1. Fail Safe Operation: The blades are spring loaded into the default full pitch position. If you lose air pressure, the fan will default to full pitch and act like a fixed pitch fan giving maximum cooling. 2. Depending on the control kit ordered (see section 2.0), the fan can be run in a neutral pitch (or any pitch in between) to solve overcooling problems and save horsepower and fuel. 3. When purging, there are no horsepower spikes (in fact the horsepower drops off as you pass through neutral pitch, then slowly builds as pitch increases).

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2.1.

MAJOR COMPONENTS

Figure 1: Fan Components MAJOR COMPONENTS: See Above for Reference

1. 2. 3. 4. 5. 6. 7. Blades Hub Counterweight Air line Mounting Bolts Adapter Plate Hub mounting bolts

2.2.

EXISTING FAN REMOVAL

2.3.

INSTALLATION

The following is a general description for the removal of an existing fan and the installation of a Flexxaire AX1000 Fan. A. Remove fan guards and safety equipment to gain access to the existing fan. B. Loosen belt(s) and remove existing fan hardware as required. C. Clean mounting surface of the fan drive.

Mounting Plates The AX1000 is supplied with either a pre-machined mounting plate or a generic mounting plate. Fan Position Ideally the fan should be centered in the shroud (30-70% immersion in acceptable). This may require modification or removal of the fan spacer or modification of the shroud.

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A. Install the Flexxaire supplied adapter plate 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 manufacturers torque and thread locking specifications when installing the mounting plate to the fan drive. Refer to Figure 2. B. Measure axial and radial runout of the installed plate. Runout should not exceed 0.005 in either direction.

Figure 3: Fan Mounting WARNING: Do not secure the air line so tight as to cause a side load on the rotary union. Failure of the bearings could result. Figure 2: Adapter Plate Mounting C. Remove the three LOOSE M8 bolts from the back of the fan. D. Attach the incoming O.D nylon air line to the front of the fan. WARNING: Do not remove the three remaining bolts. The AX1000 fan is spring loaded, improper removal of these bolts could result in injury. E. Remove the orange shipping caplug from the rear of the fan. Place the AX1000 fan onto the adapter plate, and torque the M8 bolts to 21 Ft-Lbs (28 N.m). Do not use loctite. Refer to figure 3. F. Drill a hole in the fan shroud to allow the flexible nylon hose to be routed into the engine compartment. Secure the hose using hose clamps. G. 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 to 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 air line so loose that the hose could contact the blades due to sudden air reversal, vibration, etc.. H. Install the pneumatic control. Follow the instructions included with the control kit. If you did not purchase a kit from Flexxaire, see section 3.0 for pneumatic specifications. I. Rotate the fan by hand and check for obstructions. A final check will be required once the air supply has been connected to the fan. A minimum of 90 PSI will be required to fully reverse the blade pitch. Spin the fan by hand with the blade pitch reversed and check for obstructions. J. Tighten the fan belts and replace all the fan guards and safety equipment. K. Attach the WARNING label to the machine, on a housing, guard, or any location near the fan where it can be easily seen.

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3.0.

PNEUMATIC SPECIFICATIONS

CHECK Does fan rotate in default and full reverse pitches? Is the airline secured away from the blades? Are any of the blades damaged? Does the rotary union rotate freely? Are there any air leaks in the system? Are all screens and guards secure? Have you recorded the fan S/N for future reference? S/N_______________

YES

NO

Flexxaire supplies a number of pneumatic control options, but the AX1000 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 will be required. General Specifications: Full Pitch (default position): Neutral Pitch (Stop air position): Reverse Pitch (Purge position): Max intermittent pressure: Max continuous pressure: 0 psi ~60 psi 90 psi 110 psi 90 psi

4.0.

SERVICE AND MAINTENANCE

Flexxaires AX1000 fan hub is fully sealed with orings, and contains a small amount of oil. As a result, the fan itself should not require any maintenance.

4.1.

VISUAL INSPECTIONS

Under normal operating conditions AX1000 fans do not require any scheduled maintenance and are built to provide thousands of hours of trouble free service. In moderate to extreme operating conditions a visual inspection of the moving parts in recommended from time to time to safeguard against fan blade damage which could lead to equipment downtime and/or other damages.

4.2.

MECHANICAL REVIEW

Ensure that the fan fully reverses pitch. Check for air leaks in the rotary union. Check that the rotary union bearings rotate smoothly.

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5.0.

HUB DISASSEMBLY AND ASSEMBLY

This section will describe how to perform any kind of maintenance and repairs on the AX1000 fan. -Rotary union removal and replacement. -Fan disassembly. -Component inspection. -Fan re-assembly.

5.1.

ROTARY UNION REMOVAL AND REPLACEMENT

If sufficient access to the rotary union can be gained with the fan in place, it is not necessary to remove the fan for rotary union replacement. A. With the airline disconnected, remove the beveled snap ring using a pair of snap ring pliers. B. Remove the rotary union by pulling it straight out of the hub. C. If replacing the rotary union, be sure to oil the o-ring on the new rotary union before installing it in the hub. D. Place the new rotary union in the hub. E. Replace the snap ring, make sure the beveled side is facing out. Refer to figure 14 below. CAUTION: Make sure the snap ring is fully seated before applying air pressure to the hub.

Figure 4: Rear Plate Removal B. Once all three bolts have been removed, remove the rear plate, o-ring and the spring. IMPORTANT: Make a note of the orientation of the blades relative to the hub. I.E. which way do the counterweights face? You will need to remember this for fan re-assembly. C. Using a 3mm hex, remove the 12 set screws embedded in the hub. Refer to figure 5.

5.2.

REMOVE FAN

A. Remove fan guards and safety equipment to gain access to the AX1000 fan. B. Remove the three M8 bolts which attach the fan to the adapter plate. C. Remove the airline from the rotary union.

5.3.

FAN DISASSEMBLY

A. Loosen each of the three M8 bolts that attach the rear cover to the fan. Figure 5: Set Screw Removal CAUTION: Do not completely remove any of the three M8 bolts until all three have been backed off and there is a gap of approximately 7/16 (11mm) between the hub and the rear cover. This will reduce the amount of force the spring exerts on the D. With a blunt drift and hammer, gently tap plate. Refer to figure 4. the bottom of the blade inserts from the ___________________________________________________________________________________________________ Printed In Canada 01553r1.doc AX1000 Manual 10/31/2007 Page 6

inside of the hub to remove the blades. Refer to figure 6.

Inspect each part for signs of excessive wear. Blades: -There is no need to remove the counterweights from the blades. They are attached at the Flexxaire factory, and new counterweights are supplied (attached) with every blade replacement. -Inspect the blades for signs of wear. If any wear is noted, the blades should be replaced. Hub: -The hub is hard anodized, and should not show any signs of wear. If the anodized surface appears to be worn away, consult with the Flexxaire Product Support Department at 780-483-3267. Piston: -It is normal for the piston to show signs of wear. Although the piston should last for the life of the fan, it is recommended to replace the piston and all the seals if the fan is to be reassembled as preventative maintenance. Rotary Union: -Ensure the bearings rotate smoothly. Again, it is recommended to replace the rotary union as a preventative measure.

Figure 6: Blade Removal E. Once all 6 blades have been removed, ensure that all 6 pivot blocks have been removed as well. Refer to figure 7.

5.5.

FAN RE-ASSEMBLY

Ensure all the parts are clean, and that there is a new piston and seals. A. Lightly oil the inside of the hub. Place the new quad ring into the new piston and lightly oil the quad ring. Refer to figure 8.

Figure 7: Pivot Block Removal F. The piston can now be removed by blowing shop air into the rotary union. If the rotary union is already removed, reach through the hole and push the piston out. The fan is now completely disassembled.

5.4.

COMPONENT INSPECTION

Figure 8: Oil Hub

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B. Place the piston into the hub, and ensure the piston bottoms out completely to the front of the hub. C. Lift the piston so that the pivot block groove is approximately in the middle of the bores in the hub. This will facilitate pivot block assembly. Refer to figure 9.

G. Insert the blades (in their original orientation, see Hub Disassembly procedures above) and pivot block together into the hub bore, and ensure that the pivot block seats properly into the piston. H. Press the bushing into the bore. If it is difficult, a blunt drift may be used to seat the bushing into the bore. Refer to figure 11.

Figure 9: Piston Groove in the Middle D. Place a new o-ring around the blade bushing, and lightly oil. E. Apply a light coating of oil to the dowel pin, and assemble the pivot block. F. Ensure the pivot block is square relative to the blade. Refer to figure 10. Figure 11: Use of Drift to Install Blades I. Repeat steps D-H until all 6 blades have been installed. J. Place all 12 setscrews into the 12 holes. K. Drive all setscrews down. Installed torque will vary, so ensure that all the setscrews are bottomed out in the hole, and do not protrude past the face of the hub. Refer to figure 12.

Figure 10: Pivot Block Orientation

Figure 12: Drive Down Setscrews. ___________________________________________________________________________________________________ Printed In Canada 01553r1.doc AX1000 Manual 10/31/2007 Page 8

L. Rotate the blades to seat the piston fully within the hub. M. Place the spring into the spring pocket in the piston. Place the o-ring into the groove. N. Pour cup (~125ml) of oil into the hub. O. Place the rear plate on top of the spring, and hand thread all three M8 bolts as deep as possible. This will prevent cocking of the rear plate when the bolts are tightened. Refer to figure 13.

The Hub is now completely assembled. Verify that all components have been assembled. If possible, conduct a bench test to ensure the blades reverse direction before mounting the fan on the machine. Refer to section 2.3. for fan installation instructions.

Figure 13: Hand Thread All Three Bolts P. Once all three bolts have been started, drive the plate fully down to the hub, and torque all three M8 bolts to 21 ft-lbs (28 N.m). Q. Place the new rotary union into the front of the hub. Be sure to oil the o-ring. R. Place the snap ring in the snap ring groove, beveled side out. Ensure that it is fully seated before pressure is applied to the hub. Refer to figure 14.

Figure 14: Snap Ring Installation ___________________________________________________________________________________________________ Printed In Canada 01553r1.doc AX1000 Manual 10/31/2007 Page 9

PARTS BOOK FOR AX1000 FAN SYSTEM (76020)

96227r0 ILLUSTRATIONS MAY NOT BE SPECIFIC TO YOUR MODEL ARE INTENDED FOR PARTS IDENTIFICATION ONLY

NOTE

REF NO

PART NUMBER

QTY

DESCRIPTION

NOTE

REF NO

PART NUMBER

QTY

DESCRIPTION

1 2

90387 15102 Various 90388

1 1 3 1

ROTARY UNION KIT HUB BLADE KIT SERVICE KIT

5 6 7 8

15068 14573 14583 15107

12 1 1 3

SET SCREWS SPRING REAR PLATE BOLTS

B C

3 4

A - SOLD AS A KIT ONLY B - BLADES SOLD IN KITS OF 2 BLADES C - IF BLADES FAIL FROM IMPACT, ITEM 4 NEEDS TO BE ORDERED WITH BLADE KITS

THE FAN SERIAL NUMBER IS REQUIRED WHEN ORDERING PARTS

PRINTED IN CANADA

October 31, 2007

FLEXXAIRE MANUFACTURING INC

76020PBR1.wpd