installation and service manual for the tac2000-p & tac3000
Contents
1. RONT VIE IDE E REAR E Figure 1 Fan Components 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 The TAC2000 TAC3000 fan is supplied with either a pre machined mounting adapter or a generic The following is a general description for the mounting adapter Pre machined mounting removal of an existing fan and the installation of a adapters are machined for your pilot and bolt circle Flexxaire TAC2000 TAC3000 Fan Generic mounting adapters require a pilot and bolt A Remove fan guards and safety equipment to circle machined into them to match the pilot and gain access to the existing fan bolt circle of your fan drive Contact Flexxaire for B Loosen belt s and remove existing fan machining instructions if you are using a generic hardware as required mounting adapter For some applications a wider 2 C Clean mounting surface of the fan drive piece adapter may be used and the necessary hardware for assembling the 2 parts together will be 2 3 INSTALLATION included This 2 piece adapter may be pre assembled Mounting Adapters Printed In Canada 01524r10 doc TAC2000 TAC3000 Manual 12 03 2009 Page 3 Fan Position Ideally the fan should be centered in the shroud 30 70 immersion is acceptable This may require modification or re2. supplied 4 NC lock nut See Figure 7 y BLADE m BLADE CAP m WASHER INCLUDED IF l A BOLT HEAD IS NON FLANGED on O _ i ea E Bee ac er Sy ASF Figure 7 B 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 Regular hex head bolts with washers may be substituted for the flange headed bolts Printed In Canada 01524r10 doc TAC2000 TAC3000 Manual 12 03 2009 Page 5 C Carefully torque the blade bolts with a certified torque wrench to the following specification 4 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 D Rotate the fan by hand and check for obstructions 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 pressures for each fan model Spin the fan by hand with the blade pitch reversed and check for obstructions E Ensure you have the correct blade clearance See Figure 5 on page 5 for a list of recommended minimum clearances based on fan diameter F Tighten the fan belts and replace all the fan guards and safety equipment
3. SFLEXXAIRE INSTALLATION AND SERVICE MANUAL FOR THE TAC2000 P amp TAC3000 P FAN SERIES PNEUMATIC CONTROL TAC2000 H amp TAC3000 H FAN SERIES HYDRAULIC CONTROL PUBLICATION No 01524 Revision 10 Printed in Canada 1 1 INTRODUCTION This manual P N 01524 is produced to assist in the installation operation and maintenance of Flexxaire TAC2000 P TAC3000 P TAC2000 H and TAC3000 H Series Fan Systems Flexxaire 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 Flexxaire Product Support Department 10430 180 Street Edmonton Alberta Canada T5S 1C3 Phone 780 483 3267 Fax 780 483 6099 Toll Free 866 489 3267 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 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 pa
4. Flexxaire s TAC2000 TAC3000 fan systems are designed to minimize overheating caused by debris plugged radiators screens and guards and reduce overcooling in low ambient temperatures The blades of the TAC2000 TAC3000 vary pitch not speed to control air flow volume and direction How your TAC2000 TAC3000 works The TAC2000 P TAC3000 P is a pneumatically actuated variable pitch fan The TAC2000 H TAC3000 H is a hydraulically actuated variable pitch fan The blades are held in full pitch by a heavy spring As pneumatic or hydraulic 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 Printed In Canada 01524rl0 doc TAC2000 TAC3000 Manual position The TAC2000 TAC3000 has a number of important features 1 Fail Safe Operation The blades are spring loaded into the default full pitch position If the fan loses 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 2 0 CONTROL KITS Due to the variability of machines that the TAC20
5. G 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 clearance could result in blade contact that can cause extensive damage to people and equipment 3 1 TAC3000 AIR DAM TAC3000 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 TAC3000 hub assembly See Pictures Printed In Canada 01524r10 doc TAC2000 TAC3000 Manual 12 03 2009 Page 6 4 0 PNEUMATIC SPECIFICATIONS Flexxaire supplies a number of pneumatic control options but the TAC2000 P TAC3000 P 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 TAC2000 P General Specifications Full Pitch default position O psi Neutral Pitch Stop air position 35 40 psi Reverse Pitch Purge position 70 90 psi Max intermittent pressure 110 psi Max continuous pressure 90 psi extended operation at higher pressure will reduce the life of the rotary union seal TAC3000 P General Specifications Full Pitch default position 0 psi Neutral Pitch Stop air
6. general specifications listed below If your machine has hydraulics on board then this source should be available TAC2000 H General Specifications Full Pitch default position O psi Neutral Pitch Stop air position 300 psi Reverse Pitch Purge position 450 psi Maximum allowable pressure 1000 psi TAC3000 H General Specifications Full Pitch default position 0 psi Neutral Pitch Stop air position 275 psi Reverse Pitch Purge position 550 psi Maximum allowable pressure 1000 psi 5 1 HYDRAULIC LINE INSTALL A 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 B 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 C 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 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 obs
7. 00 TAC3000 fan may be installed on the fan does not include any control components Flexxaire has a number of different control kits available to suit a wide range of applications PNEUMATIC CONTROL 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 Each kit is available with or without an air compressor 12 03 2009 Page 2 HYDRAULIC CONTROL All of these pneumatic and hydraulic kits are 2 Position kit Manual Purge available in 12V and 24V configurations Contact 2 Position kit with timer Manual and Auto Purge Flexxaire or your dealer for details and availability Full Variable Pitch Controller Full fan control 2 1 MAJOR COMPONENTS The TAC2000 TAC3000 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 TAC2000 H but all the major components are the same between the TAC2000 and TAC3000 fans NCOMING s LINE ma ATTACH TO 1 HYDRAULIC i ie J a e Sa OQ 7 A J 1 mA
8. e radiator and engine Are any of the blades damaged Does the rotary union rotate 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 12 03 2009 Page 6 3 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 union to leak 6 4 TAC2000 H TAC3000 H ROTARY UNION REPLACEMENT 3 The rotary union assembly can then be removed Applying air pressure can assist in removing the rotary union from the hole il 1 Shown above is the rotary union installed in the hub of the Flexxaire TAC2000 H fan This rotary union is held in place by a snap ring as shown 4 For re assembly of the rotary union care should be taken to ensure the o rings are in good condition and are not damaged during the installation process as the o rings slide past the snap ring groove 5 Please ensure that any side load placed on the rotary union by the hydraulic line is minimized Excessive side load will affect the life of the rotary union 2 Using snap ring pliers the snap ring can be easily removed 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 union to lea
9. ed of the fan blades while changing pitch or purging Maximum allowable working hydraulic pressure is 1000 psi 6 0 SERVICE AND MAINTENANCE Flexxaire s TAC2000 TAC3000 fan hub is fully sealed with o rings and contains a small amount of oil As a result the fan should not require any maintenance Printed In Canada 01524r10 doc TAC2000 TAC3000 Manual 6 1 VISUAL INSPECTIONS Under normal operating conditions TAC2000 TAC3000 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 is recommended from time to time to safeguard against fan blade damage which could lead to equipment downtime and or other damages 6 2 MECHANICAL REVIEW Ensure that the fan fully reverses pitch Check for leaks in the rotary union Check that the rotary union bearings rotate smoothly Verify that you have the correct blade clearance as per Figure 5 on page 5 CHECK Does fan rotate in default and full reverse pitches without obstruction Are blade fasteners torqued to 9 ft lbs Are blades installed in the correct orientation blower sucker See Fig 6 Has the side load on the pressure line been minimized Has the pressure line been constrained to prevent contact with the blades Is the pressure line flexible enough to accommodate relative movement between th
10. er to Figure 3 D Remove the silicon shipping plugs from the rear of the fan Place the TAC2000 TAC3000 fan onto the mounting adapter and torque the 3 8 bolts to 40 Ft Lbs 54 N m Do not use loctite Refer to Figure 4 _3 8 16NC TORQUE 40 3S TORQUE 40 FT LBS aaa i La a MD V 2 AEN E 4 K AS SSS Se 7 N a Wa 1 ae a jE Figure 4 3 0 ATTACHING THE BLADES Your Flexxaire fan shipped with the fan blades unattached Care must be taken to ensure the blades are attached correctly If the primary operation of the fan is to pull air towards the engine the blades must be mounted with the concave surface towards the engine assuming the fan rotates counter clockwise as viewed from the engine 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 6 12 03 2009 Page 4 BLADE CLEARANCE FOR ALL TAC FAN SERIES Fan Minimum Diameter Clearance 18 30 00 0 50 48 00 0 75 54 00 1 00 457mm 762mm 763mm 1219mm 1220mm 1372 mm 1373mm 1829 mm P
11. k Note The TAC2000 H TAC3000 H rotary union can be replaced without removing the fan from the fan drive if there is at least 3 of clearance between the front face of the rotary union and the nearest obstruction Printed In Canada 01524r10 doc TAC2000 TAC3000 Manual 12 03 2009 Page 9
12. lease refer to chart above for proper clearance required for fan blades Failure to have the proper clearance could allow for blade contact to Occur CLEARANCE NEEDED ON BOTH SIDES OF THE BLADE Figure 5 WARNING SEE FIGURE ABOVE FOR BLADE AND ROTARY UNION CLEARANCES B ES MOUNTED R BLADE BLUWER FAN CRUSHD SUCKER FAN CPULL A A 7 SEEN AIRF Figure 6 A TAC2000 TAC3000 fans are supplied with either 1 or 2 counterweights per blade If ROTARY UNION RE BE OB CLEARANCE FOR TAC P OR H FLEXXAIRE FAN HUB WITH NO BLADES SHOWN FLEXXAIRE FAN ADAPTER CUSTOM MADE FOR EACH APPLICATION COMMENDED MINIMUM CLEARANCE TWEEN ROTARY UNION AND CLOSEST JECT 9631510 two counterweights per blade are supplied install one weight on each side If only one counterweight is supplied then the counterweight can be installed on either side as long as they are all on the same side Insert the supplied 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 counterweight is being used Tighten the assembly with the
13. moval of the fan spacer or modification of the shroud See Figure 2 cup Al D JII d FIK LRE y J FAN SPACER MODIFIED FAN SPACER ORIGINAL FAN LEXXAIRE FAN Figure 2 A 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 installing the mounting adapter to the fan drive Refer to Figure 3 A U Pg oo ES AN SON Se oi Y yV Y p x Te XS LN Figure 3 Adapter Plate Mounting Printed In Canada 01524rl0 doc TAC2000 TAC3000 Manual B Set up dial gauge to measure axial deviation of the mounting adapter on the fan mounting surface Deviation should not exceed 0 005 Refer to Figure 3 C Set up dial gauge to measure radial deviation of the mounting adapter on the 1 pilot hole surface Deviation should not exceed 0 005 Ref
14. position 40 45 psi Reverse Pitch Purge position 90 100 psi Max intermittent pressure 110 psi Max continuous pressure 90 psi Recommended minimum flow rate 35cfm 70 psi The lower the flow rate the longer it takes to purge the fan at 35cfm 7Opsi it takes approximately 7 seconds to fully reverse pitch 4 1 PNEUMATIC LINE INSTALL A 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 the fan blades B 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 vibration 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 Printed In Canada 01524r10 doc TAC2000 TAC3000 Manual rotary union Failure of the rotary union could result 5 0 HYDRAULIC SPECIFICATIONS Flexxaire supplies a number of hydraulic control options but the TAC2000 H TAC3000 H can be operated using any hydraulic source that meets the
15. rts 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 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 Printed In Canada 01524rl0 doc TAC2000 TAC3000 Manual 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 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 1 2 3 HOT FLUIDS AND PARTS 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 1 3 PRODUCT SUPPORT The Flexxaire Product Support Department provides technical support information on fan in
16. stallation and maintenance parts instruction manuals and is 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 am to 4 00 pm 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 12 03 2009 Page NORMAL OPERATION NEUTRAL PITCH STOP AIR FLOW PREVENT OVERCOOLING EFFICIENT COOLING PURGE CLEAN RADIATOR PREVENT OVERHEATING SAVE HORSEPOWER 1 4 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 formula Fan Diameter Inches X 3 14 X Fan RPM 12 If your calculated tip speed exceeds 20 000 ft min contact Flexxaire directly prior to installation It is important to use Fan RPM and NOT engine RPM 1 5 FAN OVERVIEW
17. truction as per Figure 5 on page 5 12 03 2009 Page D 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 fittings 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 be applied every time the hose is attached or detached from the rotary union 5 2 HYDRAULIC LINE SPECIFICATIONS A TAC2000 H The connection on the rotary union is a 1 8NPT female thread 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 If supplying your own hose it is recommended to use a hose that is as small as possible The potential exists that a large heavy hose with bulky fittings 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 Maximum allowable working hydraulic pressure is 1000 psi B TAC3000 H The connection on the rotary union is a 1 8NPT female thread 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 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 spe
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