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Cleanfix C222 User Manual

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FANS
C162 / C222 / C252 / H162 / H222 / H252
Operating instructions – EN
https://cleanfix.org/instructions-train
EN: Scan QR code to get instructions in other languages.
DE: QR-Code scannen um Anleitung in weiteren Sprachen zu erhalten.
FR: Scanner le code QR pour obtenir des instructions dans d'autres langues.
IT: Scansione QR-Code per ottenere istruzioni in altre lingue.
ES: Escanea el Código QR para obtener instrucciones en otros idiomas.
PT: Digitalize o Código QR para obter instruções noutras línguas.
TR: Diğer dillerdeki talimatlar için QR kodunu tarayın.
Item no. 214756 (2021/02) V2.0

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Summary of Contents for Cleanfix C222

  • Page 1 FANS C162 / C222 / C252 / H162 / H222 / H252 Operating instructions – EN EN: Scan QR code to get instructions in other languages. DE: QR-Code scannen um Anleitung in weiteren Sprachen zu erhalten. FR: Scanner le code QR pour obtenir des instructions dans d'autres langues.
  • Page 2 CLEANFIX ensures less downtime and helps reduce service costs. CLEANFIX is used in a wide range of railway vehicles as well as construction, municipal, agricultural, forestry, waste and recycling machines, such as trains, tractors, harvesters, combines, sprayers, excavators, wheel loaders, dozers, skid steers, and a variety of other industrial equipment.

  • Page 3: Table Of Contents

    5.2.2 Hydraulic ..................23 ® Mounting the Cleanfix reversible fan ..........25 ® Checking the smooth movement of the Cleanfix reversible fan ..31 5.4.1 Pneumatic ..................31 5.4.2 Hydraulic ..................33 Mounting the hydraulic hose fitting (only for H162 fans) ....34 ®...
  • Page 4 7.2.3 Activating the Multi-Timer intermediate cleaning cycle ..... 67 7.2.4 Onboard compressed air system ............. 67 Operation ..................68 Maintenance ................... 70 ® Servicing the Cleanfix reversible fan ..........70 ® Servicing the Cleanfix electrical components ......... 70 Troubleshooting ................71 ®...

  • Page 5: General Information

    E-mail: service@cleanfix.org Our customer service department or one of our representatives around the world is available at any time to answer further questions. 1.1.3 Updates The most recent version of the operating instructions and other information are available at https://cleanfix.org/de/service/anleitung-bahn.

  • Page 6: Introduction

    1 GENERAL INFORMATION Introduction ® Before installing or starting up the Cleanfix reversible fan, familiarize yourself with the contents of these operating instructions. This facilitates safe and efficient handling of the product. The operating instructions are a component of the product and must always be close at hand.

  • Page 7: Liability And Damages

    1 GENERAL INFORMATION 1.2.2 Liability and damages Since we are not included in technical service updates from the manufacturer, you may be required to make adjustments when installing this product. Hägele GmbH does not assume responsibility for installation and modification costs. On account of the information provided in these operating instructions, the manufacturer accepts no liability for direct damages or indirect losses arising from improper operation or maintenance.

  • Page 8: Product Identification

    1 GENERAL INFORMATION 1.2.4 Product identification Inquiries addressed to the manufacturer must include the fan serial number. This number can be found at the following location: Fan serial number: Serial number: (Please fill in) • On the side of the fan cover.

  • Page 9: Typographical Conventions

    1 GENERAL INFORMATION 1.2.5 Typographical conventions The following symbols and terms are used in these operating instructions: • Bulleted lists. Action to be performed. ➔ Result of the action. ➢ Measure to prevent dangers. Optional feature that is not included in the standard features. (1) Labeling of a figure.

  • Page 10: Safety Information In The Text

    1 GENERAL INFORMATION 1.2.6 Safety information in the text Safe use is possible only if all information necessary for safe operation is observed. The safety information warns users about risks and informs them about how to avoid the risks. General safety information is provided at the beginning of these operating instructions in chapter 2.

  • Page 11: Product Description

    1 GENERAL INFORMATION Product description 1.3.1 Pneumatic fan components Fig. 1 (1) Pressure hose (2) Hose clamp (3) Hose screw connection (4) Fan (5) Flange (6) Flange screws...

  • Page 12: Hydraulic Fan Components

    1 GENERAL INFORMATION 1.3.2 Hydraulic fan components Fig. 2 (1) Pressure hose (2) Usit rings (3) Banjo bolt (4) Hose screw connection (5) Fan (6) Flange (7) Flange screws...

  • Page 13: Cleanfix ® Electrical Components

    1 GENERAL INFORMATION ® 1.3.3 Cleanfix electrical components ® Cleanfix offers a number of control solutions. The reversing function is activated either pneumatically or hydraulically and controlled electronically. Reversing function Hydraulic activation Pneumatic activation For vehicles with a For vehicles with a...

  • Page 14: Safety

    2 SAFETY Safety This chapter provides general safety information. The individual chapters of the operating instructions also contain specific safety information that is not provided in the “Safety” chapter. Safety information should be observed: • for your own safety. • for the safety of others.

  • Page 15: Safety Information

    2 SAFETY Safety information WARNING! Modifications to the fan may result in serious injury or death! Unauthorized modifications may impair the functioning and/or safety and the service life of the fan. Unauthorized modifications to the fan terminate the manufacturer’s warranty and liability. These modifications may result in damage to the machine as well as to serious injury or death.
  • Page 16 2 SAFETY CAUTION! Failure to resolve malfunctions may result in accidents or damage! Operation of a defective fan or fan component may lead to accidents or damage. ➢ Immediately stop the machine. ➢ Shut down the machine. ➢ Secure the machine. ➢...
  • Page 17 2 SAFETY NOTE Reversing the fan while the vehicle is in the red temperature range may result in property damage! The cooling effect is interrupted when the reversing function is activated. Reversing the fan while the vehicle is in the red temperature range causes the engine to overheat.

  • Page 18: Required Tools

    3 REQUIRED TOOLS Required tools Flange mounting • Magnetic or clamp type dial gauge • 12 Nm - 20 Nm torque wrench Pneumatic pressure hose mounting • Lubricant • Pincers Hydraulic pressure hose fitting mounting (H162) • Lubricant • 10 mm wrench •...

  • Page 19: Removing The Manufacturer's Fan

    4 REMOVING THE MANUFACTURER’S FAN Removing the manufacturer’s fan CAUTION! Risk of injury due to a hot engine! A hot engine can burn hands or other body parts ➢ Turn off the engine. ➢ Allow the engine to cool down. ➢...

  • Page 20: Installing The Cleanfix Reversible Fan

    5 INSTALLING THE CLEANFIX® REVERSIBLE FAN ® Installing the Cleanfix reversible fan ® Mounting the Cleanfix flange 1) Remove all dirt and rust from the fan drive mounting surface for the flange. 2) Loosen any belts that drive the fan pulley.
  • Page 21 5 INSTALLING THE CLEANFIX® REVERSIBLE FAN WARNING! Axial and radial circular runout may cause property damage! Imbalances damage the fan and may result in vehicle damage and serious injury. ➢ The axial and radial circular runout must be checked using a dial gauge and must not exceed 0.1 mm (0.004").

  • Page 22: Attaching The Pressure Hose To The Fan

    5 INSTALLING THE CLEANFIX® REVERSIBLE FAN Attaching the pressure hose to the fan 5.2.1 Pneumatic NOTE Bending the air intake tube may cause property damage! The bending radius of the high-pressure hose must be at least 50 mm! During mounting, the air intake tube can become bent toward the blades.

  • Page 23: Hydraulic

    5 INSTALLING THE CLEANFIX® REVERSIBLE FAN 4) Position the hose clamp as shown in Fig. 15. 5) Pinch the ears of the hose clamp together with pincers. ➔ This secures the pressure hose. Fig. 15 5.2.2 Hydraulic 1) Screw the banjo bolt together with the pressure hose and two Usit rings hand-tight in the air intake assembly on the fan.
  • Page 24 5 INSTALLING THE CLEANFIX® REVERSIBLE FAN Maximum hose length between the fan and valve Hose length → DN4 max. 2.0 m H162 → DN5 max. 1.5 m → DN5 max. 4.0m H222, H252 → DN6 max. 2.5m WARNING! An incorrectly mounted high-pressure hose may cause collision!

  • Page 25: Mounting The Cleanfix Reversible Fan

    5 INSTALLING THE CLEANFIX® REVERSIBLE FAN ® Mounting the Cleanfix reversible fan 1) Drill a hole in the shroud as close as possible to the radiator. Hole diameter in the shroud Hose type Hole diameter → 20 mm Hydraulic hose →...
  • Page 26 5 INSTALLING THE CLEANFIX® REVERSIBLE FAN NOTE Carelessly inserting the fan may cause property damage! If the fan is inserted carelessly into the shroud, the radiator fins can be damaged from impacts with the fan. ➢ If necessary, protect the radiator fins with cardboard.
  • Page 27 5 INSTALLING THE CLEANFIX® REVERSIBLE FAN 5) Attach the fan to the flange using the provided locking screws. 6) Tighten the locking screws to the specified torque. Tightening torque for locking screws Fan model: Torque → 12 Nm C162, H162 →...
  • Page 28 5 INSTALLING THE CLEANFIX® REVERSIBLE FAN Maximum airflow rate So that the fan can reach its maximum airflow rate, the optimum installation depth must be observed when the fan is installed in the shroud. • The fan must be able to move freely within the shroud, even with turned blades •...
  • Page 29 5 INSTALLING THE CLEANFIX® REVERSIBLE FAN 7) Pull the pressure hose through the hose screw connection. ➔ Make sure that the hose cannot be caught by the blades. NOTE Incorrect mounting of the pressure hose may cause property damage! When the pressure hose is mounted, it may be positioned too close to the blades.
  • Page 30 5 INSTALLING THE CLEANFIX® REVERSIBLE FAN NOTE Excessive tension on the pressure hose may cause property damage! If the air intake assembly on the fan is under tension from the hose, the seals on the air intake assembly will wear out and the fan will start leaking.

  • Page 31: Checking The Smooth Movement Of The Cleanfix Reversible Fan

    5 INSTALLING THE CLEANFIX® REVERSIBLE FAN ® Checking the smooth movement of the Cleanfix reversible fan 5.4.1 Pneumatic 1) Supply compressed air (max. 10 bar) to the fan. ➔ This causes the blades to turn to the transverse position. Fig. 25 2) Use locking pliers to pinch the pressure hose.
  • Page 32 5 INSTALLING THE CLEANFIX® REVERSIBLE FAN WARNING! Pulling in of loose objects! Loose objects can be pulled into the fan during operation, which may result in property damage to the fan and vehicle and cause serious injury! ➢ Remove loose objects or secure them with plastic ties, where appropriate.

  • Page 33: Hydraulic

    5 INSTALLING THE CLEANFIX® REVERSIBLE FAN 5.4.2 Hydraulic The blades cannot be moved to the transverse position when they are not in motion. 1) Measure whether interfering contours or obstructions are in the way. For the measurement method, see the figure: Fig.

  • Page 34: Mounting The Hydraulic Hose Fitting (Only For H162 Fans)

    5 INSTALLING THE CLEANFIX® REVERSIBLE FAN Mounting the hydraulic hose fitting (only for H162 fans) 1) Lubricate the outside of the hose end of the high-pressure hose. 2) Manually turn the screw sleeve counterclockwise (left-handed thread) onto the high-pressure hose.
  • Page 35 5 INSTALLING THE CLEANFIX® REVERSIBLE FAN 3) Use a 12 mm wrench to screw the screw sleeve counterclockwise onto the high-pressure hose until it stops. Fig. 29 4) Rotate a tube connector with right-hand thread into the screw sleeve. Fig. 30...
  • Page 36 5 INSTALLING THE CLEANFIX® REVERSIBLE FAN 5) Use a 12 mm wrench to hold the screw sleeve in place. 6) Use a 10 mm wrench to screw the tube connector onto the screw sleeve until it stops. Fig. 31...

  • Page 37: Mounting The Cleanfix Electrical Components

    6 MOUNTING THE CLEANFIX® ELECTRICAL COMPONENTS ® Mounting the Cleanfix electrical components ® This chapter describes how to mount the Cleanfix electrical components. NOTE Property damage due to fire hazard! ➢ The vertical gap between the fan and the control must be at least 200 mm and the horizontal gap at least 20 mm.
  • Page 38 6 MOUNTING THE CLEANFIX® ELECTRICAL COMPONENTS Reversing function Hydraulic activation Pneumatic activation For vehicles with a For vehicles with a For vehicles without a hydraulic system compressed air system compressed air system Push button Valve Valve Compressor unit Press the push button to...

  • Page 39: For Pneumatic Activation

    6 MOUNTING THE CLEANFIX® ELECTRICAL COMPONENTS For pneumatic activation ® 6.1.1 Cleanfix valve / for railway vehicles with a compressed air system NOTE Property damage due to fire hazard! ➢ The vertical gap between the fan and the control must be at least 200 mm and the horizontal gap at least 20 mm.

  • Page 40: System

    3) Cut the pressure hose to a suitable length. 4) Slide the hose clamp over the pressure hose. ® 5) Slide the pressure hose over the hose fitting of the Cleanfix valve. 6) Secure the pressure hose by pinching the ears of the hose clamp with pincers.
  • Page 41 6 MOUNTING THE CLEANFIX® ELECTRICAL COMPONENTS Mounting the push button 8) Determine the mounting location for the push button in the vehicle cab. Push button mounting location If an unassigned OEM push button is available in the vehicle cab, then this push button can be used to save installation time.
  • Page 42 ® Connecting the Cleanfix power supply ® 11) Determine the power supply to which the Cleanfix valve and the push button can be connected. ® Power connection for the Cleanfix valve and push button...

  • Page 43: Cleanfix

    6 MOUNTING THE CLEANFIX® ELECTRICAL COMPONENTS ® 6.1.2 Cleanfix valve unit with Mini-Timer or Multi-Timer / for vehicles with a compressed air system NOTE Property damage due to fire hazard! ➢ The vertical gap between the fan and the control must be at least 200 mm and the horizontal gap at least 20 mm.
  • Page 44 3) Cut the pressure hose to a suitable length. 4) Slide the hose clamp over the pressure hose. ® 5) Slide the pressure hose over the hose fitting of the Cleanfix valve unit. 6) Secure the pressure hose by pinching the ears of the hose clamp with...
  • Page 45 6 MOUNTING THE CLEANFIX® ELECTRICAL COMPONENTS valve unit to the vehicle’s compressed air ® Connecting the Cleanfix system ® Cleanfix valve unit connection to the compressed air system If an auxiliary consumer circuit (fused compressed air circuit) is available at the vehicle’s compressed air system, this circuit can be used to save...
  • Page 46 ® Connecting the Cleanfix power supply Fig. 44 ® 11) Determine the power supply to which the Cleanfix valve unit and the push button can be connected. ® Power connection for the Cleanfix valve unit and push button...

  • Page 47: Cleanfix Standard Compressor Unit / For Vehicles Without A Compressed Air System

    6 MOUNTING THE CLEANFIX® ELECTRICAL COMPONENTS ® 6.1.3 Cleanfix standard compressor unit / for vehicles without a compressed air system NOTE Property damage due to fire hazard! ➢ The vertical gap between the fan and the control must be at least 200 mm and the horizontal gap at least 20 mm.
  • Page 48 If the component is mounted in the engine compartment, the preferred location is on the cooler side of the engine (away from the exhaust manifold and muffler). ® 2) Use the supplied screws to mount the Cleanfix compressor unit. ® 3) Orient the air filter of the Cleanfix compressor unit downward or to the side.
  • Page 49 4) Cut the pressure hose to a suitable length. 5) Slide the hose clamp over the pressure hose. ® 6) Slide the pressure hose over the hose fitting of the Cleanfix compressor unit. 7) Secure the pressure hose by pinching the ears of the hose clamp with pincers.
  • Page 50 Connecting the Cleanfix compressor unit and push button to the vehicle’s power supply Fig. 47 ® 11) Determine the power supply to which the Cleanfix compressor unit and the push button can be connected. ® Power connection for the Cleanfix...

  • Page 51: Cleanfix Control Unit With Mini-Timer Or Multi-Timer

    6 MOUNTING THE CLEANFIX® ELECTRICAL COMPONENTS ® 6.1.4 Cleanfix control unit with Mini-Timer or Multi-Timer NOTE Property damage due to fire hazard! ➢ The vertical gap between the fan and the control must be at least 200 mm and the horizontal gap at least 20 mm.
  • Page 52 When choosing the mounting location, keep in mind that the compressor of the Cleanfix® control unit generates a faint noise and vibrations when it operates. When choosing the mounting location, make sure that the air filter of the ®...
  • Page 53 6 MOUNTING THE CLEANFIX® ELECTRICAL COMPONENTS Mounting the push button 8) Determine the mounting location for the push button in the vehicle cab. Push button mounting location If an unassigned OEM push button is available in the vehicle cab, then this push button can be used to save installation time.
  • Page 54 ® Connecting the Cleanfix power supply Fig. 50 ® 11) Determine the power supply to which the Cleanfix control unit and the push button can be connected. ® Power connection for the Cleanfix control unit and push button...

  • Page 55: For Hydraulic Activation

    6 MOUNTING THE CLEANFIX® ELECTRICAL COMPONENTS For hydraulic activation ® 6.2.1 Cleanfix valve / for vehicles with a hydraulic system NOTE Property damage due to fire hazard! ➢ The vertical gap between the fan and the control must be at least 200 mm and the horizontal gap at least 20 mm.
  • Page 56 If the component is mounted in the engine compartment, the preferred location is on the cooler side of the engine (away from the exhaust manifold and muffler). ® 2) Use the supplied screws to mount the Cleanfix valve. ® Connecting the Cleanfix valve with the pressure hose of the Cleanfix®...
  • Page 57 Return flow The return flow must be implemented via a pipe connection at least 8 mm in diameter. ® 4) Use suitable pressure hoses to connect the Cleanfix valve to the hydraulic system. Mounting the push button 5) Determine the mounting location for the push button in the vehicle cab.
  • Page 58 ® Connecting the Cleanfix power supply ® 8) Determine the power supply to which the Cleanfix valve and the push button can be connected. ® Power connection for the Cleanfix valve and push button...

  • Page 59: Cleanfix Valve Unit With Mini-Timer Or Multi-Timer / For Vehicles With A Hydraulic System

    6 MOUNTING THE CLEANFIX® ELECTRICAL COMPONENTS ® 6.2.2 Cleanfix valve unit with Mini-Timer or Multi-Timer / for vehicles with a hydraulic system NOTE Property damage due to fire hazard! ➢ The vertical gap between the fan and the control must be at least 200 mm and the horizontal gap at least 20 mm.
  • Page 60 If the component is mounted in the engine compartment, the preferred location is on the cooler side of the engine (away from the exhaust manifold and muffler). ® 2) Use the supplied screws to mount the Cleanfix valve unit. ® Connecting the Cleanfix valve unit with the pressure hose of the ®...
  • Page 61 Return flow The return flow must be implemented via a pipe connection at least 8 mm in diameter. ® 4) Use suitable pressure hoses to connect the Cleanfix valve unit to the hydraulic system. Mounting the push button 5) Determine the mounting location for the push button in the vehicle cab.
  • Page 62 ® Connecting the Cleanfix power supply ® 8) Determine the power supply to which the Cleanfix valve unit and the push button can be connected. ® Power connection for the Cleanfix valve unit and push button...

  • Page 63: Setting The Timer

    Setting the timer There are two timer controls (Mini-Timer and Multi-Timer) for the CLEANFIX® compressor and valve. The Mini-Timer control initiates a clean-out cycle once the operator presses the push button. The Multi-Timer control automatically initiates an additional clean-out cycle at set intervals and can also initiate a clean-out cycle once the operator presses the push button.

  • Page 64: Setting The Mini-Timer

    7 SETTING THE TIMER Setting the Mini-Timer The Mini-Timer control regulates the cleaning cycle of the compressor and valve. 7.1.1 Mini-Timer default setting As delivered, the following times are pre-set: Control unit Compressor (mz) approx. 20 s Valve (t1+mz+t2) 23 s Fig.

  • Page 65: Setting The Multi-Timer

    7 SETTING THE TIMER Setting the Multi-Timer The Multi-Timer automatically initiates a cleaning cycle at set intervals. 7.2.1 Multi-Timer default setting As delivered, the following times are pre-set: Control unit and E-Box Compressor (mz) The compressor switches off when the pressure reaches 8 bar or after a maximum time of 30 s.
  • Page 66 7 SETTING THE TIMER Control unit Valve unit Fig. 65 The frequency of the cleaning cycles depends on the machine and the environment it is working in. The frequency can be adjusted by sliding the DIP switches to one of seven levels. Fig.

  • Page 67: Activating The Multi-Timer Intermediate Cleaning Cycle

    7 SETTING THE TIMER If all DIP switches numbered 1-4 are in the "Off" position, the electronics carry out a self-test. In this case, the compressor and valve are switched on simultaneously for 1 second, then off for 1 second. This continues until the voltage supply is interrupted or a DIP switch is switched to "On”.

  • Page 68: Operation

    8 OPERATION Operation The reversing function is controlled electronically. The operation and ® function of the push button differs depending on the version of the Cleanfix electrical components. ® Cleanfix electrical component without a timer Press the push button to change from cooling to cleaning. The fan remains in cleaning mode for as long as the push button is pressed.
  • Page 69 8 OPERATION ® Cleanfix electrical component with a Multi-Timer Switching from cooling to cleaning and back is time-controlled, for example, every 30 minutes. This interval can be changed as desired. Intermediate cleaning can be performed at any time by pressing the push button.

  • Page 70: Maintenance

    9 MAINTENANCE Maintenance Servicing the Cleanfix ® reversible fan ® Cleanfix reversible fans are maintenance-free. ® Servicing the Cleanfix electrical components ® For pneumatic Cleanfix electrical components with a compressor, the filter must be replaced at each machine maintenance interval.

  • Page 71: Troubleshooting

    10 TROUBLESHOOTING Troubleshooting ® 10.1 Troubleshooting Cleanfix pneumatic reversible fans Error Cause of error Troubleshooting Blades do not No or low pressure 1.1.1 Check the compressed air supply at the rotate to the supply solenoid valve. cleaning position (with a compressed air...
  • Page 72 10 TROUBLESHOOTING 1.1.4 Mechanical failure. If all the above conditions are met and the blades do not rotate, then the trouble is a mechanical error. The fan must be sent to the manufacturer for testing. No or low pressure 1.2.1 Check the functioning of the supply compressor.
  • Page 73 10 TROUBLESHOOTING 1.2.4 Check the pressure hose If necessary, pull the pressure hose from the valve and connect it to the workshop compressed air supply (max. 8 bar / 116 psi) to locate possible leaks faster. The pressure hose from the solenoid valve to fan has no kinks or leaks →...
  • Page 74 10 TROUBLESHOOTING Error Cause of error Troubleshooting Blades do not Fan speed is too high 2.1.1 Reduce the speed. return from the cleaning position to the cooling mode 2.1.2 Install more springs, if possible Additional springs increase the release force. The fan must be sent to the manufacturer.

  • Page 75: Troubleshooting Cleanfix Hydraulic Reversible Fans

    10 TROUBLESHOOTING ® 10.2 Troubleshooting Cleanfix hydraulic reversible fans Error Cause of error Troubleshooting Blades do not No or low pressure 1.1.1 Check the compressed air supply at the rotate to the supply solenoid valve. cleaning position Compressed air supplied at the solenoid valve →...
  • Page 76 10 TROUBLESHOOTING Error Cause of error Troubleshooting Blades do not Fan speed is too high 2.1.1 Reduce the speed. return from the cleaning position to the cooling mode 2.1.2 Install more springs, if possible Additional springs increase the release force. The fan must be sent to the manufacturer.

  • Page 77: Troubleshooting Cleanfix Electrical Components

    10 TROUBLESHOOTING ® Troubleshooting Cleanfix electrical components 10.3 The control unit monitors the electrical circuit for electronic faults. In the case of a short circuit, the internal fuse switches the control unit off. After the fuse cools, the control unit is switched on again.

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