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Tuf-Lite III® Fans
5000K Series Hub
INSTALLATION MANUAL
Adjustable Pitch Fan Assembly
Hudson Tuf-Lite III® fan blades
Hudson Tuf-Lite III® fan blades are of single piece fiberglass reinforced plastic (FRP) construction optimized for performance, reliability, noise, and cost effectiveness. Tuf-Lite III® fan blades are constructed
of light weight, corrosion-resistant, fiberglass reinforced vinyl-ester resin, with materials, thickness, and
processes determined from finite element analysis modeling. Tuf-Edge® leading edge erosion and UV
protection is a standard with this blade.
The individually balanced blades can be replaced independently - matched sets are not required.
Installation Manual 5000K Page 1 of 8 May 2012
20’ thru 30’ Diameter
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RECOMMENDED TOOLS
Long T-Handle Allen Wrench Set (3/16" to 3/8")
Medium Size Flat Head Screw Driver
Brass Ball Peen Hammer
Flat Bastard File
240 Grit Sand Paper
Anti-Seize Lubricant
WD-40
12" Crescent Wrench
INSTALLATION PROCEDURES
ASSEMBLY WITH BUSHING
Clean all mating surfaces between hub, bushing and shaft. All
grease and lubricant should be removed, leaving the mating
surfaces dry.
If there is no shoulder on shaft to prevent bushing from sliding
down shaft, slide spacer/sleeve (not provided) on shaft before
bushing or use a thrust retainer (optional equipment) on top of
hub. Slide bushing and key onto shaft until flush with end of
shaft. The shaft size determines the bushing type (R2, S2, or
U1). Lock bushing on shaft by tightening the set screw in flange
with an Allen Wrench. Line up key and set hub on bushing.
Engage the three (3) cap screws in flange of bushing into hub
spool, using a torque wrench with a socket, and tighten evenly.
Use the following table to determine the proper tools and torque
values.
Allen
Bushing
Size
Wrench
Size
R2 3/16" 3/8" 9/16" 29
S2 3/16" 1/2" 3/4" 70
U1 3/16" 5/8" 15/16" 140
Cap
Screw
Size
Socket
Size
Torque
(-lb)
Dry
Shop Towels
Exact-A-Pitch® Digital Protractor (P/N 62375)
25 ft. Measuring Tape
Pencil or Marker
Open/Box End Wrench Set (1/2" - 1-1/2")
Socket Set for 1/2" Drive (1/2" - 1-1/2")
Torque Wrench(s) Rated for 0-200 ft-lb.
ASSEMBLY WITH STRAIGHT SHAFT
(NO BUSHING)
Clean all mating surfaces between the hub and the shaft. If there
is no shoulder on shaft to prevent hub from sliding down shaft,
slide spacer/sleeve (not provided) on shaft before hub or use a
thrust retainer (optional equipment) on top of hub. Install key in
shaft. Line up key and keyway and set hub on shaft. Tighten set
screw(s) in hub.
ASSEMBLY WITH TAPERED SHAFT
(NO BUSHING REQUIRED)
Clean all mating surfaces between the hub and shaft.
Align keyways and install hub. Install retainer plate and cap
screw(s) with lock washer(s). Shaft size determines what size
cap screw is necessary. Using a torque wrench with a socket,
evenly tighten cap screw to recommended standard per table
below.
NOTE: Retaining arrangement varies with gear shaft design.
Cap Screw Socket
Size Size
Torque Value
(-lb)
Lubricated Dry
5/8" NC 15/16" 100 110
3/4" NC 1-1/8" 125 130
1" NC 1-1/2" 150 160
Installation Manual 5000K Page 2 of 8 May 2012
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THRUST RETAINER
(optional equipment)
Install proper load bolt (not provided) into top of fan shaft and
tighten (See Figure 1). Install thrust retainer channel on top hub
plate using existing hub spool cap screws. Torque cap screws to
60-65 ft-lb. Install thrust retainer eyebolt and jam nut. Hand
tighten eyebolt. Tighten jam nut securely against top of thrust
retainer channel.
Install clamp bolts through hub plates and blade clamp, putting
bolt heads on top, lock washers and nuts on bottom. Tighten
lightly (See Figure 3).
Figure 3
Figure 1
BLADE INSTALLATION
Remove blade clamp bolts, nuts, lock washers, and blade clamp
halves from hub. Assemble blade clamp halves over groove in
blade neck, and install into hub (See Figure 2). The thick leading edge will be to your left and thin trailing edge will be to
your right as you stand at end of blade.
SET PITCH AND TRACK
Use Hudson EXACT-A-PITCH® digital protractor (See
Figure 4) or a bubble protractor to set blade pitch. Mount
protractor on a flat bar as a base and place it approximately
1" from tip of blade. Note pitch on protractor. Rotate fan
360°, noting high and low pitch readings. Locate place
where pitch reading is at mid-point between high and low
readings, and set pitch at that point.
Figure 2
Installation Manual 5000K Page 3 of 8 May 2012
Figure 4
Page 4
Rotate blade in clamp until digital protractor shows specified
pitch angle to within +/-0.2°. Fan pitch angle is shown on fan
specification sheet for design duty. After desired pitch angle is
set, raise and lower end of fan blade and find midpoint of blade
travel. Hold blade at the midpoint. Pull blade outward so that
the blade neck flange rests against the back of the blade clamps.
Push blade to the right to remove all slack.
Use torque wrench to tighten clamp bolts to 100 ft-lb
(lubricated) or 125 ft-lb (dry). Re-check pitch setting. Blade
must be set within +/-0.2° of desired pitch angle. Tighten clamp
bolts evenly. DO NOT OVER-TORQUE CLAMP BOLTS.
When bolts are tightened, hold a pencil against top end of blade
and mark the level onto a fixed object, such as a pole or the fan
ring.
Install remaining blades at same place as first blade, following
the instructions above. After tightening bolts, mark top end of
each blade in same place first blade was marked. If marks differ
by 1" or more, adjust blade.
CHECK TRACK
After fan is installed in fan stack cylinder ring, outline top side
of each blade onto fan stack cylinder ring with a marker (See
Figure 5). The difference between levels of highest and lowest
outlines should not be more than 1". Correct blade track by
loosening clamp bolts and adjusting blade to match track of
other blades. Re-tighten bolts and re-check track and pitch angle setting. Re-tighten blade clamp bolts to recommended
standard of 100 ft-lb (lubricated) or 125 ft-lb (dry) torque.
SEAL DISC ASSEMBLY & INSTALLATION
Install self adhesive rubber gaskets on both flanges of one seal
disc half. Bolt two halves of seal disc together, using 3/8" NC
bolts, flat washer, lock washer, and nut. Torque to 15 ft-lb
(lubricated) and 20 ft-lb (dry).
Install 3/8" NC bolts at six (6) places on top hub plate (See
Figure 6). Threaded portion of bolts must be pointing up to
mount seal disc. Install lock washer, nut, and flat washer on
each bolt. Tighten 3/8" NC nuts to 15 ft-lb (lubricated) and 20
ft-lb (dry).
Locate the six (6) mounting holes in seal disc and install over
the six (6) bolts pointing up on upper hub plate. If difficulty is
encountered, loosen bolts on seal flanges until seal disc can be
mounted, then re-tighten to 15 ft-lb (lubricated) or 20 ft-lb
(dry).
NOTE: The purpose of the seal disc is to prevent hot air
from recirculating back down through the hub, increasing
efficiency.
Figure 5
Installation Manual 5000K Page 4 of 8 May 2012
Figure 6
Page 5
After mounting, install flat washer, lock washer, and 3/8” NC
nuts. Ti ghten to 15 ft -lb (lub r icated ) or 20 ft - l b (d r y).
(See Figure 7)
Note: Refer to instructions included with seal disc for further
details.
Figure 7
OPERATING INSTRUCTIONS
Start fan and check rotation. Viewed from top (discharge),
fan blades should rotate clockwise.
Check motor power consumption to be sure fan is pulling
desired load. CAUTION: If positive pitch is set in summer to
use all available motor amps (nameplate rating), motor could
be overloaded in winter. Design pitch angles usually do not
use all of the available motor horsepower. This ensures that
the motors will not be overloaded at low winter temperatures.
CHECKING TIP CLEARANCE
Rotate fan in position inside fan stack to check tip clearance
(See Figure 8). The recommended tip clearance is between 1"
and 1 1/2". Check for spots where fan blade clearance is not
within the recommended tolerance. If necessary, adjust fan
stack by shimming to obtain proper clearance.
TIP CLEARANCE
Figure 8
Installation Manual 5000K Page 5 of 8 May 2012
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PART LIST
HUDSON PRODUCTS CORPORATION
Adjustable Pitch Fan Assembly 20’ thru 30’ Diameter
Series 5000K HUB
ITEM DESCRIPTION TYPE
Up to 3.62” Diameter Shaft
3.68” Diameter thru 4.19” Diameter Shaft
4.25” Diameter thru 5.50” Diameter Shaft
1 Hub Plate
(2 Per Hub)
ITEM
2 Hub Spool
3 Bushing
4
Blade Clamp Half, Powder Epoxy Coated Die Cast Alum. (Standard)
Option 1: Powder Epoxy Coated Ductile Iron**
Option 2: Coal Tar Epoxy Coated Ductile Iron**
5 Blade Clamp Bolt W/ Nut 3/4”-10 x 10” (Mech. Galv.) 79299 24 28 32 36 40 44 48
6 3/4” Lock washer (Mech. Galv.) 73738 24 28 32 36 40 44 48
7 Hub Spool Cap Screw 5/8”-11 x 1 1/2”(316 SS) 72402 16 16 16 16 16 16 16
8 5/8” Lock washer (316 SS) 73731 16 16 16 16 16 16 16
9 Pin, Grooved, 1/2” X 1-1/2 ” 74540 4 4 4 4 4 4 4
10 76” Diameter “K” Seal Disc Kit * D5177 1 1 1 1 1 1 1
11
Tuf-Lite III® Blade (Teal Green) (Varies) 6 7 8 9 10 11 12
* Includes all hardware (316 SS) to assembly and mount.
** Recommended on concrete and round towers, or corrosive environments. Contact Hudson for pricing.
DESCRIPTION TYPE
R-2
S-2
U-1
R-2 & S-2
U-1
R-2
S-2
U-1
R-2
S-2
U-1
PART. NO
Hub Assy. No.
Part. No.
Hub Assy. No.
Pat No.
Hub Assy. No.
Part No.
Part. No.
Part No.
PART. NO QUANTITY PER ASSEMBLY
65050
65055
65038
Specify Bore
D5131
65013
65013C
6 7 8 9 10 11 12
5206
H5400
5306
H5300
5806
H5600
C5282
C5283
5207
H5410
1 1 1 1 1 1 1
1 1 1 1 1 1 1
12 14 16 18 20 22 24
5307
H5310
5807
H5610
61512
61521
NO. OF BLADES
5208
H5420
5308
H5320
5808
H5620
C5282
C5283
5209
H5420
5309
H5330
5809
H5630
61514
61523
5210
H5440
5310
H5340
5810
H5640
61515
61524
5211
H5450
5311
H5350
5811
H5650
61516
61525
5212
H5460
5312
H5360
5812
H5660
C5282
C5283
STANDARD MATERIALS & FINISHES
Blades: Fiberglass reinforced vinyl ester
Hub Spool: Ductile Iron, Zinc Rich Coating
Plates: Steel, Galvanized
Bushing: Malleable Iron
Seal Disc: Fiberglass Reinforced Polyester
WHEN ORDERING, SPECIFY FAN DIAMETER, TYPE & NUMBER OF BLADES & SHAFT DIAMETER
EXAMPLE:
APT
Fan Model Fan Diameter & Blade Type Number Shaft Diameter
Adjustable Pitch (Specify “K for Tuf-Lite II® Blades) of Blades
Blade Clamps:
Powder Epoxy Coated Die Cast Alum (Standard)
Powder Epoxy Coated Ductile Iron (Option 1)
Coal Tar Epoxy Coated Ductile Iron (Option 2)
Fasteners:
Steel, Mech. Galvanized & 316 SS Opt.
Complete Fan with 316 SS (Option 1)
Complete Fan with K500 Monel (Option 2)
28K 8
3 1/2” BORE
Installation Manual 5000K Page 6 of 8 May 2012
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Series 5000K HUB
HUDSON PRODUCTS CORPORATION
Adjustable Pitch Fan Assembly 20’ thru 30’ Diameter
Installation Manual 5000K Page 7 of 8 May 2012
Page 8
9660 Grunwald Rd.
Beasley, Texas 77417-8600
Phone: 281-396-8100
Fax: 281-396-8388
1-800-634-9160 (24 Hours)
EMAIL: hudsonproducts@hudsonproducts.com
http://www.hudsonproducts.com
Hudson, Auto-Variable, Combin-Aire, Exact-A-Pitch, Fin-Fan, Heatflo, Hy-Fin, Split-Flo, Solo Aire, Stac-Flo, Steamflo, Thermflo, Tuf-Edge, Tuf-Lite, Tuf-Lite II,
Corporation.
©2012 Hudson Products Corp. All Rights Reserved.
Installation Manual 5000K Page 8 of 8 May 2012
and
Tuf-Lite III
are registered trademarks of Hudson Products
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