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SUBMITTAL / OPERATION & MAINTENANCE MANUAL FOR:

MCCONNELL AFB KC-46A HANGARS PROJECT

WALSH / ARCHER WESTERN AVIATION PARTNERS

BY: D.P. INDUSTRIES, INC. CUSTOM DOOR SYSTEMS

16 Kit Kat Road, Mound House NV 89706 USA Phone: (775) 246-9011 Fax: (775) 246-9010

Toll Free: (800) 411-8996 POC: David Paine

February 27, 2015

PLACE REVIEW STAMPS HERE:

Part V – Spare Parts List

Supplier Part Number Equipment

McMaster-Carr 69585K93 Compact Spade-terminal Relay, 4pdt, 14 Terminals, 12v Dc, 10 Amps @ 120v Ac

McMaster-Carr 69585K4 Socket For 10 Amp, 8 & 14 Terminal Relays, Compact Spade-terminal Relay

McMaster-Carr 9414T19 Set Screw Shaft Collar, For 1" Diameter, Black-oxide Steel McMaster-Carr 9414T37 Set Screw Shaft Collar, For 2" Diameter, Black-oxide Steel McMaster-Carr 7988K2 Compact Limit Switch, Adjustable Roller Lever McMaster-Carr 21685T16 Dock Bumper, Medium-hard Rubber, 5-1/2" High, Black

McMaster-Carr 15665A546 Unfinished Steel Piano Hinge w/o Holes, .075" Thick, 2" Width, 4' Length

McMaster-Carr 7563K41 Steel Washdown Enclosure With Hinged Cover, 14" X 12" X 6" McMaster-Carr 7847K26 Panel, 12-3/4" X 10-7/8" For Enclosure

McMaster-Carr 69585K91 Compact Spade-terminal Relay, 4pdt, 14 Terminals, 120v Ac, 10 Amps @ 120v Ac

McMaster-Carr 69585K4 Socket For 10 Amp, 8 & 14 Terminal Relays, Compact Spade-terminal Relay

McMaster-Carr 3434T79 Socket For 10 Amp, 8 & 14 Terminal Relays, Compact Spade-terminal Relay

McMaster-Carr 9414T15 Set Screw Shaft Collar, For 3/4" Diameter, Black-oxide Steel McMaster-Carr 9414T33 Set Screw Shaft Collar, For 1-3/4" Diameter, Black-oxide Steel

McMaster-Carr 75045K92 Oil-tight Steel Push-button Enclosure, Two 30mm Diameter Holes, 6" X 3-1/2" X 3"

McMaster-Carr 75045K91 Oil-tight Steel Push-button Enclosure, One 30mm Diameter Hole, 3-3/4" X 3-1/2" X 3"

McMaster-Carr 75045K93 Oil-tight Steel Push-button Enclosure Three 30mm Diameter Holes, 8-1/4" X 3-1/2" X 3"

McMaster-Carr 9662K48 Spring-Tempered Steel Compression Spring, 36" Length, 1.75" OD, .187" Wire Diameter

Grainger 4A960 Bell, 120VAC, 0.08 AC, Gray Mag-Trol B100BTZ13RB 100VA Transformer Mag-Trol ESV222N04TXB 3HP-2.2KW 400/480V NEMA 1 Drive Mag-Trol ESV152N04TXB 2HP-1.5KW 400/480v Nema 1 Drive

Supplier Part Number Equipment

Nord

SK12080-100L/4

CUS BRE20 HL 3HP Motor

Nord

SK12080-90L/4

CUS BRE20 HL 2HP Motor

Kaman LM104911 Bearing Cup Kaman LM104949 Bearing Cone Thor Diamond #60 Riveted Domestic Roller Chain Thor 203KRR5 Ball Bearings - Ag bearing Great Lakes 358022 5" Clutch 1-3/8" Shaft Great Lakes 303506 Bushing #60/80 Sprocket Great Lakes 709512 60A25 Sprocket

Part 1

Introduction—System overview, photos and diagrams

Part II

Operating Principles—How to operate hangar door system

Part III

Safety—Safety and environmental concerns for the operation of hangar door system

Part IV

Preventative Maintenance—Preventative maintenance items, schedules, and troubleshooting

Part V

Spare Parts—List of parts by supplier

Part IV

Illustrations—Photos and diagrams of hangar door and components

Warranty Information

Contractor Information

Miscellaneous Component Specifications

Part I - Introduction

12 PANEL INDIVIDUALLY OPERATED HANGAR DOOR SYSTEM

System description:

The system consists of 12 individually driven hangar doors. Each door panel has individual motor drives, controls, limit switches and safety edges. All doors do share a common circuit for the personnel doors in which any open personnel door will shut down all hangar door operation until all personnel doors have been securely closed. The operational buttons/key switches are mounted at each end of the door and control movement in that direction of travel only. Each door is equipped with a total of 4 safety edges, 2 per end. Limit switches are mounted at the top of the door and limit door movement. These limits are to stop the door before impacting the wall or other door panels, these switches are not designed nor required to stop the hangar door in their "park" positions.

Theory of operation:

Power is fed through a continuous run of trolley ducting to the trolley pickup. The trolley pickup transmits the power to the power feed wiring in the door to the variable frequency drive in the control panel. By depressing the operational button the VFD is commanded to start operation.

The internal relays of the VFD engage the warning device and starts the 5 second warning delay time, after which the other internal relay applies power to the magnetic release on the brake motor and the frequency drive applies power to the motor accelerating the drive motor from 0- 60Hz (or maximum Hz as programmed to achieve proper door speed). The drive motor transfers torque to the drive chain through an adjustable clutch that is set to limit the drive torque to 250 ft lbs (single spring/400 ft/lbs double spring). The drive chain then turns the drive wheel thus moving the door. Upon activation of a limit switch the control input for direction of travel is interrupted and the VFD internal relays will open causing the motor brake to engage and the VFD will slow down and stop the motor. The warning bell will turn off. The same process also happens when the safety edge is activated causing the door to stop immediately.

Part II – Operating Principles

Before attempting to open or close door system:

Operator should do visual inspection of area to insure that:

No personnel or vehicle will come in contact with the movement of the door system.

Assure that no foreign objects have been placed in the door or against the door system.

Power to the system is in normal functioning mode.

Operator will approach push button panel on door system:

TO OPEN DOOR SYSTEM:

Operator will have completed their visual inspection of door system and surrounding area prior to attempting to activate door system.

IF DAMAGE HAS OCCURRED - DO NOT OPERATE DOOR SYSTEM.

Operator will push the “OPEN” button and maintain continuous contact.

Door will continue to open until open limit switch is engaged.

Continuous pressure on button is required so that operator may maintain constant visual inspection of door and area while door is opening.

TO CLOSE DOOR SYSTEM:

Operator will have completed their visual inspection of door system and surrounding area prior to

Attempting to activate door system.

IF DAMAGE HAS OCCURRED - DO NOT OPERATE DOOR SYSTEM.

Operator will push the “CLOSE” button maintain continuous contact.

Door will continue to close until close limit switch is engaged.

Continuous pressure on button is required so that operator may maintain constant

Door and area while door is closing.

MANUAL DISCONNECT:

To disconnect motor drive for manual operation:

1. Using a 1/2” end wrench, loosen the three (3) bolts on the torque limiting clutch located on the gear box.

2. Take the hub in hand and turn counter-clockwise until noticeably loose.

3. The door has now been disconnected from the motor drive unit and is ready for manual operation.

To re-connect motor drive for power operation:

1. Tighten the hub by hand, as tight as possible.

2. Using 1/2” end wrench, tighten the three (3) bolts located on the torque hub.

3. The door has now been reconnected to the motor drive and is ready for power operation.

Part II – Operating Principles

Operator should do visual inspection of area to insure that:

No personnel or vehicle will come in contact with the movement of the door system.

Assure that no foreign objects have been placed in the door or against the door system.

Power to the system is in normal functioning mode.

Operator will approach push button panel on door system:

TO OPEN DOOR SYSTEM:

Operator will have completed their visual inspection of door system and surrounding area prior to attempting to activate door system.

IF DAMAGE HAS OCCURRED - DO NOT OPERATE DOOR SYSTEM.

Operator will push the “OPEN” button and maintain continuous contact.

Door will continue to open until open limit switch is engaged.

Continuous pressure on button is required so that operator may maintain constant door and area while door is opening.

Part III – Safety

Operator should do visual inspection of area to insure that no personnel or obstructions are in the way before attempting to activate the motor drive system.

IF DAMAGE HAS OCCURRED - DO NOT OPERATE.

All electrical connections and wiring should be checked by a professional electrician, with power turned off and in dry conditions.

Door motors are designed for movement of door system only. Any attempt to use the motor drive system for alternative purposes could damage the motor drive and/or door system and will void warranty.

Removal of Security Seals or any alterations to the door system or its components will void warranty.

Environmental

Door system should not be operated when:

Obstructions of any kind are in the operational path of the door.

Building is under flood conditions.

Damage of any kind has occurred.

Wind speeds exceed design load for the door system.

In the event of earthquake:

Before attempting to activate door system, visual inspection of entire door system should be performed paying special attention to motor drive and cable assembly to verify door and any part of the track is not structurally damaged.

DO NOT ATTEMPT TO OPERATE DOOR IF DAMAGE HAS OCCURRED!

Part IV – Preventative Maintenance

Annual Inspection:

Verify each limit switch will turn off motor drive in the proper direction.

Check cables for wearing and fray, proper tension.

All motor drive components as listed in product manual.

Check all safety devices installed, audible and/or visual warning devices, delay timer, and safety edge. (If applicable)

6 Month Inspection:

Test man door interlock switch, door should stop when man door is open. (If applicable) Test safety edge for proper operation. (If applicable)

Motor Drive Maintenance Schedule:

Every Three Months and at Annual Inspection – Drive Chain (see lubrication).

Sprockets (check for wear) Bearings (see lubrication) Every Six Months and at Annual Inspection - Motor (see product manual) Clutch (check for wear) Gear Reducer (see lubrication) Manual Disconnect (ensure it is functioning properly)

SUPPLY LIST ( for maintenance and repair):

HANGAR DOOR-

Tools Required For Service - 1-Flat Medium Size Screwdriver 1-Philips Medium Size Screwdriver 1-3/8”, 1/2”, 7/16”, 9/16” and 3/4” End Wrench 1-1/4” Nut Runner 1-Pliers Medium Size 1-Multi Meter For Voltage Measurement 3/16” Allen Wrench

MOTOR DRIVE UNIT-

SAE 30 Oil for lubrication of drive chain.

Mobil SHC75W90 All Climate Synthetic Oil for Gear reducer, Bearings, and Shafts.

1-Flat Medium Size Screwdriver 1-Philips Medium Size Screwdriver 1-3/8”, 1/2”, 7/16”, 9/16” and 3/4” End Wrench 1-1/4” Nut Runner 1-Pliers Medium Size 1-Multi Meter For Voltage

Diagnostics Problem Possible cause Action

No operation, nothing happens when either button is pushed

Is power on?

Personnel door(s) open

Address power issue Check power at control panel Check Transformer fuses

Close and secure all personnel doors

Door moves but no warning bell Blown fuse at control transformer Check & replace fuse

Door moves in one direction only Bad limit switch Check limit switch in direction not operational. Limit is NC contact

Warning bell rings but door doesn't move

Bad limit switch

If limit switch is okay but won't close

Check limit switch in direction of travel If door closes, repair safety edge

Disable safety edge

Motor turns on, but door doesn't move

Drive clutch slipping

Wheel is turning, door doesn't move

Visually watch drive clutch, if slipping, reset clutch torque per manual

Look for obstructions blocking door travel

Warning bell rings but door doesn't move, VFD displays "CL"

Control transformer issue Check control transformer voltage / fuses If OK, brake is stuck and not releasing. Usually occurs after long period of non-use in moist enviromnets. Remove fan cover, remove fan tetainer, then remove fan. Using pipe wrench turn motor shaft 1/2 turn. Test drive for 30 seconds.

If works normally, reassemble.

If not, unit requires repair

Exit light not on, on emergency power Control transformer issue Check control transformer fuses / power output

Door doesn't stop at full open / close

Limit switch

Lever missed ramp or is not activated

Check limit switch / limit switch trigger Lever activates on ramp Replace switch if bad

Repair lever or ramp as necessary

Safety edge doesn't activate

Sensor

Relay

Disable switch

Check sensor, replace if failed or stuck on

Replace relay if failed or stuck on

If disable switch is engaged, enable

Removal and Replacement of Components:

Turn off power.

Disconnect power to motor and control wiring.

Label all wires for reconnection.

Adjust motor downward to loosen chain. Remove chain. Lift motor out.

Please note: To re-install motor, reverse previous instructions.

Electrical components are easily removed with a screwdriver.

Approximate Corrective Maintenance Work Hours:

Estimated time by experienced electrician to change the following items:

Motor: 1 hour Frequency Control Drive: 20 minutes Limit Switch/Proximity Sensors: 30 minutes Motor Drive Chain Replacement: 30 minutes

Maintenance Tools Required:

Standard and Phillips screwdriver set.

1/2”, 7/16” and 9/16” End Wrench Pliers Medium Size

If you have any questions, please contact D. P. Industries, Inc. at (775) 246-9011.

Please Note: All drawings, pictures, representations and related information are proprietary and are the property of D.P. Industries, Inc. Distribution or sharing is strictly prohibited.

Chain drive should be checked for tightness and lubricated every 3 months with:

Chevron SAE 30 Oil - NEVER use grease or silicone spray.

Bearings should be checked for wear and lubricated every 3 months with:

Chevron Ultra-Duty Grease EP—”Red Moly” Motor:

Please see enclosed Motor Manual for lubrication information.

Please Note: All drawings, pictures, representations and related information are proprietary and are the property of D.P. Industries, Inc. Distribution or sharing is strictly prohibited.

Chain drive should be checked for tightness and lubricated every 3 months with:

Chevron SAE 30 Oil - NEVER use grease or silicone spray.

Bearings should be checked for wear and lubricated every 3 months with:

Chevron Ultra-Duty Grease EP—”Red Moly”

Motor:

Please see enclosed Motor Manual for lubrication information.

Please Note: All drawings, pictures, representations and related information are proprietary and are the

Door Frame Assemblies:

D.P. Industries Inc.

16 Kit Kat Rd Mound House NV 89706 Ph.(800) 411-8996

Motor Drive and Gear Box Assemblies:

Nord Gear Corp.

1121 Railroad Street Building 101 Corona, CA 92882 www.nord.com

Bearings:

Made By - Timken Company:

Canton, OH.

Ph. (216) 438-3000

Purchased From - Kamen 882 Freeport Blvd Sparks NV 89431 Ph. (775) 358-0215

Programable Veriable Frequency Drive:

Made By– AC Tech Uxbridge, MA 01569

(800) 217-9100

Purchased Through- Mag-Trol Associates, Inc.

708 Celis St.

San Fernando, CA 91340-3701 Ph. (818) 361-5015

Micron Transformer:

Mag-Trol Associates, Inc.

708 Celis St.

San Fernando, CA 91340-3701 Ph. (818) 361-5015

Warning Bell:

Made By– Federal Signal Corp

2645 Federal Signal Drive University Park, IL 60484 Ph. (800) 264-3578

Purchased from– Magtrol Mag-Trol Associates, Inc.

708 Celis St.

San Fernando, CA 91340-3701 Ph. (818) 361-5015

Torque Hub

Great Lakes Industries Jackson, Mississippi

Top Trolley Wheels:

DP Industries, In 16 Kit Kat Road Mound House, NV 89706

Support/Drive Wheels:

DP Industries Inc 16 Kit Kat Road Mound House, NV 89706

Primer Paint:

Frazee Paint 4068 Kietzke Lane Reno, NV 89502 Ph: (775) 825-3555

*Please note, due to the individuality of each system, not all components may apply to each system.

Part IV – Illustrations

The following are some drawings specific to the door system. For component specific illustrations or information, see the manufacturer’s data.

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HANGAR DOOR PLAN

EAST HALF 1/32" = 1'-0"

HANGAR DOOR PLAN

MIDDLE SECTION 1/32" = 1'-0"

HANGAR DOOR PLAN

EAST HALF 1/32" = 1'-0"

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HANGAR DOOR PLAN

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Door System Wiring Diagram

LIMITED ONE (1) YEAR WARRANTY

The Hangar Door System, manufactured by D. P. Industries, Inc. is warranted to be free from defects in material and workmanship for a period of one (1) year from date of commencement of use, substantial completion or date of notice of completion, whichever is the first to occur. All internal components are of equal warranty as the doors, one (1) year.

This Standard Limited Warranty applies and is limited as follows:

1. To the construction work that has not been subject to accident, misuse and abuse.

2. To the construction work that has not been modified, altered, defaced, and/or had repairs made or attempted by others.

3. That contractor be immediately notified in writing within 10 days of first knowledge of defect by owner or his/her agents.

4. That contractor shall be given first opportunity to make any repairs, replacements and/or corrections at no cost to owner within a reasonable period of time.

5. Under no circumstances shall contractor be liable by virtue of this warranty or otherwise for damage to any person or property whatsoever for any special, indirect, secondary or consequential damages of any nature however arising out of the use or inability to use because of the defect.

6. Please Note: Maintenance requirements on the Hangar Door System, including the Motor Drive Units, are NOT the responsibility of D.P. Industries, Inc. and is not provided for by this warranty.

7. A maintenance record must be made available to confirm that the recommended maintenance has been completed as shown in the O & M manual.

8. Each manufacturer of the components are clearly identified with their manufacturers labeling.

Please Note: All drawings, pictures, representations and related information are proprietary and are the

Hangar Door Supplier/Subcontractor:

D.P. Industries, Inc.

16 Kit Kat Road Mound House, NV 89706 USA

(775) 246-9011 Phone

(775) 246-9010 Fax

(800) 411-8996 Toll Free - 24 Hour Maintenance & Repair Hotline.

Subcontractor Team Summary This Project:

David R. Paine Catherine C. Paine David M. Paine Danielle Paine Sara Celedon Mike Edmiston Mark J. Spencer Gilbert Celedon Leah Johnson Luis Vargas Robert Harden Jesse Reeger Roger Stimson Justin Basham Jim Harrell Edward Manfredi Paul Magnussen Tim Shadle Aaron Markle Luis Palacio William Peiler Thomas Nachel Brice Wyatt

BIM-1030/2003/01 1 www.nord.com

BIM-1030/2003UNICASE® Helical Worm Gearboxes Installation and Maintenance Instructions

Retain These Safety Instructions For Future Use

INSPECTION OF UNIT

Thoroughly inspect the equipment for any shipping and handling damage before accepting shipment from the freight company. If any of the goods called for in the bill of lading or express receipt are damaged or the quantity is short, do not accept until the freight or express agent makes an appropriate notation on your freight bill or express receipt. If any concealed loss or damage is discovered later, notify your freight carrier or express agent at once and request him to make an inspection. We will be very happy to assist you in collecting claims for loss or damage during shipment; however, this willingness on our part does not remove the transportation company’s responsibility in reimbursing you for collection of claims or replacement of material. Claims for loss or damage in shipment must not be deducted from the NORD Gear invoice, nor should payment of the NORD Gear invoice be withheld awaiting adjustment of such claims, as the carrier guarantees safe delivery.

If considerable damage has been incurred and the situation is urgent, contact the nearest NORD Gear Sales Office for assistance. Please keep a written record of all communications.

RECORD NAMEPLATE DATA

Locate the gear reducer nameplate and record all nameplate data for future reference.

SK ________________________________________________________ S/N _________________________________

RATIO ______________ MAX TORQUE ____________________ RPM ______________ MTG. POS ______________

STORAGE

PROPER STORAGE UNTIL INSTALLED

Keep unit in a dry, temperature controlled area. If stored other than said, long term storage methods must be applied to the unit including complete fill with lubricant. Protect machined surfaces and rotate shafts periodically. Prior to putting unit into service, drain lubricant and refill to proper level as determined by the mounting position.

PROPER HANDLING OF THE UNIT

Exercise care to prevent damage to the unit when moving. Lift onIy at designed Iifting points. Do not attach other machinery and lift by the unit lifting points. The lifting points are to be used to lift the unit only. Insure that adequate safety measures are taken to protect personneI during transportation. Protect the mounting surface from damage.

CDN

USA

BIM-1030/2003/01 2 www.nord.com

INSTALLATION OF UNIT

To ensure Iong service and dependabIe performance, an encIosed gear drive must be rigidIy supported and the shafts accurateIy aIigned.

The foIIowing describes the minimum precautions required to accompIish this end.

FOUNDATION

The responsibiIity for the design and construction of the foundation Iies with the user. The foundation must be adequate to withstand normaI operating Ioads and possibIe overIoads whiIe maintaining aIignment to attached system components under such Ioads.

MOUNTING POSITION

UnIess a unit is specificaIIy ordered for incIined mounting, the foundation must be IeveI and fIat. The Iubrication system may not operate properIy if the unit is not mounted in the position for which it is designed. It may be desirabIe to eIevate the foundation to faciIitate oiI drainage.

CONCRETE FOUNDATION

If a concrete foundation is used, steeI mounting pads and boIts of sufficient size to distribute the stress into the concrete shouId be grouted into the foundation.

STEEL FOUNDATION

If a structuraI steeI foundation is used (i.e. wide fIange beams or channeIs), a base pIate or soIe pIate of suitabIe thickness shouId be used and shouId extend under the entire unit.

FOOT MOUNTED UNITS

Use shims under the feet of the unit to aIign the output shaft to the driven equipment. Make sure that aII feet are supported so that the housing wiII not distort when it is boIted down. Improper shimming wiII reduce the Iife of the unit and may cause faiIure.

DoweI pins may be instaIIed to prevent misaIignment and ensure proper reaIignment if removed for service.

SHAFT MOUNTED UNITS

Shaft mounted drives should be mounted as close to the driven equipment bearing support as possible to minimize bearing loads due to overhung load. Design of the joint connection between the torque reaction arm and the foundation is the user’s responsibility.

HoIIow Shaft Diameter toIerance Metric (mm) 18 = +0.018/-0.000 18 30 = +0.021/-0.000 30 50 = +0.025/-0.000 50 80 = +0.030/-0.000 80 120 = +0.035/-0.000 120 180 = +0.040/-0.000 Inch

4.375 = +0.0010 / -0.0000

4.375 = +0.0015 / -0.0000

Customer shaft diameter toIerances with keyed hoIIow shafts Metric (mm) 18 = +0.000/-0.011 18 30 = +0.000/-0.013 30 50 = +0.000/-0.016 50 80 = +0.000/-0.019 80 120 = +0.000/-0.022 120 180 = +0.000/-0.025 Inch

1.500 = +0.000/-0.002

1.500 2.500 = +0.000/-0.003

2.500 7.000 = +0.000/-0.004 Shaft finish to be 125 micro inches or smoother.

Customer shaft diameter toIerance with Shrink Disc fit h6 Metric (mm) 18 = +0.000/-0.011 18 30 = +0.000/-0.013

30 50 = +0.000/-0.016

50 80 = +0.000/-0.019 80 120 = +0.000/-0.022 120 180 = +0.000/-0.025 Inch

0.750 = +0.0000/-0.0004

0.750 1.125 = +0.0000/-0.0005

1.125 2.000 = +0.0000/-0.0006

2.000 3.000 = +0.0000/-0.0007

3.000 4.750 = +0.0000/-0.0008

4.750 7.000 = +0.0000/-0.0010

Shaft finish to be 125 micro inches or smoother.

Customer shaft diameter toIerance with Shrink Disc fit f6 (Iooser fit) Metric (mm) 18 =-0.016/-0.024 18 30 = -0.020/-0.029 30 50 = -0.025/-0.036 50 80 = -0.030/-0.043 80 120 = -0.036/-0.051 120 180 = -0.043/-0.061 Inch

0.750 = -0.0006/-0.0011

0.750 1.125 = -0.0008/-0.0013

1.125 2.000 = -0.0010/-0.0016

2.000 3.000 = -0.0012/-0.0019

3.000 4.750 = -0.0014/-0.0023

4.750 7.000 = -0.0017/-0.0027

Shaft finish to be 125 micro inches or smoother

FLANGE MOUNTED UNITS

If a structuraI steeI foundation is used (i.e. wide fIange beams or channeIs), a base pIate or soIe pIate of suitabIe thickness shouId be used and shouId extend under the entire unit. If a buIk head pIate is used it shouId be of proper strength to minimize buckIing distortions.

FIange PiIot ‘AK’ or ‘AK1’ toIerance Metric (mm)

50 80 = +0.012/-0.007 80 120 = +0.013/-0.009 120 180 = +0.014/-0.011 180 230 = +0.016/-0.013

230 315 = +0.000-0.032 315 400 = +0.000/-0.036 400 500 = +0.000/-0.040 Inch

1.969 3.150 = +0.005/-0.0003

3.150 4.724 = +0.005/-0.0004

4.724 7.087 = +0.006/-0.0004

7.087 9.055 = +0.006/-0.0005

9.055 12.402 = +0.000/-0.0013

12.402 15.748 = +0.000/-0.0014

15.748 19.685 = +0.000/-0.0016

BOLT STRENGTH

BoIt size, strength and quantity shouId be verified to insure proper torque reaction capacity whatever the mounting arrangement.

LUBRICATE SHAFTS

Both the hollow shaft and the driven shaft should be liberally lubricated before assembly. The unit must slide freely onto the driven shaft. Do not hammer or force the unit into place. For shrink disc, follow instructions below.

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AXIAL RETENTION

Each drive shaft must be retained in place relative to the gear reducer. Or each gear reducer must be retained in place relative to the drive shaft. Either way NORD recommends the use of shaft shoulders, locking collars or FIXING ELEMENTS to axially retain the shaft or gear reducer in position.

SET SCREWS

If set screws are used for axial retention, they should be tightened evenly. Flats may be filed on the driven shaft and a thread-locking adhesive used for more position retention.

SNAP RING RETENTION

Placing external snap rings on drive shafts must be performed with caution. The groove, which the snap ring fits into, may weaken the drive shaft causing premature failure. NORD does not recommend this type of shaft retention.

THRUST PLATE

In applications, which are subject to high vibratory loads, a thrust plate will provide greater resistance to axial movement. Follow the manufacturer’s recommendations for assembly.

SHRINK DISC

If a shrink disc is used to secure a reducer hollow shaft to the driven shaft, follow this assembly procedure. Start with the shrink disc mounted onto the extension of the hollow shaft disc locking bolts loosened.

1. Clean reducer bore and mating solid shaft to be free of any lubricants or dirt.

2. Slide reducer onto the solid shaft until it is about half way through.

3. Lubricate the remaining portion of the solid shaft with a #2 grease or similar lubricant. This part will be located under the bronze bushing. Do not install grease under the shrink disc gripping area. Finish installing the solid shaft into the reducer hollow bore.

4. Finger tighten all shrink disc bolts. Now, moving a circular pattern, tighten each shrink disc locking bolt 1/4 to 1/2 turn.

Do not use criss cross pattern. Continue tightening in the same circular direction with 1/4 or 1/2 turn increments until all bolts reach the specified bolt tightening torque. Bolt tightening torque is shown on the shrink disc label for the particular unit.

5. Run unit for 24 hours, then retighten shrink disc locking bolts to the proper bolt torque as indicated above.

TORQUE REACTION ARM

On the shaft mount ‘Clincher’, torque is reacted through the integral torque tab, which is part of the casting. Commonly, NORD’s optional RUBBER BUFFER bushings are installed on each side of the integral torque tab to dampen torque shocks and allow for mis-alignment received from the machinery during operation.

Torque arm connection fabrications should always be mounted perpendicular to a line through the output shaft center and the point at attachment of the torque arm to the unit housing. In this position the minimum load on the attachment structure arm will be experienced. The attachment structure must be rigid and may not deflect under any load. Doing so will place extra loads on the output bearings of the reducer.

PRIME MOVER MOUNTING

AIign the prime mover to the reducer-input shaft using shims under the feet. Make sure that the feet are supported. DoweI the prime mover to its foundation.

SHAFT CONNECTIONS

When connecting shafts to either the input or output of the reducer, consider the foIIowing instructions.

FITS

CIearance or interference fits for coupIing hubs shouId be in accordance with ANSI/AGMA 9002-A86 or as follows.

Output and Input shaft Diameter toIerance Metric (mm) 18 = +0.012/+0.001 18 30 = +0.015/+0.002 30 50 = +0.018/+0.002 50 80 = +0.030/+0.011 80 120 = +0.035/+0.013 120 180 = +0.040/+0.015 Inch

1.750 = +0.0000/-0.0005

1.750 = +0.0000/-0.0010

Output and Input shaft DriII and tap shaft end Metric (mm) 16 = M5 16 21 = M6 21 24 = M8 24 30 = M10 30 38 = M12 38 50 = M16

50 85 = M20 85 130 = M24 Inch

0.438 = #10-24 x 0.4 deep

0.438 0.813 = ¼-20 x 0.6 deep

0.813 0.938 = 5/16-18 x 0.7 deep

0.938 1.125 = 3/8-16 x 0.9 deep

1.125 1.375 = 1/2-13 x 1.1 deep

1.375 1.875 = 5/8-11 x 1.4 deep

1.875 3.250 = 3/4-10 x 1.7 deep

3.250 = 1-8 x 2.2 deep

Outboard pinion and sprocket fits shouId be as recommended by the pin sprockets with interference fits shouId be heated according to the manufacturer’s recommendations, generaIIy 250 F to 300 F, (120 C to 150 C) before assembIing to the shaft.

LOCATION

CoupIing hubs shouId be mounted fIush with the shaft ends, unIess specificaIIy ordered for overhung mounting. Pinions, sprockets and sheaves shouId be mounted as cIose as possibIe to the unit housing to minimize bearing Ioads and shaft defIections.

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WARNING:

LOCK OUT POWER before any maintenance is performed.

Make absolutely sure that no voltage is applied while work is being done on the gearbox.

The Autovent releases built-up air pressure from inside the gearbox (Max. pressure 2 psi).

COUPLING ALIGNMENT

Shaft coupIings shouId be instaIIed according to the coupIing manufacturer’s recommendations for gap, anguIar and paraIIeI aIignment. In many instaIIations, it is necessary to aIIow for thermaI and mechanicaI shaft movement when determining shaft aIignment. The coupIing manufacturer’s recommendations shouId be foIIowed.

AXIAL DISPLACEMENT

The gap between shaft ends shouId be the same as the specified coupIing gap unIess overhung mounting of the coupIing hub is specified. The coupIing gap and shaft gap must be sufficient to accommodate any anticipated thermaI or mechanicaI axiaI movement.

ANGULAR ALIGNMENT

Insert a spacer or shim stock equaI to the required coupIing gap between the coupIing hub faces and measure the cIearance using feeIer gauges. Repeat this at the same depth at 90-degree intervaIs to determine the amount of anguIar misaIignment.

PARALLEL ALIGNMENT

Mount a diaI indicator to one coupIing hub, and rotate this hub, sweeping the outside diameter of the other hub. The paraIIeI misaIignment is equaI to one-haIf of the totaI indicator reading.

Another method is to rest a straight edge squareIy on the outside diameter of the hubs at 90-degree intervaIs and measure any gaps with feeIer gauges. The maximum gap measurement is the paraIIeI misaIignment.

CHECKING ALIGNMENT

After both anguIar and paraIIeI aIignments are within specified Iimits, tighten aII foundation boIts secureIy and repeat the above procedure to check aIignment. If any of the specified Iimits for aIignment are exceeded, reaIign the coupIing.

SPROCKET OR SHEAVE ALIGNMENT

AIign the sheaves or sprockets square and paraIIeI by pIacing a straight edge across their faces. AIignment of bushed sheaves and sprockets shouId be checked after bushings have been tightened. Check horizontaI shaft aIignment by pIacing a IeveI verticaIIy against the face of the sheave or sprocket. Adjust beIt or chain tension per the manufacturer’s specified procedure.

OUTBOARD PINION ALIGNMENT

AIign the pinion by adjusting the gear tooth cIearance according to the manufacturer’s recommendations and checking for acceptabIe outboard pinion tooth contact. The foundation boIts may have to be Ioosened and the unit moved sIightIy to obtain this contact. When the unit is moved to correct tooth contact, the prime mover shouId be reaIigned.

RECHECK ALIGNMENT

After a period of operation, recheck aIignment and adjust as required.

1. Properly install unit on a rigid foundation adequateIy supported secureIy boIted into pIace IeveIed so as not to distort the gear case

2. Properly install couplings suitabIe for the application and connected equipment.

3. Ensure accurate aIignment with other equipment.

4. Furnish and install adequate machinery guards as needed to protect operating personneI and as required by the appIicabIe standards of the OccupationaI Safety and HeaIth Administration (OSHA), and by other appIicabIe safety reguIations;

5. Ensure that driving equipment is running in the correct direction before coupling to reducers with backstops (designed to operate onIy in a specific direction) or machinery designed to operate only in one direction.

CHANGES IN PERFORMANCE SPECIFICATIONS

Owner has the responsibiIity to consult with NORD GEAR if such items such as applied Ioads, operating speeds or other operating conditions have changed.

START-UP

1. Ensure that switches, aIarms, heaters, coolers and other safety and protection devices are instaIIed and operational for their intended purpose.

2. Verify that the installed mounting position is the same as the nametag mounting position. If not, adjust the oil level accordingly and relocate the vent plug, fill plug and drain plug according to the mounting position. See following.

AUTOVENT PLUG

The Autovent plug is brass in color and will be located at the highest point on the gearbox. It operates like a check-valve to allow the reducer to relieve internal pressure while preventing lubricant contamination during cooling. A spring presses a ball or plunger against a machined orifice until pressure exceeds 2 psi.

Above 2 psi the air is allowed to escape depressurizing the gearcase. When internal pressure drops below 2 psi, the autovent re-seals closing the unit to the outside environment.

After shutdown, the reducer cools along with the air inside the reducer. The unit will temporarily maintain a slight vacuum until normalization occurs. NORD Gear supplies an Autovent as a standard feature.

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Two types of plugs for maintenance

FILL LEVEL & DRAIN PLUGS

The drain plugs are metric socket head cap screws. They will be located at the lowest part of the gearbox for ease of draining. The fill level plug is a hex head cap screw. It will be located between the Autovent and drain plug. Both types of plugs will have gaskets included to prevent oil from leaking.

LUBRICANT

AII NORD reducers are shipped from the factory properIy fiIIed with Iubricant and all plugs are installed according to the mounting position given on the reducer nametag. Acceptable oil fill level is within ½ inch of the bottom of the fill plug threads.

OPERATION AND MAINTENANCE CHECKLIST

1. Operate the equipment as it was intended to be operated

2. Do not overIoad.

3. Run at correct speed.

4. Maintain Iubricant in good condition and at proper IeveI.

5. Dispose of used Iubricant in accordance with appIicabIe

Iaws and reguIations.

6. AppIy proper maintenance to attached equipment at prescribed intervaIs recommended by the manufacturer.

7. Perform periodic maintenance of the gear drive as recommended by NORD.

MOUNTING POSITIONS

These charts detail the mounting positions for horizontal and vertical mounting. The Autovent, oil fill plug and drain plug are indicated on each mounting position picture. The factory set mounting position and plug locations match that shown on the gearbox nametag. For mounting orientations other than shown consult NORD Gear.

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MAINTENANCE

Mineral lubricant should be changed every 10,000 service hours or after two years. For synthetic oils, the lube should be changed every 20,000 service hours or after four years. In case of extreme operating (e.g. high humidity, aggressive environment or large temperature variations), shorter intervals between changes are recommended.

OIL SPECIFICATIONS

NORD supplies aII reducers fiIIed with oiI from the factory. Consult the sticker adjacent to the fill plug to determine the type of lubricant installed at the factory. Standard lubricant is ISO VG680 synthetic-based oil. However, some units have special lubricants designed to operate in certain environments or to extend the service life of the lubricant. If in doubt about which lubricant is needed, contact NORD Gear.

ALL WORM REDUCERS

Worm units have a combination of hard and soft gears. SIiding action of worm gears require a higher viscosity oiI. These units are furnished with synthetic oiI as standard. CAUTION: Do not mix mineraI based and synthetic oiIs.

Standard OiI – ISO VG680

Ambient Temperature

FormuIation

Oil Manufacturer

Oil Brand Name

Origin of Gearbox Assembly

20 to 140 F (-5 to 60 C) Synthetic poIygIycoI

KIuber KIubersynth GH- 6-680

USA & Canada

Standard Bearing Grease

Ambient Temperature

FormuIation

Grease Manufacturer

Grease Brand Name

Origin of Gearbox Assembly

-58 to 230 F (-50 to 110 C) Synthetic Texaco Starfak 2202 NORD USA -20 to 140 F (-30 to 60 C) MineraI SheII Cypernia RA/C3 NORD Canada

LUBRICANT CAPACITY

Each reducer has the oil level and oil quantity adjusted according to the mounting position shown in the tables. When replacing the oil, consult the tables below to determine the proper amount of oil to be installed according to the reducer size and mounting position. Note that this is approximate and the final level will be adjusted when the reducer is installed. Acceptable oil fill level is within ½ inch of the bottom of the fill plug threads.

B3 B6I B8 V1/V5I V6/V6I B3I B6 B6II B8I B5I B5III V1 V3 B5 B5II H1 H2 H5 H6 H3 H4 SK 02040 quarts 0.48 0.48 0.63 0.53 0.53 0.63 0.63 0.69 0.63 0.53 0.79 0.53 0.53 0.85 0.63 0.42 0.69 0.53 0.53 0.63 0.85 liters 0.45 0.45 0.60 0.50 0.50 0.60 0.60 0.65 0.60 0.50 0.75 0.50 0.50 0.80 0.60 0.40 0.65 0.50 0.50 0.60 0.80 SK 02050 quarts 0.63 0.63 0.74 0.74 0.74 1.22 1.27 1.22 1.27 0.48 0.95 1.06 1.06 1.48 1.32 0.48 0.95 0.85 0.85 1.16 1.16 liters 0.60 0.60 0.70 0.70 0.70 1.15 1.20 1.15 1.20 0.45 0.90 1.00 1.00 1.40 1.25 0.45 0.90 0.80 0.80 1.10 1.10 SK 12063 quarts 0.42 0.42 1.27 1.06 1.06 1.64 1.80 1.64 1.80 0.53 1.48 1.59 1.59 1.69 1.90 0.53 1.27 1.16 1.16 1.48 1.53 liters 0.40 0.40 1.20 1.00 1.00 1.55 1.70 1.55 1.70 0.50 1.40 1.50 1.50 1.60 1.80 0.50 1.20 1.10 1.10 1.40 1.45 SK 12080 quarts 0.85 0.85 1.80 1.80 1.80 2.85 2.75 2.85 2.75 1.00 2.64 2.64 2.64 3.49 3.91 0.95 3.17 2.33 2.33 3.17 3.28 liters 0.80 0.80 1.70 1.70 1.70 2.70 2.60 2.70 2.60 0.95 2.50 2.50 2.50 3.30 3.70 0.90 3.00 2.20 2.20 3.00 3.10 SK 32100 quarts 1.69 1.69 3.59 3.38 3.38 5.71 5.81 5.71 5.81 1.59 5.18 4.65 4.65 7.50 7.50 1.59 4.02 4.02 4.02 5.60 5.50 liters 1.60 1.60 3.40 3.20 3.20 5.40 5.50 5.40 5.50 1.50 4.90 4.40 4.40 7.10 7.10 1.50 3.80 3.80 3.80 5.30 5.20 SK 42125 quarts 2.96 2.96 6.55 6.13 6.13 10.89 11.63 10.89 11.63 3.49 6.45 7.19 7.19 11.84 10.99 3.38 6.45 6.66 6.66 11.10 13.64 liters 2.80 2.80 6.20 5.80 5.80 10.30 11.00 10.30 11.00 3.30 6.10 6.80 6.80 11.20 10.40 3.20 6.10 6.30 6.30 10.50 12.90

SK 13050 quarts 1.00 1.00 1.16 1.00 1.00 1.53 1.64 1.53 1.64 0.95 1.22 1.32 1.32 1.90 1.85 0.90 1.32 1.22 1.22 1.43 1.85 liters 0.95 0.95 1.10 0.95 0.95 1.45 1.55 1.45 1.55 0.90 1.15 1.25 1.25 1.80 1.75 0.85 1.25 1.15 1.15 1.35 1.75

SK13063 quarts 0.90 0.90 1.69 1.32 1.32 2.11 2.43 2.11 2.43 1.00 1.74 1.85 1.85 2.22 2.27 0.95 1.64 1.53 1.53 2.22 2.22 liters 0.85 0.85 1.60 1.25 1.25 2.00 2.30 2.00 2.30 0.95 1.65 1.75 1.75 2.10 2.15 0.90 1.55 1.45 1.45 2.10 2.10

SK 13080 quarts 1.80 1.80 2.22 2.06 2.06 3.59 3.38 3.59 3.38 1.48 2.91 2.91 2.91 4.44 4.44 1.80 3.81 2.70 2.70 3.81 3.96 liters 1.70 1.70 2.10 1.95 1.95 3.40 3.20 3.40 3.20 1.40 2.75 2.75 2.75 4.20 4.20 1.70 3.60 2.55 2.55 3.60 3.75

SK 33100 quarts 2.22 2.22 4.23 3.91 3.91 7.19 8.03 7.19 8.03 2.43 5.81 5.13 5.13 8.03 8.24 2.22 5.07 4.44 4.44 6.98 6.45 liters 2.10 2.10 4.00 3.70 3.70 6.80 7.60 6.80 7.60 2.30 5.50 4.85 4.85 7.60 7.80 2.10 4.80 4.20 4.20 6.60 6.10

SK 43125 quarts 8.24 8.24 7.61 7.08 7.08 14.27 14.80 14.27 14.80 4.55 7.50 8.14 8.14 13.64 12.79 5.07 7.82 8.46 8.46 15.33 14.27 liters 7.80 7.80 7.20 6.70 6.70 13.50 14.00 13.50 14.00 4.30 7.10 7.70 7.70 12.90 12.10 4.80 7.40 8.00 8.00 14.50 13.50

Note: Filling quantities are approximate figures. Oil level must be checked according to oil level plug after final installtion.

Acceptable oil fill level is within 1/2 inch of the bottom of the fill plug threads. For mounting angles not shown, consult factory.

OIL FILL QUANTITIES

Vertical

SHAFT MOUNT UNIT

Horizontal Vertical

FOOTED UNIT

Horizontal

FLANGED UNIT

Horizontal Vertical

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SPARE PARTS LISTS

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SPARE PARTS LISTS

SK 02050 A - SK 42125 A

Shaft mounted

SK 13050 - SK43125

Worm geared motor triple reduction

5 Driving gear 6 Driving pinion

27 Bolt 28 Seal 29 Supporting disc 30 Third reduction gearcase 45 Ball bearing 46 Key 48 Ball bearings 52 Circlip 53 Key 54 Circlip 55 Intermediate shaft, plain 56 Intermediate shaft, gearcut 57 Circlip 58 Circlip 59 Shim 60 Circlip 61 Circlip 62 Plug 63 Seal

301 Worm wheel 302 Worm 305 Driving gear 306 Driving pinion 307 Hollow shaft 309 Shaft seal 310 Shaft seal 311 Circlip 312 Shim 313 Ball bearing 314 Seal 315 Gearcasecover 316 Drain plug 317 Vent screw 318 Seal 319 Socket head screw 320 Key 322 Spacer 323 Flanged eye bolt 324 Gear caser 325 Seal 328 Locking cap 329 Supporting disc 332 Circlip 333 Key 334 Circlip 335 Shim 336 Supporting disc 337 Angular ball bearing 340 Disc 341 Washer 342 Socket head screw

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SPARE PARTS

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NOTES

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TROUBLE SHOOTING

PROBLEM WITH THE REDUCER POSSIBLE CAUSES SUGGESTED REMEDY

Overloading Load exceeds the capacity of the reducer

Check rated capacity of reducer, replace with unit of sufficient capacity or reduce load

Insufficient lubrication Check lubricant level and adjust up to recommended levels

Excessive lubrication Check lubricant level and adjust down to recommended levels

Runs Hot

Improper lubrication

Wrong lubrication Flush out and refill with correct lubricant as recommended

Weak mounting structure Inspect mounting of reducer. Tighten loose bolts and/ or reinforce mounting and structure Loose foundation bolts

Loose hold down bolts Tighten bolts

Worn RV Disc Overloading unit may result in damage to disc

Disassemble and replace disc. Recheck rated capacity of reducer.

May be due to lack of lubricant Replace bearing. Clean and flush reducer and fill with recommended lubricant. Failure of Bearings

Overload Check rated capacity of reducer.

Runs Noisy

Insufficient Lubricant Level of lubricant in the reducer not properly maintained.

Check lubricant level and adjust to factory recommended level.

Overloading of reducer can cause damage.

Replace broken parts. Check rated capacity of reducer. Internal parts are broken Key missing or sheared off on input shaft. Replace key. Output Shaft Does Not Turn

Coupling loose or disconnected. Properly align reducer and coupling.

Tighten coupling.

Worn Seals Caused by dirt or grit entering seal. Replace seals. Autovent may be clogged.

Replace or clean.

Overfilled reducer. Check lubricant level and adjust to recommended level.

Autovent clogged. Clean or replace, being sure to prevent any dirt from falling into the reducer.

Oil Leakage

Improper mounting position, such as wall or ceiling mount of horizontal reducer.

Check mounting position. Name tag & verify with mounting chart in manual.

Operator should do visual inspection of area to insure that:

no personnel or vehicle will come in contact with the movement of the door system.

assure that no foreign objects have been placed in the door or against the door system.

Power is off.

MANUAL DISCONNECT:

To disconnect motor drive for manual operation:

1. Using a 1/2” end wrench, loosen the three (3) bolts on the torque limiting clutch located on the gear box.

2. Take the hub in hand and turn counter-clockwise until noticeably loose.

3. The door has now been disconnected from the motor drive unit and is ready for manual operation. Please see drawing below.

To re-connect motor drive for power operation:

1. Tighten the hub by hand, as tight as possible.

2. Using 1/2” end wrench, tighten the three (3) bolts located on the torque hub.

3. The door has now been reconnected to the motor drive and is ready for power operation.

EMERGENCY OPERATION

HUB CHAIN

BOLT BOLT

BOLT

3/4” Eye bolt for tractor tow pull tab.

1. After manually releasing the torque hub, the bolt is for manually towing the door panels in the event of power failure.

2. Attach a forklift or “tug” device to the eye bolt using a towing strap/cable rated at 8,000 lbs. to the tractor tow eye bolt located on the leading door panel.

3. Tow the panel to the desired position and disconnect the towing device.

4. After power is restored to the door system, re-tighten the torque hub and the door system will function in a normal manner.

Please note: the torque hub MUST be tightened under normal operation to prevent damage to the clutch plates and motor drive system.

Please note: All drawings, pictures, representations and related information are proprietary and are the property of D.P. Industries, Inc. Distribution or sharing is strictly prohibited.

SHOULDER PATTERN EYE BOLT

Shoulder Pattern No.

Bolt Diameter N.C.

Standard Shank Length

Part No.

28 3/4” 2” 261760

HOT GALVANIZED—Made in the USA

08362-2.2,C Tractor Pulls

OIL TIGHT PUSHBUTTON ENCLOSURE

Item # 2W835

Manufacturer WIEGMANN

Mfr. Model # PB-2

Include neoprene gasketing and mounting flange. Finish is ANSI 61 powder paint on 14-ga. steel enclosures (inside and outside), and grained finish on stainless enclosures. Push-button holes are 1 13/64" in diameter (30mm). All models conform with Joint Industrial Council (JIC) Standard EGP-1-1967

Item Oil Tight Pushbutton

Number of Columns 1

Number of Holes 2

Standards JIC, EGP-1-1967

Material 14-gauge steel

Height (In.) 5 3/4

Width (In.) 3 1/4

Depth (In.) 2 3/4

Hole Dia. (In.) 1 13/64

Includes Neoprene gasketing and mounting flange

08362-2.6,A General