Propulsion Systems Inc CPP Tech Pub Addendem for ACOE Wheeler Repower SY2012.pdf

Propulsion Systems, Inc.

Seattle, WA.

www.psiprop.com service@psiprop.com

206-789-0944 ph

PSI Controllable Pitch Propeller Technical Publication

Addendum:

S/N 374 and 375 ACOE Wheeler (Repower)

PSI Job No. 7894

Worked performed at Signal Ship Repair, Mobile, AL.

http://www.psiprop.com/ mailto:service@psiprop.com

Table of Contents

Section A – General Data: (replacement data) Page

Forward A-1

Service Information A-2

Hydraulic Oil Type A-5

General Data A-8

Table of Bolt Torques A-9

Section F - Drawings: (replacement data)

22189-F rev K E105/4 Propeller Hub Assembly

22076-H rev G Shafting Assembly

22437-F rev K Servo Box Assembly RH

11333-AF rev D Propulsion Systems Dual 25 HPU Hydraulic Schematic

11333-M rev A HPU General Arrangement 3 of 3

11333-E Propulsion System, Inc. Electrical Schematic 3 of 3

Section G - Parts List: (replacement data)

22189-PL rev K E105/4 Propeller Hub Assembly Parts List

22076-H rev G Shafting Assembly Parts List

22437-F rev K Servo Box Assembly RH Parts List

11333-AF HPU Parts List

11333-AF HPU Electrical Parts List

Section I – Venders

See HPU Supplied CD

Section J - CD: (new data)

PSI Hydraulic Power Unit Technical Publication

PSI Controllable Pitch Propeller Technical Publication Addendum

Direct all correspondence to:

609 NW 45th St.

Seattle, WA. 98107

206-789-0944 phone

206-789-1071 fax service@psiprop.com email

A-1

For maintenance, service and technical assistance contact:

Seattle, WA. 98107

206-789-0944 phone 0600 – 1600 PST

206-390-1965 cell 24/7 service@psiprop.com email

A-2

Hydraulic Oil Type

UCON Trident AW-46 PAG

Suitable grease for all CPP and hydraulic system assembly: Lux WRHD-2

Oil analysis information:

1. Quarterly Sample Intervals

2. A minimum 4 ounce sample be pulled and submitted for analysis

3. Label the bottle (with permanent marker) with unit ID / Product Name / Date / Hours

4. Send sample/s to:

American Chemical Technologies, Inc.

485 East Van Riper Road

Fowlerville, Michigan 48836

Attn: Lab

A-5

General Data

Shaft RPM 178

Engine Manufacturer Caterpillar

Engine Brake HP 6100 BHP

Reduction Gear Manufacturer Reintjes

All other information remains the same.

A-8

Table of Bolt Torques (modified)

22076-H Shafting Assembly

9,10,11 Hub Bolts 1750 ftlbs

22189-D Blade Bolts 1750 ftlbs

Torques on all other fasteners remains the same.

A-9

SHAFT

SHAFT

SHAFT LINE CROSS SECTIONAL VIEW

SCALE 1 : 3

Reintjes Red Gear Low Speed Shaft

9 8 29

35 18 1737472322 4335 3920

19307116 332

13 14 1516

40 4751

Notes:

12 22 23

See Note 4

See Note 4

G G

2 - Bolt torque ratings:

item Torque (LB-FT) Item Torque (LB-FT) 9,10,11 1750 27 37 22 1040 29 40 26 57 30 10

3 - Name plate information - Servo Box Model E105/4 - 95

HP 6100

RPM 178

Rotation S/N

RH 375

LH 374

Spare 376

4 - Secure w/ Loctite 242 "blue" 6 - Special tools - see PL 22082 7 - "A" dimension, in Servo Box, will be determined at installation and recorded of each shaft line. See dwg. 22437-F

G

G

REVISIONS

ZONE REV. DESCRIPTION DATE APPROVED

A Strut liner shortened approx. 2.6 from tail shaft flange end. mf

B Changed item 21, added item 37, dimensions "A" & "B", notes 8&9, oil tube end machining detail. 2/1/80 mf

C finished to length 2/21/80 mf D Finished notes 5/22/80 mf tm E Changed note 4 8/25/80 tm F Added torque values for items 29 & 30 1/5/81 cm

G Redrawn in SW see attached 22076-PL, deleted notes 1 and 5, modified note 3, modified note 2 torques.

1/29/201 3 smm

D

C

B

A A

B

C

D

12345678

8 7 6 5 4 3 2 1

E

F

E

F

E

RE

V

22076

SHEET 1 OF 1

Shafting Assembly

1/29/13smm

G

UNLESS

OTHERWISE SPECIFIED:

SCALE: 1:3 WEIGHT:

REVDWG. NO.

E

SIZE

TITLE:

PROPULSION SYSTEMS INC

SEATTLE WASHINGTONNAME DATE

COMMENTS:

Q.A.

MFG APPR.

ENG APPR.

CHECKED

DRAWN

FINISH

MATERIAL

INTERPRET GEOMETRIC

TOLERANCING PER:

DIMENSIONS ARE IN INCHES

TOLERANCES:

FRACTIONAL

ANGULAR: MACH BEND

TWO PLACE DECIMAL

THREE PLACE DECIMAL

APPLICATION

USED ONNEXT ASSY

PROPRIETARY AND CONFIDENTIAL

CODE IDENT NO.

27046

THE INFORMATION CONTAINED IN THIS

DRAWING IS THE SOLE PROPERTY OF

PROPULSION SYTEMS INC. ANY

REPRODUCTION IN PART OR AS A WHOLE

WITHOUT THE WRITTEN PERMISSION OF

PROPULSION SYTEMS INC IS

PROHIBITED.

Wheeler

40k lbs

G

PARTS LIST PL -A REV.

List Title

Used on Assembly

Drawn smm Date 1-28-13

Checked Date

Approved Date

Cage Code

27046

Sht of

Shts

Item No.

Qty Req’d

Drawing or Part No.

Description Location Material Spec. and/or Manufacturer

22076-H Shafting Assembly

2A

3 1 21965-D Tail Shaft B7 PSI

4 1 21964-D Line Shaft B3 PSI

5 1 21976-D Coupling Assembly B5 PSI

6 1 22038-D Shaft Flange Cover B8 PSI

7 1 22041-B Seal Retainer B7 PSI

8 1 22039-B Cover E7 PSI

9 1 25522-C Bolt – Register E8 PSI

10 14 25523-C Bolt – Regular C8 PSI

11 1 25524-C Bolt – Torquing B8 PSI

12 24 20350-B Bolt – Shaft Flange E2 B4 PSI

13 1 25604-D Oil Tube – Outer – Tail Shaft B7 PSI

14 1 22933-D Oil Tube – Inner – Tail Shaft B6 PSI

15 1 22934-D Oil Tube – Outer- Line Shaft B3 PSI

16 1 22935-D Oil Tube – Inner – Line Shaft B3 PSI

17 1 25605-D Oil Tube – Outer – Red. Gear B1 PSI

18 1 25606-D Oil Tube – Inner – Red. Gear B1 PSI

19 1 24037-B Nut B5 PSI

22076 G

Shafting Assembly

Wheeler Repower

Title

Used on Assembly

Drawn smm Date 1-28-13

Shts

Item No.

Qty Req’d

Drawing or Part No.

Description Location Material Spec. and/or Manufacturer

20 1 24038-B Nut B5 PSI

21 1 22945-B Seal Sleeve E2 PSI

22 24 1 ¾ - 5 Nut Heavy B4 E2 PSI

23 24 1 ¾ -5 Nut Jam B4 E2 PSI

26 8 5/8 – 11 x 2 lg Soc Hd CS Lockwire E4 Alloy

27* 8 5/8 - 11 x 2 lg Soc Hd CS E7 SS316

29* 4 ½ - 13 x 1 lg Soc Hd CS E4 Alloy

30* 6 Supplied w/ Coupling B5 Alloy

31* 12 1/4 – 20 x 5/8 lg Soc Hd Countersunk CS B7 SS316

32* 1 22076-32 O-ring B8 PSI

33* 1 22076-468 O-ring B4 PSI

34* 1 22076-464 O-ring E7 PSI

35* 1 22076-437 O-ring B2 PSI

36* 2 22076-238 O-ring E4 PSI

37* 1 22076-441 O-ring B2 PSI

38* 2 22076-226 O-ring D8 B2 PSI

39* 1 22076-137 O-ring B4 PSI

40* 1 22076-349 O-ring E8 PSI

22076 G

Shafting Assembly

Wheeler Repower

Title

Used on Assembly

Drawn smm Date 1-28-13

Shts

Item No.

Qty Req’d

Drawing or Part No.

Description Location Material Spec. and/or Manufacturer

41* 1 22076-354 O-ring D8 PSI

45 A/R 1/32 Lockwire E4 PSI

47* 24 3/16 x 2 lg Cotter Pin B3 E2 PSI

48 1 ¼ x ¾ Lg Dowel Pin E1 PSI

50* 8 22076-50 Sealing Washer E7 PSI

51 8 25606-C Lock Bar E8 PSI

1 22076-SK Shafting Assembly Seal Kit consisting of * items PSI

22076 G

Shafting Assembly

Wheeler Repower

Title

Used on Assembly

Drawn smm Date 1-28-13

Shts

Rev. Ltr. Date Description Appd.

A 1-30-80 Changed Dwg number on items 14-18 ECR 2039 Tm

B 2-5-80 Added items 21, 35, & 37 ECR 2058 Tm

C 7-8-80 Changed item 34 part no. from Fabricated, changed items 19 & 20 from 21715-B and 21716-B, changed item 36 from 241 to 238.

Tm

D,E,F See 22076-H Dwg

G 1-28-13 Deleted items 1, 2, 2A, 25, 28, 42, 43, 53 changed part no.’s of items 9, 10, 11, 13, 17, 18, 32-40, 50, 51, changed description of items 31, 41, added locations & seal kit part no.

sm

22076 G

Shafting Assembly

Wheeler Repower

A

B

B

F

F

17860 67 39

40418331

FOR SECTION F-F SEE SHEET 2

FOR SECTION F-F SEE SHEET 2

D

D

C

C

E

E

J

J

119 132 251

FOR SECTION J-J SEE SHEET 2

SECTIO

SECTION D-D

SCALE 1 : 2

SECTION D-D

SCALE 1 : 2102 10141 40 8383

L

SECTION A-A

SCALE 1 : 2

SECTION A-A

SCALE 1 : 2.5

227 89 156 59112

H

H

SECTION C-C

SCALE 1 : 2

143 174 181 246 113 228 80 224

203169

Section H-H see Sheet 2

182 256

SECTION B-B

SCALE 1 : 2

128 55 16

FOR SECTION E-E SEE SHEET 2

SECTION E-E

SCALE 1 : 2

SECTION F-F

SCALE 1 : 2

SECTION H-H

SCALE 1 : 2

SECTION J-J

SCALE 1 : 2

FOR SECTION E-E SEE SHEET 2

D

C

B

A A

B

C

D

12345678

8 7 6 5 4 3 2 1

E

F

E

F

E

RE

V

SERVO BOX ASSEMBLY RH

SHEET 1 OF 2

1-21-13smm

UNLESS

OTHERWISE SPECIFIED:

SCALE: WEIGHT:

REVDWG. NO.

E

SIZE

TITLE:

PROPULSION SYSTEMS INC

SEATTLE WASHINGTONNAME DATE

COMMENTS:

Q.A.

MFG APPR.

ENG APPR.

CHECKED

DRAWN

FINISH

MATERIAL

INTERPRET GEOMETRIC

TOLERANCING PER:

DIMENSIONS ARE IN INCHES

TOLERANCES:

FRACTIONAL

ANGULAR: MACH BEND

TWO PLACE DECIMAL

THREE PLACE DECIMAL

APPLICATION

USED ONNEXT ASSY

PROPRIETARY AND CONFIDENTIAL

K

CODE IDENT NO.

27046

THE INFORMATION CONTAINED IN THIS

DRAWING IS THE SOLE PROPERTY OF

PROPULSION SYTEMS INC. ANY

REPRODUCTION IN PART OR AS A WHOLE

WITHOUT THE WRITTEN PERMISSION OF

PROPULSION SYTEMS INC IS

PROHIBITED.

22437 KWHEELER

950#

SECTION F-F

SCALE 1 : 1.5

108 35 33 154 135 145 45 115 185 18

142 49 46 43 42

FROM SHEET 1

SERVO

SERVO

T

T

AB

AB

G

G

I

I

SECTION E-E

SCALE 1 : 1.5

51 211 206204 20552 53

2001996100 195711051062710410794 26

109 294 28 12 93

99100

196120 160

111 13 131 77

189114

193 192

FROM SHEET 1

149 148

SECTION G-G

SCALE 1 : 2

154 115 185 142

H

H

SECTION T-T

SCALE 1 : 1.5

H-H

SECTION H-H

SCALE 1 : 1.5

SCALE 1 : 2

81202

80202

169170

AA

SECTION I-I

SCALE 1 : 1.5

SECTION I-I

SCALE 1 : 2

AC

SECTION AB-AB

SCALE 1 : 1.5

SECTION J-J

SCALE 1 : 5

FROM SHEET 1

209146

138141138

247 248 258257 259 260 261 262

D

C

B

A A

B

C

D

12345678

8 7 6 5 4 3 2 1

E

F

E

F

E

RE

V

SERVO BOX ASSEMBLY RH

SHEET 2 OF 2

UNLESS OTHERWISE SPECIFIED:

SCALE: WEIGHT:

REVDWG. NO.

E

SIZE

TITLE:

NAME DATE

COMMENTS:

Q.A.

MFG APPR.

ENG APPR.

CHECKED

DRAWN

FINISH

MATERIAL

INTERPRET GEOMETRIC

TOLERANCING PER:

DIMENSIONS ARE IN INCHES

TOLERANCES:

FRACTIONAL

ANGULAR: MACH BEND

TWO PLACE DECIMAL

THREE PLACE DECIMAL

APPLICATION

USED ONNEXT ASSY

PROPRIETARY AND CONFIDENTIAL

THE INFORMATION CONTAINED IN THIS

DRAWING IS THE SOLE PROPERTY OF

<INSERT COMPANY NAME HERE>. ANY

REPRODUCTION IN PART OR AS A WHOLE

WITHOUT THE WRITTEN PERMISSION OF

<INSERT COMPANY NAME HERE> IS

PROHIBITED.

22437 K

WHEELER

K smm 1-21-13

950#

PROPULSION SYSTEMS, INC.

SEATTLE, WASHINGTON

Owner Typewritten Text

Owner Typewritten Text

Owner Typewritten Text

Owner Typewritten Text Section View H-H From Sheet 1

Title

Used on Assembly

Drawn Date

Shts

Item No.

Qty Req’d

Drawing or Part No.

Description Location Material Spec. and/or Manufacturer

Servo Box Assembly

1 1 19787-C 2 Stage Servo Valve Assembly G95 F7 SHT 2 PSI

2 1 25578-F Servo Box RH Mod. C6 SHT 1 PSI

2a 1 25578-F Servo Box LH Mod. C6 SHT 1 PSI

3 1 19727-F Servo Shaft B8 SHT 2 PSI

4^ 2 19722-B Seal Ring - Servo Shaft B7 SHT 2 PSI

5 1 19696-F Servo Valve Housing E8 SHT 2 PSI

6 1 19718-C Follow - up Spool B5 SHT 2 PSI

7 1 19694-C Shoe - Follow Up Link C4 SHT 2 PSI

8 1 19706-D Follow Up Lever – RH B4 SHT 1 PSI

8a 1 19900-D Follow Up Lever – LH B4 SHT 1 PSI

9 1 19707-D Feed Back Lever B3 SHT 1 PSI

10 1 20132-D Outer Oil Tube D8 SHT 2 PSI

11 1 25600-D Inner Oil Tube D8 SHT 2 PSI

12 1 19763-D Retainer – Seal Ring B6 SHT 2 PSI

13 1 19704-B rev c Cover – Back B4 SHT 2 PSI

14 1 19703-B rev c Cover – Top F8 SHT 2 PSI

15 1 19684-D Pivot Housing B4 SHT 1 PSI

16 1 19716-C Brake Shoe – Follow – Link B4 SHT 1 PSI

17 1 19714-B Retainer – Spring Follow Up Bolt B4 SHT 1 PSI

22437 K

Servo Box Assy RH G95 with take-home capability without controls

Wheeler Repower

Title

Used on Assembly

Drawn Date

Shts

Item No.

Qty Req’d

Drawing or Part No.

Description Location Material Spec. and/or Manufacturer

18 1 19712-B Bolt – Feedback Lever F1 SHT 2 PSI

19 1 19713-B Screw – Clamping, Follow Up Lever B4 SHT 1 PSI

20^ 2 19686-B Bushing – Pivot, Feedback Lever B3,4

SHT1

PSI

21 1 19687-B Disc – Upper Follow Up Lever B3 SHT 1 PSI

22^ 1 19690-B Bushing – Lower Follow Up Lever A4 SHT 1 PSI

23^ 1 19720-B Bushing – Aft Servo Shaft D8 SHT 2 PSI

24 1 19725-B Lantern Ring – Hub and Gear Oil Seal D8 SHT2 PSI

25 1 19723-B Lantern Ring – Hub Oil Seal D8 SHT 2 PSI

26 1 19719-B Spacer Tube – Servo Shaft B6 SHT 2 PSI

27^ 1 19724-B Seal Ring Spacer B7 SHT 2 PSI

28^ 1 19721-B Bushing – Fwd Servo Shaft B6 SHT 2 PSI

29^ 1 19726-B Seal Ring – Seal Ring Spacer B6 SHT 2 PSI

30 1 24111-B Pitch Scale F4 SHT 1 PSI

31* 1 25591-B Gasket – Servo Box Red Gear B7 SHT 1 1/16 Velumoid

32 1 20134-B-1 Key E4 SHT 2 PSI

33 1 20134-B-2 Key F3 SHT 2 PSI

34 1 19859-C Shaft – Control Handle E4 SHT 2 PSI

35 1 19788-B Pinion – Control Handle F3 SHT 2 PSI

36 1 19888-B Ring – Clamp, Bearing Housing Control Handle E4 SHT 1 PSI

37 1 19855-C Housing – Control Shaft E4 SHT 1 PSI

22437 K

Servo Box Assy RH G95

Title

Used on Assembly

Drawn Date

Shts

Item No.

Qty Req’d

Drawing or Part No.

Description Location Material Spec. and/or Manufacturer

38 1 19856-C Hub – Control, Disconnect Pin E4 SHT 1 PSI

39 1 19798-B Handle – Control Disconnect Pin F5 SHT 1 PSI

40 1 25575-B Plug – Exhaust Port A1 SHT 1 PSI

41 1 25574-B Plug – Servo Supply Port A2 SHT 1 PSI

42 1 25583-B Supply Pipe – Anti Rotation F1 SHT 2 PSI

43 1 25579-B Sleeve – Supply Port F1 SHT 2 PSI

44 1 20634-B Sleeve – Exhaust Port E1 SHT 2 PSI

45 1 25584-B Gauge Bracket – Servo Box F2 SHT 2 PSI

46* 1 25585-B Gasket – Supply Sleeve F1 SHT 2 1/16 Velumoid

47* 1 25586-B Gasket – Exhaust Sleeve E1 SHT 2 1/16 Velumoid

48 1 25576-C Exhaust Pipe E1 SHT 2 PSI

49 1 25577-C Supply Pipe F1 SHT 2 PSI

50 1 19853-C Cover – Servo Valve Housing B8 SHT 2 PSI

51 1 19742-B Clevis – Servo Valve E6 SHT 2 PSI

52 1 19744-B Pin – Clevis, Servo Valve E5 SHT 2 PSI

53 1 19743-B Link – Servo Valve E5 SHT 2 PSI

54 1 25603-B Nameplate PSI

55 1 19822-B Gear – Follow Up Lever B4 SHT 1 PSI

56 1 19865-B Link – Control Linkage C8 SHT 1 PSI

57 1 20134-B-3 Key D6 SHT 2 PSI

22437 K

Servo Box Assy RH G95

Title

Used on Assembly

Drawn Date

Shts

Item No.

Qty Req’d

Drawing or Part No.

Description Location Material Spec. and/or Manufacturer

58 1 19848-B Shaft – Pivot Arm A8 AHT 1 PSI

59 1 19851-C Bearing Housing B7 SHT 1 PSI

60 1 23044-C Spring Cylinder Assembly F6 SHT 1 PSI

61 1 21140-B Bracket – Mounting Pitch Scale E4 SHT 1 PSI

62 1 19935-B Ring – Follow Up Shoe A4 SHT 1 PSI

63 2 19632-B Plug – Orifice, Servo Valve E8 SHT 2 PSI

64 15 3/8-16 x 1” Lg Socket Head Cap Screws

F5 SHT 1

B8 SHT 2

E8 SHT 2

Alloy

65 3 3/8-16 x 5/8” Lg Socket Head Cap Screws C4 SHT 1 Alloy

66 8 3/8-16 x 7/8” Lg Socket Head Cap Screws C1 SHT 2 Alloy

67 10 3/8-16 x 1-3/8” Lg Socket Head Cap Screws F6 SHT 1 Alloy

68 4 ½-13 x 7/8” Lg Socket Head Cap Screws D4 SHT 1 Alloy

69 4 ¼-20 x 1 ¼ Socket Head Cap Screws F1 SHT 2 Alloy

70 8 5/8-11 x 1-3/4” Lg Socket Head Cap Screws D1 SHT 2 Alloy

71 8 5/8-11 x 2” Lg Wire Head w/ 1/32 Diameter Monel Lockwire D1 SHT 2 Alloy

72 8 M16-2 x 35 Soc Hd CS C8 SHT 2 Alloy

73 2 #6 x 3/16” Lg Socket Head Cap Screw E4 SHT 1 Alloy

74 1 ½-13 x 1-1/2” Lg Socket Head Cap Screw D4 SHT 2 Alloy

75 8 M24-3 x 50 Soc Hd CS B8 SHT 2 Alloy

22437 K

Servo Box Assy RH G95

Title

Used on Assembly

Drawn Date

Shts

Item No.

Qty Req’d

Drawing or Part No.

Description Location Material Spec. and/or Manufacturer

Hex. Head Cap Screws

76 2 10-32 x ½” Lg B5 SHT 1

77 22 ½-13 x 1-1/4” Lg F4 SHT 1

D4 SHT 1

Stainless

78 2 ¼-20 x ½” Lg A5 SHT 1 Alloy

79 1 G41-21 Spur Gear A5 SHT 2 PIC

80 1 G41-51 Spur Gear B5 SHT 1 PIC

81 1 G41-20 Spur Gear A5 SHT 1 PIC

82* 2 RR250 Retaining Ring E8 SHT 2 Steel

83 12 1/4 -20 x ¾ lg Soc Hd CS A1 SHT 1 Alloy

Studs

84 1 3/8-16 x 1-3/4” Lg B3 SHT 1 Steel

85* 1 25420-B Gasket – Top Cover F8 SHT 2 Clothed impregnated rubber

86* 1 25422-B Gasket – Brake Housing B4 SHT 1 1/16 Velumoid

Dimco Knobs

87 1 B11 1-7/8 Dia. 5/8 Tapped Hole F5 SHT 1 Plastic

88 2 3100-39 External Retaining Ring A4 SHT 2

Spirolox Retaining Rings

89* 1 RR-185 B7 SHT 1 Steel

90* 1 RS-125 A4 SHT 1 Steel

22437 K

Servo Box Assy RH G95

Title

Used on Assembly

Drawn Date

Shts

Item No.

Qty Req’d

Drawing or Part No.

Description Location Material Spec. and/or Manufacturer

91* 1 RR-216 F4 SHT 2 Steel

92* 1 RRT-393 D8 SHT 2 Steel

93* 1 RRT-412 B6 SHT 2 Steel

94* 1 RR-712 B8 SHT 2 Steel

95* 2 RS-100 F3 SHT 2

E4 SHT 2

Steel

96* 1 RS-62 DI SHT2 Steel

97* 4 RRN-118 A,B4

SHT 2

Steel

O-Rings

98* 1 -113 B4 SHT1 Buna N

99* 4 -222 D8,C6,B5

,6 SHT 2

Buna N

100* 2 -227 B6 SHT 2 Buna N

101* 2 -339 A1 SHT 1

A6SHT 2

Buna N

102* 2 -332 A1 SHT 1

B6 SHT 2

Buna N

103* 2 -335 B4 SHT 1

D8 SHT 2

Buna N

104* 1 -340 B7 SHT 2 Buna N

105* 1 -346 B6 SHT 2 Buna N

106* 1 -365 B7 SHT 2 Buna N

107* 1 -329 B7 SHT 2 Buna N

108* 1 -155 F3 SHT 2 Buna N

109* 1 -361 B8 SHT 2 Buna N

22437 K

Servo Box Assy RH G95

Title

Used on Assembly

Drawn Date

Shts

Item No.

Qty Req’d

Drawing or Part No.

Description Location Material Spec. and/or Manufacturer

110* 2 -210 A4 SHT 2 Buna N

111* 1 25421-B Gasket – Cover Front A4 SHT 2 Cloth Impregnated Rubber

112* 1 25423-B Gasket – Pivot Arm B7 SHT 1 1/16 Velumoid

Hex Jam Nuts

113 1 ½-13 Hex Jam Nut B5 SHT 2 Steel

114 1 5/8-18 Hex Jam Nut E6 SHT 2 Steel

115 2 ¾-16 Hex Jam Nut F2 SHT 2 Brass

Esna Nut

116* 3 29NE-048 ¼-28 E8 SHT 1 Steel

117* 2 49NE-120 ¾-10 D8 SHT 1

B4 SHT 1

Steel

119* 5 29NE-066 3/8-16

F8 SHT 1

C8 SHT 1

B3 SHT 1

Steel

Driv-Lok Pins

`120 1 ¼ Dia. X 5/8 Lg Type D B3 SHT 1 Alloy

121 2 ½ Dia. X 2” Lg Type D B4 SHT 1 Alloy

122 2 6-32 x 3/8 Lg Socket Head Set Screw B4 SHT 2 Alloy

123 1 ¼-28 x 2-1/2” Lg Threaded Rod E8 SHT 1 Steel

125 2 #3 x 1” Lg Taper Pin C4 SHT 1 Steel

126 1 1G11-P-3-03-S Fluid Controls Relief Valve (optional valve ECR-600-S-4 Parker) B2 SHT 2

Title

Used on Assembly

Drawn Date

Shts

Item No.

Qty Req’d

Drawing or Part No.

Description Location Material Spec. and/or Manufacturer

Belleville Washers

127* 4 28mm x 12.2mm x 1.5 mm E1 SHT 2 Steel

128 10 80mm x 30.5mm x 2.5 mm B4 SHT 1 Steel

Flat Washers Steel

129 2 ¼ Type A Series N E8 SHT 1

130 2 #6 Flat F4 SHT 1 Steel

131 22 ½ Flat F4 SHT 1

D4 SHT 1

S/S

132 3 3/8 Flat C8 SHT 1 Steel

Pipe Plug Hex Socket

133 5 1/8 NPT A3,4

SHT 1

Steel

134 1 1/4 NPT D5 SHT 2 Steel

135* 2 25424-B Gasket – Servo Valve Housing Flange E1 SHT 2

F2 SHT 2

1/16 Velumoid

136 1 25590-B Feed Back Lexan Cover F7 SHT 1

137* 1 25589-B Gasket Lexan Cover A8 SHT 2

Parker Fittings

138 5 4C50X ST. THD. ELBOW 90 E8 SHT 2

B2 SHT 2

139 2 8CTX MALE ELBOW 90 B2 SHT 2

140 1 8V50X ST. THD. ELBOW 45 B2 SHT 2

141 1 4STX MALE BRANCH TEE B2 SHT 2

22437 K

Servo Box Assy RH G95

Title

Used on Assembly

Drawn Date

Shts

Item No.

Qty Req’d

Drawing or Part No.

Description Location Material Spec. and/or Manufacturer

142 1 24C5BU ST. THD. ELBOW 90 F2 SHT 2

143 14 1/4-20 X ½” Lg Socket Head Cap Screws B6 SHT 1 Alloy

144 1 1/2 SHPS PLUG Inboard side of box

145 2 Gage to Bracket Adapter F2 SHT 2 Brass

146 3

2807-4 63-190600-4

1/4” Hose 10” long (Approx.) with JIC swivel both ends B2 SHT 2

147 1

2807-8 63-190600-8

1/2” hose 16” long with JIC swivel both ends

B3 SHT 2

148 1

2651-5 411-5B

5/16 Hose 18” long with JIC swivel both ends E5 SHT 2

149 1

2651-4 411-4B

1/4” hose 36” long with JIC Swivel both ends E5 SHT 2

150* 3 12196-LUP JM Seal B8 STH 2

151* 1 9625-LUP JM Seal F3 SHT 2

152 8 3/8-16 x 1 ¾ Hex Hd CS A6 SHT2

153 1 3/32 Cotter pin E5 SHT 2

154 2 2-1/2” BC 0-1000 PSI Gage F2 SHT 2

155* 4 9500 Single Row Radial Bearing B5 SHT 2

156* 2 6005-2RS Bearing B7 SHT 1

157* 2 6006-2RS Bearing F4 SHT 2

160* 1 N-09 SKF Locknut C1 SHT 2

22437 K

Servo Box Assy RH G95

Title

Used on Assembly

Drawn Date

Shts

Item No.

Qty Req’d

Drawing or Part No.

Description Location Material Spec. and/or Manufacturer

163* 1 W-09 SKF Lockwasher C1 SHT2

169 3 #L2-2 Motor Mount Cleats (potentiometer) A6 SHT 1

170 3 #Y1-4-U Fillister Head Screws 4-40 x 5/16 A6 SHT 1

171 3 1770-B-1 45 degree grease zerk-fitting C8 SHT 1

A2 SHT 2

174 4 #5-40 x 1/2 Pan head screw B6 SHT 1

175 8 ¾”x10 x ¾ lg Socket Head Set Screws C1 SHT 1

178 1 P562524 Air breather for Top Cover F6 SHT 1

181 1 MS10-140 Terminal Marker Strip (Xmitter) B6 SHT 1

182 1 10-140 Terminal Strip (Xmitter) B6 SHT 1

22437 K

Servo Box Assy RH G95

Title

Used on Assembly

Drawn Date

Shts

Item No.

Qty Req’d

Drawing or Part No.

Description Location Material Spec. and/or Manufacturer

184 3 4P50N PLUG (Parker Fitting) F1 SHT 2

185 2 2501-04-04 90 degree elbow F2 SHT 2

188 1 5F5X ST.THD. CONN (5/16”) D1 SHT 2

189 1 0103-4-4 NIPPLE E5 SHT 2

190 1 2103-4-5 MALE ELBOW F5 SHT 2

192 1 3/8-16 x 1” Lg Dog Point Set Screw E6 SHT 2

193 1 3/8-16 x ½” Lg Socket Head Set Screw E6 SHT 2

195 1 20102-B Jacking Piston (Take-home) B6 SHT 2

196 1 20103-B Liner – Oil Inlet Ring (Take-home) B5 SHT 2

197 1 20101-B Shaft – Oil inlet adapter (Take-home) D1 SHT 2

198 1 20099-B Spacer–Oil inlet adapter (Take-home) C1 SHT 2

199 1 20104-B Ring – Oil inlet B5 SHT 2

200 1 20100-B Bracket – Adapter Shaft B4 SHT 2

201 1 20105-B Adapter – Oil inlet D1 SHT 2

202 4 6-32 x 1/8” Lg. Socket Head Set Screw B4,5

SHT 2

203 1 8517 2-Stage Potentiometer 5K (Markite) A5 SHT 1

204 1 Double A Check Valve E5 SHT 2

205 1 0505-8-4 Adapter (parker) F5 SHT 2

22437 K

Servo Box Assy RH G95

Title

Used on Assembly

Drawn Date

Shts

Item No.

Qty Req’d

Drawing or Part No.

Description Location Material Spec. and/or Manufacturer

206 1 012T-4-4 Tee F5 SHT 2

207 1 01SP-4 Plug D5 SHT 2

208 1 0537-4-4 TEE B2 SHT 2

209 1 3903-4 Swivel nut B2 SHT 2

210 1 2093-6-6S Male pipe Tee B2 SHT 2

211 1 0101-4-4 Nipple F5 SHT 2

222 1 23084-A Shaft-Idler gear A5 SHT 2

223 1 23085-A Bearing HSG A5 SHT 2

224 1 23086-A Mounting Plate Potentiometer B5 SHT 1

226 1 23088-A Outer Clamp-Pivot Arm A8 SHT 1

227 1 23089-A Inner Clamp-Pivot Arm B7 SHT 1

22437 K

Servo Box Assy RH G95

Title

Used on Assembly

Drawn Date

Shts

Item No.

Qty Req’d

Drawing or Part No.

Description Location Material Spec. and/or Manufacturer

228 1 23090-A Pivot Shaft-Repeat-Back Lever B6 SHT 1

232 1 23094-A-1 Bearing Spacer B5 SHT 2 PSI

233 1 23094-A-1 Bearing Spacer B6 SHT 2 PSI

234 1 23095-A Clamp Ring – Bearing Housing B5 SHT 1 PSI

236 1 23097-A Gear – Repeat Back Lever B5 SHT 2 PSI

238 1 23099-A Standoff-Potentiometer A5 SHT 1

240 1 23101-A Repeat-Back Lever B5 SHT 2

241 1 23102-A Pivot Arm-Control Linkage E8 SHT 1

245 2 1/16 x 1/2 Roll pin A5 SHT 2

246 1 23108-C Cover Box-Repeat Back Assembly B6 SHT 1

247 1 23111-A Adjustment Rod-Repeat Back Link B2 SHT 2

22437 K

Servo Box Assy RH G95

Title

Used on Assembly

Drawn Date

Shts

Item No.

Qty Req’d

Drawing or Part No.

Description Location Material Spec. and/or Manufacturer

248 1 23112-A Stand Off A2 SHT 2 PSI

249 1 24059-A Stand Off B2 SHT 2 PSI

251* 3 48399-LSS-8 Spherical Bearing

D4 SHT 1

C8 SHT 1

F8 SHT 1

252* 4 1/2-13 x 1 Socket Head Shoulder Screw

D4 SHT 1

C8 SHT 1

F8 SHT 1

256* 1 25588-B Gasket B6 SHT 1 Cloth impregnated rubber

257 1 1/4-20 x ¾” Lg Socket Head Shoulder Screw B2 SHT 2

258 1 TR-4N Female rod end B2 SHT 2

259 1 TRL-4N Female rod end B2 SHT 2

260 1 Jam Nut LH1/4-28 B2 SHT 2

261 1 Jam Nut RH 1/4-28 B2 SHT 2

262 1 SHCS 1/4-20 x 2-1/2 B2 SHT 2

1 22437-SK Seal Kit Consists of * Items

1 22437-RK Repair Kit Consists of ^ Items

Title

Used on Assembly

Drawn Date

Shts

Rev.

Ltr.

Date Description Appd.

A 7/16/79 Changes made per ECR 1592

B Added No. 126, Added auxiliary descriptions ECR 1966

C 5/23/80 Deleted item 42, Added item: 56,58-60,69,72,75,76,78-83,88,89,97,113,115,116,118,119, 122,129,136,143,145, 155,156, 169-171,174,180-182,194,202,221-261, Changed item 117 Qty from 1 to 2, Changed item 126 from 1G11-P-3-03-S to ECR-600-S-4 per ECR 2385

D 6/19/80 Changed item 126 back to previous part no. from ECR-600-S-4 to 1G11-P-3-03-S, listing ECR-600-S-4 Parker as optional.

Added “New Departure” to item 155, added Grease Fitting to item 171 per ECR 2433

TM

E 7/7/80 Deleted items: 185,186,187, added qty of 1 to item 256 per ECR 2478

F 9/4/80 Added to item 248: 1 A24059 Stand – Off ½ OD x ¼ ID SMT. ECR 2585, item 257 was changed to 1, added 262: ¼-28 x 2 ½ Soc Hd CS Gr 8, changed item 122 from Drive Lok Spring Pin to 6-32 x 3/8 lg Soc Hd Set Screw (2)

G 9/18/80 Item 251 changed to 48399-LSS-8 form 65397-LSS-8 and Matl’ Spec. was changed to Boston Gear form Bost-Ball. –(Heim) was added to the description. (ECR 2642)

H 1/22/81 Changed dwg. no. of item 30 to 24111-B from 20699-B for Job 3141 and to 24117-B for Job 3406. Removed “Without Controls” from title block. Added item 263, qty 2, Soc Hd CS, 1/4 -20 x 1.25 lg., Gr. 8 ECR 2795

TM

J 12/10/81 Added items 40-44, and 264-270 and hardware MF

K 1/22/13

Redrawn in SW for repower. Changed item 2 p/n from 20130-F to 25578-F and item 11 from 20106-D to 25600-D, item 54 from 20922-A to 25603-B. Changed item 13,14 dwg to rev. C, changed items 40- 44,48,49,69,72,75,83,115,131,136,145,178,248, changed qty of items 76,78,101,102,138,143 and desc,174, added items 31, 45-47,82,111,112,135,137,152,154,175,185,249, deleted items 82,118,172,180,194,221,225,229- 231,235,237,239,242-244,250,253-255,262-266, added p/n’s to items 85,86,256. Added Seal Kit p/n 22437-SK and Repair Kit p/n 22437-RK with individual item asterisks to reflect what is included.

SMM

Side view

Side view

A

SECTION Side view-Side view

SCALE 1 : 2.5

94 25 86

72 69 70 35

1 5

7A

6A

8 9 12

1519 20 23

33 33

SECTION A-A

SCALE 1 : 2.5

5A

D

C

B

A A

B

C

D

12345678

8 7 6 5 4 3 2 1

E

F

E

F

E

RE

V

22189

SHEET 1 OF 2

1-25-13djg

K

UNLESS

OTHERWISE SPECIFIED:

SCALE: 1:2.5 WEIGHT:

REVDWG. NO.

E

SIZE

TITLE:

PROPULSION SYSTEMS INC

SEATTLE WASHINGTONNAME DATE

COMMENTS:

Q.A.

MFG APPR.

ENG APPR.

CHECKED

DRAWN

FINISH

MATERIAL

INTERPRET GEOMETRIC

TOLERANCING PER:

DIMENSIONS ARE IN INCHES

TOLERANCES:

FRACTIONAL

ANGULAR: MACH BEND

TWO PLACE DECIMAL

THREE PLACE DECIMAL

APPLICATION

USED ONNEXT ASSY

PROPRIETARY AND CONFIDENTIAL

K

CODE IDENT NO.

27046

THE INFORMATION CONTAINED IN THIS

DRAWING IS THE SOLE PROPERTY OF

PROPULSION SYTEMS INC. ANY

REPRODUCTION IN PART OR AS A WHOLE

WITHOUT THE WRITTEN PERMISSION OF

PROPULSION SYTEMS INC IS

PROHIBITED.

E/105 Propeller Hub Assembly

8700 lbs.

smm 1-23-13

Wheeler

73 26

37 84

49 8050 81

D

C

B

A A

B

C

D

12345678

8 7 6 5 4 3 2 1

E

F

E

F

E

RE

V

22189

SHEET 2 OF 2

K

UNLESS OTHERWISE SPECIFIED:

SCALE: 1:3 WEIGHT:

REVDWG. NO.

E

SIZE

TITLE:

NAME DATE

COMMENTS:

Q.A.

MFG APPR.

ENG APPR.

CHECKED

DRAWN

FINISH

MATERIAL

INTERPRET GEOMETRIC

TOLERANCING PER:

DIMENSIONS ARE IN INCHES

TOLERANCES:

FRACTIONAL

ANGULAR: MACH BEND

TWO PLACE DECIMAL

THREE PLACE DECIMAL

APPLICATION

USED ONNEXT ASSY

PROPRIETARY AND CONFIDENTIAL

THE INFORMATION CONTAINED IN THIS

DRAWING IS THE SOLE PROPERTY OF

<INSERT COMPANY NAME HERE>. ANY

REPRODUCTION IN PART OR AS A WHOLE

WITHOUT THE WRITTEN PERMISSION OF

<INSERT COMPANY NAME HERE> IS

PROHIBITED.

K

E105 Propeller Hub Assembly

PROPULSION SYSTEMS, INC

SEATTLE, WASHINGTON

8700# smm 1-23-13 djg 1-25-13

Title

Used on Assembly

Drawn smm Date 1-23-13

Shts

Item No.

Qty Req’d

Drawing or Part No.

Description Location Material Spec. and/or Manufacturer

1 1 21984-F rev c Propeller Hub E8 SHT 1 PSI

2A

5 4 25520-D Crankdisc E105 RH E7 SHT 1 PSI

5A 4 25521-D Crankdisc E105 LH E7 SHT 1 PSI

6 1 21989-D Fwd Guide Block RH A7 SHT 1 PSI

6A 1 21991-D Fwd Guide Block LH A7 SHT 1 PSI

7 1 21990-D Aft Guide Block RH A6 SHT 1 PSI

7A 1 21992-D Aft Guide Block LH A6 SHT 1 PSI

8 1 25602-D Piston Rod A5 SHT 1 PSI

9 1 22019-D Piston A5 SHT 1 PSI

10 1 22017-B Nut – Piston Rod C4 SHT 1 PSI

11 1 25542-C Toothed Coupling C8 SHT 1

12 1 21986-D Cylinder – Servo Motor A5 SHT 1 PSI

13 1 21985-D Cylinder Cover – Servo Motor A5 SHT 1 PSI

14 1 21997-C Fwd Support Bearing B8 SHT 1 PSI

15 32 25568-B Bolt – Blade E7 SHT 1 PSI

17 4 22011-C Stud – Guide Blocks C1 SHT 1 PSI

22189 K

E105 Propeller Hub

Assembly

Wheeler Repower

Title

Used on Assembly

Drawn smm Date 1-23-13

Shts

Item No.

Qty Req’d

Drawing or Part No.

Description Location Material Spec. and/or Manufacturer

19* 32 22015-19-B Washer – Blade Bolt E8 SHT 1 PSI

20 8 22034-A Dowel Pin – Propeller Blade E7 SHT 1 PSI

23^ 4 25384-C Bearing Ring – Hub E6 SHT 1 PSI

25 2 21996-B Centering Pin E7 SHT 1 PSI

26 2 21987-B Centering Disc – Blade D3 SHT 2 PSI

27^ 4 21994-B Sliding Block – Crankdisc E1 SHT 1 PSI

28^ 2 21995-B Sliding Block – Centering Pin E2 SHT 1 PSI

30 4 22028-A Dowel Pin – Guide Block C1 SHT 1 PSI

31 4 22012-A Nut – Guide Block C1 SHT 1 PSI

32^ 2 22009-B Bushing – Fwd and Aft Support Bearing A6.7

SHT1

PSI

33 2 22010-B Retaining Ring – Piston Rod Seal E6,8

SHT 1

PSI

34 1 21998-B Cylinder Cover – Aft C4 SHT 1 PSI

35* 2 22020-A Piston Ring E5 SHT 1 PSI

36 1 22018-A Key – Piston Rod D4 SHT 1 PSI

37* 1 25601-B Lock Bar – Servo Cylinder Bolts D6 SHT 2 PSI

22189 K

E105 Propeller Hub

Assembly

Wheeler Repower

Title

Used on Assembly

Drawn smm Date 1-23-13

Shts

Item No.

Qty Req’d

Drawing or Part No.

Description Location Material Spec. and/or Manufacturer

39 1 22021-D Inner Oil Tube C8 SHT 1 PSI

40 2 23016-A Retainer Disc D8 SHT 1 PSI

45 2 22029-A Dowel Pin – Piston Rod C4 SHT1 PSI

49* 32 25537-B Washer – Servo Motor Cylinder A5 SHT 2 PSI

50* 4 25538-B Washer – Servo Motor Cylinder Jacking Screw A5 STH 2 PSI

53* 8 25539-B Lock Bar – Blade Bolts E2 SHT1 PSI

57* 2 -020 O-ring D8 SHT 1 PSI

59* 1 -348 O-ring C4 SHT1 PSI

22189 K

E105 Propeller Hub

Assembly

Wheeler Repower

Title

Used on Assembly

Drawn smm Date 1-23-13

Shts

Item No.

Qty Req’d

Drawing or Part No.

Description Location Material Spec. and/or Manufacturer

60* 1 -370 O-ring C4 SHT 1 PSI

62* 1 -472 O-ring E5 SHT 1 PSI

68* 1 -475 O-ring D4 SHT 1 PSI

69* 1 22189-69 O-ring E5 SHT 1 PSI

70* 1 22189-70 O-ring E5 SHT 1 PSI

72 4 5/8-11 x 2 ½ Soc Hd CS E6 SHT 1 Gr 8

73 8 ½-13 x 1 Soc Hd CS D3 SHT 2 Gr 8

76 4 5/8-11 x 3 Soc Hd CS E2 SHT 1 Gr 8

77* 12 5/8-11 x 1 ½ Soc Hd CS B5 SHT 2 SS316

78 12 5/8-11 x 2 Soc Hd CS E8 SHT2 Gr 8

79 4 3/8-16 x 5/8 Soc Hd CS C8 SHT 1 Gr 8

80 32 1 1/8-7 x 3 ¼ Soc Hd CS A5 SHT 2 SS316

22189 K

E105 Propeller Hub

Assembly

Wheeler Repower

Title

Used on Assembly

Drawn smm Date 1-23-13

Shts

Item No.

Qty Req’d

Drawing or Part No.

Description Location Material Spec. and/or Manufacturer

81* 4 5/8-11 x ¾ Soc Hd CS A5 SHT 2 SS316

82 2 ½-13 x 1 Soc Hd Set Screw D4 STH 1 Gr 8

83* 1 3/8-16 x 1 Soc Hd Set Screw D4 STH 1 Gr 8

84 2 5/8-11 x 1 Soc Hd Set Screw D6 sht 2

86* 2 RRN950 Retaining Ring E6 SHT 1 Spirolok

87 1 3/8 x 1 Spring Pin C8 sht 1

90* 2 ½ NPT Pipe Plug A7 SHT 1 SS

91* 1 3/8 NPT Pipe Plug SS

93* 2 23020015 Rod Seal B8 SHT 1

94* 4 25332-A rev D Blade Seal E8 SHT 1 PSI

95* 1 C2949S10Q Check Valve D8 SHT 1 PSI

96* 1 C2949S10Q14 Check Valve D8 SHT 1 PSI

98 1 22189-SK Seal Kit identified by *

99 1 22189-RK Repair Kit identified by ^

22189 K

E105 Propeller Hub

Assembly

Wheeler Repower

Title

Used on Assembly

Drawn smm Date 1-23-13

Shts

Rev. Ltr. Date Description Appd.

A 7-27-79 Changed items 73,76 and 80 per ECR 1620 Tm

B 11-5-79 Deleted item 63 per ECR 1832 Tm

C 1-4-80 Changed qty’s on items 15,19 and 28. Changed item 52 to 53 and changed qty per ECR 1967 Tm

D 2-4-80 Deleted item 2 and 2A per ECR 2056 Tm

E 3-13-80 Added items 19,38,49,50 and 79 per ECR 2199 Tm

F 4-23-80 Changed item 38 to 40. Changed item 109 from C29495 to C2949S. Deleted item 87 per ECR 2286 Tm

G 5-22-80 Deleted item 48 per ECR 2375 Tm

H 6-13-80 Changed item 62 from 393 to 24x.21cs to 472 22.94x.275cs Tm

J 7-22-80 Changed item 20 from A22034 to A24047 per ECR 2517 Tm

K 1-23-13 Revised Prop Hub dwg, changed p/n’s 5, 5A, 15, 19, 20, 23, 37, 49, 50, 53, 57, 93, 94. Added items 11, 70, 84, 87, 91, 98, 99. Changed item # 105 to 95 and 109 to 96. Added item locations.

smm

22189 K

E105 Propeller Hub

Assembly

Wheeler Repower

ATLANTIC INDUSTRIAL TECHNOLOGIES

90 Precision Drive Shirley, NY 11967 Ph: (800) 254-3131 www.aitzone.com

Two (2) Hydraulic Power Units

Two (2) HPU Motor Control Enclosures

Seattle, WA 98107

October 4, 2012

HYDRAULIC POWER SYSTEMS

Atlantic Industrial Technologies

TABLE OF CONTENTS

1 AIT WARRANTY

2 OPERATION AND MAINTENANCE INSTRUCTIONS

3 GENERAL ARRANGEMENT DRAWING

4 HYDRAULIC SCHEMATIC

5 ELECTRICAL SCHEMATICS

6 HYDRAULIC BILL OF MATERIALS

7 ELECTRICAL BILL OF MATERIALS

8 HYDRAULIC DATASHEETS

9 ELECTRICAL DATASHEETS

10 ACCEPTANCE TEST PROCEDURES

1 AIT WARRANTY

LIMITED WARRANTY

Atlantic Industrial Technologies Inc. (Seller) warrants that its products are free from defects in material and workmanship for a period of one (1) year from the date of shipment from the factory. "O" rings and seals are specifically exempt from this warranty. Seller does not accept responsibility of any type for, and this warranty shall not apply to, any of its products that have been subjected to improper installation or application, negligence, tampering, abuse, or which have been repaired or altered by anyone other than the Seller. Seller’s liability under this warranty shall extend only to replacement or correction, F.O.B. our factory, of any part or product determined by Seller’s inspection as not conforming to this warranty.

INSTALLATION DISCLAIMER

Due to the custom nature of the installation and system being proposed, actual field conditions and unforeseen environmental factors on-site may affect the duration and complexity of the installation. The design of every system, circuit, structure and assembly is thoroughly tested and inspected at our Long Island facility prior to shipping for fit, form and function. We invite you to our facility to witness these tests and inspections at a mutually convenient time to verify results. However, AIT will not be held responsible for delays in production, machine down-time or any other losses resulting from complications which arise during field start-up or installation for circumstances beyond our control. Every effort will be made to minimize such delays and stay within estimated installation times.

1-11-1

2 OPERATION AND MAINTENANCE INSTRUCTIONS

Two (2) Hydraulic Power Units Two (2) HPU Motor Control Enclosures

Propulsion Systems, Inc.

Seattle, WA 98107

ATLANTIC INDUSTRIAL TECHNOLOGIES INC.

90 Precision Drive Shirley, NY 11967

PH: (631) 234-3131

WWW.AITZONE.COM

December 6, 2012

OPERATION & MAINTENANCE INSTRUCTIONS

http://www.aitzone.com/

Operation & Maintenance Manual

December 6, 2012 Atlantic Industrial Technologies

TABLE OF CONTENTS

TABLE OF CONTENTS

1 INTRODUCTION

1.1 General Specifications

1.2 Component Specifications

1.3 Environmental Conditions

2 OPERATING INSTRUCTIONS

2.1 Safety Precautions

2.2 Operator Prestart

2.2.1 Mechanical Installation

2.2.2 Electrical Installation

2.2.3 Prime Hydraulic Power Unit

2.3 Normal Operations

2.3.1 Operator Interface and Operating Sequences

2.4 Emergency Operations

2.4.1 Oil Spills

2.4.2 Fire and Explosion

2.5 Shutdown, Post-Shutdown

3 PREVENTATIVE MAINTENANCE

3.1 Operator Service Requirements

3.2 Preventative Maintenance Plan & Schedule

3.3 Cleaning Recommendations

4 CORRECTIVE MAINTENANCE (REPAIR)

4.1 Troubleshooting Guides & Diagnostic Techniques

4.1.1 System Does Not Turn On

4.1.2 Low output pressure/flow

4.1.3 Blockage

4.2 Wiring Diagrams & Control Diagrams

4.3 Maintenance & Repair Procedures

4.4 Removal & Replacement Instructions

4.5 Corrective Maintenance & Work-Hours

December 6, 2012 Atlantic Industrial Technologies

5 APPENDICES

5.1 Warranty Information

5.2 Contractor Information

December 6, 2012 Atlantic Industrial Technologies Page 1 of 10

1 INTRODUCTION

This manual provides descriptive operation and maintenance instructions for the Hydraulic Power Systems.

1.1 General Specifications

Oil Flow 48 GPM, 750 PSI

Electrical Service 460 VAC, 35 A, 60 Hz, 3 φ

Control Voltage (Internal) 120 VDC, 2A

Operating Time Continues

1.2 Component Specifications

Main Oil Pump Motors 25 HP, 1,770 RPM, 284 TC Frame, 3 Phase

Main Oil Pump Vane Pump, 6.83 in3/rev, 2,500 PSI max

Oil Filters Supply Filter , 2 μm, 25 PSI bypass

Element: Parker 932618Q

Parker 932612Q

Parker 932670Q

Parker 932670Q

Reservoir Capacity: 110 Gallons

1.3 Environmental Conditions

The operation temperature range is 20˚F to 150˚F. Operation outside this temperature range will reduce the performance of oil and cause damage to the hydraulic seals and machinery. The HPU machinery should be sheltered from rain where possible.

December 6, 2012 Atlantic Industrial Technologies Page 2 of 10

2 OPERATING INSTRUCTIONS

2.1 Safety Precautions

Warnings and cautions are provided in this manual to help avoid serious injury and/or possible damage to equipment.

Read this manual in its entirety before operation or service. Also read all relevant datasheets and original manufacturer instructions for service requirements. Do not adjust the factory/commissioning settings. Any adjustments should be made by qualified personnel.

Wear appropriate personal protective equipment when operating or servicing this unit.

Lock out electrical disconnects and valves during maintenance.

460VAC and 120VAC is present within the electrical enclosure. Disconnect power source from unit before servicing.

Electrical or oil-containing components may be hot during or after operation.

December 6, 2012 Atlantic Industrial Technologies Page 3 of 10

2.2 Operator Prestart

2.2.1 Mechanical Installation

The following includes procedures required to install, set-up and prepare the system for use. Ensure that there is room for maintenance personnel to access the HPU. Install HPU inside pumping station, make all necessary hydraulic connections.

2.2.2 Electrical Installation

Wire the main power to the enclosure circuit breaker, ensuring that it that can meet the electrical service requirements. Run interconnect wiring among the terminals of the HPU’s and control enclosures as called out on the suggested installation wiring schematic on drawing 11333.E001-B.

2.2.3 Prime Hydraulic Power Unit

HPU, Motor and brake cylinder are factory-primed and flushed.

Fill the HPU reservoir with pre-filtered oil. Take care to not overfill the reservoir.

2.3 Normal Operations

2.3.1 Operator Interface and Operating Sequences

The HPU can be operated manually or automatically from the control panel using the selector switches mounted on the control panel. For maintenance purposes, the HPU pump motors can be forced on, disabled, or allowed to run automatically via the pump Hand-Off-Auto (HOA) switches. When in manual operation mode (when HOA switch is in "HAND" position), the HPU motor will engage immediately.

There are two (2) main pump motors, which run as a primary and stand-by. When using the "HAND" position, the motor selected on the "MOTOR SELECTION SWITCH" will be the active motor running. To switch between motors, the operator should first disengage the "HAND" setting and turn the switch to "OFF", then move the "MOTOR SELECTION SWITCH" to the opposite motor, and re-engage the "HAND" setting on the HOA, to start the motor again. The function of the "Hub Oil" pump is the same, to manually engage the "Hub Oil" system, the operator must move to the "HAND" position, and the motor will start immediately. There is only one "Hub Oil" pump so there is no "MOTOR SELECTION SWITCH" for the "Hub Oil" system. The normal positions for the HOA switches are the “auto” position allowing the system to automatically run. When the system is set to "Auto" via the local switches, control of the main pumps will be commanded by the remote control stations. "Auto" mode means that both main pumps will always be in a primary/stand-by configuration, when one fails the other will automatically start up after a short 5 second delay. When in "Auto" the "Hub Oil" pump will only start pumping when the Normally Open Contact of the "Low Level" switch, in the Hub Oil Tank, is open indicating low oil level.

The pump will continue to fill the Hub Oil Tank until the Normally Closed Contact on the "High Level" switch opens, indicating the tank is filled to the level of the switch. If at any time the pump motors lose oil pressure, as per the pressure switches locally mounted on the HPU, the motors will switch primary/back-up configuration, and the non-faulted motor will automatically become the primary motor. When a pump motor faults, the working non-faulted motor will run as sole primary motor until the faulted motor can be checked for defects and the fault is cleared. To clear any faults, after faulted

December 6, 2012 Atlantic Industrial Technologies Page 4 of 10 pump motors is checked, the operator must depress the E-Stop push button, turn the main breaker to the system "OFF", then the operator must turn the main breaker back to the "ON" position, and finally pull out the "E-STOP" push button. This will set the system back in to its automatic primary/stand-by feature. Within the programming of the control system, there is also an active feature which will switch the running pump primary/stand-by configuration, each time pump motors are commanded on and then off. This allows the pump motors to run with balanced running times, when a pump motor changes from "running" to "off", the system will automatically switch the opposing motor to the "new" primary, and the previous primary motor will become the stand-by motor. This configuration will improve the life of the system components and the pump motors. To switch motor operation, the user only has to turn the system off and then back on again.

All control power is 120 VAC and any dry contacts or switches must either use the control power from within the local control panel or a separate 120 VAC power source. It is recommended to use control power from the local control panel as to keep references voltages the same.

Diagnostic Indicators

The control panel has electrical indicators to show when the pump motors are running.

On the HPU, a pressure gauge displays Hub Oil pressure, Exhaust Oil pressure, Control Oil pressure, and Servo Oil pressure. The oil level and temperature are indicated at the oil level sight gauge on the reservoir. The operator should monitor these gauges and indicators and shut off the system in the event of anomalous gauge readings, differential pressures, or temperatures.

2.4 Emergency Operations

To perform an emergency stop for any reason, push the “Emergency Stop” pushbutton on the control panels to shut down the operating machinery.

2.4.1 Oil Spills

Should a spill or leak occur, care should be taken to avoid slipping hazards. Care should be taken to avoid environmental contamination. Use oil absorbent spill cleanup materials and dispose of according to state and local regulations (see section 3.33 for further details on cleaning). Notify relevant authorities of the incident in accordance with all applicable regulations. The phone number for the National Response Center is 1-800-424-8802.

2.4.2 Fire and Explosion

Should a fire or explosion on or near the operating machinery occur, contact the relevant emergency response authorities. Disconnect electrical service from a safe location.

2.5 Shutdown, Post-Shutdown

Turn off the main power to the enclosure.

December 6, 2012 Atlantic Industrial Technologies Page 5 of 10

3 PREVENTATIVE MAINTENANCE

3.1 Operator Service Requirements

The HPU should be visually inspected regularly, especially after extended periods of non-use. The preventative maintenance steps for the HPU machinery, shown in the table in section 3.22, should be maintained as a minimum.

3.2 Preventative Maintenance Plan & Schedule

After initial commissioning, the unit should be visually checked over the following few days to ensure nominal operation without abnormal noise or pressure readings. A brief visual inspection of major components should be made before use on a regular basis. The included specification sheets should be reviewed for the required maintenance actions for each component.

Additional required preventative actions are as follows:

Required Action

Frequency Description

As -N ee de d

M on th ly to

M on th s to

M on th s

M on th s

Filters - Change X X

Filter element indicator should be monitored to ensure that the filter differential pressure doesn’t exceed 25 psi. Replace after first 25 hours of operation.

Reservoir Fluid X X

Test for particulate count and moisture yearly at most.

Replace as needed. Increase sampling frequency if unacceptable contamination is shown to occur.

X Change oil

Hoses X Inspect

O-Ring Seals for all components and mating surfaces

X Replace within 10 years at maximum

X X Replace every 7-10 years or when deficient in sealing ability

December 6, 2012 Atlantic Industrial Technologies Page 6 of 10

3.3 Cleaning Recommendations

Before cleaning any parts, the machine needs to be completely turned off, depowered, and locked out according to local and site regulations. Take caution as parts that circulate the hydraulic oil may be hot after operation. It is important to make sure the machine has enough time to cool off.

In the event that a leak or spill occurs within the hydraulic power unit skid, the following recommendations for cleaning shall be followed.

• Use only lint free rags or eco-friendly oil absorbent pads to soak up any oil leakage.

• Use as many pads as necessary to soak up all exposed oil.

• Follow OSHA regulation on properly disposing of oil or oil-soaked rags. Do not dispose the oil-soaked materials in ordinary waste containers. Do not leave oil-soaked rags lying around as they pose a fire hazard.

• Use an eco-friendly, bio-degradable oil degreaser and lint-free rags to wipe down the unit to remove any residual oil from the hydraulic power unit surfaces.

4 CORRECTIVE MAINTENANCE (REPAIR)

4.1 Troubleshooting Guides & Diagnostic Techniques

Recommended tools:

• Assorted English-size Allen keys

• Assorted SAE thin open ended wrenches

• Assorted screwdrivers, flat and Philips heads

• Oil cleanup material (e.g. rags)

• Electrical test equipment (e.g. multimeter, amp meter, voltages tester, etc)

The following corrective action should be taken in the event of:

4.1.1 System Does Not Turn On

Verify the status of the following components:

• Main circuit breaker is closed

• Motor rotor is not locked

• Overload is not tripped

4.1.2 Low output pressure/flow

• Verify that the filter differential pressure is not excessive, indicating the need for filter replacement. Differential pressure should not exceed 25 PSI.

• Ensure sufficient oil supply in the reservoir

4.1.3 Blockage

In the event of foreign object or contaminant blockage, the system should be shut down, depowered, and locked out. Contact the original equipment manufacturer, Atlantic Industrial Technologies, for guidance before proceeding. Disconnect the hydraulic lines from the system to locate the source of the blockage. Drain the system, December 6, 2012 Atlantic Industrial Technologies Page 7 of 10 and disassemble any fitting, pipe, or components necessary to access the blockage to carefully and thoroughly remove it. Reassemble the components, installing new gaskets where necessary. Be sure to re-prime the system before returning to operation.

4.2 Wiring Diagrams & Control Diagrams

See the electrical schematics 11333.E001-B for electrical and control details.

4.3 Maintenance & Repair Procedures

Follow the maintenance instructions in the attached appendix, 5.2 Manufacturer’s Instructions. Please see the above section 4.1 for recommended tools.

To check the relief valve setting, manually start pump with the “Hand / Off / Auto” selector switch with system electrical power supplied. Observe the relief valve pressure on the corresponding pressure gauge.

4.4 Removal & Replacement Instructions

Follow the installation instructions in the attached appendix, 5.2 Manufacturer’s Instructions, for individual components. Electrical work should be performed by certified electricians, and all work performed on the HPU should be conducted by an IFPS Fluid Power Certified Mechanic.

4.5 Corrective Maintenance & Work-Hours

Standard wrenches, ratchets and screwdrivers are required for performing basic maintenance, (replacing filters, etc). No special tooling is required. Please see the above section 4.1 for recommended tools.

Action Duration (Man Hours)

Approximate Frequency

Estimated Hours Per Year

Filters Filter Element Replacement 8 Every 6 Months 16

Reservoir Fluid Particulate Count Test 2 Once/Year 2 Change Oil 8 Every 5 Years N/A

Hoses Replace 16 Every 10 Years N/A

O-Ring Seals Replace 24 Every 7-10 Years N/A

December 6, 2012 Atlantic Industrial Technologies Page 8 of 10

5 APPENDICES

5.1 Warranty Information

5.2 Contractor Information

December 6, 2012 Atlantic Industrial Technologies Page 9 of 10

5.1 Warranty Information

LIMITED WARRANTY

Atlantic Industrial Technologies Inc. (Seller) warrants that its products are free from defects in material and workmanship for a period of one (1) year from the date of shipment from the factory. "O" rings and seals are specifically exempt from this warranty. Seller does not accept responsibility of any type for, and this warranty shall not apply to, any of its products that have been subjected to improper installation or application, negligence, tampering, abuse, or which have been repaired or altered by anyone other than the Seller. Seller’s liability under this warranty shall extend only to replacement or correction, F.O.B. our factory, of any part or product determined by Seller’s inspection as not conforming to this warranty.

INSTALLATION DISCLAIMER

Due to the custom nature of the installation and system being proposed, actual field conditions and unforeseen environmental factors on-site may affect the duration and complexity of the installation.

The design of every system, circuit, structure and assembly is thoroughly tested and inspected at our Long Island facility prior to shipping for fit, form and function. We invite you to our facility to witness these tests and inspections at a mutually convenient time to verify results. However, AIT will not be held responsible for delays in production, machine down-time or any other losses resulting from complications which arise during field start-up or installation for circumstances beyond our control.

Every effort will be made to minimize such delays and stay within estimated installation times.

December 6, 2012 Atlantic Industrial Technologies Page 10 of 10

5.2 Contractor Information

3 GENERAL ARRANGEMENT DRAWING

GAUGE PANEL w/

ISOLATORS AND TEST PORTS

PRESSURE SWITCHES

HYDRAULIC MANIFOLD

FLOW METER

HUB OIL PUMP/ MOTOR GROUP

1HP / 5GPM

HUB OIL FILTER

LOW FLOW

SERVO OIL FILTERS

SERVO PUMP/ MOTOR GROUP

25HP / 48GPM

SERVO PUMP/ MOTOR GROUP

25HP / 48GPM

HIGH FLOW

SERVO OIL FILTERS

RESERVOIR DRAIN

HEAT EXCHANGER

CENTRALIZED FIELD CONNECTIONS

WATER CONNECTIONS

FOR HEAT EXCHANGER

CUSTOM RESERVOIR,

110 GALLONS

w/ LIFTING PADS

ON 4 CORNERS

FILLING PORT

REVISIONS

REV. DESCRIPTION MODIFY BY DATE

A REVISED AS PER REQUESTED JN 7/13/2012

B FINALIZED DESIGN FOR MANUFACTURING JN 7/18/2012

D

C

B

AA

B

C

D

12345678

8 7 6 5 4 3 2 1

THE INFORMATION CONTAINED IN THIS

DRAWING IS THE SOLE PROPERTY OF

ATLANTIC INDUSTRIAL TECHNOLOGIES. ANY

REPRODUCTION IN PART OR AS A WHOLE

WITHOUT THE WRITTEN PERMISSION OF

ATLANTIC INDUSTRIAL TECHNOLOGIES IS

PROHIBITED.

PROPRIETARY AND CONFIDENTIAL

DRAWN

CHECKED

NAME

SIZE

B

DWG. NO. REV

6/28/2012

SHEET 1 OF 3DO NOT SCALE DRAWING

11333.M001-

TITLE:

B

AF-11333

JOB #:

UNLESS OTHERWISE SPECIFIED

DIMENSIONS ARE IN INCHES

jasonng

DATE

JG

ESTIMATED DRY WEIGHT:

2252LBS 5%

8/29/2012

HPU GENERAL ARRANGEMENT

THIRD ANGLE

PROJECTION

MATERAL Steel

SO

LI

D M

O D

EL

L

O C

A

TIO

N

S:

\A

IT

En gi ne er in g\ A

IT

D ra w in gs

\A F

0-

9\

A F-

3_ Pr op ul sio n

Sy st em s, In c\

So lid w or ks M od el s\

HP

U-

Epoxy Painted

0.01" 0.005" 1/2"

2 PLACE DECIMALS: ±

3 PLACE DECIMALS: ±

FRACTION: ±

ANGLE: ±

FINALIZED FOR MFG.

FINISH

55 1 4 "

COG

23 1

2 "±2"

47 1 16 "

79 11 16 "

30"

COG

17 9

16 "±1"

72 11 16 "

COG

35 3

8 "±1"

34.40 34.40

28.00

6X 7

8 " THRU

MOUNTING HOLES

D

C

B

AA

B

C

D

12345678

8 7 6 5 4 3 2 1

THE INFORMATION CONTAINED IN THIS

DRAWING IS THE SOLE PROPERTY OF

ATLANTIC INDUSTRIAL TECHNOLOGIES. ANY

REPRODUCTION IN PART OR AS A WHOLE

WITHOUT THE WRITTEN PERMISSION OF

ATLANTIC INDUSTRIAL TECHNOLOGIES IS

PROHIBITED.

PROPRIETARY AND CONFIDENTIAL

DRAWN

CHECKED

NAME

SIZE

B

DWG. NO. REV

6/28/2012

SHEET 2 OF 3DO NOT SCALE DRAWING

11333.M001-

TITLE:

B

AF-11333

JOB #:

UNLESS OTHERWISE SPECIFIED

DIMENSIONS ARE IN INCHES

jasonng

DATE

JG

ESTIMATED DRY WEIGHT:

2252LBS 5%

8/29/2012

HPU GENERAL ARRANGEMENT

THIRD ANGLE

PROJECTION

MATERAL Steel

SO

LI

D M

O D

EL

L

O C

A

TIO

N

S:

\A

IT

En gi ne er in g\ A

IT

D ra w in gs

\A F

0-

9\

A F-

3_ Pr op ul sio n

Sy st em s, In c\

So lid w or ks M od el s\

HP

U-

Epoxy Painted

0.01" 0.005" 1/2"

2 PLACE DECIMALS: ±

3 PLACE DECIMALS: ±

FRACTION: ±

ANGLE: ±

B

TP9 ON MANIFOLDJ

A

O LK

DETAIL A

SCALE 1 : 6

P H M G N IN N OUT

DETAIL B

SCALE 1 : 6

TP5 TP6…