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OPERATION AND MAINTENANCE MANUAL
for DT~C
sMAY u 1 1968
DRAW OFF-HOLDBACK D
(DOHB)
TENSION MACHINE
'K>
MANUFACTURED FOR USE WITH kA
CABLE LAYING SYSTEM
MANUFACTURED FOR
OCEAN CONSTRUCTION EQUIPMENT INVENTORY
CHESAPEAKE DIVISION
NAVAL FACILITIES ENGINEERING COMMAND
MANUFACTURED BY pevdipubcmM
Wetern Gea Wwd *nt
WO8T6......ahlnM Co.
GSA% CORPORtATION A SubSdallfof ksiein Geat Co'poralion
1) OINAVE NUE
EVERETTWASHINGION98201
PHONE(206) 269092
Waso 42816 DECEMBER 1982

S4Z 1/207
DISCLAIMER NOTICE
THIS DOCUMENT IS BEST QUALITY

PRACTICABLE. THE COPY FURNISHED
TO DTIC CONTAINED A SIGNIFICANT
NUMBER OF PAGES WHICH DO NOT
REPRODUCE LEGIBLY.
Unclassified
SECURITY CLASSIFICATION OF THIS PAGE
REPORT DOCUMENTATION PAGE
la. REPORT SECURITY CLASSIFICATION lb. RESTRICTIVE MARKINGS
Unclassified
2a. SECURITY CLASSIFICATION AUTHORITY 3. DISTRIBUTION AVAILABILITY OF REP.

Approved for public release;
distribution is unlimited
2b. DECLASSIFICATION/DOWNGRADING SCHEDULE
4. PERFORMING ORGANIZATION REPORT NUMBER 5. MONITORING ORGANIZATION REPORT #

WGSO 42816 FPO 8240
6a. NAME OF PERFORM. ORG. 6b. OFFICE SYM 7a. NAME OF MONITORING ORGANIZATION
Western Gear Machinery Co. Ocean Engineering
& Construction
Project Office
CHESNAVFACENGCOM
6c. ADDRESS (City, State. and Zip Code) 7b. ADDRESS (City, State, and Zip 14
2100 Norton Ave. BLDG. 212, Washington Navy Yard
Everett, WA 98201 Washington. D.C. 20374-2121
8a. NAME OF FUNDING ORG. 8b. OFFICE SYM 9. PROCUREMENT INSTRUMENT INDENT
*0
Sc. ADDRESS (City. State & Zip) 10. SOURCE OF FUNDING NUMERS C
PROGRAM PROJECT TASK WORK UN N
ELEMENT * # # ACCESS q v
11. TITLE (Including Security Classification) 0

Operation & Maintenance Manual for Draw Off-Holdback (DOHB) Tension Machine
z
12. PERSONAL AUTHOR(S)
N
13a. TYPE OF REPORT 13b. TIME COVERED 14. DATE OF REP. (YYMMDD) 15. PA04 .
FROM TO 82-12 36 m
16. SUPPLEMENTARY NOTATION x
M
z
17. COSATI CODES 18. SUBJECT TERMS (Continue on reverse if nee.

FIELD GROUP SUB-GROUP Cable installation, retrieval & repair.
Tension machine
19. ABSTRACT (Continue on reverse if necessary & identify by block number)

This manual provides description, installation, operation, troubleshooting.
maintenance, and parts list information for the DLaw Off-Holdback (DOHB)
Tension Machine and its power unit manufactured by Western Gear Machinery Co..
Everett, Washington.
20. DISTRIBUTION/AVAILABILITY OF ABSTRACT 21. ABSTRACT SECURITY CLASSIFICATION
SAME AS RPT.
22a. NAME OF RESPONSIBLE INDIVIDUAL 22b. TELEPHONE 22c. OFFICE SYMBOL
Jacaueline B. Riley 202-433-3881
DD FORM 1473. 84MAR SECURITY CLASSIFICATION OF THIS PAGE
/ -- , -- I • m A mm m md
Unclassified
SECURITY CLASSIFICATION OF THIS PAGE
REPORT DOCUMENTATION PAGE
la. REPORT SECURITY CLASSIFICATION lb. RESTRICTIVE MARKINGS
Unclassified
2a. SECURITY CLASSIFICATION AUTHORITY 3. DISTRIBUTION AVAILABILITY OF REP.

Approved for public release:
distribution is unlimited
2b. DECLASSIFICATION/DOWNGRADING SCHEDULE
4. PERFORMING ORGANIZATION REPORT NUMBER 5. MONITORING ORGANIZATION REPORT #

WCSO 42816 PPO 8241
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TABLE OF CONTENTS
SECTION PAGE
LIST OF ILLUSTRATIONS........... . . .... .. .. .. .. .. . ... i
LIST OF TABLES................ . . .......
.. .. .. .. .. .. ...
SAFETY SUMMARY............ . .... ....
. .. .. .. .. .. ...
I GENERAL INFORMATION.........
. ...
. .. .. .. .. .. ...
1-1 Introduction......... . .. .. .. .. .. .. ...
1-3 Equipment Purpose.......... .. .. .. .. .. .. ...
1-5 Equipment Supplied........ .. .. .. .. .. . ....
1-7 Equipment Specifications....... .. .. .. .. .. .....
1-9 General Description .. .. .... ..... ......... 1-5
II INSTALLATION. .. .. ..... ..... ..... ..... .. 2-1
2-1 Introduction. .. .... ..... ..... ...... 2-1
2-3 Safety Surmmary .. ... ..... ..... .... ... 2-1
2-4 Installation. .. .... ..... ..... ...... 2-1
2-5 DOHB Tension Machine. .. .... ..... ..... .. 2-1
2-6 Power Unit. .. .................. 2-2
2-7 Hydraulic and Pneumatic Hoses..............2-2
32-8
2-10
Preparation of Hydraulic Piping .. .. .... ....... 2-2
Electrical Connections. .. .... ..... ...... 2-2
III OPERATION. .. .... ..... ..... ..... ...... 3-1
3-1 Introduction. .. .... ..... ..... ...... 3-1
3-3 Safety Sunmmary .. ... ..... ..... ..... .. 3-1
3-5 Controls and Indicators. .. .. ..... ..... ... 3-1
3-8 Operator Maintenance. .. .... ..... ..... .. 3-1
IV TROUBLESHOOTING. .. .... ..... ..... ..... ... 4-1
4-1 Introduction. .. .... ..... ..... ...... 4-1
4-3 Functional Description. .. .... ..... ...... 4-1
4-4 DOHB, Machine General. .. ..... ..... ...... 4-1
4-5 Reducer Assembly .. ... ..... ..... ....... 4-1
4-6 Brake Assembly .. ... ..... ..... ......... 4-1
4-7 Track Assemblies .. ... ..... .... ....... 4-2
4-8 Main Pressure Cylinder. .. .... ..... ...... 4-2 11
4-9 Track Squeeze Cylinder. .. .... ..... ..... 4-2
4-10 Track Tightener. .. .. ..... ..... ..... .. 4-3
4-11 Power Unit Assembly ........ ...... .... .. 4-3
4-13 Power Unit Function .. .. .... ..... ..... .. 4-3
4-19 Pneumatic System .. ... ..... ..... ....... 4-4
,deS
or
0,
( ~Dhj
, cia
TABLE OF CONTENTS (Cont)
SECTION PAGE
V MAINTENANCE ..... .. .......................... . 5-1
5-1 Introduction ..... ... ...................... 5-1
5-3 Safety Precautions ..... .. ................... 5-1
5-4 Preventive Maintenance ...... ................. 5-1
5-6 Inspection ...... ....................... 5-1
5-7 Cleaning and Parts Inspection. ............... 5-5
5-9 Lubrication ...... ....................... .. 5-6
5-10 Fluid Maintenance ....... .................... 5-6
5-11 Introduction ...................... 5-6
5-12 Fluid Storage and Handling. ............... 5-6
5-13 In-Operation Care ....... .................... 5-6
5-14 Hydraulic Fluid Sampling .... ................... 5-7
5-15 Corrective Maintenance ...... ................. 5-12
5-16 Introduction ..... ... ...................... 5-12
5-17 Upper or Lower Track Removal ... ................. 5-12
5-18 Idler Shaft Disassembly ..... ................. 5-12
5-19 Drive Shaft Disassembly ...... ................. 5-13
5-20 Upper Support Rollers Disassembly .... ............ 5-14
5-21 Upper Pressure Rollers Removal and
Disassembly ...... .. ...................... 5-14
5-22 Track Cylinders Disassembly ..... ............... 5-15
5-23 Lower Pressure Rollers Disassembly .. .............. 5-15
5-24 Pressure Roller Disassembly ..... ............... 5-16
5-25 Lower Rocker Shaft Removal ..... ............... 5-16
5-26 Squeeze and Lift Cylinder Disassembly . .......... 5-17
5-27 Forward or Aft Dragboard Power Cylinder Removal. ..... 5-17
5-28 Dragboard Removal ...... .................... 5-18
5-29 Upper and Lower Reducer Removal .... ............. 5-18
5-30 Reducer Disassembly .... ...................... 5-18
5-31 Hydraulic Brake Disassembly ..................... 5-20
5-32 Hydraulic Pump and Actuator Removal .... ........... 5-21
VI PARTS LISTS ..... .. .......................... . 6-1
6-1 Introduction ..... ... ...................... 6-1
6-3 Illustrated Parts Lists .... .................... 6-1
6-12 How to Use the Parts List ...... ................ 6-2
6-14 How to Order Parts ..... ................... ... 6-2
APPENDIX
A Pneumatic and Hydraulic Piping ...... ................. A-I
B ARP 598, Fluid Contamination Particle Count Procelure . . .. B-1
C Vendor Data for Pneumatic Equipment . . . ....... . C-i
D Vendor Data for Hydraulic Equipment ............ D-1
E Vendor Data for Electrical Equipment ..... .............. E-I
li
3LIST OF ILLUSTRATIONS SUC
FIGURE TITLE DRAWING PAGE
1-1 outline and General Arrangement. .. . .. ... ... D316405 1-2
1-2 Shipboard Location .. .. ... . . ... .. ... . . ..... 1-7
2-1 Outline and General Arrangement. .. . .. ... .... 316405 2-3
2-2 Interconnecting Hose Diagram. .. .. .. .. .. ... D316407 2-9
2-3 Interconnect Wiring List. .. .. .. .. ... .... A307881 2-11
2-4 Electrical General Arrangement .. .. ... .. ..... 316125 2-31
4-1 Hydraulic Schematic. .. . .. . .. .. ... ..... 316371 4-13
4-2 Pneumatic Schematic. .. . .. ... .. ... ..... 316383 4-17
4-3 Electrical System Schematic .. .. .. ... .. .... 316126 4-19
5-1 Lubrication Diagram - DOHB Machine. .. .. .. ..... 316406 5-9
5-2 Lubrication Diagram - DOHB Power Unit .. .. . ..... 316406 5-11
6-1 Draw Off-Holdback (DOHB) Machine Assembly. .. . ... 0316127 6-7
6-2 DOHB Piping Assembly .. .. ... . . .. . .. .... E106791 6-23
6-3 Lower Frame Modification and Refurbishment-
DOHB Machine. .. .. .. .. . .. .. ... ..... 316387 6-31
6-4 DOHB Lower Reducer. .. .. .. .. . .. .. ...... 316292 6-37
6-5 DOHB Machine Reducer .. . ... .. ... . . .... E106787 6-43
6-6 Not Used. .. .. .. .. ... .. . .. .. ... .. . . . 6-49
6-7 Not Used .. .. ... .. ... .. ... .. ... .. ..... 6-49
6-8 DOHB Power Unit Assembl y. .. .. .. .. . .. ..... 316128
3 6-9
6-10
Power Unit Piping Diagram .. .. .. ... . . ..... 316464
Power Unit Wiring Diagram .. .. .. ... . . ..... 316129
6-51
6-67
6-77
6-11 DOHB Machine Wiring Diagram .. .. .. ... . . ... C312802 6-81
6-12 W4 Cable Assembly .. .. .. ... .. ... . . ... B312548 6-83
6-13 W5 Cable Assembly .. .. .. ... .. ... .. ... B312549 6-87
6-14 W6 Cable Assembly .. .. .. ... .. ... . . ... B312550 6-91
6-15 W7 Cable Assembly .. .. .. ... . . ... .. ... B312551 6-95
6-16 W8 Cable Assembly .. .. .. ... . . ... .. .... 312552 6-99
6-17 Hose Bundle Assembly .. .. ... . . ... .. ..... C313737 6-103
6-18 Hose Bundle Assembly .. .. ... . . ... .. .... C313738 6-107
6-19 Hose Bundle Assembly .. .. ... . . ... .. .... C313739 6-111
LIST OF TABLES
Table Title Page
1-1 Equipment Supplied .. .. ... . . ... .. ... .. ..... 1-1
1-2 Equipment Specifications .. .. ... .. ... .. ... .... 1-5
2-1 Maximum Contamination Limits per NAS1638. .. .. .. .. . ... 2-2
3-1 DOHB Tension Machine and Power Unit Local Controls. .. .. ... 3-2
4-1 Tension Machine Troubleshooting .. .. .. ... .. ....... 4-5
4-2 Power Unit Troubleshooting .. .. ... .. ... . . ....... 4-7
5-1 Preventive Maintenance Schedule .. .. .. ... . . ....... 5-2
5-2 Inspection Guide .. .. ... .. ... .. ... . . ....... 5-4
SAFETY SUMMARY
Extreme caution should be exercised when working with high-pressure, heavy
mechanical equipment. Developing and practicing good safety habits are an
essential part of maintenance. Follow the maintenance procedures given in this
manual, paying special attention to WARNINGS, CAUTIONS, and NOTES. WARNINGS
describe hazards to personnel, CAUTIONS describe hazards to equipment, and NOTES
call attention to preferred techniques or present helpful information. Failure
to follow the maintenance procedures given may result in injury to personnel or
damage to equipment.
I WARNINGI
Western Gear Machinery Co. has taken every reasonable pre-

caution to ensure personnel safety by installing appropriate
guards, covers, interlocks, and other safety devices. It is
the responsibility of the user to review the operation and
maintenance procedures with regard to safety requirements, and
to exercise reasonable caution and observance of those re-
quirements. It is incumbent upon the user to ensure that this
equipment has been installed safely by providing guard rails
beside walkways, around moving machinery, and around hazardous
electrical sources; by providing safety lines and attaching
points for use while working on elevated equipment; by posting
signs alerting personnel to safety requirements, and by
initiating procedures required to prevent injury or death to
personnel.
When repairing hydraulic or pneumatic components, make certain
that line pressure is zero before disconnecting hydraulic or
pneumatic lines.
Never tighten leaking connections or fittings while lines are
pressurized. Application of torque to fittings or connections
while lines are pressurized may rupture the lines and result
in injury to personnel.
Direct discharge of high pressure air can seriously injure

personnel. Open discharge valves cautiously after standing
clear and warning others away from the area.
Make certain that all electrical circuits are deenergized at the main
breaker before performing maintenance on electrical components.
When performing maintenance operations, tag the equipment con-

trols: DANGER - DO NOT OPERATE - EQUIPMENT BEING REPAIRED.
Make certain work area is safe and clear of unnecessary per-

sonnel and equipment.
iv4
SECTION I
GENERAL INFORMATION
1-1.; INTRODUCTION.
1-2. This manual provides description, installation, operation, troubleshoot-

ing, maintenance, and parts list information for the Draw Off-Holdback (DOHB)
Tension Machine and its power unit manufactured by Western Gear Machinery Co.,
Everett, Washington. -
1-3. EQUIPMENT PURPOSE.
1-4. The DOHB tension machine (figure 1-1) ensures proper tensioning of the
cable as it is payed out or hauled in. The DOHB power unit provides hydraulic
power for operating the DOHB tension machine. Both the DOHB tension machine and
power unit are located on the main deck, aft of the superstructure.
1-5. EQUIPMENT SUPPLIED.
1-6. Table 1-1 lists the quantity, nomenclature, drawing number, approximate
weight, and dimensions of the DOHB tension machines and their dual power unit.
Table 1-1. Equipment Supplied

DIMENSIONS
DRAWING APPROX INCHES
QTY NOMENCLATURE NUMBER WT LBS HGT LG WD
I DOHB Tension Machine 0316127 8,500 64.8* 127.8 75.4

Assembly 52.4**
1 DOHB Power Unit D316128 3,500 48.0 59.4 44.8

* - track up
** - track down
1-7. EQUIPMENT SPECIFICATIONS.
1-8. Table 1-2 lists the design characteristics of the DOHB tension machine
and power unit.
1-1
SQUEEZE ~ AD PNEUMATICSS
IPIUL
= E,*p% PPME
OPNGS
TW OPC*T C
6405
DAM
f 30-1
a r an e e t (he
Ou l n4n.ee
Figure~~~~~~~~~
1-2
MEX&E SIDE
SEE -
DTAIL 2
SE DETAIL I
00
,LODIA LIFTING
EYE
JUNCTION BOX ,_ •. .
41.0A -2 R CONDITIONER
Fire -, tine nd
DEETAIL 2
IMIF -1-7DETAIL I
_______________________________________________ 0316405
Figure 1i-1. Outline and General Arrangement (Sheet 2 of 3)
1-3
RTEL VATER PORT HEAT EXCHANGER
OIL FILLIN Oft OUT
.75 NPT RETURN FILTER
SERVO FILTER SUCTION FILTER

ELECTRIC MOTOR
MR NOTES:
MOTOR CONTROLLER PLAN VIEW 1. POWER UNITSPECIFICATIONS:
ELECTRIC MOTOR: 440VAC, 60Hz.
3 PHASE, 30 HP,1800 RPM.
3
~PLACEMENT.
MOTOR LIFTING EYE TRACK DRIVE: 6.01N /REV DIS-
HYDRAULIC: 1750 RPM.
PUMP: 43GPM MAX FLOW, 2100PSI
MAX PRESSURE. 200PSI REPLENISH-
MENT PRESSURE. CLOSED LOOP
APPLICATION.
HYDRAULIC RESERVOIR: TOTAL
VOLUME CAPACITY 110 GALLONS.
HEATER: OIL IMMERSION, TYPE
2.5 KW, 120 VAC, SINGLE PHASE,
INTERNAL THERMOSTAT CON-
TROLLED.
HEAT EXCHANGER: WATER COOLED
_-.SGPM SUPPLIED BY SHIP, MAX 90oF.
'-.69 DIA LIFTING EYE

(4) PLCS
.I I ,.J POWER UNIT

DRAIN
. 75
PORT
NPTASIEVEA
RESERVOIR A D316405
D360
Figure 1-1. Outline and General Arrangement (Sheet 3 of 3)
1-4
Table 1-2. Equipment Specifications
DOHB Tension Machine
Low Gear Tension 2,250 pounds at 315 fpm

High Gear Tension 1,125 pounds at 670 fpm
Height - Upper Frame Raised 64.8 inches
DOHB Power Unit
Electric Motors
Horsepower 30 hp
Electrical Input 440 vac, 3 phase, 60 Hz
Full Load Speed 1,800 rpm
Enclosure Watertight
Motor Controllers
Type AC Magnetic
Electrical Inputs 440 vac, 3 phase, 60 Hz
115 vac, 1 phase, 60 Hz
Enclosure Watertight, NEMA IV
Hydraulic Tank
Capacity 120 U.S. gallons
Immersion Heater
Rating 2,500 watts, 120 vac, 60 Hz
Thermostatic Control On at 50*F (10*C)
Off at 80'F (27'C)
Relief Valve Settings
High Pressure Relief Valves 2,100 psi
Replenishing Relief Valves 300 psi
1-9. GENERAL DESCRIPTION.
1-10. The DOHB tension machine is a hydraulically powered, pneumatically oper-

ated machine capable of applying 2,250 pounds of tension at a cable speed of 315
fpm. Power to drive the machine is provided by an electrohydraulic power unit.
Air for operation of the pneumatic controls is supplied through the control
console from ship's air supply. For high speed operation (670 fpm), tension is
reduced to 1,125 pounds.
1-11. The major components of the DOHB tension machine (figure 6-1) are:
1. Bedplate, upper frame, and lower frame assemblies.
2. Upper and lower track assemblies, two drive and two idler sprockets,
drive shafts, idler shafts, two pair of pillow blocks with a track support
roller connected between each pair, three roller frames with four pressure
rollers each, and three rocker shafts. See figure 6-1.
1-5
3. Two reducer gearboxes (figures 6-4 and 6-5), one for each track assembly,
with a hydraulic drive motor each.
4. A main pressure (lift and squeeze) cylinder. See figure 6-1.

5. Three track cylinders located within the lower track loop. See figure
6-1.
6. Two sets of dragboards with one air power cylinder each.
1-12. The major components of the power unit (figure 6-8) are:
1. One 120 gallon tank.

2. One 30 hp electric drive motor.
3. One variable delivery pump with integral replenishing pump.

4. One hydroelectric actuator.
5. One heat exchanger.

6. One dual relief valve assembly.
7. One bypass and brake control valve. See figure 6-10.

8. One motor controller.
1-13. A functional description of the DOHB tension machine and power unit is
contained in section IV.
1-6
ICAU|1l FEET
OUTBOARD PROFILE ma CUT41
tsl NO
n PR4IL"f.-
IEX\AA
LAVMV,\ /
IIC 01ftS
UI A M
TANK
,'"LN
]GI
"",o=' Al
OITA
MAINDE
. ARRANGEMENT6L
l i nC w
i'dA TiA w n g Int o of
,N........ -\ .......... /./.
SHADED
PORT O EOTE PILE LOAIO-F DOHB TESOE3YTM
spci l rp.se..equipment..Atog
.. the. yste will usually be Instalednth
MAIN DECK ARRANGEMENT
cofgrain adterfr exat loain/o themDH tensioner c hine aen

d
NOTE:
SHADED PORTION DENOTES POSSIBLE LOCATION OF DOHIB TENSIONER SYSTEM.
Due to the multipurpose design of SEACON, its inventory of equipment includes

many systems which can be easily removed or installed anywhere on the main deck
to accommodate its present mission. The DOHB tensioner system built for instal-
lation onboard SEACON is designed to be a part of this wide ranging inventory of
special purpose equipment. Although the system will usually be installed on the
main deck aft of the superstructure, varying missions dictate varying equipment
configurations and therefore exact locations for the DOHB tensioner machine and
control console cannot be shown in this manual.
Figure 1-2. Shipboard Locations
1-7/(1-8 blank)
SECTION II
INSTALLATION
2-1. INTRODUCTION.
2-2. This section contains precautions and procedures for the initial instal-
lation or reinstallaion, if extensive repairs require the removal of the
machinery for major component replacement.
2-3. SAFETY SUMMARY.
---.
,. I
Western Gear Machinery Co. has taken every reasonable pre-
caution to ensure personnel safety by installing appropriate
?uards, covers, interlocks, and other safety devices. It is
h sponsibility of the user to review the operation and
maintenance procedures with regard to safety requirements, and
to exercise reasonable caution and observance of those re-
quirements. It is incumbent upon the user to ensure that this
equipment has been installed safely by providing guard rails
beside walkways, around moving machinery, and around hazardous
electrical sources; by providing safety lines and attaching
points for use while working on elevated equipment; by posting
signs alerting personnel to safety requirements, and by
initiating procedures required to prevent injury or death to
personnel.
Use extreme care when handling, moving or lifting to avoid

injury to personnel or damage to equipment.
Use a sling to lift the tension machine at all four lifting

points. Also, use a sling to lift the power unit at all four
lifting points.
2-4. INSTALLATION.
I AONI
Failure to install the machinery properly can cause compo-

nent damage and result in equipment failure.
2-5. DOHB TENSION MACHINE. See figure 2-1 for tension machine installation
and clearance requirements. Refer to figure 1-2 and ship's plans for the loca-
tion of each DOHB tension machine. Drill mounting holes as required and shim to
compensate for any unevenness in the deck surface.
2-1
2-6. POWER UNIT. See figure 2-1 for power unit dimensions and mounting hole
locations. Drill mounting holes as required and shim as required to compensate
for any unevenness in the deck surface.
2-7. HYDRAULIC AND PNEUMATIC HOSES. See figure 2-2 for interconnecting hoses.
After the power unit and tension machines have been located and installed, make
the interconnecting hose connections in accordance with figure 2-2 and flush the
system. Use pumping and flushing units of sufficient capacity to ensure
thorough flushing. Cleanliness is acceptable only when unfiltered flushing oil
samples taken in accordance with paragraph 5-14 conform to NAS 1638, class 8,
cleanliness levels; see table 2-1. Fill the hydraulic reservoir with the
specified hydraulic fluid and determine that its cleanliness level meets the
contamination limits specified in table 2-1 for class B.
Table 2-1. Maximum Contamination Limits per NAS 1638
(Based on a 100 ml sample size)
PARTICLE CLASSES
SIZE RANGE
(Microns) 5 6 7 8 9 10 11 12
5 to 15 8.000 16.000 32.000 64,000 128.000 256.000 512.000 1.024,000

15 to 25 1,425 2.850 5,700 11.400 22,800 45.600 91,200 182,400
25 to 50 253 506 1.012 2.025 4.050 8,100 16.200 32.400

50 to 100 45 90 180 360 720 1,440 2,880 5,760
Over 100 8 16 32 64 128 256 512 1.024
Pickle all piping and flanges in accordance with the proce-

dures given in appendix A.
2-8. PREPARATION OF HYDRAULIC PIPING. Whenever hydraulic piping is replaced
with another section of untreated piping, or repaired by welding, or any other
method which could introduce contaminants, it shall be cleaned and preserved in
a suitable solution as prescribed by appendix A.
2-9. After the pickling process has been completed, seal all piping openings
until ready to install.
NOTE
Use plastic caps on hydraulic piping and plywood on the flanges.
DO NOT USE cork or rags.
2-10. ELECTRICAL CONNECTIONS. See figure 2-3 for electrical cable inter-
connections.
2-2
DETAIL 2
SEE DETAIL I 00i I_
0 0 INSPECTION COVER
1.0DIA LIFTING
EYE
JUNCTIN BOX46
SHIP'S AIR IN
IOPSItDRY"
41.0 -1 CONDITIONER
° w'
G 'N o o,
DETAIL 2 ~N
DETAIL I
. -33.8
IN6PECTION COVER
" LIFTING
0-I.ODIA .w
EYE
46
-INSPECTION
COVER
--- 50 NPT
SHIP'S AIR IN
100 PSI ( DRY)
--- R CONDIONER
% AF/N 3 CONTROL CONSOLE
32DRAIN PLUG .38NPT
L .38
~-82DIA MOUNTING
HOLES (4) PLCS.
SECTION A-A
Figure 2-1. outline and General

Arrangement (Sheet 1 of 3)
DETAIL 1 2-3/(2-4 blank)

- - -A
OIL TO WATER
BREATHER AND HEAT EXCHANGER
OLFILL
IN O OUT2.0
75 NPT 594RETURN FILTER 10 73
.56 DtA THRU
PUMP .00 8) HOLES

44.6HYRAULIC
0 2.00
34.5 TP~
HETR1.00 SECTION AmA
________________NOTES:
1. POWER UP
GAGESELECTA
SUCTION FILTER TRACK
ELECTRICJMOO-SERVO FILTERPup
MOTOR CONTROLLER PLAN VIEW

H4YDR A
HE AT El
rMOTOR LIFTING EYE HA
2. QRWPG
F/W (4 HOSE
F/N ® ,HOSE
4LO ,;12 1 F/ (DHOSE
460.69 DIA LIFTING EYE 3- NTEI
PLEJPOWER UNT
A
33 A
ZDRAIN PORT RESERVOIR
.75 NPT
SIDE VIEW
1.001 47.31
TIRU
.56 DIA
AULIC PUMP 3.00 '(8) HOLES
T2.00
NOTES
1. POWER UNIT SPECIFICATIONS:

)ELECTRIC MOTOR' 44OVAC
3
,6OHz .3PHASE, 30 HP, 1800 RPM.
TRACK DRIVE: 6.0 IN /REV DISPLACEMENT
HYDRAULIC: 1750 RPM
PUMP43 GPM MAX FLOW, 2100 PSI MAX PRESSURE.
200 PSI REPLENISHMENT PRESSURE,
CLOSED LOOP APPLICATION
HYDRAULIC PESERVOIR; TOTAL VOLUME CAPACITY 10 GALLONS
HEATER: OIL IMMERSION. TYPE 2.5 I(w -120 VAC.SINGLE PHASE.
INTERNAL THERMOSTAT CONTROLLED
HEAT EXCHANGER: WATER COOLED, 5GPM SUPPLIED BY SHIP.
MAX 9OPF
2. QBWNSNTSON
F/W (4) HOSE BUNDLE ASSY...-- -- .. C3I3737
F/N(D HOSE BUNDLE ASSY...--------C313738
F/IN ~HOSE BUNDLE ASSY.. 39
-~.C3137
REFERENCE DRAWINGS,
;.HYDRAULIC SCHEMATIC -- -- -- --- 316371
2. F-LECRICAL SCHEMATIC---- ----- 316126
FTING EYE 3. INTERCONNECT WIRE LIST-----.- .A307861
4. INTERCONNECT PIPING D:AGRAM .- -- 316 704
5. LUBRICATION DIAGRAM.-- -- -- ---- 316406
6. PNEUMATIC SCHEMAIC -- -- -- --- D316383
7. ELE CTRPICAL GEINERAL ARR.- D31612?5
POWER UJNIT
F/N a
D3T16405A
Figure 2-1. Outline and General

Arrangement (Sheet 2 of 3)
2-5/(2-6 blank)
AIR PRESSURE OPERATED
UPPER FRAME SQUEEZE HYDRAULIC AND PNEUMATIC
L HYDRAULIC DRIVE MOTOR
TWO SPEED REDUCER ASSY
75.4
60.00
0 T" 043.
19.0 0 0 0
______________C=31_____
CABLELOAD
330- 33.0 THIS SIDE (OPEN SIDE)

FWD PLNVE64.8
____ _______ ___ ____

____ ___ ____ ___ ENDLESS BELT LINK TRACK
UPPER
RAISED FRAME ASSY
POSITION) rTROACE
T
SSPPPRORAM
LR SPORTRAEDRV
--
WITH RUBBER GRIPPING PADS
S RCK T
IDLER__ DRIV SPROKET

I D L E R S P R O K E T SD RAGBOARD A SSY
ASSO0R0
AIR PRESSURE 0)
DRAGBOARD CO,
64.8
52.4
SIDE
IE \TRACK TENSION SPRING
A 0 1w OUT~m
LOO
AT ED
EEZE ,HYDRAULIC AND PNEUMATIC
PIPING CONNECTIONS
HYDRAULIC DRIVE MOTOR
CLUTCH LEVER
-TWO SPEED REDUCER ASSY

0.21)
(RATOS____________________ .- ... 812 DIA THRU
56.00
=0 * 0 17.00- 1.001 -2 .00= L360'

CABLE LOAD -60
- 33.0 4 THIS SIDE (OPEN SIDE)
3-.
64.8
ENDLESS BELT LINK TRACK

WITH RUBBER GRIPPING PADSSETO A
PR FRAME
DRIVE SPROCKETS
NTS
I. mAxIMUM OPERATING CONDITIONS: 0 TO 2,200 LBS AT
ASSY
DRAGBOARD ~ 2. CALCULATED WEIGHT 8500 LBS.0TO34FM
AIR PRESSURE OPERATED

DRAGBOARD CONTROL
CYLINDER
gQ-HB. MIACHINE
Q LOWER FRAME
2-1. Outline and General
D316405A
LOADCELLFigure
LOADCELLArrangement (Sheet 3 of 3)
:NSIO SPRNG A2-71(2-8 blank)

NOTES:
L. HOSE DESIGNATIONS ARE AS FOLLOWS:
AIR - - - - - - - - -
NYD.
7. SHIPS PIPING TO BE CLEANED AND FLUSHED BEFORE CONNECTION.
FILTER UNITS ARE TO BE OF SUFFICIENT CAPACITY TO INSURE THOROUGH
FLUSHING. PIPING CLEANLINESS IS ACCEPTABLE WHEN UNFILTERED FLUSHING
OIL SAMPLES ACHIEVE NAS-I638.CLASS B CLEANLINESS LEVEL.
3. ALL CONNECTIONS ARE SUPPLIED WITH QUICK DISCONNECT FITTINGS.
4. ALL INTERCONNECTING MOSESFURftISHED By WGMC.
5. MAXIMUM CLEANLINESS OF ALL INTERCONNECTING HYDRAULIC AND

PNEUMATIC PIPING IS OF UTMOST IMPORTANCE.
&. PRESSURE OR PLOW IS DETERMINED BY WHAT IS PROVIDED BY THE SHIP.
PRDEIGNATION CHART
I TAK SUE DECIPTION PORT SIZE AND TYPE - F W
WCI PPERFRAM L
E NTQ
II PPRFAMESL iu p I I
Uf C9WN ________________J)
I. R ULFE ' _________________
DSDAGBAD IN IQ.5 SE NOT6

NIb PMTRE55URE GAGE 2OO PSI GE I
BRAKE S3 PSM
PUIj19 ____________________ P51SIF
_ _ __ULI zlo S PMP
DRIN 7.~
75______________ PM
SHIPS AIR NP FMAE10 L0 O 6
HETECANGR 75 PTFEMALE I8GPM
Figure 2-2. Interconnecting Hose Diagram (Sheet I of 2)
2-9
-- - - - - - - - - - - - - - - - -
---
- - - - - - - -- - - - - - -- - - - - - -
!,
-- - - -- - - -- - - -- - -
II, a-bL MOEa
-- - - - - - - - - -- - - - - W IN
SI -- - - - - - - -- - - - - - - - 548M*
:: ------------------
ge -- -- -- - -- -- -- -
eCWg I *
SI(M I
Inecnetr Fiur 2-2 oeDarm(he f2
S2l10
REVISIONS
ZONE LTh 3IrPm DATE APPROVED
A SYSTEM INTERCONNECT WIRING MODIFIED TO 11-4- . --

CONSIST OF CABLEASSEMBLIES WITH QUICK 1981 ,M'
DISCONNECT ELECTRICAL FITTINGS. REVISEr)
THIS WIRE LIST TO SUPPORT THAT MODIFI-
CATION.
SH 1: REVISED REV. STATUS.
B
SH 17: REVISED WIRING FROM 2 COND. TO
4 COND.
NOTES: SH 18. 19: CHANGED WIRING TO INTERFACE
WITH SH 17 WIRING.
1. INTERCONNECT WIRING SHOWN ON SHEETS 2 & 4 TO BE ACCOMPLISHED BY CUSTOMER.
THE REMAINDER OF THE INTERCONNECT WIRING SHOWN TO BE ACCOMPLISHED BY WGC.
2. INSULATED RING TERMINAL LUGS AND WIRE NUMBERS SHOULD BE USED WHERE APPLICABLE.
3. CARE MUST BE TAKEN TO INSURE THAT D.C. WIRE SHIELDS DO NOT TOUCH J-BOX SIDES
OR ANY METAL OBJECT. REFERENCE WGC INSTALLATION PROCEDURE A303505.
4. SEE ELECTRICAL GENERAL ARRANGEMENT D316125 FOR LOCATION OF PLUGS AND

RECEPTACLES MENTIONED IN THIS WIRE LIST.
5. ELECTRICAL CONTROL SCHEMATIC D316126.
-REVISION STATUS
_,_SHT 1 2 3 4 5 6 7 18 9 10
REV B A A A I A A I A I AA
I D316125 42816E SHT 11 12 13 14 15 16 17 18 19
/N NEXTASSY OTY USEDON
-. __
__ __ __- EV_ A A A A A A 8 8
APPLICATION
LIMITS
ON
MACHIED DIMENSIONSW
We sTe R HEAVY MACHINERY DIVISION
NG
EXCEPT AS NOTED kg 1-26-81 A CORPOATON EVERETT, WASHINGTON
0
ANULA ± 1 0' DRAWN LEON McCABE INTERCONNECT WIRE LIST
LINEAR_
x .2.1
m CHECK ACo3b CABLE MACHINERY SYSTEM
J= .2
jot
___*_____0______ NAUBUC
FRACTIONAL± 1132 -
2-5-li SIZE CODEIDENT NO REV
I____AL_____ A 16603 A307881 B
HARP EDGES gSCALE w. a
A307881B
Figure 2-3. Interconnecting Wiring List (Sheet 1 of 19)
2-11
SPACEHEATER
& CONTROL
POWER CABLENO. Wi
CABLETYPE THOF-4 UNIT A (120 VAC)

SOURCE
POWER
SPARES WIRES 0 UNIT 8 X1-1
UNIT A UNIT B
TERM NO. WIRE NO. WIRE COLOR TERM NO. FUNCTION
101 BLK PIN 1 120 VAC HOT
102 WHT PIN 2 120 VAC RETURN
100 RED PIN 3 GROUND
R EV
CODE IDENT NO.
SwsmIZE
4 ... R, ivision A 16603 A307881 A
EVERETT, WASHINGTON W A201. S
0114
A307881B
2-12
SPACE HEATER & CONTROL POWER CABLE NO0. -
CABLE TYPE 14 AWG UNIT A PI1
SPARES WIRES - ______ UNIT B TB3 (3-BOX 1)
UNIT A UNIT B
PIN 1 101 RED TB3-1 120 VAC HOT
PIN 2 102 RED TB3-3 120 VAC RETURN
PIN 3 100 WHlT 4UNTING SCREW GROUND
SIZE A307BENTO AE
A 16603A378A
EVERETT. WASHINGTON 90201 SCLSHE 3
9314 =.,
A307881B
2-13
POWER UNIT TANK HEATER POWER CABLE NO. W3
CABLE TYPE TNOF-4 UNIT A POWER SOURCE (120 VAC)
SPARES WIRES 0 UNIT s J3-4
UNIT A UNIT B
TERN NO. WIRE NO. WIRE COLOR TERM NO. FUNCTION
144 81K PIN 1 120 VAC NOT
145 WHlT PIN 2 120 VAC RETURN
100 RED PIN 3 GROUND
[WeMI1= A 16603 A307881 A

EVERtETT. WASHINGTON U201 SCLISHE 4 1
A307881B
F1gure 2-3. Interconnecting Wiring List (Sheet 4 of 19)
2-14
POWER UNIT TANK HEATER POWER CABLE NO. "
CABLE TYPE 10 AWG UNIT A P3-4
SPARES WIRES - UNIT B TANK HEATER (POWER UNIT)
UNIT A UNIT B
PIN 1 144 RED 120 VAC HOT
PIN 2 145 RED 120 VAC RETURN
PIN 3 100 WHT GROUND
REV
S
A ~f NO.
0 0 CI
16603 A30881 A
EVERETT. WASHINGTON SM" B" a1
131
MICROFIUMMI A
A307881B
2-15
-I- mI
POWER UNIT PUMPMOTOR POWER CABLE NO. W4
CABLETYPE FHOF-42 UNIT A POWER SOURCE (440 VAC)
SPARES WIRES 0 UNIT B J4-2
UNIT A UNIT B
L_ BLK PIN 1 440 VAC PHASE 1
,__, __ L2 WHT PIN 2 440 VAC PHASE 2
. L3 RED PIN 3 440 VAC PHASE 3
100 GRN PIN 4 GROUND
REF: WGC lWG 8312548
II
wen IZE MRO
IO NYE REV
A 16603 A307881 A
EVERErl, WASHINGTON MIS201
SCALE SHEET 6 .
MCRIC ' '.

A307881B
2-16
POWER UNIT PUMP 140TORPOWER CABLE NO. _
CABLE TYPE 4 AMG UNIT A P4-2
SPARES WIRES - UNIT B CONTACTOR INPUT (J-BOX 2)

UNIT A UNIT B
PIN 1 Li Li 440 VAC PHASE 1
PIN 2 L2 L2 440 VAC PHASE 2
PIN 3 L3 L3 440 VAC PHASE 3

/P4-2
PIN 4 100 MOUNTING SCREW GROUND
I I
SIZ COOE IDcNT NO. REV

A 16603 A307881 A
EVERETT, WASHINGTON U201
SCALE SMUT 7
'A
A307881B
2-17
POWER UNIT INDICATION& CONTROL CABLE NO. -
CABLE TYPE 14 AWG UNIT A j5-I
SPARES
WIRES 1 UNIT B TB2 (J-BOX 1)
UNIT A UNIT B
PIN I
PIN 2
PIN 3 103 RED TB2-2 120 VAC HOT

PIN 4 104 RED TB2-4 120 VAC RETURN
PIN 5 106 RED TB2-6 MOTOR RUN IND.
PIN 6 113 RED TB?-8 RUN LATCH CONTACT
PIN 7 114 RED TB2-10 MOTOR START

PIN 8 117 RED TB2-12 MOTOR OVLD IND.
PIN 9 119 RED TB2-14 SERVO PRESS LOW IND.
PIN 10 123 RED TB2-16 SUMP TEMP HIGH IND.
PIN 11 136 RED TB2-18 SPACE HTR 120 VAC HOT
PIN 12 137 RED TB2-20 SPACE HTR 120 VAC RET

PIN 13 126 RED TB2-22 BRAKE RELEASE SOL
PIN 14 130 RED TB2-24 BRK REL STROKE O 0SOL

iS-1
PIN 15 100 WHT 4OUNTING SCREW GROUND
PIN 16 SP RED T82-23 SPARE
SIZE[ CODE CC NNo.RE
A 16603 A307881 A
EVERETT, WASHINGTON M01 , -
,,,. - r,ICROFIkMEDA
A307881B
2-18
POWER UNIT INDICATION L CONTROL CABLE NO. W5
CABLE TYPE NHOF-14 UNIT A P5-1
SPARES WIRES 1 UNIT 8 J5-2
UNIT A UNIT B
PIN 1 PIN 1
PIN 2 PIN 2
PIN 3 103 BLK PIN 3 120 VAC HOT

PIN 4 104 WHT PIN 4 120 VAC RETURN
PIN 5 106 RED PIN 5 MOTOR RUN IND.

PIN 6 113 GRN PIN 6 RUN LATCH CONTACT
PIN 7 114 ORN PIN 7 MOTOR START
PIN 8 117 BLU PIN 8 MOTOR OVLD IND.
PIN 9 119 WHT-BLK PIN 9 SERVO PRESS LOW IND.
PIN 10 123 RED-BLK PIN 10 SUMP TEMP HIGH IND.
PIN 11 136 GRN-BLK PIN 11 SPACE HTR 120 VAC HOT

PIN 22 137 ORN-BLK PIN 12 SPACE HTR 120 VAC RET
PIN 13 126 BLU-BLK PIN 13 BRAKE RELEASE SOL

PIN 14 130 BLK-WHT PIN 14 BRK REL STROKE 9-0 SOL
PIN 15 100 RED-WHT PIN 15 GROUND
PIN 16 SP GRN-WHT PIN 16 SPARE
REF: WGC DWG B312549
We nI=W
SMe TU E
......... A 16603 A307881A
EVRT.WSIGO 81 SCALE SMEET 9
1314
A307881B
2-19
POWER UNIT INDICATION & CONTROL CABLE NO. "
SPARES WIRES 1 , UNIT B J-BOX 2 TB'S
UNIT A UNIT B
PIN 1
PIN 2
PIN 3 103 RED CDS 120 VAC HOT
PIN 4 104 RED CDS 120 VAC RETURN
PIN 5 106 RED TB15-10 MOTOR RUN IND.
PIN 6 113 RED TB15-12 RUN LATCH CONTACT
PIN 7 114 RED TB15-14 MOTOR START
PIN 8 117 RED TB15-16 MOTOR OVLD IND.
PIN 9 119 RED TB15-2 SERVO PRESS LOW IND.
PIN 10 123 RED TB15-4 SUMP TEMP HIGH IND.
PIN 11 136 RED CDS SPACE HTR 120 VAC HOT
PIN 12 137 RED CDS SPACE HTR 120 VAC RET
PIN 13 126 RED TB15-6 BRAKE RELEASE SOL
PIN 14 130 RED TB15-B

P5-2 BRK REL STROKE O SOL
PIN i5 100 WHT MOUNTING SCREW GROUND
PIN 16 SP RED TB16-1 SPARE
SIZE COOE IDENT NO. REV

lWesreRn DmHaea
Machinery A3781
I... ......... A 16603
EVERETT. WASHINGTON 2O-
SCA. SHEET 10
9314
IM..-K lrILIiL U7
A307881B
2-20
POWER
UNIT PUMP ACTUATOR
COMMAND CABLENO.
CABLETYPE 4 COND WITH SHIELD UNIT A 36-1
WIRES
SPARES 2 ______ UNIT B T81 (J-BOX 1)
UNIT A UHIT
TERM NO. WIRE NO. WIRE COLOR TERMNO. FUNCTION
PIN 1 247 OLK TOI-18 ACTUATOR
PIN 2 246 RED TBl-20 ()ACTUATOR

PIN 3 ________ SHLD TBI-16
PIN 4 SP GRN TBl-22 SPARE
PIN 5 SID WHT TBl-24 SPARE
Mcne SIZE CODEIOENITNO. REV

Wn~lm =
@,a ~ sr A 16603 A307881 A
EVERETT. WASHINGTON 98201 SCL -7 HET 1
MIflROALMED ,4
A307881B
2-21
POWER UNIT PUMP ACTUATOR COMMND CABLL NO. W6
CABLE TYPE TTRS-2 UNIT A P6-1
SPARES WIRES 2 _______UNIT B 36-2

UNIT A UNIT B
PIN 1 247 BLK-BLK PIN 1 ()ACTUATOR
PIN 2 246 BLK-WHT PIN 2 ()ACTUATOR
PIN 3 SHLD PIN 3
PIN 4 SP WHT.BLK PIN 4 SPARE
PIN 5 SP WHT-WHT PIN 5 SPARE

PIN 3 SHLD PIN 3
REF: WGC DWG 8312550
Mahm SIZE CODEIDENT NO. REV

1wesTe~ x.ahnr 60 A307881 A
EVERETT. WASHINGTON 98201[,CLI
Er
A307881B
2-22
POWER
UNIT PUMPACTUATOR
CONMAND CABLE
NO.
CABLE TYPE 4 COND WITH SHIELD UNIT A P6-2
SPARES WIRES 2 , UNIT B TB16 (3-BOX 2)
UNIT A UNIT B
PIN 1 247 BLK TB16-11 + ACTUATOR
PIN 2 246 RED T816-12 (-) ACTUATOR
PIN 3 SHLD TB16-10
PIN 4 SP GRN TB16-8 SPARE

PIN 5 SP WHT TB16-9 SPARE
I9
"! fkw SIZE CODE IDENT NO. REV
I sIR n o A 16603 A307881 A

EVERETT, WASHINGTON 98201
SCALE $MEET ]3
A307881B
2-23
DOHB SIGNALS (SYNCHRO) CABLE NO. -
CABLE TYPE 14 AWG UNIT A J7-1
SPARES WIRES 1 ______ UNIT B TB2 (3-BOX 1)

UNIT A UNIT B
TERN NO. WIRE NO. WIRE COLOR TERM NO. FUNCTION~
PIN 1I ______ ___________________
PIN 2 __________________________
PIN 3 _______ ____________________
PIN 4 150 RED TB2-1 51
PIN 5 151 RED TB2-3 S2
PIN 6 152 RED TB2-5 S3
PIN 7 103 RED TB2-7 Ri

PIN B 104 RED T132-9 R2
PIN 9 100 WHT MOUNTING SCREW GROUND
PIN 10 SP RED T82-13 -SPARE
CODEIDENi,No REV
lWeSTeRn momy
uahnr I cieySIZE
6 0 A307881 A
EVERETT, WASHI-NGTON 9B201[SAEFEEr1
A307881B
2-24
DOHB SIGNALS (SYNCHRO) CABLE NO. W7
CABLE TYPE MHOF-7 UNIT A P7-1
SPARES WIRES 1 UNIT B J7-3
UNIT A UNIT B
PIN 1 PIN 1
PIN 2 PIN 2
PIN 3 PIN 3
PIN 4 150 BLK PIN 4 Si
PIN 5 151 WHT PIN 5 S2
PIN 6 152 RED PIN 6 S3
PIN 7 103 GRN PIN 7 RI
PIN 8 104 ORN PIN 8 R2
PIN 9 100 BLU PIN 9 GROUND
PIN 10 SP WHT-BLK PIN 10 SPARE
REF: WGC DWG B312551
SIZE CODE IDENT NO. REV

~
'
[ STORn Df4.nA378
t4/,'t D
rmA
N aT hlnery
t]MeowM
16603 Ao
A307881B
2-25
DOHB SIGNALS (SYNCHRO) CABLE NO.
SPARES WIRES I UNIT B TB14 (J-BOX 3)
UNIT A UNIT B
TERM NO. WIRE NO. WIRE COLOR TERN NO. FUNCTION
PIN I
PIN 2
PIN 3
PIN 4 150 RED T814-2 SI

PIN 5 151 RED TB14-4 S2
PIN 6 152 RED TB14-6 S3
PIN 7 103 RED TB14-8 Rl
PIN 8 104 RED TB14-10 R2
PIN 9 100 WHT MOUNTING SCREW GROUND
PIN 10 SP RED TB14-12 SPARE

wesTeRn.-
C- A 16603 o
EVERETT. WASHINGTON 98201 SHEET 16
"" ibL;uriiv}EI i
A307881B
2-26
DHD SIGNALS (LOAD CELL, TACH) CABLE NO.
CABLE TYPE 4 COND WITH SHIELD UNIT A 38-1
SPARES WIRES 2 , UNIT B TB1 (,-8OX 1)
UNIT A UNIT B
PIN 1 201 WIT T81-1 SYS A LOAD CELL (4) EXCIT.
PIN 2 200 GRN T81-3 (-)EXCIT.

PIN 3 SHLD T81-5
PIN 4 202 RED .Tl- ( ) SIGNAL
PIN 5 203 BLK TBI-9 (-ISIGNAL

PIN 6 ..
PIN 7 251 WHT TBI-2 SYS B LOAD CELL (4) EXCIT.
PIN 8 200 GRN TBI-4 C-)EXCIT.

PIN 9 SHLD T81-6
PIN 10 252 RED TB1-8 (4) SIGNAL
PIN 11 253 BLK T8I-1O (- SIGNAL

PIN 12
PIN 13 250 WHT TB1-11 TAC1 (4) SIGNAL
PIN 14 200 GRN TB-13 C-) SIGNAL
PIN 15 ..
PIN 16 SP RED T1-21 SPARE
PIN 17 SP BLK TB1-23 SPARE
PIN 18 SHLD TB1-15
PIN 19.
REV
e
........we n m Joa,..
Mah, SIZE
A COE IDENT NO,
16 6 0 3 A307881 B
EVERETT, WASHINGTON 26201 1
SCALE SHEET 17
Iv 1B ! I
A307881B
2-27
I -
1DOHB
SIGNALS (LOADCELL, TACH) CABLE NO. W8
CABLE TYPE TTRS-6 UNIT A P8-1
SPARES WIRES 2 , UNIT B 38-3
UNIT A UNIT B
PIN 1 201 BLK-BLK PIN 1 SYS A LOAD CELL (4) EXCIT.
PIN 2 200 BLK-WHT PIN 2 C-)EXCIT.

PIN 3 SHLD PIN 3
PIN 4 202 WHT-BLK PIN 4 () SIGNAL
PIN 5 203 WHT-WHT PIN 5 C-) SIGNAL

PIN 3 SHLD PIN 3
PIN 7 251 RED-BLK PIN 7 YS B LOAD CELL (+) EXCIT.
PIN 8 200 RED-WHT PIN 8 (-)EXCIT.

PIN 9 SHLD PIN 9
PIN 10 252 GRN-BLK PIN 10 + SIGNAL
PIN 11 253 GRN-WHT PIN 11 (-) SIGNAL

PIN 9 SHLD PIN 9
PIN 13 250 ORN-BLK PIN 13 rACH (+) SIGNAL
PIN 14 200 ORN-WHT PIN 14 C-)SIGNAL

PIN 18 SHLD PIN 18
PIN 16 SP BLU-BLK PIN 16 SPARE
PIN 17 SP BLU-WHT PIN 17 SPARE
PIN 18 SHLD PIN 18
PIN 19 PIN 19
REF: WGC DWG 8312552
eayb oySIIE ICODE IDENT NO. REV
........ 1
lhnr
1we sraD t HIv
o I Vnll D~tslofl A 16603 A307B81 8
EVERETT. WASHINGTON 98201
A307881B
2-28
f . -
DOHB SIGNALS (LOAD CELL, TACH) CABLE NO.
CABLE TYPE 4 COND WITH SHIELD UNIT A P8-3
SPARES WIRES 2 , UNIT B TB14 (3-BOX 3)
UNIT A UNIT B
PIN 1 201 BLK TB14-1 SYS A LOAD CELL (+) EXCIT.
PIN 2 200 RED TB14-3 (-)EXCIT.

PIN 3 SHLD TB14-5
PIN 4 202 GRN TB14-7 (+) SIGNAL
PIN 5 203 WHT TB14-9 -)SIGNAL

PIN 6
PIN 7 251 BLK TB14-15 SYS B LOAD CELL N+) EXCIT.
PIN 8 200 RED TB14-17 C-)EXCIT.

PIN 9 SHLD TB14-19
PIN 10 252 GRN TB14-21 (+) SIGNAL
PIN 11 253 WHT TB14-23 (-)SIGNAL

PIN 12
PIN 13 250 BLK TB14-22 TACH (+) SIGNAL
PIN 14 200 RED TB14-24 C-) SIGNAL

PIN 15
PIN 16 SP GRN TB14-16 SPARE
PIN 17 SP WHT TB14-18 SPARE

PIN 18 SHLD TB14-20
PIN 19
SZE CODEIDENT NO. REV

.......... S n A 16603 A307881 B
EVERETT. WASH INGTON 98201 11- I

SCALE SHEET 19
A307881B
2-29/(2-30 blank)
POWER
CONSOLE
CONTROL UNIT L -
( TANK
HEATER
120 VAC, 10, 6014
N
= .. < SEE J-BOX I DETAIL P4-2

... ,4.VAC,30 : MOTOR
, -0 HI OTOR SUPPLY -- ,.CONTROLLER
P1_
\ Si' LIL...-I-- -RLOAD
I--J'-6"I A
FULL AMP
LOAD CURRENT 62 :,u
1I -J-BOX
'.
*2)
SE -BOX
SH44
W5
P8-3
2:::L pI7-.
J130X3
DRAWINGS:
REFERENCE
1. INTERCOINECT
WIRELIST.... ............. A307RA1
2. $YSTEMELECTRICALSCEMATIC.. .......... D316l26 O.-H. 1.
3. SSESLY-OHOMACHINE .... ............. 0316127 MACHINE
A POWERUNIT................
ASSEMBLY-DOIB 031612R
5. WIRINGOIAGRAM-.O.MACHINE .............. C3128D2
6. WIRINGDIAGRAM-D"POWERUNIT ............ 0316129
T. WIRING CONSOLE
DIA&GPP-CONTROL .. ......... D316130
8. ASSEMIBLY-CONTROL
CONSOLE ... ............ 0316;31
9. TESThAiDALIGIENr PROCEDIJRO. .. .. . . . ... A79A4
REVISION STATUS
SI 123l 1 5
/
POWER SEE TANK HEATER
UNIT DETAIL,SH3
( TANK
HEATER "-
W3---- t0
60 C
VAC,
P3.4: 2.5 MVA

-. HEATER SUPPLY
P4 2
440VAC, 3 0 w- j MOTOR
60 HZ MOTOR SUPPLY CONTROLLER
APPRO . 38 AMP 01 2
FULL LOAD CURRENT
P6-
SE J-BOX 2 DETAIL,
SH4
_ W5 INTERCON'NECT CABLES
. CUSTOMER FURNISHED
- W6 WGC FURNISHED
W--1 THOF-4
_ W_____________________
W21 DELETED
-SEE J-BOX 3 DETAIL, w3 THOF-4

SHS W4 FHOF-42 F/N 10
P-- "--3
(
W5 MHOF-14 FIN I
J-10X P3 )6 w7
TTRS-2
MHOF-7
F/N 12
F/N 13
W81 TTRS-6 F/N 14
.O;H, .
MACHINE
TUS
D316125B
Figure 2-4. Electrical General Arrangement

(Sheet 1 of 5) -
2-311(2-32 blank)
THOF-4 (AbLE
CUSTOMER PROVIDED)
EF
NOTE
CAL-IBSEE
25 130 DRILL TH
(4) PL5 i)
335E N07 DETAI
(2)~~~~~E PL 5ET/5EN7
SEE NOarc DEAI r5IDTI
~
5EE ~ ~ ~ DFA fl.0
L07 EEDTI
~35 ____+_
J16-
.7 8
REF
.19 D IL T
+
BLE-W
VAI
NO-TE5:
+ .EE
I,5 VAC OWC, NO C31286 ;'OR I-BOX A5Y.
REF 2.A-55EMI!SY iNCLUDES PLUC,.CD'N'AC7 INSERT
OU5T COVER ANZ) CA5'E GRiP 4WE N APPL CABLE.
3.REPLACE D)UST COVER CH~AIN WI- 1CAB E
3.O 65 N I,.
C-00 SEE DETAIL n 4. APPLY 'LOCTITE' 24a2'TO ALLT REA12I A7 A,5,5f
5.7AG OIR MARK VIiRES -% TH AIRE NUM5ERS,
r.O0u5T COVER CAB -E 4ASSY EYELET TO6E A-VACHED
CJ ONE LANC.E AS SI-OWN UbING MOUN'TING
I-%ARgDWAqE.
F
7 F/N 5 1-74 8 TO BE S ;IPPED LOO)SE FOR CI.j51MWR
MOUN'TING ON CUSTMER PROVIDED CABLE.
9.vyiRE PLUGS AND PECFPTACLES PER WOC.
3.50 4 OWG No. A30785k.
DETAL
15EE 1E
"484
r I~ 1
1.77
--
LL- 2 i -BOX I DETAIL
)ETAIL I
687 D316 125B

-- 7 .375Figure 2-4. Electrical General Arrangement
(Sheet 2 of 5)
-1A7 FTILa 2-33/(2-34 blank)

TAP .50-i4 .PT
IN) RILL 1iIRU,
TAPeR
9TZC X.75 ClP
P3-4~£ -- --- L.3
SEEAR
I DEAI z1B WO WON.
4 APPLY'LOCTITE" 24- 'TO ALL T

5 , AG OR MARK WIPE5 WITH %.C
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(Sheet 5 of 5)
2-39/(2-40 blank)
SECTION III
OPERATION
3-1. INTRODUCTION.
3-2. This section contains a safety summary, a description of the controls
located on the DOHB tension machine and power unit, and operator maintenance
information.
3-3. SAFETY SUMARY.
3-4. Operating personnel must observe the following safety WARNING and CAUTION
when operating the
DOHB tensioner.
The power unit for this machine contains lethal voltages.

Keep away from live electrical circuits. Never try to make
repairs or to replace components when power is on.
CAON
Before operating the tension machine, look around. Make

sure that no stowed equipment or other material will inter-
fere with the operation of the machines.
3-5. CONTROLS AND INDICATORS.

3-6. The DOHB tension machines and power unit are controlled from the Machine
Operator Control Console. Refer to the Operation and Maintenance Manual for
Control Console for description, function, and operation of controls and indi-
cators located on the control console.
3-7. Functions of controls located on the DOHB tension machine and power unit
are described in table 3-1.
3-8. OPERATOR MAINTENANCE.

3-9. Operator maintenance includes inspecting, cleaning, and lubricating the
equipment as described in table 5-1. Operators shall be alert to detect mal-
functions and shall secure the equipment as soon as possible to determine the
cause and to have the malfunction corrected. Section iV includes tables which
give logical steps to be followed to locate and correct malfunctions.
3-1
3-10. The specific indications of trouble include:
1. Overheating of any part, smoking or discoloration of painted surfaces.
2. Excessive vibration.
3. Unusual noises.
4. Failure of machine to respond to control movements.
5. Track slippage at rated squeeze pressure.
6. Metal dust or shavings around moving parts.
7. Low pressure readings in hydraulic system.

3-11. Operators are not qualified by rating or training to repair DOHB tension
machines. They shall report the exact indications they have observed but in no
case shall they attempt repairs without responsible supervision. Unauthorized
attempts at quick repairs may hide the true cause of malfunctions and cause
severe damage.
Table 3-1. DOHB Tension Machine and Power Unit Local Controls
CONTROL AND POSITIONS FUNCTION

LOCATION
DOHB Reducer - IN Engages gear for low speed operation.

High/Low Speed
Control Lever OUT Engages gear for high speed operation.
(14, figure 6-5)
NOTE: Control levers on both
reducers must be at tho same
position (IN or OUT) before
operating the tension machine.
Do not shift control levers
while machine is operating.
DOHB Power Unit When pressed, mechanically resets
Motor Controller - overload relays to extinguish red
RESET button OVERLOAD indicator on control console
(see figure 1-1, sheet 3).
DOHB Power Unit ON/OFF When in ON position, energizes space

Motor Controller - heaters in motor and motor controller
Heater Switch (if space heater AC voltage if
(figure 4-3, present).
sheet 2)
When in OFF position, deenergizes

space heaters.
3-2
SECTION IV
TROUBLESHOOTING
4-1. INTRODUCTION.
4-2. This section contains a functional description of the DOHB Tension
Machines and their power units. Troubleshooting tables are provided (tables 4-1
and 4-2) which contain information useful for determining the location of faults
which may develop in the equipment.
4-3. FUNCTIONAL DESCRIPTION.
4-4. DOHB MACHINE GENERAL. Two kinds of force are applied to the cable in
the DOHB tension machine by the tracks of the machine. Squeeze pressure applies
a force perpendicular to the cable and acts to hold the cable between the
tracks. Movement of the tracks by the hydraulic drive motors of each track
assembly produces a longitudinal force which causes the cable to move in a plane
horizontal to the tracks. Each tension machine is designed to produce a maximum
longitudinal force or tension of 2,250 pounds at a speed of 315 feet per
minute.
4-5. REDUCER ASSEMBLY. See figures 6-4 and 6-5. Drive power for each track
assembly is supplied by a hydraulic drive motor through a gear reducer assembly.
Two ranges of speed are available through the assembly. These are 0 to 315 fpm
when the speed control lever on the gearbox is positioned to the IN positon and
0 to 670 fpm when the lever is in the OUT position. The reduction gear
mechanism consists of high speed shaft (4), intermediate pinion shaft (5), spur
pinion shaft (6), and output shaft (7). The high speed shaft is gear coupled to
drive the intermediate pinion shaft through either of two gears (10 or 11) which
are spline engaged to the intermediate pinion shaft by the positioning of clutch
collar (20). Selection between the two gears provides the speed control. The
clutch collar is shifted to engage either low speed gear (11) or high speed gear
(10) when lever handle (14) is actuated. Moving the lever handle causes shift
rod (16) to be repositioned and held by a detent mechanism consisting of a
spring and ball and two grooves in the shift rod. When the rod is shifted, the
ball is caused to be seated in a groove for the new position. Fastened to the
shift rod is fork (68) which engages the clutch collar and moves it when the
shift rod is moved. Output from intermediate pinion shaft (5) is coupled
through helical gear (8) which is keyed to spur pinion shaft (6). Output from
the spur pinion shaft is coupled through spur gear (9) keyed to output
shaft (7). The ends of all shafts are supported by bearings and the entire gear
mechanism is submerged in 90 weight gear oil.
4-6. BRAKE ASSEMBLY. See figure 6-5. Intermediate pinion shaft (5), which
extends through reducer base (2), has brake gear (64) mounted on its end. The
brake mechanism consists of brake gear (64), five separator plates (59), six
friction plates (58), backing plate (62), piston (60), and ten springs (63).
The brake mechanism is spring set and hydraulically released. Thus, when there
is an absence of hydraulic pressure acting on the piston, the springs force the
4-1
-- m i 1 Ik
backing plate to engage the friction plates with the separator plates of the
brake gear. With contact thus established, the brake gear holds the intermediate
pinion shaft and prevents it from turning and the brake is set. When hydraulic
pressure acts on the piston, spring tension is overcome and the brake is
released. The brake is cooled by oil from the reducer seeping through
bearing (39).
4-7. TRACK ASSEMBLIES. See figure 6-1. Each track assembly consists of a
welded steel box structure with a pair of sprockets (5) attached at each end.
Each pair of sprockets is connected by a shaft: idle shaft (73) at the forward
end and drive shaft (59) at the aft end. Looped around the sprockets and frame
assembly is track (4). In the upper track assembly, the upper span of track
between the two sprocket assemblies is supported by a pair of track support
rollers (71) which are connected between four pillow blocks (43). Support for
the lower track span of the lower track assembly is provided by another pair of
track support rollers connected in a similar manner beneath the lower track
span. Also, located within each track loop are three roller frame mechanisms
which support four pressure rollers (111) each. The twelve pressure rollers
within the upper track loop are located along the lower track span and each
roller frame assembly is attached to the welded steel box structure. Squeeze
pressure exerted on the upper track assembly by the MAIN PRESSURE cylinder (98)
is transmitted as a holding force on the cable between the tracks by the twelve
upper pressure rollers. The three roller frame assemblies located within the
lower track assembly are each attached to a rod of a track cylinder (122). Each
track cylinder holds its four pressure rollers along the underside of the upper
span of track on the lower track assembly. The three track cylinders allow the
lower track to be forced down to allow the passage of cable repeaters through
the tension machine.
4-8. MAIN PRESSURE CYLINDER. Main pressure cylinder develops the force which
squeezes the cable between the upper and lower tracks. This perpendicular force
is controlled by the amount of air pressure applied to cylinder by the posi-
tioning of UPPER FRAME SQUEEZE control valve handle on the control console. The
amount of air pressure that can be applied is variable between 0 and 80 psi. A
pressure regulator limits air pressure to control valves to 80 psi. Actual
movements of load force applied by the upper track assembly to the cable is
determined by several factors which include the movement of the arms through
which cylinder rod is connected to the upper track assembly, the effect of
longitudinal force (tension) on the upper track, the direction of operation -
forward or aft (the direction of movement causes tension to aid or oppose the
load), and the weight of the upper track. In normal operation, squeeze pressure
is set by positioning control valve handle toward DOWN and observing the oper-
ation of the tracks: when the tracks do not slip, adequate squeeze pressure is
set for that tension and speed. When control valve handle is positioned toward
UP, the entire upper track assembly is raised by reversing the direction of air
pressure to squeeze and lift pneumatic cylinder.
4-9. TRACK SQUEEZE CYLINDERS. The TRACK SQUEEZE control valve controls both
pressure and air flow for the three track squeeze cylinders. Air pressure at
the outlet port may be increased or decreased by positioning the hand lever.
Maximum air pressure that can be set by the valve is limited to 80 psi as set by
the pressure regulator. When the TRACK SQUEEZE control valve handle is moved to
4-2
the SQUEEZE position, the track cylinders extend to press pressure rollers along
the underside of the upper span of track of the lower track assembly. The track
cylinders are operated at low pressure to allow the track to be forced down by
cable repeaters as they pass through the tensioner machine. When the handle of
the control valve is positioned to the RELEASE position, the air circuit is
vented to atmosphere and the track cylinders retract.
4-10. TRACK TIGHTENER. See figure 6-1. The idler shaft (73) of both the upper
and lower track frame assemblies may be moved forward or aft to loosen or
tighten the track assemblies. The mechanism which permits this adjustment is
called the track tightener and consists of two tightener assemblies. Each
tightener assembly consists of a spring (8), a backing plate (7), a nut (36),
and a screw (6) arrangement of which screw (6) is the manual track tightener
adjustment. Each pair of assemblies is located within the forward end of each
track frame assembly between a bearing plate and the idler shaft assembly.
4-11. POWER UNIT ASSEMBLY (figure 6-8). Each DOHB tension machine is powered
by a separate electrohydraulic power unit. The power unit consists of a 30
horsepower electric drive motor (3) coupled to a variable delivery hydraulic
pump (11) mounted on a 120-gallon hydraulic tank (2). A motor controller (27),
mounted to the side of the hydraulic tank controls the electric motor. Pump (1)
output is controlled by remote control actuator mounted on the pump.
4-12. The hydraulic tank (2) is equipped with a filter breather (20), a sump
filter (47), a 10-micron replenishment filter a water to oil heat exchanger
(10), and an immersion heater (15). Heater is a 2,500-watt, 120-volt unit that
is thermostatically controlled to go on at 50°F (100 C) and off and 80OF (270C).
4-13. POWER UNIT FUNCTION. See figure 4-1. The primary function of the power
unit is to provide hydraulic drive power to drive the DOKB tension machine
tracks by means of hydraulic motors and gear reducers. Electric motor (20)
rotates variable delivery hydraulic pump (25) shaft in a constant direction.
However, no hydraulic pressure is developed unless the pump is placed on stroke
by the hydroelectric actuator. The replenishing pump is an integral part of
pump (25) and produces an output of replenishment fluid flow whenever electric
motor (20) is operating.
4-14. The hydroelectric actuator controls the amount and direction of fluid
flow developed by the pump and thereby controls the speed and direction of fixed
hydraulic motors (27) which drive the DOHB machine reducers. Track speed and
direction is thus controlled by the actuator.
4-15. The actuator receives pressurized hydraulic fluid from replenishing pump.
A dc linear motor in the actuator controls positioning of the actuator pilot
spool to direct hydraulic fluid to the actuator pistons causing the actuator
output rod to move in the required direction. The actuator output rod is con-
nected to the pump control arm to control pump output. The pump control arm can
be used to manually control the pump during maintenance operations.
4-16. Operation of the actuator is controlled from the control console. With
MODE SELECT switch set to SPEED position, PAYOUT/HAUL IN quadrant furnishes the
electrical signal input for actuator operation. Quadrant is manually positioned
4-3
by the operator to directly control track speed and direction. CABLE TENSION
dial indicator provides readings of tension developed at the DOHB tension
machine as sensed by load cells.
4-17. With the MODE SELECT switch set to the BRAKE position, the brake release
solenoid and the brake release stroke 9 0 solenoid are deenergized. This closes
off the flow of hydraulic fluid to the spring set/hydraulically released brake,
thereby setting the brakes and stoping the DOHB.
4-18. With MODE SELECT switch set to TNSN position, the DOHB electronic
tension/speed controls furnish the electrical signal input for the actuator to
operate and maintain a preset tension. TENSION SET potentiometer is set to the
desired tension. When TENSION SET READOUT pushbutton is depressed, CABLE
TENSION indicator shows the amount of tension set by potentiometer. TNSN MACH
GEAR MODE switch must be set to correspond with the gear position (HIGH or LOW)
selected at the DOHB reducers for the electronic controls to function properly.
The electronic controls are a redundant system (A or B) and either system may be
used as selected by SYSTEM SELECT switch. Load cells provide an input signal of
actual tension to the electronic controls. The electronic controls provide the
electrical signal to the actuator that will result in the tension being main-
tained at the level set by TENSION SET potentiometer.
4-19. PNEUMATIC SYSTEM. See figure 4-2. The DOHB tension machine pneumatic
system consists of an air pressure source of approximately 100 psi (supplied by
the ship), a shutoff valve (10), an air filter (11), a pressure regulator (12),
an air lubricator (13), and one complete set of the following items: three
hand-operated, four-way directional control valves (15A, 15B and 18); a pressure
regulator (17); five pressure gages (14A, B, C, D, and E); upper frame squeeze
cylinder (21); three track squeeze cylinders (22); and two dragboard cylinders
(20 and 23).
4-4
Stay clear of the tension machine tracks when the equipment
is operating. Shut down power unit(s) and tag controls to
prevent operation when making adjustments or performing
maintenance actions. Ensure that all junction box covers,
coupling guards, and equipment shields are in place before
operation.
Table 4-1. Tension Machine Troubleshooting

ITEM MALFUNCTION PROBABLE CAUSE CORRECTIVE ACTION
1 Hydraulic motor Internal damage in Disassemble motor and
(25, figure 4-1) motor. inspect. Refer to
unusually noisy. appendix D.
(See also 11,
figure 6-8.) Air leak in hydraulic Pour hydraulic fluid over
piping. piping joints while
listening for change in
sound of operation. Tighten
flanges or replace 0-rings
as required.
2 Hydraulic motor Internal damage. Disassembly motor and

(25, figure 4-1) repair. Refer to
overheating, appendix D.
3 Squeeze cylinder Ships air pressure Connect ships air to the
(21, figure 4-2) not connected. control console.
inoperative.
Defective squeeze Replace defective valve.
cylinder control
valve (158, fig-
ure 4-2).
Defective squeeze Repair defective squeeze
cylinder, cylinder.
4 Track squeeze Ships air pressure Connect ships air to the
cylinders (22, not connected. control console.
figure 4-1)
inoperative. Regulator (17, figure Adjust or replace
4-2) air pressure regulator.
less than 80 psi.
Defective track Replace defective valve.
cylinders control
valve (18, fig-
ure 4-2).
4-5
Table 4-1. Tension Machine Troubleshooting (Cont)
5 Forward dragboard Ships air pressure Connect ships air to the

cylinder (20, not connected. control console.
figure 4-1)
inoperative Ships air pressure Increase ships air pressure
less than 110 psi. to minimum 110 psi.
Defective dragboard Replace defective air
air control valve control valve.
(15A, figure 4-2).
Defective forward Replace defective forward
dragboard cylinder. dragboard cylinder.
6 Aft dragboard Ships air pressure Connect ships air to the
cylinder (23, not connected. control console.
figure 4-2)
inoperative. Ships air pressure Increase ships air pressure
less than 110 psi. to minimum 110 psi.
Defective aft drag- Replace air control valve.

board air control
valve (15A, fig-
ure 4-2).
Defective aft Replace aft dragboard
dragboard cylinder. cylinder.
7 Hydraulic motors Refer to appendix D. Refer to appendix D and
malfunction. troubleshoot, adjust, or
repair as required.
8 Brake unit Brake not completely Disassemble brake and check
overheating. released. piston travel; check for
damaged discs.
9 Brake sets during Loss or reduction of Check the filter unit for
operation. replenish pressure. restriction and the pump
for proper operation.
Electrical defect. Check the electrical circuit

of the solenoid operated
valve of the bypass and
brake valve unit. Check
hydraulic operation of
brake and bypass valve.
4-6
I- - - ' -. i m'
Stay clear of the power unit when the equipment is operating.
Shut down power unit and tag controls to prevent operation
when making adjustments or performing maintenance actions.
Ensure that all junction box covers, coupling guards, and
equipment shields are in place before operation.
Table 4-2. Power Unit Troubleshooting
1 Electric motor does Power disconnected. Check for 440 vac at motor
not rotate. starter; connect external
power.
POWER ON/OFF (discon- Set switch to ON.

nect) switch on
controller enclosure
set to OFF.
Controller enclosure Close and secure door.
door open.
POWER OFF/ON (discon- Check and/or replace as
nect) switch defec- necessary.
tive.
Wiring defective. Check wiring continuity
and replace if defective.
Contactor defective. Repair or replace operat-

ing coil or contacts.
Refer to appendix E.
Electric motor is Repair or replace. Refer
defective, to appendix E.
Drive shaft frozen. Disconnect hydraulic pump
coupling. Start motor.
If motor starts, proceed
to the hydraulic pump MAL-
FUNCTION. If motor does
not start, proceed to
other PROBABLE CAUSES.
Open, short or ground Test for open, shorted

in motor circuits, or grounded circuit and
repair.
Bearings stiff. Replace bearings.

4-7
Table 4-2. Power Unit Troubleshooting (Cont)
2 Electric motor Intake pipe blocked. Check filter (24, figure
rotates but hydrau- 4-1).
l ic pump does not
deliver oil or de- Oil viscosity too Drain tank and replace with
livers insufficient heavy, proper oil. See figure 5-2.
oil.
Drive shaft disengaged Check drive shaft, repair or
or sheared. replace as necessary.
Pump has internal worn Repair or replace as
parts. required. Refer to
appendix D.
Pump improperly Correct in accordance with
reassembled. instructions in the
appendix.
Pump is noisy. Check in accordance with
appendix D.
Pump actuator (B, Check hydraulic and
figure 4-1) not electrical inputs. Repair
functioning properly, or replace actuator as
required. Refer to
appendix D.
3 Electric motor Motor running Stop motor and restart.
noisy. single-phase. Motor should not start on
single-phase. Repair the
open circuit.
Noisy bearings. Lubricate or replace
bearings as required.
Motor housing or Realign and tighten housing
mounting bolts loose, and mounting bolts.
Debris caught between Disassemble, clean, lubri-

impeller and motor cate, and reassemble motor.
endbell.
Pump adapter coupling Check alignment and tighten
loose, coupling bolts.
4 Electric motor Bearings binding or Replace bearings. Refer to
overheated or worn. appendix E.
smoking.
4-8
4 Incorrect current or Measure voltage and

(Cont) voltage, current values.
Motor windings shorted Test for shorted or grounded
or grounded. circut and repair.
Motor shaft binding. Correct alignment with pump
adapter coupling or replace
bent stator shaft.
5 Electric motor Bearings improperly Properly lubricate or

bearing lubricated, replace bearings. Refer to
overheating, appendix E.
Bearings misaligned Replace bearings and
and binding, straighten motor shaft, if
required. Refer to
appendix E.
Motor drive shaft Correct drive shaft
binding, alignment or replace
stator shaft. Refer to
appendix E.
Motor endbells loose. Tighten motor housing bolts.

6 Pump making exces-
sive noise. Restricted or partially Inspect and clean line or
clogged intake line, replace filter elements as
strainer, or filter. necessary.
Coupling misaligned. Realign, replace oil seals
if necessary.
Shaft oil seal leaking. Inspect shaft for scoring,
replace if necessary.
Replace oil seal. Refer to
appendix D.
Air leak in intake or Locate and tighten loose

return line. connection.
Insufficient fluid Fill reservoir to prescribed

level in reservoir, level.
4-9
6 Relief valve not Adjust to prescribed setting

(Cont) properly set or or repair.
sticking.
Internal pump damage. Replace or repair. Refer to

appendix D.
7 Loss of pressure Loose connection. Check all piping and inter-

from pump. connecting hoses and flanges
for fluid leakage. Replace
all suspected seals, O-rings,
and gaskets.
8 Pump vibrates Loose foundation bolts. Tighten.
excessively.
Worn parts. Locate and replace.
Misal ignment. Real ign.

9 Pump overheats. Misal ignment. Real ign.
Incorrect level of Check level, correct as

lubricant, necessary.
Heat exchanger Inspect for formation of oil

malfunctioning. sludge, scale, and other de-
posits. Clean as necessary.
Overloading. Reduce load.

10 Abnormal wear or Failure to fill case Replace or repair worn
scoring on moving with fluid before parts. Refer to appendix D.
parts of pump. starting.
Contaminated fluid. Clean fluid to 10 micron

level or replace fluid.
Always filter new fluid.
Clean reservoir & plumbing.
Low level in Fill reservoir with clean

reservoir. 10 micron level fluid.
Use of unapproved Drain, flush, and replace

;luid or of a fluid with proper fluid of 10
with a nonrecommended micron cleanliness. See
v iscosity. figure 5-2.
4-10
10 Operation of pump Don't operate above rated

(Cont) above rated continuous pressures.
operating pressure for
sustained period.
Operation of pump with Do not operate pump under

fluid at temperatures these conditions.
not recommended by
manufacturer.
11 Foul odor emitted Hydraulic fluid has Drain reservoir and replace
from fluid remaining broken down due to with clean filtered fluid.
in reservoir tank. moisture contamination
or over heating.
4-11!(4-12 blank)
T p 05)
42 GPM
4 p 42 GPM
(I?)14) ~ (8 REPLENISH
SERVO FILTER
( AG H (19)
(171-- - -
f13) 33 TO530 PSI

(70
'A-
(REJ'L. PRESS),%
P1
- '1
117 INDICATEFU.
FLOWCAPACITI.
W10 PSI HNISON SER:ES 6 PRESSURE C MPENSATED PUMP aG ~ F8 25) C ~

REPLENISH PJMP-
SUCTiCN .4I -i'
!26, 2~
POWER UNIT '
SH-UTOFF VALVE
6Y SHIPYARD)
III~) 0'WATER IN
___________
wvAEFR OUT
-- 2-
P4
4P4I
P5420
P5
-
t P5
Ip6
14- REPLENISH
SERVO FILTER
TI
ID) -6 D5 D4
7.6 GPM,
II HP
F8~28 i 2 s!
r2)
IINOICAT FIL
-4 LE1S I- 4-4 -t-

I , I I
-F 125--- C_ , • 2--
3) I 0.O.HB. MACHINE ____________
121 033162)3F 1A7
1 j_29I SEE ITEM LIST AND

] / ' REFE RNCE DWS.
94JT "jFF VALVE SHT. .'
BY SH4IPYAR) Y
WATERIN wATER OUT
Figure 4-1. Hydraulic Schematic

... .-.- 4 1 = n (Sheet 1 of 2)
-- ,(
, 4-131 (4-14 blank)
ITrN PARTOR
U. WWENCLATURE QTY 0O.NME
01G. F O
USEO
I J77501 MARSH 38 0314131

10 GUAGE30O PSI
11 GUAG 3000PSE I J'3777T S 3 D316131
GUAGEO PSI I J778 NW IN 0316128

12
I3 5A .vM0PSI 2 J7178 PARM5 12 0316128
IN GUAGE1300PSI I J7S72 8RSH 13 0316128
Is FLOWCONTROL
VALVE I F-375--OC REGON.N 1 03146
16 VALVE
OIECTIONAL I 4S"'-K-SO VICKERS 16 0316128
37 NEW.1.VALVE 0 M3432 1ARSM 9 0316128
is FILTERREPLIN. I 3O?977 N&C 6 0316120
19 VALVE
CONTROL
FLOW I F600S PARKER 2 0316L"
20 ELECTRICOTOR 1 A3078%5 wC 3 D316128
21 THEMoVAL'E I IA C
MODEL CONTROLS
N/IOT 8 0316128
22 FILTERRETURN' 1 A307918 WGC 5 0316128

23 4EAT£004 8CNT-6 YOUNG 10 0316128
24l FILTERSUCTION I A307919 WGC 4 0316128
2S PUMP
HYDRAULIC I A307924 MGC (DENISON) It 0316128
I 22SSE2T1
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0316128
26 HEATER
27 MOTOR
HYORAULIC 2 MF05-020-31 DENISON 14 D316127
28 HIDRAULIC
RRAKE 2 0316127
29 IESERVOIR 1 0316390 WGC 2 0316128
EFEENCEORAINS:
1. WGC OG. NO. 031605
OUTLINE& GENERAL
UGUINGEMETKAIA UC
2. WGC 0 . NO. D316-3
PNEUMATICSCHEMATIC
D316371
Figure 4-1. Hydraulic Schematic (Sheet 2 of 2)
4-15/(4-16 blank)
ITEM PARTOR
NO, NOMENCLATURE J . o.
oTY NAME F/ dSED ON
10 SHUT OFF VALVE I 9Z598-3PO CIRCLE SEAL I 0316203
11 FILTER I PF7502-11004 iABCO I 0316233
12 REGULATOR I PRTS64-31004 WABCO 1 0316203
13 LUBRICATOR I P67602-24004 WABCO I 0316203

|4 GuAE 5 J77sP MARSH 37 0316131
is CONTROLUIRVALVE --
MOOELHC-2-FX 2 PSO976-0002 WASCO I4 0316131
I1 REGULATOR I PR756-1003 WASCO If 0316131
Is CONTROLAIR
MOEL H-2-FX -VALVE I P G904-0002 WARCO 13 0316131
20 ORA-8 CYLINDER 1 LW 4-I/ HANNIFIN 24 0316127
21 -LFUER SQUEEZE IIFRMED200,537 WGC 98 0316127
100o[ 22 TRACKSQUEEZE
CYLINOER I C200,697 WGC 122 0316127
23 0RAGBOCYLINOER I Lm 1-1/a HANNIFIN 2N 0316127
oP1i
SHIPS
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(DRY o 11 1) 12
too PSI Il
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ORI 7602-2.04' wABCO I 036203
5 750 MARSH 37 D316131

10 VALVE( 2 PW1-M WASCO 0u 0316131
PR7564-iT003 W48CC 11 0316131

R
VALVE 1 P50494-0002 WASCO 13 D316131
2-Fx_______
T , -1/2
WlE HNNIFIN 2111 0316127 REFERENCE DRAWINGS;
SQUEEZE 02057 C 98 0316127 I.WGC. DWG. NO. D313405
-E7 OUTLINE ff GENERAL
-(U Ln.(g.6i IC200,697 wGC 122 0316127 ARRANGEMENT NAUaL C
LW4-1/2 HANNIFINI 24 0316127 2.WGC. DWIG. NO. c-,316371
LI1.OER I
______ ______ HYDRAULIC SCH-EMIATIC
NAUBUC
,k 0piC9 094
' (Tfj22)
(14)6=
UI
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_________ DCHB MACH~INE __
D316383
Figure 4-2. Pneumatic Schematic
J, 4-17/(4-18 blank)
POER 10 107- SE35
OFF ON- - PRESS
T33-1 FI ro-2 M4-1 1114 ~1 mi-2 0

m?-!
Id Z POWERII
102 IAT4 slot EIPRS
0203
LAW TEST 112?K
RELAYAIR PRESS
90 PSI
171 1 4 - 1 0~5 1 1 6 S0
It9- 1815- S0213 ThS- VlI ThiS' K
51
B-0% 13 KS-i 1003 Ti-1 1 KSl ;B TBSPTM
-1
1 11T ms-iai mOS-r 03i 10221
START TB36-lPEE
7 BSN K2 1365-9
20-q F I2
KK2
510-1 12-I KA2 T3 -0T8 u T
TOC Su 2
116
itEM R EV TATU
RESE EFIE
111 10 4
PRRESS
517-2 Ila 19 RES
RELAY PRETSS:
\ PRES
3.RCOSLKIIGDORO 363
AIR PRIRE NDS1ER

NOTES:IO
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LO-1 0NI3 MTORC1 TR1.R
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T117E1 1 -1 3 ' -2 R -61 123 LC 13-
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HEATER NEATER
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01 _-_ D316126A
113 TBI"
Figure 4-3. Electrical System Schematic

(Sheet 2 of 3)
4-21/(4-22 blank)
1' %
___________
_______________
- ELECTRONICS
TSi ACHINE JOX REF.ONG NO, 1311463
COKTRQI
LOADlTaAR (IAOvtOLB) MACHINETENSION

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INAU S______
PO- G- (Set (3) 491 (-
-21 lak
SECTION V
MAINTENANCE
5-1. INTRODUCTION.
5-2. This section of the manual contains instructions for preventive and cor-
rective maintenance of the DOHB tension machines and power unit. Major compo-
nents of the tension machine are identified in figure 1-1. Refer to the
appendix at the back of the manual for maintenance procedures relating to vendor
suppl ied equipment.
5-3. SAFETY PRECAUTIONS.
WARN~M
High voltage in the DOHB tension machine power unit is suf-

ficient to cause death.
1. Follow standard safety precautions when working on electrical, pneumatic,

hydraulic, and mechanical equipment.
2. Before repairing electrical components, ensure that electrical power

source is OFF and tagged. If absolutely necessary to have the power applied,
use instruments rated for high voltage.
3. Tag the control panel, motor controller, and equipment O0 NOT ENERGIZE
when performing maintenance.
4. Ensure that the work area is safe and clear of unnecessary personnel and
equipment.
5. Before disconnecting hydraulic or pneumatic lines, depressurize the
system and slowly bleed pressure from the lines.
5-4. PREVENTIVE MAINTENANCE.
5-5. Preventive maintenance consists of maintaining the equipment in clean,

ready-to-operate condition. A good preventive maintenance program can reduce
the frequency of unscheduled repairs and down time caused by equipment failure.
Therefore, to ensure trouble-free service of the DOHB tension machines and power
unit, a scheduled maintenance procedure shall be followed in accordance with
table 5-1. Thus potential malfunctions and defective parts can be found before
they cause trouble and/or equipment breakdown. Also, a lubrication and main-
tenance log shall be kept with entries made of all lubrications and maintenance
actions performed.
5-6. INSPECTION. Periodically inspect the tension machines and power unit in
accordance with table 5-2. Inspect internal parts whenever disassembly is
required for repair or replacement. Disassembly is not required unless there is
a known malfunction or a suspicion of one.
5-1
Table 5-1. Preventive Maintenance Schedule
TIME SCHEDULE PROCEDURE
Prior to initial startup. Fill hydraulic motor and hydrulic pump
housings in accordance with figures
5-1 and 5-2.
Prior to every operation. INSPECT:
a. Tension machines and power unit
surfaces for dirt.
b. Tension machine and power unit for
excess buildup of grease.
c. Tension machine and power unit for
foreign objects.
d. Tension machine and power unit for
security of mounting.
e. Tension machine and power unit com-
ponents for security of mounting.
f. Gear reducers oil level.
g. Electric motors for blockage of
cooling air and evidence of mis-
alignment, bearing wear, or
overheating. Clean and repair as
necessary.
h. Pneumatic and hydraulic lines,
fittings, and connections for
leaks, abrasions, cracks, and other
damage and deterioration.
j. Hydraulic tanks fluid level.
k. Controls for ease of movement.
During operation. INSPECT:

a. Cable for proper lay.
b. Hydraulic and electric motors for
signs of overheating.
After operation. INSPECT:

a. Tension machine and power unit com-
ponents mount bolts for security.
b. Gear reducers oil level.
c. Hydraulic tanks fluid level.
Every 100 hours of operation. INSPECT:

a. Machinery outer surfaces for rust,
corrosion, paint scaling.
b. Bare exposed surfaces for proper
coating of grease (completely
covered).
c. Machinery for excessive buildup of
dirt.
5-2
Table 5-1. Preventive Maintenance Schedule (Cont)
TIME SCHEDULE PROCEDURE
Every 100 hours of operation. INSPECT:

(Cont) d. Mount bolts for security.
e. Condition and tension of tracks.
Take up tension where required and
maintain sprocket alignment. Keep
these parts clean and well
lubricated.
f. For loose connections or clamps and
damaged wiring. Repair or replace
as necessary.
g. The electric motor for blockage of
cooling air and evidence of mis-
alignment, bearing wear, or over-
heating. Clean and repair as
necessary.
h. Components for visible structural
damage.
j. Controller enclosure for mechanical
and electrical integrity. If dust,
lint, or other foreign matter is
present, deenergize the equipment
and remove the foreign matter. Use
a vacuum cleaner if available.
LUBRICATE:
Tension machine components as required
in accordance with figure 5-1.
After first 150 hours of operation. Drain and refill reducers in accordance
with figure 5-1.
Every 6 months. Replace system suction filter element
(D, figure 5-2 and 58, figure 6-8).
As required by operating conditions Lubricate electric drive motor.
(see appendix).
Annually. Drain and clean hydraulic system.
Replace hydraulic fluid in accordance
with figure 5-2.
Every 2,500 hours of operation. Drain reducers and check for the
presence of metal particles. If metal
particles are found, inspect to deter-
mine the source. Disassemble and
repair as required. Refill reducers
in accordance with figure 5-1.
Every three years. Disassemble, clean, and repack the
power unit coupling in accordance
with figure 5-2.
5-3
Table 5-2. Inspection Guide
1. DOHB tension machines. Inspect for rust and chipped paint.

Remove rust and scale and touch up
paint where required. Periodically
clean and lubricate. Check for over-
all security c. subassemblies,
mounting fasteners, and adjustments.
Tighten all loose nuts and bolts and
ensure that track adjustments are
secure.
2. Power unit. Inspect for rust and chipped paint.
Remove rust and scale and touch up
paint where required. Check for
accumulated dirt, grease, and oil,
especially around moving parts.
Remove excess lubricant and foreign
material.
3. Hydraulic and pneumatic piping, Check for leakage. Depressurize the
flanges, and connections, system and check leaking connections
for security. Tighten loose fittings.
Replace O-rings and/or fittings where
neces ,ary.
4. Hydraulic pumps and motors Inspect for evidence of leakage.

shaft seals. Replace shaft seals if leaking.
5. Hydraulic pump and motor. Check for unusual noises, vibration,
and overheating. Check mounting bolts
to ensure that units are secured.
Check areas around shaft bearings for
overheating by feeling with your hand.
Unusual noises from a pump or motor
may be caused by air in the system or
by cavitation.
WAING
To prevent injury to personnel cr damage to the equipment,

stay away from machine movinq parts when the equipment is
i7 operation. Shut down the power unit(s), switch off
electrical power, and attach tags to controls to prevent
operation when making adjustments and repairs.
5-4
5-7. CLEANING AND PARTS INSPECTION. Observe the following precautions when
cleaning machinery components and detail parts.
Do not breathe cleaning solvent vapors. The toxic effect

of some solvents is cumulative. Continued inhalation may
lead to permanent disability or death.
When using flammable cleaning solvents, take all appropri-
ate fire safety precautions to prevent injury to personnel
and damage to equipment.
Do not direct compressed air against any part of the body.

High pressure air can cause injuries. Do not rotate ball
or roller bearings with compressed air. Do not direct com-
pressed air against a fire; this will spread the fire and
increase the rate of burning.
5-8. Clean all metal parts using a treated or refined solvent which has a
boiling range of 310 to 400OF (160 to 2050 C) and a flash point above 100°F
(38°) (Shellsol 345, Stoddard solvent, Federal Specification P-D-680 or
equivalent). Use a fiber bristle brush where necessary. Dry parts with a
clean, dry cloth or clean, dry compressed air. Turn ball and roller bearings by
hand only. When parts are exposed during disassembly, perform the following:
1. In gears and shafts, check the fit of all keys in respective keyways.
Replace worn keys. Oversize keyways may be fitted with oversize keys and should
be machined if necessary.
2. Inspect pistons, cylinders, and rods of hydraulic components for scored
areas, scratches, cracks, and evidence of foreign material. Remove all
scratches and nicks in cylinders, pistons, and rods of hydraulic equipment only
if the repaired area will not interfere with operation of equipment or cause
leakage. Otherwise, damaged parts must be replaced.
3. Inspect all ball and roller bearings and races for cracks, chips, cor-
rosion, brinneling, and other signs of fatigue and abnormal wear. Bearings
should rotate freely and smoothly by hand. Bearings are not reparable and must
be replaced if defective in any way.
4. Check bushings for damage and excessive wear. Minor damage may be re-
paired by filing and burnishing to a finish equal in smoothness to the
original.
5. Check gears and shafts for broken teeth, nicks, cracks, and abnormal
wear. Repair damaged areas by filing or grinding smooth and sanding to a finish
5-5
equal in smoothness to the original. If damage cannot be removed without affec-
ting the strength, reliability, or safety of the part, or the subassembly as a
whole, the damaged part must be replaced.
6. Replace all gaskets and O-rings of components which are disassembled.
5-9. LUBRICATION. Lubricate the DOHB tension machine and power unit
components in accordance with figures 5-1 and 5-2.
5-10. FLUID MAINTENANCE.
5-11. INTRODUCTION. Optimum life from the hydraulic equipment supplied by

Western Gear Corporation to its customers can be obtained only with proper hy-
draulic fluid maintenance. This includes checking the fluid at the time of
installation and at properly determined intervals thereafter. The fluid should
be evaluated for: (1) particle contamination, (2) water contamination, (3) pH
value, and (4) viscosity. Of all of the fluid qualities which must be evaluated
in a properly maintained hydraulic system, control and detection of particle
contamination can be the most critical. Most hydraulic fluids are expensive and
changing the fluid in a system and flushing or cleaning an improperly maintained
system is costly and time consuming. Therefore, it is very important to ensure
proper fluid cleanliness levels. Keeping fluid clean and free from particle
contamination can be achieved in a properly executed fluid maintenance program.
5-12. FLUID STORAGE AND HANDLING. To prevent contamination of hydraulic fluid

during storage and handling, follow these simple rules:
1. Store drums on their sides and, if possible, keep them inside or under a
roof.
2. Before opening a drum, clean the top and bung thoroughly so that no dirt
can get into the fluid.
3. Use only clean containers, hoses, and other equipment to transfer fluid
from a drum to a hydraulic reservoir. Use a transfer pump equipped with a
proper micron filter (nominally 10 microns or finer). The hose between filter
and reservoir must be given special attention.
5-13. IN-OPERATION CARE. Proper hydraulic fluid maintenance includes the

following:
1. Keep the reservoir filled to the proper level to prevent moisture from
condensing on inside walls and to take advantage of a full reservoir's heat
dissipating characteristics.
2. Repair all leaks immediately. Prevent contamination by keeping the

system tight.
3. Establish a fluid sampling interval in accordance with the procedures

given in paragraph 5-14.
4. Establish a fluid change interval so as to replaLe fluid before it breaks

down. Use the fluid sampling data as a guide to establishing change intervals.
5-6
5. Establish a filter maintenance schedule which is compatible with the con-
ditions under which the equipment is operated.
6. Do not operate the system unless all filtration devices are installed and
properly serviced.
7. When changing filter elements, inspect the elements and filter housings
for particles (size, material, or quantity) which may indicate impending com-
ponent failure.
8. Watch and listen to the system operate. Investigate unusual actions or
sounds that could indicate problems.
5-14. HYDRAULIC FLUID SAMPLING. System hydraulic fluid must be sampled period-
ically during operation to determine that the fluid meets cleanliness levels
specified for the system. When taking samples, observe the following procedure:
1. Take the sample from the system's main loop and sufficiently down stream
from the power unit(s) to ensure that a true sample is acquired. Use only sur-
gically clean sample bottles (bottles can be obtained from WGC or drug supply
house).
2. Allow enough fluid to run out at the sampling point to thoroughly flush
the valve and piping before the sample is taken.
3. Take the first sample before operation under load is begun. If the
cleanliness level does not meet the required level specified, refilter the fluid
to the required cleanliness level before proceeding with operation under load.
When refiltering the fluid, use the equipment's filtration system or an auxil-
iary filtration system. Use a centrifuge, if necessary, to remove excess
moisture.
4. Take another sample within one hour of starting operation under load.
Again, filter the fluid if necessary.
5. Take another sample after four hours of operation under load. If this
sample is satisfactory the system can be considered acceptable for service.
6. Take samples at weekly intervals for three or four weeks to verify that
the system is continuing to remain in satisfactory condition.
7. If the weekly samples are satisfactory, check the cleanliness level on a

monthly basis to assure that the system fluid remains in satisfactory condition.
8. At yearly intervals (6 months if the oil operating temperature exceeds

160°F/71.1*C), make a complete laboratory analysis of the fluid to verify that
viscosity, pH value, and strength of additives (if any) remain within the
supplier's tolerances.
9. See table 2-1 for the maximum contamination limits allowable for the
hydraulic fluid to meet various classes of NAS 1638.
5-7/(5-8 blank)
X ORAIN.-FAA SIDE
- U.PPEA BELT
A R-EFI O
-RELEF FITINGAPP. AT UNIT NAME
C Z 6~p;VE SHAF T
Ld AF -T
F r#,F'z r _E S-AFT
i; : ILEA S-AFT
C'AI
LS 5,W__T
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Q, LT~ " 4P
Vl'EP NAf:
Z R____
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~C.OSG
EC1Y
EV I ,.EI __' __
7 -. _qE -4
2. TWO (2' :UPLINGS.CdE FITTING ON EACH.

5. SIX (6) FITT NGS C9N Er.-m SIDE OF FRAME.
4. 'NELVE ('Z' FIT rINGS 'N~ EACH S 'E OF FRAME.
3. 04 FI - N7 , . ~
-- I - 1IT F-r -1ELT.
A U6. PACK aPA..E BLTWEN BEASHN55 AT AbSSEMOLS.

(TYP 3 CY,-NOERS'
7. FILL ANO MA'NT,%'N OIL LEVEL WITH'N T
.25 '%CH
'-AN~r OIL AF ER FIRST
~
x 011AIN-FARIOEOF
ORAN.. AR SlE150
OI1 LFV:L
HRS.
PORT.
PE. 471CH ANO EVERY 2500 .- R5.
CP
THEPEAF .E R.
e. REFILL A L. SEAOING f CIEFS(XVOI- S AN-
XCIL LEVEL C-7AT 1
AA FILL
UPPER
BELT
REF I'~ LOWER BELT -LOEFRAM
(REF) IP
SECTION A-A
0
FITTING AT UNIT NAMEN_7 'T5 TA- ( SPEC SYMBCLI FREQUENCYOF LUSeE
________~~ A~~AE L ~ SE .. P EOO

AS___ _____ '0PMS OF SERVICE
VImELT~O
C ..L'sSP OP'NE SHAFT 1

FM I-ASE. ASSF00 ____
E 'F 's SHAPT 'Lf'III _:E_____

0 F 'ro#%5A L...ERSS .AFT A'-MITE 'E '
05PmIDER SHLAFTI 11-- . 4 S,-EO _____ _____
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SCrz S HF EEJ. AS ______
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AC ZiIAL
01 5-__(5-1 blank)
PLANVIEWPOWE UNI
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G.REASE ITEONEHLEMUNTI LEIANNGRASEY APPWEAR
I-CNTHET HE DINAEAB.LSISEVERAN
REPACK EVERY THREE (3) YEARS.
AF OFPRIN
NM LUBRICATION INSTRU TIONS ______________
NAM F - TYP KIND T S PEC SYMBOL FEQUENCY OF LUBE
HYDRAULIC PUMP - I DRAIN PIEOOI A IL-L-177 2110 TH NT
HY R ULICRESERVOIR I_ ILR AIPI :MTT7 211 MNTI ILEE
P' L U _ __ _ NOTE
IPE PLUG GRES A-S p ___ HI MELT 403~7 "-E
RIIOT F TO JU IN__ _ I
D316406
Figure 5-2. LubrIcation Diagram - DOHB Power Unit
5-11
10. Refer to appendix B for procedures to perform the particle count.
5-15. CORRECTIVE MAINTENANCE.
5-16. INTRODUCTION. Remove and disassemble only to the extent necessary to

perform required maintenance actions, repair, or replacement procedures. Before
disassembling a component suspected of malfunctioning, operate it under load if
possible and determine the trouble. Refer to the troubleshooting tables in sec-
tion IV for additional information. When disassembling hydraulic components,
prevent contamination and loss of fluid by capping all open lines and fittings
after disconnection. Assembly procedures are, with few exceptions, the reverse
of disassembly procedures. Tighten all fittings and fasteners in accordance
with standard tightening procedures unless otherwise noted.
WAR,GI
Before removing hydraulic and pneumatic components, remove
electrical power and pneumatic/hydraulic pressure and tag
system controls to prevent operation. Depressurize the hy-
draulic and pneumatic systems and slowly bleed pressure from
the lines before disconnecting.
5-17. UPPER OR LOWER TRACK REMOVAL. See figure 6-2. Some repair actions will
require the removal of the track from the upper and/or lower track assembly.
Remove a track as follows:
NOTE
To remove the lower track, raise the upper frame and

secure in the raised position.
1. Loosen the track by adjusting the track tightener adjusting screw (6),
figure 6-1.
2. Unfasten two hex head bolts and jam nuts (1 and 2, figure 6-2), securing
pad (7) on two adjacent links.
3. Remove both pads (7) and support plates (10).
4. Remove a pipe plug (3) and insert a special tool with an 1/8-27 NPT male
threaded end. Attach tool to track pin (6) and pull out.
5. Remove other pipe plug (3) and track pin (6).
6. Separate track links (9) and remove the track.

7. Reinstall the track in the reverse order of removal.
5-18. IDLER SHAFT DISASSEMBLY. See figure 6-1. Remove either idler shaft (73)
as follows:
1. Remove the track in accordance with paragraph 5-17.
5-12
2. Remove six capscrews (33) and lockwashers (34) securing each bearing cap
(60 and 74) and remove the bearing caps. This exposes bearings (61).
3. Unfasten snapring (79).
4. If upper idler shaft (73) is being removed, remove two nuts (39),
lockwashers (38), and bolts (37) securing each end plate (9) and remove the end
plates.
5. Support idler shaft (73) and slide the idler assembly forward until
bearing housings (72 and 78) are free. Take care not to lose compression
springs (8).
6. Remove bearing housings (72 and 78) along with bearings (61) and seals
(53).
7. Use a bearing puller to extract bearing (61) from the bearing housing (72
or 78) when necessary for replacement.
8. Press out seals (53) from bearing housings (72 or 78) when necessary for
replacement.
9. Remove idler shaft (73) with sprockets (5), and sprocket hub (55)
attached.
10. Remove bolts (88), nut (39), and lockwashers (38) securing sprockets (5).
Remove both sprockets (5) and keys (56) from idler sprocket hub (55).
11. Press idler shaft (73) from sprocket hub (55).

12. Inspect and replace or repair damaged or worn idler shaft components.
Then reassemble the idler shaft in the reverse sequence of disassembly.
5-19. DRIVE SHAFT DISASSEMBLY. See figure 6-1. Remove either drive shaft (59)
as follows:
1. Remove the track in accordance with paragraph 5-17.

2. Unfasten the capscrews and separate coupling (47) halves.
3. Remove six capscrews (33) and lockwashers (34) securing bearing cap (60)
and remove the bearing cap. Remove snapring (79).
4. Support the drive shaft assembly.

5. Remove four capscrews (151), nuts (80), and lockwashers (22) securing
bearing housing (58). Remove bearing housing (58) with bearing (61) and seal
(53). When necessary for replacement, use a bearing puller to extract the
bearings; and press the seal out of the housing.
5-13
6. Remove six capscrews (33) and lockwashers (34) securing cover (49).
Remove four capscrews (151), nuts (80), and lockwashers (22) securing bearing
housing (52).
7. Carefully move drive shaft (59) outboard and remove coupling (47) half,
key (48), bearing cover (49), and bearing housing (52) from drive shaft (59).
Seal (50) may be pressed from cover (49) when necessary for replacement. When
necessary for replacement, use a bearing puller to extract bearing (61) and
press seal (53) out of bearing housing (52).
8. Remove drive shaft (59), sprockets (5), and sprocket hub (55).
9. Remove bolts (88), nuts (39), and lockwashers (38) securing sprockets
(5). Remove both sprockets (5) from sprocket hub (55).
10. Press drive shaft (59) from sprocket hub (55).
11. Inspect and replace or repair damaged or worn drive shaft components.
Then reassemble the drive shaft in the reverse sequence of disassembly.
5-20. UPPER SUPPORT ROLLERS DISASSEMBLY. See figure 6-1. Remove and dis-
assemble upper support rollers as follows:
1. Remove the upper track in accordance with paragraph 5-17.
2. Remove two bolts (44), lockwashers (34), and nuts (42) securing each
upper pillow block (43). Remove pillow blocks (43) and pressure rollers (71).
3. Remove retainers (170) and remove pillow blocks (43) from pressure roller
(71).
4. Repair or replace any damaged components. Reassemble the pressure roller
in the reverse sequence of disassembly.
5-21. UPPER PRESSURE ROLLERS REMOVAL AND DISASSEMBLY. See figure 6-1. Remove
and disassemble the upper pressure rollers as follows:
1. Remove the upper track in accordance with paragraph 5-17.
2. Remove snapring (66) and washer (65) from each end of rocker shaft (64).
3. Remove a grease fitting (45) from either end of shaft (64) and tap out
the shaft from upper roller frames (19).
4. Remove the upper pressure roller assembly.
5. Flange bushings (67) and bushings (68) are exposed.
6. Disassemble the upper pressure rollers in accordance with paragraph 5-24.

7. Reassemble the upper pressure roller assembly in the reverse sequence of
disassembly.
5-14
- - •
5-22. TRACK CYLINDERS DISASSEMBLY. See figure 6-1. Remove and disassemble the
track cylinders as follows:
1. Remove the lower track in accordance with paragraph 5-17.
2. Refer to paragraph 5-23 and remove the lower pressure roller assemblies.
3. Disconnect lubricator hose (155) to cylinder head (119).
4. Disconnect connector (156) and tubing (157) to cylinder head (119).

5. Support the cylinder before continuing disassembly.
6. Remove four capscrews (35) and lockwashers (22) securing each cartridge
(130). Carefully remove cartridges (130) from cylinder head (119). Removal of
the cartridges exposes bushings (132) for replacement.
7. Remove the track cylinder from lower frame (2).

8. Remove eight nuts (42) and lockwashers (34) from studs (41) and separate
cylinder heads (119 and 123). This releases cylinder (122) with O-rings (128)
and exposes the internal cylinder components.
9. Remove cotter pin (102) and slotted nut (101). Then remove lockwire
(169) and capscrews (168) from spacer (164) and remove along with piston (121).
O-ring (129) may be replaced when required.
10. Piston rod (120) may be removed from cylinder head (119) to expose flange
bushing (131) and seal (127) for replacement when worn or damaged.
11. Inspect and repair or replace damaged or worn cylinder components. Then
reassemble the cylinder in the reverse sequence of disassembly.
5-23. LOWER PRESSURE ROLLERS REMOVAL. See figure 6-1. Remove the lower
pressure rollers as follows:
2. Support equalizer frame (18).
3. Remove snapring (66) and washer (65) from each end of roller frame
shaft (69).
4. Remove a grease fitting (45) from either end of shaft (69) and tap the
shaft out of frame (18), drag link (118) and cylinder shaft connection.
5. Remove equalizer frame (18) and roller assemblies.
6. Flange bushings (70) and flange bushings (67) are exposed for
replacement.
5-15
7. Disassemble the lower pressure rollers in accordance with paragraph 5-24.
9. Support drag link (118). Remove a grease fitting (45) from either end of
shaft (64) and tap the shaft out of lower frame (2) and drag link (118).
10. Remove drag link (118). Flange bushing (67) and bushing (68) are exposed
for replacement.
11. Inspect and replace or repair damaged or worn shaft components. Then
reassemble in the reverse sequence of disassembly.
5-24. PRESSURE ROLLER DISASSEMBLY. See figure 6-1. With roller frame removed
from machine, disassemble each pressure roller assembly as follows:
1. Remove four capscrews (115) and lockwashers (116) securing each retainer
(113). Remove retainers (113) and shims (145).
2. Remove four capscrews (91), four lockwashers (116), one capscrew (153),
and one lockwasher (34) securing each bearing cap (112) and remove the bearing
caps. This releases rollers (111) with associated components.
3. Remove rollers (111) from equalizer frame (18).

4. Remove bearings (108) and seals (110).
5. Sleeves (109) are secured to rollers (111) with loctite sealing compound
and, if worn, must be removed by grinding.
6. Inspect and replace or repair damaged or worn roller assembly components.
Then reassemble the rollers in the reverse sequence of disassembly.
5-25. LOWER ROCKER SHAFT REMOVAL. See figure 6-1. Remove the lower rocker
shafts as follows:
2. Support equalizer frame (18) assembly.
4. Remove a grease fitting (45) at either end of rocker shaft (64) and tap
out the shaft from lower frame (2) and drag link (118).
5. Flange bushings (67) and bushings (68) are now exposed.

6. Inspect and replace or repair damaged or worn rocker shaft components.
Then reinstall the rocker shaft in the reverse order of disassembly.
5-16
5-26. SQUEEZE AND LIFT CYLINDER DISASSEMBLY. See figure 6-1. Disassemble the
squeeze and lift cylinder as follows:
1. Remove plumbing to squeeze and lift cylinder (98).

2. Remove snapring (104) and plain washer (103) securing pin (106) to clevis
(92) at top of cylinder. Tap out pin (106). This releases clevis (92) and
lever (82). Bushing (105) and flange bushings (107) are exposed for replacement
as necessary.
3. Unscrew clevis (92) from piston rod (97).

4. Support cylinder (98). Remove snapring (104) and plain washer (103) se-
curing pin (106) at bottom of cylinder. Tap out pin (106). This releases main
pressure cylinder (98). Bushing (105) and flange bushings (107) are exposed for
replacement as necessary.
5. Remove main pressure cylinder (98) to a convenient work area.
6. Remove 12 capscrews (154) and lockwashers (34) securing cylinder head

(94). Remove cylinder head (94) and piston rod (97) from main pressure cylinder
(98). This exposes O-rings (100 and 95) for replacement when necessary.
7. Remove cylinder head (94) from piston rod (97). Bushings (93) and seal
(96) are exposed for replacement as necessary.
8. Unfasten cotter pin (102), unscrew slotted nut (101) and remove piston
(99) from piston rod (97).
9. Inspect and replace or repair damaged or worn squeeze cylinder com-

ponents. Then reassemble the squeeze cylinder in the reverse sequence of
disassembly.
5-27. FORWARD OR AFT DRAGBOARD POWER CYLINDER REMOVAL. See figure 6-1. Remove
the forward or aft dragboard power cylinder as follows:
1. Disconnect the plumbing to air power cylinder (24).
2. Unfasten the snaprings (23) and remove the pins (12) to release rod end
knuckle (25). Swing lever (75) out of the way.
3. Remove air power cylinder (24). Inspect, replace, or repair damaged or
worn power cylinder components. Refer to appendix C for maintenance
Information.
4. Install the power cylinder in the reverse order of removal.
5-17
5-28. DRAGBOARD REMOVAL. See figure 6-1. Remove aft dragboard as follows:
1. Remove snapring (32) and washer (31) securing each dragboard (54 and 57)
to pin (17), and remove the dragboards. This exposes flange bushings (30) for
replacement when necessary.
2. Remove air power cylinder (24) in accordance with paragraph 5-27.
3. Remove lower snapring (29) from lever shafts (15) and remove levers (75
and 77) and stabilizer (76) as a unit.
4. Remove upper snapring (29) from lever shafts (15) and remove levers (14
and 16). Take care not to lose keys (28).
5. Tap out lever shafts (15). Flange bushings (26) are now accessible for
replacement if necessary.
6. Replace or repair dragboard components and reassemble in the reverse
order of disassembly.
5-29. UPPER AND LOWER REDUCER REMOVAL. See figures 6-1 and 6-5. Maintenance
actions which require disassembly of a reducer or brake assembly, require the
removal of the reducer from the tension machine. Remove a reducer assembly as
follows:
1. Drain the lubricating oil from the reducer housing (140, figure 6-1).
2. Disconnect all interconnecting hydraulic lines at the reducer. Cap open
fittings and ports.
3. Separate coupling (47) halves.
4. Attach a sling to the reducer assembly for support and movement.
5. Remove six capscrews (82, figure 6-5) and lockwashers (85), two nuts
(92), capscrews (83), and lockwashers (94).
6. Remove the reducer to a convenient work area.
7. Installation of the reducer assembly is the reverse order of removal.
5-30. REDUCER DISASSEMBLY. See figure 6-5. After the reducer has been removed
from the tension machine to a convenient work area, disassemble as follows:
1. Remove speed control lever (14) by removing cotter pin (53), washers
(54), pin (28) retainer ring (52), and pin (27). Remove eight capscrews (75),
lockwasher (865, and bracket (15).
2. Remove hydraulic motor (73) by removing four capscrews (80) and lck-
washers (88). Remove coupling (66) and key (31) from motor shaft. Refer to
appendix D for motor repair information.
5-18
h
3. Remove eight capscrews (90) and lockwashers (89) and remove adapter
housing (3). Remove male coupling (65) and key (31) from high speed shaft (4).
4. Invert the reducer assembly and remove the brake assembly in accordance
with paragraph 5-31.
5. Remove eight capscrews (76), lockwashers (86) and nuts (93). Tap out two
dowels (101) and remove reducer base (2).
6. Remove spur pinion shaft (6) from housing (1).
7. Use a bearing puller to remove bearings (40) from shaft (6).

8. Press off helical gear (8) from shaft (6) and remove key (33).
9. Inspect and repair or replace any worn or damaged spur pinion shaft com-
ponents. Then reassemble the shaft in the reverse sequence of disassembly.
(24) and remove the retainers and shims (44). Remove the bearing cups for
bearings (40).
11. Remove output shaft (7) from housing (1).
12. Use a bearing puller to remove bearings (41) from shaft (7).
13. Press off spur gear (9) from shaft (7) and remove key (30).
14. Inspect and replace or repair any damaged or worn output shaft compo-
nents. Then reassemble the shaft in the reverse order of disassembly.
(12 and 13) and remove the retainers and shims (45). This exposes seal (46) and
bearing cups for bearings (41).
16. Remove four capscrews (75) and lockwashers (86) securing retainer (23)
and remove retainer and shims (43). This exposes the bearing cup for bearing
(38).
17. Loosen jam nut (95) and setscrew (51) to release spring (50) tension on
detent ball (49). Remove jam nut (96) and capscrew (26). The ball and spring
may than be removed.
18. Remove four capscrews (75) and lockwashers (86) securing retainer (25)
and remove the retainer with seal (47) from shift rod (16).
19. Unfasten lockwire (97) and four capscrews (84) to release fork (68).
20. Tap out shift rod (16) from reducer housing (1) and remove fork (68).
This exposes bushings (48).
21. Inspect and replace or repair any damaged or worn clutch components.
5-19
22. Remove intermediate pinion shaft (5) from reducer housing (1) along with
high speed shaft (4) and associated parts.
23. Use a bearing puller to remove bearings (38 and 39) from pinion
shaft (5).
24. Remove gear (11) and clutch collar (20) from shaft (5). This exposes
bushing (18).
25. Press off clutch spline (21) from shaft (5) and remove key (35).
26. Remove gear (10) from shaft (5). This exposes bushing (19).
27. Inspect and replace or repair any damaged or worn intermediate pinion
shaft component parts. Then reassemble the shaft in the reverse sequence of
disassembly.
28. Use a bearing puller to remove bearings (37) and grease rings (29) from
high speed shaft (4).
29. Press off gear (17) from shaft (4) and remove key (32).
30. Inspect and replace or repair damaged or worn components of the high
speed gear shaft. Then reassemble the shaft in the reverse sequence of
disassembly.
31. After all internal components of the reducer have been inspected and re-
paired or replaced, reassemble the reducer in the reverse order of disassembly.
5-31. HYDRAULIC BRAKE DISASSEMBLY. See figure 6-5. Disassemble the hydraulic
brake as follows:
1. Unfasten union nuts (98) and remove tubing (100).

2. Remove six capscrews (77) and lockwashers (86) and remove spring housing
(57) and cylinder cap (61).
3. Unfasten four capscrews (78) evenly and slowly release the spring load on
cylinder cap (61). Remove cpascrews (78) and lockwashers (86).
4. Remove cylinder cap (61) from spring housing (57). This exposes O-ring
(70) for replacement when necessary. Note location of ten springs (63) in
spring housing (61) and remove the springs.
5. Remove lockwire (97) and three capscrews (79) and remove piston (60) from
backing plate (62) and spring housing (57). This exposes O-rings (69 and 71)
for replacement as necessary.
6. Remove brake gear housing (56). Remove six friction plates (58) and five
separator plates (59). Unfasten snapring (72) and remove brake gear (64) and
key (36) from intermediate pinion shaft (5).
5-20
7. Remove four capscrews (91) and lockwashers (88) and remove brake adapter
(55) and shims (44). This exposes intermediate pinion shaft (5) and bearing
(39).
8. Inspect and replace or repair any damaged or worn hydraulic brake
components. Then reassemble the hydraulic brake in the reverse sequence of
disassembly.
5-32. HYDRAULIC PUMP AND ACTUATOR REMOVAL. See figure 6-8. Remove hydraulic
pump (11) as follows:
1. Disconnect all external hydraulic lines at pump (11). Cap all open lines
and fittings.
2. Separate coupling (1) halves.
3. Support pump (11) with a sling or other device. Remove two hex nuts
(53), hex head capscrews (48) and lockwashers (58) securing pump (11) to adapter
(30). Carefully remove pump.
4. Move pump to a clean work area.
5. Repair pump and/or actuator in accordance with maintenance instructions

contained in appendix D.
6. Reinstall pump (5) by carefully reversing removal procedure. Fill pump

with clean, filtered hydraulic fluid before operating.
5-21/(5-22 blank)
SECTION VI
PARTS LIST
6-1. INTRODUCTION.
parts
6-2. This section comprises illustrations and parts list for replaceable
for the equipment covered by this manual.
6-3. ILLUSTRATED PARTS LIST.

A
5-4. ILLUSTRATIONS. Each major assembly or component is illustrated. (part)
assigned each illustration. The drawing
figure number and title is
in the lower right
number for each illustrated assembly or component is shownletter of the drawing
corner of the illustration. If applicable, the revision
is shown as a letter suffix to the drawing number.
each part
6-5. PARTS LIST. Each illustration is preceded by a table listing at the top
in the illustration. Each parts iist table is captioned
identified table comes in two
to identify the corresponding illustration. The parts list of four columns.
variations. One table consists of six columns and the other
the four column table
The following descriptions pertain to both variations with
headings and additional information in parentheses.
find numbers
6-6. ITEM (FIND NO.) Column. The item numbers correspond to the
in the corresponding illustration.
the noun
6-7. DESCRIPTION (ITEM NOMENCLATURE) Column. This column contains
or limited infor-
nomenclature of the assembly or part followed by descriptivethread information,
mation. (This column may also contain lengths, diameters,
type material, tempering, and manufacture name.)
total quantity
6-8. QTY (QUANTITY PER ASSEMBLY) Column. This column lists the
parts used in the assembly or component listed on the first
of the individual
line of the parts list.
lists the part number
6-9. MANUFACTURER P/N (ITEM NUMBER) Column. This column
manufacturer. Assemblies or parts modified by Western Gear
as assigned by the
Corporation are assigned Western Gear part numbers.
Federal Supply
6-10. MANUFACTURER VENDOR CODE Column. This column lists the Catalog
(FSCM), as listed in Defense Supply Agency
Code for Manufacturers or part. The word
Handbooks H4-1 and H4-2, for the manufacturer of the assembly
commercially available
Coml in this column indicates that the part is a common in table 6-1 in
item. The code numbers used in the parts list are listed
numerical sequence with the corresponding manufacturer's name and address.
information
6-11. REMARKS Column. This column contains additional descriptive to other
such as indicator markings, sizes of threaded fasteners, reference
inches unless spec-
figures for further breakdown, etc. All dimensions are 'n Higher Assembly.
ified otherwise. PB means Parts Breakdown and NHA means Next
6-1
6-12. HOW TO USE THE PARTS LIST.
6-13. Following are procedures for finding a specific part in the parts list.
1. Figure 6-1 is the top drawing for the equipment covered in the manual.
Refer to this figure and locate the specific part desired, or the assembly/
component containing the part desired. Note the index number for the part or
assembly/component.
2. Refer to the parts list for figure 6-1. Locate the index number in the
ITEM column. The adjacent columns provide the description, quantity per assem-
bly, part number, manufacturer's vendor code, and any other pertinent informa-
tion. If the item so identified is an assembly or component, the REMARKS column
will contain a cross-reference to another figure for the parts breakdown of the
assembly or component.
NOTE
If the assembly or component is not manufactured by Western
Gear Corporation and is deemed economically repairable, the
REMARKS column will refer to an appendix for further break-
down. The first page of each appendix lists the contents of
that appendix.
3. To identify a part within an assembly or component, turn to the refer-

enced figure and locate the specific part desired. Note the index number for
the part.
4. Refer to the parts list for the figure being used. Locate the index
number in the ITEM column. The adjacent columns provide all pertinent
information for the item.
NOTE
If the item so identified is a subassembly or repairable com-

ponent, the REMARKS column will contain a cross-reference to
another figure for the parts breakdown of the subassembly or
repairable component. In such cases, repeat steps 3 and 4 to
identify a part within the subassembly or repairable component.
6-14. HOW TO ORDER PARTS.

6-15. Western Gear Corporation recognizes the need for expeditious service and
endeavors to provide the best possible service in filling your order. To avoid
error and possible delay in your receipt of parts, it is important that we re-
ceive complete and accurate identification of the ordered part.
6-16. Parts may be ordered by mail, telephone, or Telex. An order form is pro-
vided for ordering by mail. If the order is placed by telephone or Telex, use
the order form as a guide to help ensure that adequate information is provided.
When possible, orders placed by telephone or Telex should be confirmed (to avoid
error) by mailing an order form as a followup.
6-2
6-17. The following instructions for completing the order form are keyed to the
numbered blocks in the sample Customer Parts Order form. Copies of the Customer
Parts Order form, for use in ordering parts, are provided immediately after the
sample.
1. ORDERED BY: Name, title, and phone number of individual placing
the order. This must be legible.
2. DATE: Date the order is written.
3. FROM: Name and address of ordering firm.
4. P.O. NO.: Your purchase order number.
5. SHIP TO: Give complete address for shipment of parts.
6. SHIP VIA: Specify preferred method of shipment; i.e., air
freight, UPS, most economical method, etc.
7. EQUIPMENT Provide complete nomenclature of the basic equipment
NOMENCLATURE: as provided on the title page (first page inside the
front cover) of the manual . (Include model number,
type number, part number, etc., if given.)
8. MANUAL NO. The manual number is shown in the lower left corner
AND DATE: of the title page. The manual date is shown in the
lower right corner of the title page.
9. MANUAL CHANGE NO. The manual change number and change date are shown
AND DATE: in the lower right corner of the title page.
10. FIG NO.: Enter number of the figure that the part is
illustrated on.
11. PAGE NO.: Enter the page number of the table that lists the
part.
12. ITEM NO.: Enter the item number for the part from the ITEM NO.
column of the parts list table.
13. DESCRIPTION: Enter the complete description as shown in the
DESCRIPTION column of the parts list table.
14. PART NO.: Enter the part number as shown in the PART NO.
column of the parts list table.
15. VENDOR CODE: Enter the five-digit number as shown in the VENDOR
CODE column of the parts list table.
16. QUANTITY ORDERED: Enter the total quantity ordered.
NOTE
For those items covered by vendor data (located in the
appendix(es) provide as complete identification of the item
as possible in accordance with the preceding.
6-3
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61. W WT1SO FT 6 C-200.713 'AG' ST.Sl'ELQ-S-Yfilb .4 CLASS304 A

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61 FLANGEBUASHING AD 111202-3 KI.NELL OILIEN COSM ...
64 BSHSING I: AA.IAI!1-3KINGAL. GILITE COMM.
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CONDITION
10 FLANGEBSHSING 25 AIGHELL
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71 NEASISSHOULSING A 4-200.516 -GC C.SOEE, C-T--68l -- CLASSI
73 MSESHAFT 1
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75 LISTA .2 C-2T.'1N .;C___ C.STEEL QQ-S-60lb 1G.! CLASSI (15.5 I L.A.)
A 0-200.476
2TSLIE 50 ST.STEE!QQ-S-763b CLASS316
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7 LEVER A C- J 16- WGC I CLASSI (I
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-00--
NX AUTEz COWLt STEEL -CONKS. - - - - - (13000
81 BUSHING- A
4 -0,A5SEE A 660
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Figure 6-3. Lower Frame Mod

Refurbishment - DOHB Machine
g CW1I.
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D316387
Figure 6-3. Lower Frame Modification and

Refurbishment - DOHB Machine (Sheet I of 3)
6-31/(6-32 blank)
.122 CS J2 I PLCS
( REF)
5106 PLATE SD LT
DETAIL 13
(AIR PIPE)
SJCALE:
Iii
NOTE: POSjITION F/N'5 4.5 6( A5 IJ1OWN
ON PLAN VIEWJ (SHT 0).
EX1I5TING FLANGE'
A (TO 5E REMOVED)
-AREA ~ ~ NE ' LNEF RFP.T
TO E REMOVED
Figure 6-3. LU
Refurbishment
2 2FtCS .4 .PtC9
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I. .25 -I0 NPT

(RE F)
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TAIL 13
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EXISING FLANGE
(TO 5E REMOVED)
10
(REFI-
A-A
DER FLANGE
D316387
B Figure 6-3. Lower Frame Modification and

Refurbishment - DOHB ? chlne (Sheet 2 of 3)
6-33/(6-34 blank)
- -/
2.0
(REF)
NOT ES*
STRAIGHTEN BENT PLATE 7REMaiE AND L MODIFY E15Tj
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NOTES(CONT) WYELD
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A. INSPECT FRAME FOR 1*MfkGE NOT CORRECTED I ALL WELD$ TO
MY TH415 DRAWING AND REPORT TO ENGIVIEERING.
BREWORK FRAME A12'jHOWNI.
C. AFTER REWORK CLEAN MACHINED BORE 5 AND CHECK
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&. WELD P/N 2 AS SHOwni.
C. FIT FIN I A~j SH4OWN BY AEPMOVING AREA
OF PLATE UNDER FLANGE AS 'SHOWN AND
ITES (ONT) VELO F/N I A,2 SmHOWN.
4,EWOR FRAE S FLLW$ 2. WELD PER W.G.C. PRCEDURE N.J. 151.
A. INSPECT FRAME PO R OAM&GE Norr CoR~erEo, 1 ALL WVELDSTO OE CONTINvOLI5.

OY' TH15 DRAVWNG ANO REPORT TO ENGIqIEERIPJG.
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D. PROTECT MACmNEO 'NCRES \No TAPPED HOiueL-ESoeraeMdiiaio n
' EN 53ANdOeLA.T 4NU PA INT. Fgr -. LwrFaeMdfcto n
Refurbishment - DOHB Machine (Sheet 3 of 3)
6-35/(6-36 blank)
RF LIE YL E~~~*2405'V)MITLL ' TkU
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1 Figure 6-4. DOHB Lower Reducer

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Figure 6-5. DOHB Machine Reducer
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(Sheet 3 of 3)
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Figure 6-6 and 6-7. Not Used
6-49/(6-50 blank)
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NOTES:
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ASSEMBLY.
2.REF 0316505 FCR VENDOR DWG
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if.; 3WEIGHT OF POWER UNIT:
RESERVOIR DRY - 1500 LBS
15 35RESERVOIR FULL- 2340 LBS
REV. STATUS-
6 43 4 36
51 38 D316128B
56 55Figure 6-8. DOHB Power Unit Assembly

(Sheet 1 of 8)
6-51/(6-52 blank)
43
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D316128 B
Figure 6-8. 00KB8 Power Unit Assembly

(Sheet 2 of 8)
6-53/(6-54 blank)
MOTOR AND
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ELECT RO-HYDRAULIC
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CONNECTION
BOX
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4, SEE Wr4CQWG NO A'507881 FOR TANK
HEATER AND I- 5OX 2 OLIICKD15CONNECT
D3161288
Figure 6-8. DOHB Power Unit Assembly

(Sheet 3 of 8)
6-55/(6-56 blank)
REVISIO14S
RE VISIONS
LTR OESCRIP ION DATE APPROVED LTR TDESCRIPTION DATE APPROV
A SH 1: REVISED REV. STATUS. SHEET ' '

f-1is'tj
WAS I OF 4. JIM "7
SH 2: SHEET WAS 2 OF 4.
SN 3: F/N 29 P/N WAS 17800-0.
SHEET WAS 3 OF 4.
SH 4: ADDED F/N'S 65-81.
SHEET WAS 4 OF 4.
SH 5: ADDED SHEET. ADDED F/N'S
82 1I IRL 96
Figure 6-8.
(Sheet 4 of
REVISIO14S
IATE APPROVED LTR DESCRIPTION DATE APPROVED
D316128B
Figure 6-8. BOMB Power Unit Assemrbly

(Sheet 4 of 8)
6-57/(6-58 blank)
hO ciMANWFACTUREN REG' CERh RN E
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(Sheet 5 of 8)
11 6-59/(6-60 blank)
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(Sheet 6 of 8)
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66 _ CABLE (4COND) I FSGA-4
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67 _ CABLE (3-COND) I ITSGA-14 ANIXTER VAR MIL-C-915E!3d
68 _ CABLE (2-COND) I ____2SJ-18 ANIXTER VAR M'IL-C-91SE/6 __
69 _ ARMOR BRAID (1/4") 1 ____2142 ALIPHA VAR COMI ___
70 _ CONNECTOR 1 4 EQUIVOR VAR MI L-C-50 15 ____
71 _ CORD CONNECTOR 3 2682 *JR........ VAR COMI ____
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73 1_STUFFING TUBE (#4 STR) 2 M19622/1-005 DORN OR EQ NYLON MIL-S-19622 -____
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U3-004 DORN OR EQ NYLON MIL-S-19622--------__ ________________
1-005 ON OR EQ NYLON IL-S-19622______

19-00111 DORN OR EQ VAR IL-S-19622 -- _____
. DORN OR EQ VAR IL-S-1%22 - ----
2/1-002 DORN OR EQ NYLON 'IL-S-19622 - -----
1774 W RI- .- IL-S-19622__________ _________
2211-001 DRN OR EQ T - - 9 ______________________
22170 nlyri A MIL-S-19622 _____________ _______
______ TYL COM'L ___________________
129 WGC - _ _ _ _ __ _ _ _ _ _ _ _ _ _ _ _
D3161288

(Sheet 7 of 8)
I,- 6-63/(6-64 blank)
ZOEcWCAo ~. P A I.FCTIAEO MATL iStC SPECFap5
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82 STUFFING (UBE (#2) 1 M1962212-002 DOMN OR EQ. NYLON MIL-S-19622
83 TER.M. BLOCK 1 6TB24 jKULKA VAR. COML._____
84 RELAY I D26MR804A MTER-H -",'?'ER
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85 _ RELAY I 26MR20C
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86 MITG. CHANNEL 1 D26MC4 UTLER-HA.,,.ER VAR. COML.
87 __ v aO.___ V130LAIOA GE VAR. COMIL. ____
88 LABELS 1 A308138 WGC VAR. COML. __lllI_
89 MAOI.SCREW 7 116164 WGC STL COML. ____llll
90 FLAT WASHER 27 108975 WGC STL COML. II!111!

91 MACH. SCREW 22 __ 116132 WCGC STI COML. ____
92 CLAMP, CUSH. 4 112100 WGC VAR COML.

93 __ CLAMP, CUSH. 8 114101 WGC VAR COML.
j
94 CLAMP, CUSH. 4 114102 WGC VAR COML. ___ilill
95 _ CUSH.
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(Sheet 8 of 8)
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D316464B
Figure 6-9. Power Unit Piping Diagram
(Sheet 3 oif5)
>6-71/(6-72 blank)
CTU
MANUPACTSEN RE00 CENTS ALTEENATE WT

FED M. COD MATL AAATLSPECSPIC P0l GOVTMAK
mil mul MRIECACEIENT. NAME LC P HKC N N REFERENCE LOSEK
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D316464B
Figure 6-9. Power Unit Piping Diagram
(Sheet 4 of 5)
)6-73/(6-74 blank)
MA*JfAC TUIN EQMCETESEM F
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Figure 6-9. ;,~o, Jilt Piping Diagram
(Sheet 5 of 5)
6-75/ (6-76 blank)
A307PY2
VEORCORTNOLLEQ
_____________________________________
DORINTERLOCK--
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K14
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02 I2 3 NOTES:
1. REMOVE INSTALLED
ALL ill AlE VENDEOR L _____ ___________
0 HIRING ANDPEWIPE PERTHISONG. TSGA-14
DE AIS 610 10 6
21NrI
2FOR
14A1(0 WIPE,COLOR RED. 4. SEEHOCING NO. 031612S, SH 3,
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RESERELANCE TTHE NM9ES TH4AT CONTROLLER.________
MAY ACTUALLY APPEARONTHEGIVEN IRVIAIA
CONTACTS. S. SEEWGCONG NO, A3307881
FORTONE
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'O j -BO 2 DETAIL SHOW4 0D31129
36 ~
ASSE%LYOFQUICK DISCOISIECT
ELECTRICAL FITTINGS ONOIL REV.STATUS
'IMRSION HEATER
ICONTRO~L AND MOTOR Figure 6-10. Power Unit WiigDiagram
RQ. IAIA (Sheet 1 of Wiin
5SE407EOAND0J-NAO2 QUICKbank
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A301881 FOR
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D316129A
Figure 6-10. Power Unit Wiring Diagram

(Sheet 2 of 2)
4
I
6-79/(6-80 blank)
3MV/VNOTES:
U SYSEM 81. SEE WGC OWG NO. 0316125, SH 5, FOi

SH4OWINGASSEMBLY OFQ DC
ISCONNI
FITTINGS ON DOO-H.B. J- OX.
2. SEE WGC DWG NO. A301981 ORJ-BOX
FITTING WIRING.
O.O.-H.B. MACHINLE J-BOX J-BOX NO.
R 201 12 250f-
LB
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NOTES:
1. SEE WGC DWG NO. 0316125, SH 5, FOR J-BOX 3 DETAIL
SHOWING ASSEMBLY OF QUICK DISCONNECT ELECIRICAL
FITTINGS ON O.O.-H.B. J-BOX.
2. SEE WGC OWG NO. A30788I FOR J-BOX 3 QUICK DISCONNECT
FITTING WIRING.
O.O.-H.8. MACHINE J-BOX J-BOX NO.
(iIEXCIT,
GR -R 1814
201 1 2 -150
BLK 200 --
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3 - 151 - SIGNAL GENERATOR ASSY
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W
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C312802 A
Figure 6-11. DOHB Machine Wiring Diagram
6-81/(6-82 blank)
STY-RAP
ZREK22-6-REF
-440 VAC
UI3 PHASEO
5CABLEW4 REF
~B312548 I J-2
DETAIL
__ I ZREK-2216-38S
PYLE-NATIONAL
1440 VAC, 30 L2 "-----2L2440 VAC, P

60 HZ POWER - 3 440 VAC, P
UNIT MOTOR L3 L3
SUPPLY 100 100 4 GROUND
ESEE NOTE 6 SEE NOTE

& DETAILDIE
NOTES SEE NOTE
1. ASSEMBLY INCLUDES PLUG, CABLE GRIP, AND DUST COVER.

2. BEFORE SOLDERING WIRES TO THE PINS OF PLUG, VERIFY THAT THE PLUG
ASSEMBLY'S RUBBER GROMMET FITS SNUGLY ON CABLE. IF GROMMET FIT IS
NOT SNUG, NOTIFY ENGINEERING SO THAT SMALLER GROMMET MAY BE OBTAINED.
3. REPLACE DUST COVER CHAIN WITH CABLE ASSEMBLY, F/N 2.
4. TAG OR MARK WIRES WITH WIRE NUMBERS.
5. THE LEGEND ON THIS LABEL SHOULD READ:
"J4-2"
"CABLE-W4"
"B312548"
"440 VAC" "B312548"
"3 PHASE"
"POWER"
"CABLE-W4"
i-TY-RAP
3 REF
J440 VAC
3 PHASE
POWERRE
CABLE -W4 RE
B312548 J4-2
DETAILL IZREK-2216-38S
DETA IPYLE-NATIONAL
Li 1 '440 VAC, PHASE 1
L2 - 2 440 VAC, PHASE 2
L3 - 3 440 VAC, PHASE 3U
100 4 GROUND
3j
1 SEE NOTES I& 2 REF I
TE6 2 SEE NOTE 3

REF -'
4 SEE NOTE 5
II
SDETAIL j
THAT THE PLUG RF 4CBEW

F GROMMET FIT IS8324
ETMAY BE OBTAINED.
2. DETAILLU
B312548A
Figure 6-12. W4 Cable Assembly

(Sheet 1 of 2)
'2 6-83/(6-84 blank)

P/L NUMBER ENG REV P/L NOMENCLATURE CODE IDENT
B312548 - W4 CABLE ASSEMBLY 16603
FIND ITEM ENG ITEM QUANTITY

NO NUMBER REV NOMENCLATURE REQUIPED
1 ZREK-2216-38SR RECEPTACLE-W/BASKET WEAVE 1 EA
CABLE GRIP PYLE-NATIONAL
2 CL-22-KA-6.O CABLE ASSY 1 EA
CARR LANE MFG
3 B312548-3 CABLE (FHOF-42) 1 EA
100 FT LG
4 A308569-8 LABEL-ELECTRICAL CABLE 1 EA
B312548
Figure 6-12. W4 Cable Assembly (Sheet 2 of 2)
6-85/(6-86 blank)
3 EES NOTE 5 6 SEE NOTE 6
& DETAIL I E
& DETAIL
1 SEE NOTES 5
P5-i ,--2 1 &2 J5-2
pPEK 2 SEE NOTE 3 2 ZREKL-1016-25S
PYLE-NATIONAL C PYLE-NATIONAL
2 2
1 I 03- - 3 120 VAC HO
4 0 N104 - 4 120 VAC RE'
5 - 106 ( REF 106 - 5 MOTOR RUN
6 - 113 - REF 113 6 RUN LATCH
-- 1 -- 5 -_,1T
~~P 114 7 MOTOR STAR
-
8C 117 ACBLE-W5 3 REF 117 8 MOTOR OVLD
9 - --
119- - B312549 'DE TAIL I 119 9- SERVO PRES!
10 123 123 - 10 SUMP TEMP
11 - 136 136 - 11 SPACE HTR
12 - 137 137 - 12 SPACE HTR
13 126 126 - 13 BRAKE RELE
14- 130 , ,
130- 14 BRAKE REL
15 - 1
o - 100 - 15 GROUND
L6 - Sp SP 16
NOTES:
1. ASSEMBLY INCLUDES PLUG, CABLE GRIP, AND DUST COVER.' 6. THE LEGEND
"J 5-2"
ON THIS LABELI
ASSEMBLY'S RUBBER GROMMET FITS SNUGLY ON CABLE. IF GROMMET FIT IS "CABLE-W5"
NOT SNUG, NOTIFY ENGINEERING SO THAT SMALLER GROMMET MAY BE OBTAINED. "B312549"
3. REPLACE DUST COVER CHAIN WITH CABLE
ASSEMBLY, F/N 2.
"P5-1"
"CABLE-W5"
"B312549"
E5 &
SEED1NOTE 6
LI &DETAIL II
NOTES 5
2 J5-2
NOTE 3 2 ZREKL-1016-25S
PYLE-NATIONAL
1
2
103 3 120 VAC HOT
104 4q 120 VAC RETURN
1 REF 106 55 MOTOR RUN INDICATION
REF 113 6 RUN LATCH CONTACT

114 7 MOTOR START
REF 117 8 MOTOR OVLD INDICATION
JTAIL I 119 - 9 SERVO PRESS LOW IND
-"123 - 10 SUMP TEMP HIGH IND
136 11 SPACE HTR 120 VAC HOT
137 - 12 SPACE HTR 120 VAC RETURN
126 13 BRAKE RELEASE SOL
130 14 BRAKE REL STROKE X 0 SOL
100 15 GROUND REF 5
SP 1
REF 2
REF 6 J5-2
6. THE LEGEND ON THIS LABEL SHOULD READ: 83125
"J5-2"
HE PLUG
IET FIT IS "CABLE-W5" DETAIL 11
BE OBTAINED. "B312549"
B312549
(Sheet I of 2)
6-87/(6-88 blank)
- W5 CABLE ASSEMBLY 16603
B312549

NUMBER REV NOMENCLATURE REQUIRED
NO
ZPEKL-1016-25P STR PLUG WITH CABLE GRIP I EA
1
PYLE-NATIONAL
CABLE ASSY 2 EA
2 CL-22-KA-6.0
CARR LANE MFG
A308569-11 LABEL-ELECTRICAL CABLE 1 EA
3
B312549-4 CABLE (MHOF-1) 1 EA

4
50 FT LG
5 ZREKL-1016-25S RECEPTACLE-W/BASKET WEAVE 1 EA
6
B31254Q
6-89/(o-90 blank)
1 SEENOTE &
2 SEE NOTE 3
3 """SEE NOTE I
5 1 REF
& DETAIL
P6-1 2 REF J6-2
ZPEK- 101 2-24P ZREK- 10124
PYLE-NATIONAL P6-I PYLE-NATIOt
E247 O 2247
2 246 DETAIL 26
3 3
- SP SP 4
5I SP SP 5
NOTES:
1. ASSEMBLY INCLUDES PLUG, CABLE GRIP, AND DUST COVER. 5
ASSEMBLY'S RUBBER GROMMET FITS SNUGLY ON CABLE. IF GROMMET FIT IS
NOT SNUG, NOTIFY ENGINEERING SO THAT SMALLER GROMMET MAY BE OBTAINED.
3. REPLACE DUST COVER CHAIN WITH CABLE ASSEMBLY, F/N 2. 6
1"P6-I" 1
"CABLE-W6"
"B312550"
"J6-2"#
"CABLE-W6"
"B312550"
I REF
2 REFJ6-2
2 REFZREK-1012-24S
P6-I PYLE-NATIONAL
ALE-W6 3 REF 2147 - ( ) ACTUATOR
B31 2550I I
"CT DETAIL 1 216 2 (-) ACTUATOR
3
SP 4
SP 5
'4
5 SEE NOTE I & 2

COVER. THAT THE PLUG_(
NO T VERIFY
2 SEE NOTE 3 REF 5

NO'BLE. IF GROMMET FIT IS
:R GROMMET MAY BE OBTAINED. I
6 SEE NOTE 6 REF
NO Y, F/N 2.
'TA & i " REF 6 J6-2
9312550
DETAIL II
B312550A

(Sheet I of 2)
->
6-91/(6-92 blank)
j
-I _ ----. -
P/L NOMENCLATURE CODE IDENT
P/L NUMBER ENG REV
W6 CABLE ASSEMBLY 16603
8312550 -
QUANTITY
FIND ITEM ENG ITEM REQUIRED
NO NUMBER REV NOMENCLATURE
1 EA
I ZPEK-1212-24P STR PLUG WITH CABLE GRIP
PYLE-NATIONAL
2 EA
2 CL-22-KA-6.0 CABLE ASSY
CARR LANE MFG
1 EA
3 A308569-15 LABEL-ELECTRICAL CABLE
1 EA
4 B312550-4 CABLE (TTRS-2)
50 FT LG
1 EA
5 ZREK-1212-24S RECEPTACLE-W/BASKET WEAVE
I EA
6 A308569-16 LABEL-ELECTRICAL CABLE
B312550
6-93/(6-94 blank)
3 SEENOTE 5 6 SEENOTE6
& DETAIL I & DETAIL 11
P7-I J7-3
PYLE-NATIONAL
ZPEK-0812-17P I SEE NOTE 5 ZREK-0812-17S
I&2 PYLE-NATIONAL
I-1
5352
6 52 527 iS3
NOTES:NOT 6
._.99 00 - 100G
lO
10 SP ---SP 1
| 1. ASSEMBLY INCLUDES PLUG, CABLE GRIP, AND DUST COVER.

i 2. BEFORE SOLDERING WIRES TO THE PINS OF PLUG, VERIFY THAT THE PLUG
~ASSEMBLY'S RUBBER GROMMET FITS SNUGLY ON CABLE. IF GROMMET FIT
IS NOT SNUG, NOTIFY ENGINEERING SO THAT SMALLER GROMMET MAY BE
OBTAINED. 1-REF
3. REPLACE DUST COVER CHATN WITH CABLE ASSEMBLY, F/N 2.
3&
3-.
4. TAG OR MARK WIRES WITH WIRE NUMBERS. 2 ) REF

--L,,,
|5. THE LEGEND ON THIS LABEL SHOULD READ: P7-1
|"P7-1" CABLE-Wi REF
"CABLE-W7"
"B312551" B312551 DETAIL I_
"CABLE-W7"
"B31255 1"
3 SEE NOTE 5 6 SEE NOTE 6
& DETAIL I & DETAIL
, SEE NOTE 3J 2 J7-3
SEE NOTE 5 ZREK-0812-17S

1 &2 PYLE-NATIONAL
2
3
150 4 S1
151 5 S2
S3 FATHOM COUNTER
152 -~6
SYNCHRO SIGNALS
t 103
104
100
7
8
9
RI
R2
GROUND
SP r10
4
COVER. FIT
VERIFY THAT THE PLUG 5

BLE. IF GROMMET FTREF
LLER GROMMET MAY BE -REF REF 2
F/N 2. 2Y, REF REF 6 J7-3

CABLE-W7
B--"---51
P7-1 DETAIL l
CALE-
7 REF
8312551

(Sheet I of 2)
6-95/(6-96 blank)

NO NUMBER REV NOMENCLATURE REQUIRED
1 ZPEK-0B12-17P STR PLUG WITH CABLE GRIP 1 EA
PYLE-NATIONAL
2 CL-22-KA-6°0 CABLE ASSY 2 EA
CARR LANE MFG
4 B312551-4 CABLE (MHOF-7) 1 EA

50 FT LG
5 ZREK-0812-17S RECEPTACLE-W/BASKET WEAVE 1 EA

6
B312551
6-97/(6-98 blank)
P8-i J8-3
ZPEKL-1416-I IP ZREKL-1416-I IS
PYLE-NATIONAL PYLE-NATIONAL
1 201 201 ' 1 ()EXCIT
ISEE NOTE 2 200 200 2 -)EXCIT
I &2
2 SEE NOTE 3 3 3
202
20202 4 SIGNAL
3SEDTAL
__ 5 20 203 5 (-) SIGNAL
6 6
7 21251 7
7 (+) EXCIT
8 20200 8 -)EXCIT
9 9
10_________
25- 252 10 ()SIGNAL
1123253 11 -)SIGNAL
12 12
1320250 , 13 TACH ()SIGI
14 20 200 5 S'4
15& DSE
NTIE
REF RE SPI&2P54 1
J8-3
ZREKL-1416-1IS
PYLE-NATIONAL
201 1 (+) EXCIT
200 ,>
2
-- (-) EXCIT SYSTEM A
3 LOAD CELL
202 4 (+)SIGNAL
203 5 (-)SIGNAL NOTES:
6 1. ASSEMBLY INCLUDES PLUG,
1 -- CABLE GRIP, AND DUST COVER.
25 -7 2. BEFORE SOLDERING WIRES TO
200 8 (-)EXCIT THE PINS OF PLUG, VERIFY
9 SYSTEM B THAT THE PLUG ASSEMBLY'S
LOAD CELL RUBBER GROMMET FITS SNUGLY
252 10 (+)SIGNAL ON CABLE. IF GROMMET FIT IS
I- NOT SNUG, NOTIFY ENGINEERING
L 253 11 (-) SIGNAL S--THAT SMALLER GROMMET MAY
12 BE OBTAINED.
2S0 13 TACH ()SIGNAL 3. REPLACE DUST COVER CHAIN WITH
2- CABLE ASSEMBLY, F/N 2.
200 14 TACH (-)SIGNAL 4. TAG OR MARK WIRES WITH WIRE
5 SEE NOTE 15 NUMBERS.
I& 2 5. THE LEGEND ON THIS LABEL
SEE NOTE 3 ,, - SHOULD READ:
Sp 17 "P8-1", "CABLE-W8",
6 SEEDETAIL
NOTE 611 j18 "B312552"
&
D 19 6. THE LEGEND ON THIS LABEL
19 SHOULD READ:
"J8-3", "CABLE-W8",
"B312552"
B312552A
(Sheet I of 2)
fl 6-991(6-100 blank)
FIND ITEM ENG ITEM

NO NUMBER QUANTITY
REV NOMENCLATURE REQUIRED
1 ZPEKL-1616-11P PLUG-W/BASKET WEAVE CABLE I EA
GRIP PYLE-NATIONAL
2 CL-22-KA-6.o CABLE ASSY 2 EA
CARR LANE MFG
4 B312552-4 CABLE (TTRS-6) 1 EA

50 FT LG
5 ZREKL-1616-11S RECEPTACLE-W/BASKET WEAVE 1 EA
B312552
6-101/(6-102 blank)
5 SEE NOTL-1 E NT
N CT ES
1. STEEL. STAPIM Z5 Hi6GH LE7TER I-AOSE. CES16NATIC
ONi F/N ©AS SHOWN,AT ASS-f.
Figure 6-17. Hose Bun

(Sheet 1 of 2)
5 SEENOE
TE
1STEEL STAM? Z~5 HIGH LYTE.R IAOSL DESIGNATIONS

®AS !5MOWN,AT AS5-N.
ONM F/N
C313737
Figure 6-17. Hose Bundle Assembly

(Sheet I of 2)
6-103/(6-104 blank)
CCEMANUFACTURER REWO CERTS
FI ZOINE NOECAUEQTY. CO PART OR MATL MATL SPEC -
NOMNCATREIDENT. OGO.NAME _ _ _ __ _ C P H CJN
D
1
i H____S* 2 HAAGNo WGCc CDFA L

2 CULK EICND~C 4VHC (.-(.EF SNAP-TITE STNL MU
3 DUST PLUG~ 4 p02-6 SNAP-TE P\AST C C'OAL
PLASTIC COIL SLEEVE 5 4554-2?OCO SY NFLE.X LASTIC CCM L
5 HOSE. MARKER? 4 1
T-100 9ssT MM AFKE STL COM-L
______________~mp' __ _ _ v~_ co _ _ _ _ _ _ _ _
_ _ _ __ _ _ _ _ _ _ _ _ _ __ _ _ _ _ _ _ _ 7
UFACTURER - -REO'D CERT5S ALTERNATE W
NAMENAEMAIL SPEC
1AATL TN
CI% JN
C P, ,C/SPEC R E EC
FORGOVT LSREMARKS
'WGC ,-( Z GO -_PE. -L D31725"7

F SNAP-TITESALN r_ M__ _ _
SriAP.TTE. PLAqSTIC COML

S"YNFLEX PLASTIC COML ZO FT LEGTW
MA STL COML
C313737

(Sheet 2 of 2)
6-105/(6-106 blank)
I.APPROX 5FT.
6 5 4
SEE NTE. 2SEE NOTE 2
NOTES:
1. D0 NOT ASSEMBLE. PARTS UNTIL HOSE LENGTH HAVE
f3EE.N CONFIRMED 5' FITTIM6 TO UNITS.
Z. 5TEEL STAMP .25 HIGH LETTER HOSE. DESIGNATIONS

ON F/N g AS SHOWN AT ASS'Y.
Fi
OX 5 FT.
(TY'PJ
12
SEE NOTE. SEE NOTE 2
HOSE. LENGTH HAVE

UNITS.
DES IGN AT IOS
C313738A
1 Figure 6-18. Hose Bundle Assembly
(Sheet I of 2)
6-107/(6-108 blank)
QTY. CT AT MANFATU E MTL MATLSE REO'O CER TS -
FID 0* NOMENCLATURE
N__
NJZ-C~I wc,.c VA K CCML
QUIC -NE 4 ___Y1412-IZ-F SNAP.TITE ST.STL COML _
__ D~UST PLUG ___ PDP- 12 SNAP-PITE 1'LA5TIC CCML

4 HOSE. ASSY (52') Z ____ G2 c____ V_
__6% e O
5 __CONNECTOR E-SODV 4- 134?a1 WC, C STL. COM L _
OUICY, DEC6MiECT 41 ~1C1-0 F SNAP-TITE

1-7 STL COML
I _ DUST cOVER.- 41 1 CC1(o SNAP-TITcI RUMN, COML
NOSE. M~ARKSER T -1MO9.SS7 i'\IA.L 77K -rSL COM L.
19 PLASTIC COIL SLEEVE. 1( ____554-?20)OO~ iN FLEX PLASTIC COML _
E F
NUFACTURER
UP UETL MATL SPEC - REQ*
E CER TS AL TERNATE
SPEC FO GOVT WT REMARKS
"ME CP.CN N REFERENCE IS
_ _6% _ _ _ _ _ _ _ _ _ _ _ _ _ PF iR 0 3 1 72 5 7
F SNAP.TIT1_ 5T. STL COML
0 SNAP-TITE P'LATIC CCML
o
WCGc VAIr-- COML jER D3192-57
WCC STL COML. 2.0 F5OX-S PA E ._
- F SNAP-TiTE STL COML
SIN AP-TIT5 RUBBER COML
r.[
/.Jt:TL M'APKL--
7 _-_L__L__ 5TL COM .
0 S 'NFLEX PLASTIC COML 20O-r La
Z-r 1-4
C31373CA

(Sheet 2 of 2)
6-109/(6-110 blank)
_ /L
2 2
SEE NTL ISEE NOTE 1
N 0-T_. S,
2. STE.EL STAMP .25 H16H LETTER HOSE DE'
OM F/N (g AS SHOWN, AT ASS'Y.
Figure 6-19,
(Sheet 1 of
I __ __ _------ - -.- _ -
2
3
S~ES:E
1. STELL SJAM? .25 HIGH LflTEr HoSE. OESIGNATIONS

ON F/N W~)AS SHOWN, Ar ASS'.
C3 137 39A
(Sheet 1 of 2)
6-111/C6-112 blank)
TS
PEOODCER ALTERNATE
FW ONG ursCOoDE
NoiEICLATURE OTY ET. I MANUFACTURER
PARTOR
-
AATL MATI PEC -- - SPECFC2 GOVI
MIT OWGNO. MAMIE Il INJC/J IN REFERENC
I HOSE A55EMBL 5 - 0 -&DD WG. OM L-

2 ___________END 10 ___SPIHCro-(& F SrNF 7 -TITE STL COML
3 IDUST PLUG 10 PDP-6 SNAP-TRE~ PLASTIC COM L
4 PLASTIC COIL SLELVL/E 5 4 554-2,2000 SYNFLEX PLASTIC CcOML____
-HOSE MARKER iCn T-1069-SST "k'L .T - L
C0_____ -__
6o MALE CONNECTOR iD 8 FTX-S PAFRKER sTL COPAL __

IMNUFWTUMER ffQ'O CETS ALTERNATE ,T
PART01 MAIL MAIL SPEC SPECFC2 GOVT LOREMARKS
C P " C N REFERENCE
OWGNO. HAWn
rco = 'PEP. JO D 31-725"7
3-(000_
_G C COM L ,,.
:C,-& F 51A-TITE STL COML
P-(V SiNAP.TIIE PLASTIC COM L
i4-2200 C"YNFLEX PLASTIC COML 20 FT LENSTH
)O9-SST M P6' cO
MAiN: STAL
-TL COML
TX- - PARKER STL COM L
C313739A

(Sheet 2 of 2)
1 6-113/(6-114 blank)
- - 4, -/,
APPENDIX A
PNEUMATIC AND HYDRAULIC PIPING
FABRICATION AND INSTALLATION PROCEDURES
A-1/(A-2 blank)
1M LTD 11,11 DAT AP*O
___ A Add time limit to 4-3. 09 page 17 6-9-77~

B Sht 17: Para d-d. Added to PICKLI14G--- 3-4-01
"ANDCLEA.NINIG. After "steel pipe" added 1
"Corrosion resistant..."_____
C Eliminated socket wield
fittings; revised 7-30-01
Sht 5. 8. 10, 12.A 13;deleted Sht 9 A
D Revised Sht6.8,ID.1I,12,513 to reflect -2-62

new welding procedure as described in
___ Note 2A. slit6.
E Add Rev status to Sht 1. Clarified 1-26
1
Sht 9 and lA.3-22
PNEUMATIC AIIDHYDRAULIC PIPING
RECOMtIENDED
FABRICATION, CLEANING, TESTING AND INSTALLATION PROCEDURES
FOR INTERCONNECTION OF WESTERN GEAR SUPPLIED EQUIPMIENT.
__i__ __
__ E [29-
1920212223242562728
2LNI'FAu
j~ t O IEV E I-D IE D D
ID D E
PLICATWe HT 12 13 14 15 16 17 18 19 I111 12*13 14 18
MAHIO
ON
DCEPYM
00111m1INS
CU AS NOT=
227
2--7
r ST Rf
_______________MACHINE
pAR COMPORAeTp
-SOE
MIVMAHNRY DIVISION
MtVI T, WASHINGTON
LMJ .:~
ft*3 C. LARSEN PNEUMATIC ANDHYDRAULIC PIPING
me C. LARSEN
76
B*L#MALLAA3
A-3
APPROVAL SHEET
DATE
QUALITY CONTROL MANAGER c 3 -L -- 7

PRODUCT SERVICES MANAGER 3--.
ENGINEERING MANAGER . - '7
PRODUCT SAFETY COMMITTEE
CHAIRMAN 3-1 -~77
SIZE CODE IDENT NO.
[w.,,
16603 A30576$
SCALE SHEET 2
A-4
TABLE OF CONTENTS
SHEET
1-0 Introduction .......... .......................
2-0 Piping Design and Arrangement .......... ... 5
3-0 Fabrication ........... ........................ 6
4-0 Cleaning and Pickling . . . . . . . . . . . . . . . . . 16

5-0 Hydrostatic Testing Prior to Installation ........ . 19
6-0 Installation . . . . . . . . . . . . . . . . . . . . . . 20
7-0 Hydrostatic Testing and Flushing After Installation . 21
6-0 Charging Hydraulic System ... ........ . 23
Appendix A - Carbon Steel Pipe Pickling E Treatment 25
Appendix B - Corrosion Resistant Steel Pipe Pickling

and Treatment . . . . . . . . .. . 27
Appendix C - Nonferrous Pope Pickling and Treatment . 28
SIZE CODEIDENT NO.
,J.. .. .......... A 16603 A305765

SCALE JSHEET 3
A--5
1-0. INTRODUCTION
The purpose of this document is to provide guidance for construction and cleaning
of Customer Supplied interconnecting piping for Western Cear Corporation (WCC)
equipment, thus reducing the potential for contamination problems affecting WCC
auppl ed components.
Satisfactory performance of a hydraulic or pneumatic piping system can be

attained only by following proper procedures and methods throughout the con-
struction process. Improper cleaning eventually results in particles of mill scale.
sand. and other foreign material being forced into the system. These particles
will damage critical parts and impair the operation of the equipment, causing
costly component and equipment failures and shutdowns of entire systems.
It is imperative that the end product provide clean and structurally sound piping
systems. This objective can be attained by following the basic requirements of
this document.
Failure of WCC customers and their customers, in turn, to continually monitor
the cleanliness of Lhe entire hydraulic system and to periodically cleanse the
system following Initial installation and during subsequent operation of the
equipment will cause premature and costly equipment failures and shutdowns of
entire systems which are not the responsibility of W.C and for which WGC dis-
claims all liability.
The utilization of the procedures outlined herein can involve certain safety hazards
for which certain precautions must be employed, either as expressly set forth here-
in or as may be customary and usual in the industry. WGC expressly disclaims
any responsibility for injury to person or property resulting from the use of the
procedures outlined herein.

wes .n A 16603 A305765
SCALI SHEET
A-6
YI
2-0. PIPING DESIGN AND ARRANGEMENT
1. Piping sizes, allowable stresses and other physical design features must be as
dictated by contractual requirements: Codes. ANSI, USCG,USN, ABS. etc. No
responsibility for structural design Is assumed or Intended In these specifica-
tions.
2. When cleanliness of the piping system affects the warranty of equipment pro-
vided by WGC. it Is mandatory that the piping design provide for completely
demountable systems.
3. The most practical and widely used material for high pressure hydraulic piping
is cold-drawn seamless steel pipe of low or medium carbon content ASTM A 106
GR. 8, or MIL-T-20157. Type E. This material Is smoother and far easier to
clean than hot-drawn seamless or welded steel pipe, which often contains deep
pits or scratches in the interior. and usually is coated with mill scale. Other
grades of pipe and tubing may also be used if surface finishes are of comparable
nature and if all conditions such as factors of safety and material certifications
satisfy the applicable job specifications.
4. The most commonly used piping material for high pressure pneumatic service
is seamless copper, copper-nickle (70-30 alloy), or stainless steel piping
Piping of this material is easy to clean and will not corrode due to condensa-
tion and moisture in the air supply system.
5. Except for watertight deck and bulkhead penetrations, each length of pipe must
be so constructed and arranged that it can be removed for pickling and cleaning
after fabrication.
6. Air vents should be installed in high points of hydraulic piping runs Air
pockets in the lines may cause erratic response and operation.
7. Provision for temporary jumpers at ends of the pipe runs must be provided
to facilitate flushing of the lines and pressure testing prior to operation.
SIZE CODE IDENT NO, REV

WeA 16603 ARn6T
OB201
EVERETT. WASHIINGTON
SCALE rSHEET 5
A- 7
3-0. FABRICATION
1. The equipment and components should be finally located and fixed In place
before fabrication of the interconnecting piping is started. All case brenthers
and shaft seals should be tightly masked, no units dlaassmbled nor opened
for inspection nor any hydraulic piping attempted while welding. chipping.
sandblasting or painting Is being done in the Immediate area.
2. Welding and brazing must be performed by qualified welders using Customer

Specification procedures. These procedures, if properly followed, shaH.1produce
welds which are free of defects that would adversely affect the service of tne
weld joint.
2A. It is required that the pipe be purged with inert gas during the root pass.
This practice reduces the possibility of root pass embrittlement due to
atmospheric contamination.
3. All inside edges of pipe and tubing must be reamed or deburred to remove a.'
sharp or feather edges remaining after cutting the pipe to length.
4. All stress relioving if required must be done after fabrication and prior to
the cleaning process.
5. It is desirable to have not more than one band in each length of pipe. The
entire length of pipe should be visible for inspection. Flange or union
joints must be provided In pipe runs i,hichinclude more than one bend (see
figure 1).
FLANG( OR UNION
JOINTtyp I
FIG I
SIZE CODE IDENT NO

.......... . A 16603 A30575
EVERETT. WASHINGTON 1I SCEH
SCALE SHEET A
A-8
3-0. (Cont)
11i. Cold bends in the piping are preferable to welded elbows. The bend radius
should be a minimum of five times the nominal pipe size as shown In figure 2
However, any contract specifications relating to minimum bend radius.
flattening at bends, thinning of wall% at bends. etc.. must be adhered to.
'MIN BEND
P AD ;15 NO.
PIPE SZE
DONOTPACK
NOTE
PIPE WITHSAND
WHIENSENDING
PREFIPAED METI CC
A 16603 A305765
EVERETT. WASHINGTON *201
SCALE -- SHECT 7
A-9
3-0. (Cont)
V. When elbowi-s
must be used due to space limitations, use long radius butt weld
elbows of the same size and wall thickness (schedule) as the piping. Do not
use socket weld elbows.
Butt kelded elbows with backup rings are to be avoided unless the rings are
completely removed after welding. The backup rings catch foreign material that cannot
be dislodged during cleaning, yet often will be dislodged during hydrostatic
testing or when operating the equipment (figure 3).
Butt welded elbovwsithout backup rings can be welded successfully by using
gas tungsten arc welding (hellarc wielding) for the first pass with inert gas
purging as previously described.
HILIARC I., PAU
DIRT COLLECTS
LIFIER MING
SIJ"T WELDING "T
mI Ew.C
IACKUP IING
ITOSE AVOIDEDI
FIG 3
SIZE COOEIDENT NO.
EVERETT. WASHINGTON 0=HE1r

W2l SCALE S
A-1O
S. DELETED
SIZE CODE IOENT NO. V
EEETWAHNTNmlA 16603 A305765~~ ER
A-11
3-0. (Cant)
9. Water tight deck or bulkhead penetrations should be straight lengths of pipe or
tubing not more than 18 inches In length, with a flange or fitting on each end.
See figures 7 and I for suggested design details. These methods will allow
pickling of the pipe assembly prior to final installation, permitting visual
Inspection and cleaning if required after installation.
K
DIC 044 BULKMEAD 4 PLTE 00 AN HOLE INOECK
OP .O LARGE ENOUGHTO
cLEA.PIPE OES
UWELOTOPIPE PRIOR TO
PICKLING AND CLEANING
, , LANGE
V LTO BVLKMEAD OR
0DECR
AT RINL IPISTALLATON
PIG 7
i SIZE CC IDENT NO. A
Y~~BR
~A 16603 REV76
EVERETT, WASHINGTON U201 1 1

SCALE SHEET 10
A-i12
1-0. Nonwterih eko ukedpntainmtosaesgetdi
SLLiiiA OROE'
WELDLT
TBRO RT SLEEV DoANOLE I
PICKINGAND
LEA IG
SIZEE
CODEIDNEN
SCA-LM SHEET,,
A- 1
3-0. (Cont)
IN NG
IMPMC -LAM114
;
VJLPENNAD" OPENINGLAAEICO
UG"
TO CLEAR PIE END
PiTTING ON FLANGE
*ULK145A0ON
DECK
11. Flange connections, O-ring unions, or Crayloc type couplings must be used to
join all high pressure assemblies. The flanges must fit squarely on the
mounting face and be drawn up evenly to avoid distortion or uneven compression
of the sealing elements, and to prevent the formation of pockets that will hinder
the flushing operation.
type. Butt iweld

12. Use butt weld (veld neck) flannes instead of the socket i.,eld
flanges provide a more uniform transition between pipe and flanne as compared
to socket weld fittings, and thus avoiding stress concentrations at the joint.
The interior of the pipe and flanges must be carefully cleaned tr rcrove all
welding slag or spatter, brazing flux, scale under a surface weld, and other
contaminants. If backinn rinns are used with butt welds to attach flanges, the
backing rings should be completely removed after welding (figure 11). lutt-
welded joints 11thout backup rings may be welded successfully by using heliarc
(GTAW) welding for the first pass (figure 12) and inert oas purging as noted
earlier.
SIZE NO
CODE bDENT
" A 16603 A3057,5 REV 0

EVERETT, WASHINGTON ,
SCAU SHEET _12
A-14
WIrTID FLANGS
U4R"IOTICTIED "FJACE
EASILY DAMAGED DIRT COLLfCTS
DURING HANDLING REMOVE 0ACE LIDE
LEAKS RESULT RING IF U Ij
NnT RECOMMENDED
FIG It
PRO~fCTIvt caVERHELIPCSTAS
SlEF ACIFL-
RECOMMENDED
FIG t2
SIZE COOE IOENT N REV
weSe~n Mac A 16603A0S6D

ScALE SMEET 13
A-15
3-0 (continued)
BLANK PAGE
SIZE 0001 IDENT NO. REV

IWO8TR "N w*-'y A 16603 A305765 E
EVERETT, WASHINGTON Owl20I1
SCALE Z SEEET 14
1314
A- 16
3-0. (Cont)
13. It Is imperative that blanking material be installed between~ pumtp or motor

openings and their respective flanges during the pipe fabe~kating process
to keep weld spatter and other contaminants out of the pre?iously cleaned
hydraulic system componients. All pump, motor or valve Wots and ends of
&IlIcompleted piping must be kept closed and protected at allI times except
when fitters are maki-n-71nal joints at assembly.
14, All piping should be fitted so that when each Section of pipe is in place, all
fittings and connectors align with their corresponding fittings and connectors
without forcing. This will reduce stress on the pipe and the possibility of
damage to components.
15. After the piping Is fabricated, fitted. and supported in place, each pipe section
should be identified prior to cleaning and inspection. The inspector should keep
record of the pipe assemblies as they are processed through cleaning and final
installation to assure conformance to all cleaning, installation and hydrostatic
testing procedures for all piping components.
SIZE CODE IDENT NO.

W :TRf1 l~" IA 16603At5S
EVERETT.1111,11,9iNGTON U201 jSCM.I ISEE 15~is
A- 17
4-0. CLEANING AND PICKLING
4-1. Cleaning and pickling of Interconnecting piping is required to fully remove

foreign substances such as oil, grease, paint, soil, mill scale, etc.. which would
otherwise cause damage to equipment components. These components have under-
gone a similar cleaning and pickling process at the factory and must not be contain-
mated by dirty piping.
The pickling process for Interconnecting piping should be accomplished immediately

prior to hydrostatic testing, Installation and charging of the system.
Many different products and processes are available which will effectively clean
and pickle pipe, provided the manufacturers' instructions are followed. No
preference for a given product is implied; however, the following basic steps
must be taken to ensure that the piping Is cleaned and Is kept clean.
11-2. CLEANING. Prior to fabrication the piping should be cleaned by wire brushing,
Including the interior, and blasted with high pressure air to remove loose particles
Boiler tube brushes or commercial cleaning apparatus may be used for this purpose
4-3. PICKLING CARBON STEEL PIPE. See appendix A for suggested makeup and
temperature of cleaning and pickling solutionsL
Face shield, protective gloves and other protective clothing must

be worn when working with pickling solutions to prevent injury
to personnel.
1. Immerse in a caustic bath solution for 15 minutes or longer to remove paint,

varnish, grease, etc.
2. Rinse in clean water.
3. Immerse in acid solution and exercise caution with respect to duration of

immersion. Leave pipe in bath only long enough to permit adequate pickling
as determined visually. This caution is necessary to ensure and protect the
mechanical properties of the pipe, tubing, and end fittings
4. Rinse in a clean water bath immediatly following completion of the previous

step.
S. Immerse In a hot water neutralizer bath for several minutes,
6. Rinse in a clean water bath.
Allow to drain and dry, Drying by air blasting is not recommended because
it
7.
will contaminate the piping
A 16603 A3O,7,5
EVERETT WASHINGTON "201
SCALE 7SN[ET 16
A-18
4-3 (Cont)
8. Inspect the pipe for cleanliness. One suggestavd method is to pull a clean,
lint-free cloth soaked In kerosene through the pipe. Another method.
especially if the pipe is not straight, is to tape the ends Closed and with
the taped end down, tap the pipe with a hammer In various places. If foreign
material is found on the cloth or tape, the pipe must be repickled. Inspection
tion and preservation should be completed with a maximum tim delay of one hour.
9. Coat the inside of ferrous piping with clean preservative fluid (solution
determined by consideration of the fluid used In the system.) Capthe ends
and wrap the end fittings (flanges) with protective material.
4-4 PICKLING AND CLEANING CORROSION-RESISTANT STEEL PIPE. Corrosion-resistant
steel pipe that is not to be welded may require only steam cleaning, and where
adherent contaminants persist, interior and exterior steel wire brushing and
blasting with high pressure air is required. See Appendix B for suggested makeup
and temperature of cleaning and pickling solutions.
I .ARM I
Face shield, protective gloves and other protective clothing must be worn
when working with pickling solutions to prevent injury to personnel.
1. Immerse in a caustic bath solution for 15 minutes or longer to remove paint,
varnish, grease, etc.
2. Rinse in clean warm water.

3. Immerse the piping assenly for 10 to 15 minutes In the acid solution and
rinse in a clean warm Water bath immediately following.
4. Allow to drain and dry. Drying by air blasting Is not reconmended because it
will contaminate the piping.
4-5 PICKLING NONFERROUS PIPING (copper, copper-nickel, bronze). See Appendix C
for suggested makeup end temperatures of cleaning and pickling solutions.
[I-
Face shield, protective gloves and other protective clothing must be worn
when working with pickling solutions to prevent Injury to personnel.
1. Imerse in a caustic bath solution for 15 minutes or longer.
2. Rinse In clean warm water bath.
3. Immerse in acid solution at room temperature.
1wesTeRn
............ Utn
m
SIZE
A
C00£ IDENT NO.REV
16603 356
EVERETT. WASHINGTON 912 LE SHE 1
A-19
4-S. (Cont)
4. Rinse in a clean warm water both.

5. immerse In a neutralizer solution for several minutes.
6. Rinse in a clean warm water bath.

1. Allow to drain and dry. Drying by air blasting is not recommended because it
will contaminate the piping.
B. Additional flushing of the assembled equipment is required to remnove the

brazing fluxes. Suggested solutions for this are given in Appendix C
SIZE CODEIDENT NO. REV
fE.VERETT. WA ,SHINGTON 3201 [ 6 0 356
A-20
S-0. HYDROSTATIC TESTINC PRIOR TO INSTALLA~TION.
Observe appropriate safety precautions to prevent injury %apersonnel

and damage to equipment during tasting procedures.
A hydrostatic test should be performed prior to installation using clean filtered

preservative fluid for hydraulic lines and water for corrosion-resistant pneumatic
lines.
The pipe assemblies may be tested Individually or In groups. If leaks occur. they
must be repaired and the pipe recleaned, repickled and retested. After the hydro-
static test, drain the lines and cap the ends. being careful to avoid introducing
contamination. Allow pneumatic piping to dry before capping the ends.
SIZE CODEIDENT NO.

1GST8..
'0.-.- A 16603
EVERETT, WASHINGTON 9"201]
A-21
.6-0. INSTALLATION
I. The piping should be installed as soon as possible after pickling and hydro-
static testing. Hydraulic piping should be filled with the recammended
operating fluid within one week after Installation. A shorter period is
preferred in especially humid areas.
2. No abrasive blasting, chipping, grinding or use of air tools may be permitted
In the area during Installation. Airborne dust must not be permitted in the
area while the clean pipes are uncapped and installed.
3. No turning, drilling, tapping, welding (except deck or bulkhead penetrations)

nor heating of pipe. will be allowed. If any rework of the pipe is necessary
during installation, the pipe sections must be cleaned, pickled and hydrostatic
tested again before final Installation.
4. When welding deck or bulkhead penetration sections in place, make sure that
the openings are covered and that the end fittings are protected from weld
spatter.
5. When installing end joining pipe sections make sure that the sealing surfaces
are clean, free from nicks and scratches and that 0-rings and gaskets are new
and compatible with the fluid tobe used in the system.
6. Tighten flange bolts evenly.
r~ii~n~ey Machinery 116603A356

AestR
SIZECOOEIDENTNO. REV
EVERETT WASHINGTON 1201 ,A

SCALE SHEET 2o
A-22
7-0. HYDROSTATIC TESTING AND FLUSHING AFTER INSTALLATION.
7-1. GENERAL. The entire piping system must be pressure Misted before
crneiicting to WCC equipment. The opening of and connecti 'u to WCC components
should take place In the presence of customer Inspection pers.Wmel and a WCC
reresentative.
1-2. HYDRAULIC PIPING. The pressure test and flushing operation should be
accomplished using a separate (commercially available) hydraulic power unit.
The pump must have adequate capacity to provide at least 20 feet per second flowN
velocity in the lines when flushing. Use the same fluid that will be used in opera-
tiont of the hydraulic system.
When practicable, more than one pipe run may be tested and subsequently flushed
at the same time. See figure 15S.
PIPING
INTERCONNESCTING
PRESSUREGAGE
PRSUR IE RE JNPI.E
JUMPSG I
EVERETT. WASHINGTON ff201

I ISIZE ICODE IDENT NO.I
SCALE
ITeRn.111" A305765
A-23
7-2. (Cont)
Inspect the return filter element frequently and replace elements as required. When
the elements appear clean and frele of particles, take a fluid sample from the return
end of the piping. A particle count of the sample should meet WNAS Class 7* (noteci
below) for piping that serves piston pumps. For piping serving vasne Pumps and
Ceor pumps the cleanliness level should be Class 95. Keep flushing until the clean-
Unes.lve is met. When flushing hydraulic lines It is good practice to switch the
supply and returr hoses from the test unit at least once, thus reversing the flow in
the pipe runs.
TAUS 1. MAXiMVM CONTAMINdATIONI

LIMITS PS11N13Ia
______ aA
ONse Im iL LAMPLI SIZEIl
11.025 1.4211 ,16 11.750 IIA50 2A0 4550 III= 182.400
4500 6,100 1:20o 2 .400

2113 9 1.012 2 505
BW S0
1010 's 50 IGO 380 720 1A40 no8 5.760
o" 100i a 1e 32 ee In 214 S12 1,024
*unless otherwise specified on system drawings or specifications.
7-3. PNEUMATIC PIPING. The hydrostatic pressure test and flushing of corrosion
resistant steel piping should be accomplished using clean fresh water and dried with
clean filtered air.
Flushing of nonferrous piping (copper, Copper-nickel, bronze) is required to

remove all brazing fluxes. Suggested solutions for this are given in Appendix C
When hydrostatic testing and flushing operations are complete, connect the piping
to respective components. When opening the port or any component, first clean
the immediate area around the port. Use extreme caution when connecting to a
previously cleaned system to prevent foreign material from entering the system
SIZE CODE IDENT NO.

J8'rRflj= "d A 16 6 03 A305765
EVE RE".,WASHINGTON SM6 SCAE01
.i LiV;.L -U
A-24
I-0. Charging Hydraulic System.
I. To repeat, the purpose of this document is to provide guidance for construction
and cleaning of customer supplied interconnecting piping for Western Cear
Corporation equipment, thus reducing the potential for conlaminlltion problems
affecting WOC supplied components.
2. Where WGC supplied components are not shipped charged with appropriate
fluid they must also be flushed and inspected prior to charging
3. Customer supplied reservoirs where used must be similarly prepared
4. When the system interconnecting piping has been properly assembled, hydro-
static tested and flushed and all other components prepared as noted in steps 2
and 3 above, the equipment can be plumbed and system charging begun.
S. All hydraulic fluid added to the system must be filtered through a 3-10 micron
filter. Good housekeeping procedures must be followed to minimize all
potential contamination problems in transferring fluid from the shipping
containers to the hydraulic reservoir.
SIZE CODE IDENT NO.

we s'reRnl D.=
"......Y 16603 A30576S
EVERETT. WASHINGTON 9g201
SCALE SHEET 23
m,(.P(Ii.o ,rfl -
A-25
APPENDICES
Appendix A -Carbon Steel Pipe Pickling and Treatment
Appendix B8 Corrosion Resistant Steel Pipe Pickling and Treatment
Appendix C -Nonferrous Pipe Pickling and Treatment (copper.

copper-nickel, bronze)
REV
CODE IDENT NO.
... .. f1.h~n SZf
A 16603 A305165
EVERETT. WAS14INGTOt U20 SCALE I SMEET2li
A-26
APPENDIX A
Carbon Steel Pipe Pickling 9 Treatment
1. Caustic Bath (Cretase and Paint Removal)

Solution: Roprepp Rt (R. 0. Hull Co. 2 Pounds
Water: 1 gallon
Temperature: 180 * 5 degrees (82 * 3 degrees C)
Time. 1S minutes or longer, depending upon
degree of contamination.
Neutralizer: Rinse in clean water.
2. Acid Solution Pickling (Scale and Rust Removal)
The acid should always be added carefully to the water. Do not

add the water to the acid
Solution. Hydrochloric Acid t35 to 36 5
assay) with commercial inhibitor 43 gallons
Water 1 gallon
Temperature Ambient
SIZE ICODE IDENT NO. REV
T. *A .SHINGTON
fE.VERE"T N201 A 16 0A375
SCALESHEET 25
A-27
Appendix A (Cont)
Leave pipe In bath only long enough to permit adequate pickling

as determined visually.
Time: As visually determined by removal of scale and rust
3. Treatment Following Pickling

Solution. Sods Ash (as required to maintain
a 9to 10Phi 2 - 4ounces
Non-Ionic welting agent VWR9N9

(VanWaters and Rogers Co.) 3.8 ml
Water. 1 gallon
Temperature. Ambient
Caution The maintenance of the Ph value noted above is critical and

must be frequently monitored. The product of neutralization
of acid carry-over from the pickling tank is common salt
(NACLI which if allowed to accumulate will promote flash
rusting of the pickled pipe.
SIZE COOEIDENTNO. REV

lwsenA 16603 A305765
IVIREfl. WASI4INGTOt4 "201 SET 2
A-28
APPENDIX B
Corrosion Resistant Steel Pipe Pickling & Treatment
1. Caustic Both (Grease and Paint Removal)
Solution: Trisodium Phosphate (TSP) or

Sodium Hydroxide (lye): 7-10 ounces
Detergent. nonionic (Polyethylene-
glycol Monoalkylaryl ether) 1 fluid ounce
Water 1 gallon
Temperature: 200 + 10 degrees F (94 - 6 degrees C)

Time: 15 minutes or longer, depending upon degree of
contamination.
Neutralizer. Rinse in clean warm water, 120 degrees F (48 degrees C)
or higher
2 Acid Solution-Pickling (Passivation)
The acid should always be added carefully to the water. Do not

add the water to the acid.
Solution Nitric Acid 13-20 Fluid Ounces
Hydrofluoric Acid (60%) 1-2 Fluid Ounces

Water 1 gallon
Temperature: 130 * 10 degrees F (55* 6 degrees C)
Time 10 to
1I minutes
Neutralizer: Rinse In a clean warm water bath

we eRn "W A 16603 A305765
N3201
EVERETT. WASHINGTON
SCALE ISHEET 27
A-29
APPENDIX C
Nonferrous Pipe Pickling and Treatment (Copper, Copper-nickel. Uronre)
I.Caustic Bath (Grease and Paint Removal)

Solution: Trisodlum Phosphate (TSP) or
Sodium Hydroxide (lye) 7-10 ounces
Detergent, nonionic (Polyethylene-
glycol Monoalkylaryl other) 1 fluid ounce
Water: I gallon
Temperature. 200:*tO degrees IF (Si4 - 6 degrees CQ

Time. IS minutes or longer, depending upon degree of
contamination.
Neutralizer: Rinse in clean warm water, 120 degrees F (it8 degrees C)
or higher
2. Acid Solution - Pickling
The acid should always be added carefully to the water. Do not add
the water to the acid.
Solution Sulfuric Acid. 66 degrees Baume.
Specific Gravity 1.93 7-14dfluid ounces
Water. 1 gallon
Note If red stains appear add 2-4l ounces per gallon

of water of sodium dichromate to above solution
Temperature. Room Temperature

Time As visually determined by removal of surface
contaminants.
SIZE CODE IENT NO. REV

IO ~~ A ' 16603 IA1105765
[VaE ET. WAsING1ON 96201 1sCL =ET2
A-30
Appendix C (Cant)
3. Treatment Following Pickling
a. Rinse In clean water bath
b. Immerse for several minutes In an, alkaline bath containing four ounces
(par gallon of water) of soda ash
c. Rinse in clean warm water bath
4t. Flushing of installed system for removal of brazing fluxes

Solution: Glacial Acetic Acid 5 gallons
Water 95 gallons
Temperature: 120-1410 degrees F (419-60 Degrees C)
Time: Circulate for one hour
Neutralizer: Flush with warm water. Repeat flushing procedure

as necessary. Drain and dry piping upon completion.
SIZE CODE IEN NO REV
A 166030 A30576S
EVERETT. WASHINGTON N0 29
SCA IS"EE
A-31/(A-32 blank)
APPENDIX B
ARP 598
Fluid Contamination Particle
Count Procedure
B-1/(B-2 blank)
PROCEDURE FOR THE DETERMINATION OF PARTICLE CONTAMINATION
OF HYDRAULIC FLUIDS BY THE PARTICLE COUNT METHOD
(Extract from ARP 598 Society of Automotive Engineers, Inc.)
1. SCOPE:
This test describes a self-checking procedure for the determination of
particulate contaminant five microns or greater in size in hydraulic fluids by
the particulate count method. A maximum variation of two to one (+33% of the
average of two runs) in results should be expected for replicate counts on the
same sample, providing that the procedure is followed closely and the precau-
tions presented in paragraphs 18 through 21 of the procedure, regarding mani-
pulation, check samples and self-checking aspects, are observed.
2. OUTLINE OF METHOD:
A fluid is filtered through a type HA Millipore filter disc using vacuum
to impinge the contained contamination particles upon the surface of the filter.
The filter disc is examined microscopically (using oblique incident lighting) to
determine the amount of contaminant present in stated size ranges.
3. APPARATUS:
Pyrex filter holder, Millipore Cat. No. XX 10047 00, or equivalent, which
includes:
a. A fritted glass base and rubber stopper.

b. A holding clamp.
c. A 250 ml Pyrex glass funnel

d. A filter cover for the glass funnel to minimize contamination from the
air passing through the funnel during the vacuum filtration process.
e. The optimum cover would incorporate a Millipore filter in the cover
device.
f. 0.45-micron Membrane Filter, type HA Black Grid 047 mm diameter Millipore
or equivalent. These to have an imprinted grid on 3.08 mm centers. Each grid
square is equal to 1/100th of the total effective filtering area of the filter
disc when used in the Millipore Pyrex filter holder (above).
g. Vacuum flasks.
h. Aspirator or Vacuum Pump, capable of pulling a minimum 26" of mercury.
i. Plastic Petri Dishes, disposable, Millipore Cat. No. PD 10 047 00, or

equivalent.
J. Forceps with unserumed tips.
B-3
k. Sample bottles, small mouth, glass, etched or otherwise permanently
marked to indicate 100 ml sample size.
1. Microscope with mechanical stage, capable of magnification of approxi-

mately 45X and 90X. For 90X magnification, the recommended objective is 10 to
12X but at least 1X with a numerical aperture of at least 0.15. The optimum
equipment is a binocular microscope with a micrometer stage. A stereo
microscope should not be employed with this procedure.
m. Measuring eyepiece - Ocular Micrometer - Baush & Lomb Cat. No. 31-16-01,
or equivalent. (See figure 1 following paragraph 17.)
n. Stage micrometer, 0.1 to 0.01 mm calibration.
o. Microscope lamp, high intensity, variable. This lamp is to be used as a

source of oblique incident light; Leitz microscope lamp "Monla"' (or equiva-
lent); 5,000-6,000 candlepower at filter surface.
p. Wash bottles, Pyrex glass.
q. Mylar plastic films, 2" x 2" x .002".
4. REAGENTS:
a. Distilled water.
b. Acetone free, reagent grade isopropyl alcohol.

°
c. Petroleum ether 30"-60 boiling range (Freon TF or equivalent may be
substituted where explosive vapors are not accepted.)
5. FILTRATION OF REAGENTS:
a. Filtration Process: (for initial establishment of clean conditions for

filtration of reagents).
b. Clean all apparatus as follows:
(1) Wash with self-rinsing type detergent and water.

2
(2) Thoroughly rinse with hot soft tap water.
c. Assemble Pyrex filter holder with filter disc in place.
"Monla"--6-5. A microscope lamp with focusing illuminating lens on pillar

stand with separate transformer.
2 When filtered distilled water, filtered isopropyl alcohol, and filtered petro-
leum ether have been obtained, the apparatus should be cleaned as outlined in
paragraph 7.
B-4
d. Filter 100-200 ml of isopropyl alcohol into the filter flask. Remove
entire Pyrex Filter assembly and rinse the filter flask with the filtrate.
e. Repeat paragraph 5d three times.
f. Filter a 100-200 ml volume of petroleum ether into filter flask. Remove
the funrel assembly and rinse the filter flask with the filtrate.
g. Repeat paragraph 5f three times.
h. Filter the desired volume of the solvent.
6. CONTROL ANALYSIS FOR REAGENT CLEANLINESS:
a. Clean a Pyrex filter holder and a wash bottle using the process outlined
in paragraph 7.
b. Place 500 ml of the filtered reagent in the cleaned wash bottle.

c. Rinse the upper surface of the filter disc with the filtered reagent from
the wash bottle. Place the disc on the fritted glass base and complete the
assembly of the filtration apparatus.
d. Pour a 150 ml portion of the filtered reagent into the funnel directly
from the filter flask. Filter the sample using the method for processing a
blank described in paragraph 15a, except that the filter disc is to be rinsed
only once and with a 50 ml volume of the filtered3 reagent from the wash bottle.
If the desired cleanliness level is not obtained, repeat the cleaning and fil-
tration process using the filtered reagents on hand for the cleaning process.
7. CLEANING METHOD FOR APPARATUS AND SAMPLE BOTTLES:
8. GENERAL INSTRUCTIONS: Lint-free coats should be worn by personnel per-

forming cleaning operations to preclude excessive fiber contamination.
9. CLEANING METHODS: Each item of filtration apparatus will be cleaned
before each run of samples and each sample bottle and cap will be cleaned before
each use by the following method:
a. Rinse with two successive rinses of petroleum ether.
b. Wash thoroughly in a solution of detergent and hot water. Rinse twice in

hot tap water (soft).
c. Rinse with filtered distilled water twice.
3 Contamination content of a 150 ml sample of filtered reagent, so processed,

should be greater than the values specified for a blank analysis. See foot-
note 6, page B-6 for blank analysis specifications.
B-5
d. Rinse with filtered isopropyl alcohol to remove water.
e. Rinse with filtered petroleum ether.
(1) Filtration Apparatus: After rinsing with petroleum ether, hold in

an inverted position for 15 seconds to allow drainage and evaporation of the
petroleum ether.
(2) Sample Bottles: After rinsing with petroleum ether, allow a small
quantity of petroleum ether to remain in the bottle since the vapor pressure
will help to preclude contamination when the bottle is opened. Rinse a pre-
viously clean 2" x 2" plastic film with filtered petroleum ether. Place the
plastic film over the top of the bottle and install the bot+le cap.
10. SAMPLES:
11. A 100+5 ml sample is to be used for this procedure.
12. SAMPLING PROCEDURE: Samples for this test method should be as repre-
sentative as possible of the fluid being sampled. Procedures for procuring such
samples will, of necessity, have to be established by individual plants or
laboratories. Extreme care should be taken to preclude the introduction of
external contamination at this point. To assure reproducibility, the sampling
program should be checked at the outset by the testing of replicate samples from
the sampling port.
13. TEST PROCEDURES:
14. TEST INFORMATION:
a. Personnel performing contamination analysis should wear lint-free

laboratory coats.
b. Samples are to be obtained in accordance with specified sampling
procedures.
c. The filtration apparatus is to be cleaned just prior to use by the method
outlined in paragraph 7.
d. The microscope and its accessories should be maintained in a state of
maximum cleanliness. The microscope and accessories should be protected by a
dust cover when not in use.
4 When high humidity conditions exist, paragraph 9e miy be followed by an

additional isopropyl alcohol rinse to prevent condensation.
B-6
e. The processing and microscopic analysis of samples should be performed in
as clean an area as possible within the confines of a modern, air-conditioned
laboratory. A dust control room5 is desirable, but not essential for validity
and reproducibility. Smoking should be prohibited, both as a safety factor and
to prevent the extra contamination of samples. The ingress and egress of per-
sonnel in the laboratory area should be limited.
15. FILTRATION PROCEDURES:
a. Procedure for Blanks: Prior to each sample analysis, a blank analysis is

to be performed on 50 ml of filtered petroleum ether contained in a regular,
clean sample bottle. The procedure used will be identical with that described
below, with the exception that step 15b(S) will be omitted. (The total amount
of petroleum ether used in the blank analysis should be 200 ml, which is approx-
imately the volume used in the filtration of sample.) The blank analysis is
performed to determine the amount of contamination being introduced by the
sample bottle, filtering process, filtering equipment, filter disc, and the
filtered petroleum ether. Identify the blank as to the sample number or an
identification tag and attach it to the lid of the petri dish.6
b. Procedure for Samples: Using forceps, remove one filter disc from its
container. Rinse the top surface of the filter disc with a stream of filtered
petroleum ether from a wash bottle. Place the filter disc printed grid side up
on the fritted glass base.
(1) Immediately lower the filter funnel onto the fritted glass base,
secure with the holding clamp and place cap on top of the filter funnel. (D:
not slide filter funnel over the filter disc during this process.)
(2) Thoroughly agitate the sample bottle to assure that all solid
particles are in suspension.
(3) Remove the sample bottle cap and plastic film. Remove the filter
cap and pour sample into the filter funnel. Replace the filter cap.
(4) Pour 100 ml of filtered petroleum ether into the sample bottle;
replace the plastic film and bottle; agitate and proceed as in 15b(3).
(5) Rinse funnel walls with approximately 50 ml of filtered petroleum

ether from wash bottle.
(6) Apply vacuum to the filtering apparatus. When the filtration is
APPROXIMATELY ONE-HALF COMPLETE, release the vacuum.
5 A hood pressured with filtered air is especially advantageous for both

microscopy and filtration. At a minimum, a dust cover such as a polyethylene
bag, with appropriate openings, pulled over the barrel of the microscope, is
required to preclude fall out of dust from the air.
6 The maximum particle count value of a blank analysis shall be no greater than
10% of the count of an acceptable sample for a specific laboratory.
B-7
(7) While some liquid still remains in the funnel, using the stream from
a wash bottle, carefully wash down the sides of the funnel with filtered petro-
leum ether (approximately 50 ml). Replace the filter cap.
(8) Apply vacuum and allow to operate until the filter disc is com-
pletely dry. Do NOT rinse the funnel walls further after the filter has become
dry, as this will upset the distribution of particles on the filter surface.
Turn off the vacuum and simultaneously remove the holding clamp and filter
funnel so that the filter disc remains on the fritted glass base.
(9) Using forceps, carefully remove the filter disc from the top of the
fritted glass base. Place the filter disc, grid side up, in a clean petri dish
and replace petri dish cover. Identify the petri dish using a sample identifi-
cation tag. The test may be delayed overnight, if necessary, after completing
this step.
16. MICROSCOPE ANALYSIS PROCEDURE: Particles are to be counted and tabulated

in the following order: fibers, particles greater than 100 microns, 50-100
microns, 25-50 microns, and 12-25 microns, and 5-15 microns. Particles smaller
than 5 microns are not to be counted by this method. Fibers are defined as any
particle whose length to diameter ratio exceeds 10 to 1 regardless of composi-
tion. Fibers are counted as particles and not differentiated unless their
length exceeds 100 microns. The size of a particle is determined by its great-
est dimension. [See paragraph 16d(7).]
a. Place petri dish under the microscope dust cover and remove petri dish
cover.
b. Adjust the microscope lamp intensity to obtain maximum particle
definition.
c. A magnification of approximately 45X shall be used for counting particles

25 microns or larger; approximately 90X for particles smaller than 25 microns.
The recommended objective to obtain the 9OX magnification is 10 to 12X power in
conjunction with the appropriate eye-piece.
(1) Using a stage micrometer, calibrate the measuring eye-piece (ocular

micrometer) for each magnification.
d. Method of Counting Particles: Other statistical methods may be employed

provided that the method shows agreement with the values of the certified
standard samples as described in section 18.
(1) In obtaining the number of particles of a given particle size range,

the number of particles on a representative number of grid squares on the filter
disc are counted. From this count, the total number of particles, which would
be present on the total effective filtration area of 100 imprinted grid squares,
is calculated.
B-8
(2) If the total number of particles of a given particle size range is
estimated to be between 1 and 50, count the number of particles over the entire
effective filtering area.
estimated to be between 50 and 1,000, count the number of particles on 20
randomly-chosen grid squares and multiply the number by 5 to obtain the total
statistical particle count.
estimated to be between 1,000 and 5,000, count the number of partiles on 10
randomly-chosen grid squares and multiply the number by 10 to obtain the total
statistical particle count.
(5) If the estimated total number of particles of a given size range

exceeds 5,000, count the particles within at least ten (10) randomly-chosen unit
7
areas. To arrive at the total statistical count, the sum of the particles
counted in the areas is multiplied by the calibration factor.8
(6) In no case shall the total number of particles in a unit area exceed
50 particles of a size range. See figure 1 for the alternate unit area.
(7) If a particle lies on the upper or left boundary line of a counting
area, count this particle as if it were within the boundaries of the counting
area.
(8) The largest dimension of the particle determines the size category
into which the particle is placed.
17. CALCULATION OF CALIBRATION FACTOR:
a. The calibration factor is the ratio of the effective filtration area (100
grid squares or 9.6 sq cm) to the area counted.
b. To arrive at the calibration factor, start with the microscope adjusted
for the power under consideration.
c. Using the stage micrometer, measure the length of the ocular micrometer
scale which is used to define the width of the unit area. The length of the
unit area is defined by the side of the grid square or 3.08 mm.
7 The basic unit area for the statistical count not based on the grid markings
on the filter, when using the ocular micrometer, will be the area defined by
scanning the length of an individual grid square with the length of the ocular
micrometer scale or any appropriate portion of the scale.
S Calibration factor defined in paragraph 17.
B-9
FIELD OBSERVED
THROUGH MICROSCOPE
1
SUGGESTED
UNIT AREA
ALTERNATE UNIT
AREA FOR HIGHLY
OCULAR CONTAMINATED
SAMPLE
MICROMETER
SCALE
GRID SQUARE
Figure I
Figure 1 shows two possible unit areas within the grid square for statistical
counting. The calibration factor is defined as the effective filter area
divided by the total area counted and may be calculated from the following
formula:
960 312
F= x x N or
where F - the calibration factor
N = the number of basic unit areas counted

L = The calibrated length of the ocular micrometer scale or portion of
scale used in defining unit area in millimeters
3.08 - the side of a grid square in millimeters
For example: Using a lOX objective and a 5 mm ocular micrometer, counting 10

basic unit areas, the calibration factor would be:
312
F a 0.5 x 1U . 62.4
and the total number of particles of a size range would be:
NT - 62.N c
where Nc - the number of particles actually counted in the 10

basic unit area
B-10
18. SELF-CHECKING PROCEDURE:
19. MANIPULATION OF THE MICROSCOPE: Facility in the manipulation of the

microscope can only be acquired by practice in perfecting focus, adjusting
illumination, and sizing particles with the ocular micrometer. In order to
obtain accurate results in contamination analysis, the operator must determine
the capabilities and characteristics of his optical equipment and be able to use
this equipment without hesitation and in such a manner as to take full advantage
of these capabilities. The widest variable in results obtained in applying the
ARP is caused by the variance between companies in microscope techniques. It is
therefore important, in order to establish meaningful and comparable analytical
results, that the optical techniques described in the ARP be followed closely.
and that these techniques be checked by means of check samples as defined in
paragraph 20. Calibration of the ocular micrometer and individual interpreta-
tion of the size range limits defined by the ocular micrometer rulings should
also be checked by means of calibrated standards.
20. CHECK SAMPLES: Sample filter discs, permanently mounted and containing
representative contaminant from hydraulic fluid systems should be used to check
the optical portion of the analytical procedure. The actual particle count of
these filter discs should be known within the limits of statistical accuracy
and, if possible, should be verified by more than one laboratory. The procuring
agency may provide these check samples or may recommend a source of suitable
samples.
21. SELF-CHECKING ASPECT OF THE PROCEDURE: By employing blank analysis for

checking the filtration and mounting techniques, and samples for checking the
microscope counting aspect of the ARP, laboratories may provide themselves with
a means for checking the repeatability and reproducibility of the procedure. By
analyzing replicate samples from the same sampling port, the laboratories may
determine the accuracy and reproducibility of sampling procedures.
a. Repeatability: (precision) The precision of results obtained with the
ARP should be initially checked and periodically retested by analyzing replicate
blanks, samples, and viewing fields in accordance with the ARP. The precision
of results obtained in a single laboratory should also be checked by having all
operators concerned occasionally analyze duplicate test samples and compare
results.
b. Calibration: (accuracy) In order to establish meaningful inter-
laboratory acceptable contamination levels and filtration efficiency data, it is
important that the accuracy of the analytical procedures as employed in any
individual laboratory be established by means of the calibrated industry-wide
check samples. In this manner the Aircraft Recommended Procedures as described
herein becomes a self-checking procedure on both an individual and inter-
company scale, as well as on an industry-wide basis.
B-11/(B-12 blank)
APPENDIX C
VENDOR DATA FOR PNEUMATIC EQUIPMENT
CONTENTS
COMPONENT
(MANUAL
REFERENCE) VENDOR DATA PAGE
Air Power Cylinder, Parker- Catalog 0920, Medium Duty Air
Model CO (Fig. 6-1) C-3
Hannifin Cylinders, Seriec C
Bulletin 0920-Mi, Installation C-5

and Service Instructions
C-1/(C-2 blank)
Parker Series C e Features
Medium Duty Air Cylnders Specificalios
RENEWABLE FLOATING NON-SCORE, LOW-FRICTION
CUSHION BUSHING WITH BUILT IN CHECK VALVE PISTON CONSTRUCTION
4CAP END)
BRNE USHINGm
SO
HARD COATED ALUMINUM CYLINDER BODY
WIPE RSEAL CUSION
CASE HARDENED AND

CHROME PLATED
PISTON D LO
IHEAD END) ALUMINUM

mH EAD AND CAP
MOUNTS AT EITHER END
Here how you benefit from

using Parker Series C" cylinders Specifications
These are standard cylinders, designed score design compensates for wear Bore Sizes: 1-1/4", 1-3/4", 2-1/2".
and engineered with two objectives in assuring long leak-proof service. 3-5/8", and 4-1/2".
mind . . .to provide industry with the Strokes: Available to 20" as standard.
best possible air power cylinder at a PlUS PerfOrTaice For longer strokes, consult Parker.
price; to fuse quality and economy in -High Efficiency Cylinder Division.
one basic design. Operating Pressures: to 200 p.s.i. maxi
Day-in, day-out production of a stand- You get maximum force because of low mum.
ard item provides the quality construe- friction design of piston, gland and rod Operating Temperatures: for best seal
tion and quality control that gives you a seal. Better cushioning action due to li , S operating
0
temperatures should not
near-perfect end product . .. an experi- floating bushing design. These better exceed 165 F. Cylinder can be operated
ence-crafted power cylinder, cushions reduce impact at stroke ends, to 2000F. maximum.
Mass produced Series "C" cylinders protecting load and cylinder on fast Spring Returned Models: provided to
give you the benefits of our research stroke or heavy load applications. They order with spring at either end as speci-
engineering, tooling and inventory, give better control on "slowdown"- flied. Call out end to which pressure will
There has been no sacrifice in quality; faster "get-away" when moving Out. be applied. Cylinder will be longer than
this is a "ready-to-go" cylinder, quickly Optional cushions are furnished when standard. Consult factory for addition
available in any quantity. ordered, or may be easily added in the to dimensions LB or LD.
field to any Series "C" cylinder without Force Data: To determine force, multi.
Cycle After Cycle increasing overall length. Cushions are ply your air pressure by these area fig-
-Long Trouble-Free Ufe readily adjustable. ures:
Day-in, day-out . . . millions of repeti- Versatility CAP END HEAD END

tive cycles... Parker has taken careful C n... BORE MAJOR AREA MINOR AREA
stern to counteract the effects of con-
stant abrasive wear. Piston rods are case CotvrienCe 1-1/4" 1.23 sq. in. 1.03 sq. in.
hardened, then chrome plated and given eBasic cylinder design provides three dif- 1-3/4" 2.40 sq. in. 2.10 sq. in
a highly polished finish. This prevents ferent mounting positions . . . flush 2-1/2" 4.91 sq. in. 4.60 sq. in.
rod damage in service, thus increasing bottom, front and rear 3-5/8" 10.32 sq. in. 9.54 sq. in
seal life. The "Woerseal" is made of aAdditional mountings are provided in 4-1/2" 15.90sq n 1512sq n
synthetic rubber-acts asboth rod wiper kit form . . . end lug, rectangular
and pressure adjusted sealing element to flange, detachable clevis and detach
keep air in, dirt out. Friction is mini- able eye
mized by an oil impregnated bronze rod eRod end accessory kits provide long PIr i'ctliof
bushing which keeps rod lubricated. Clvis, short clevis and rod button Series C ait cylinders are factory pre
Pistons do not make metal-to-metal con- attachments, lubricated. Parker Lube-A-Cyl is applied
tact on either the cylinder body or the * Optional floating cushions are supplied to cylinder bore, piston rod and seals.
non-corfosive aluminum head and cap. without increase in cylinder length Lube-A-Cyl is an extreme pressure lubri-
This is made possible by molding a stel a Choice of five bore sizes from 1-1/4" cant which adheres to the surfaces and
disc into a synthetic rubber compound, through 4-1/2" for medium duty service, additional
making a precision molded piston. Non eStrokes to 20 inches are standard lubrication is not necessary.
Cylinder Division
501 South Wolf Road FhidPAW
Des Plaines. IL 60016
C-3
Paikei Series C
Medium Duty Air Cylinders Dbemnions
Sngle End Rod Cylidceus Double End Rod Cylinders
w~~Isto 9 v-i94
K I I 1 t% it% Mounting Kit

IF 1.9 94 %o I 114 Eakiagd kitsl.DillChili Can.,l 1 innri~k
aslningSs am anilabOI@ in with Pivot and Wit.r
1%~1 1% 4 Ito F% 14 ofn. Se "HowTo Order" sctir Below.
*Fi to
% t t ENDOLUGS t L tf I) q(I LVI
C ~ ~ ~ d ~ W~j ~ : ~to t ~ CapEnd)
ca to %o %o t."W4 - - i
Cto to to o
ifc -t
CH 'A I leto -
CE154
Ih.I91
__RECTANGULA
% o -FLANGE
R A ~h CYE
E
Ckd)EJr.
CER 1%4 3 jCe End

CDl. rCtoie rlv~ an DetitilbI Eere maintg cans ithat provide f0or icnting of Cylinder to
'Aot to%99 Rod End Accessories
CU ii- tos toii P69 AoCessb~r~il
S.0 siv,155. P.Ckilgd fuli".t.'. tGi00is furnished Cournplet. witl Pivoti and Coiter
C It__214 __
It 1 n,S.. "How To Order" secion below for K1tNunmbers
CA 'A-3 %24 16-2tod_4 414%3 C,
t %I
o V._t ' ROD BUTTON j w ~ -- ~~ LONG CLEVIS
EL __
6. o to____
% t 'A S- nrfi.
CO %o tos to 1; -U*- - -SH.5ORT CLEViS tfisinst
CU
to to
to to ~ Now to order Parker Series C Cylinders
~ ,~ ~ ___Specify thea following: *sRod End Accessory Kits (if requjired)
ftIt It l' ~t Bore
*Basic Model N umber'
--specify kit number**
*Spring Returned (if required) -specify
S9.1.Io Ito___ 1% -Stroke Length end of cylinder to wthich pressure willf
1 IV . I-_ I1o IVA Vt *Optional Cushions (if required) - be applied. Cylinder will be longer
EE N-2 143 143a to14 %, specify cap end, heed end or both ends than standard. Consult factory for
to~~9 14 It It *Mounting Kits (if required) -spercily additionto dimensions LBor LD.
JA -r.1%Ito _Il t
PAI kit number I *Oumntities
Ls r.Poy. lt 4%o n. n ho, pPco cotnun prdc a Shipment Schedule Desired
Lot 4% alto
11% O l to1 1111 ss, ti
osRtrO ri in this Catalogare sublsorto shniest
n.
M% 14H 14 t =o
%_111%-3fAt
s Illds Non. nd
Had c KC
NI34 % to%l tl toll Atl4.d CcO CCO
'to
*94 it 1% r nd
E~d cc ic
I O CKO-cc
3 I LI
ll .3 WNotea Al standard besc cy id.r are, fun d with1aim"r nut owthepiston rod.
1%It 1%9 106 Ito Ito cytiads. EnLeL srs - I
11 I.11 fal L" in 1 MERTNO. MART O. MARTNM MERTNO.

_____________ .34L 450640 L-4511 il
IN ilk Y. 1% 1 - 14 21/2: L 45o3 L.4 1 08 L4513 L.4518
1 3-5 Li 5s L4 L-4514 Lat
asF1% 1%. 44 Ito to "2" L.41S85 I L-4510 L-49115 L-4520
o o A _ _ _ _ _ to as as
IT 1% tY i.
"Ito S 294 PART.n FARTN. PRTNo
I Is It% I96 like Is 11 L-4521 L-4523 111153
CR22 L 424 IsR
I ta I~t W 4 5914
Ito~~~~~ ~ ~ t tpu i t otri.
LE
~~~L-4S24
Lt
L4625
-oP4 14710
1
Cylinder Division
501 South Wolf RoadFh ojs
Des Plaines. IL. 60016
C-4
fiew
BULLITIN 0920-Mi
Revised Marh, 1964
AN I 1 4 1 W4 INSTALLATION AND SERVICE INSTRUCTIONS

Series "C" Air Power Cylinders, 1 "-41/2 Bores
Whem ordering, always give following information

H-4nn standard Sem "C" Cylinders are medium duty general I. Serial Number
it cylinders for service at working pressures to 200 psi. 2. Bore cylinder
Thi rupplpied with Hannifir designed seals (patented). 3. Stroke name plate
To protect tae al and other vital cylinder parts, the air sapply 4. Model Number
must be clean, lubricated and free of water, pipe scale, dirt and all S. Symbol Number Shown on drawing
foreign materials. Air line filters and lubricators are necessaryto 6. Name of Kit or Part linside this bulletin
provide this protection. The Serial Number is especially important, particularly if there
is an "S" in the Model Number.
HOW TO INSTALL
1. Standard Series"C" C~linders will give esiellent service under must also be pivoted at rod end with either a short or long t]e,,.
normal operating Lnditions. Hotweser, tare must be exercised in or customer's particular type of pivot member. Pivot pin at tar
theinstallation of the cylinder it) make certain it %ill be prolteted end mounting must be parallel to pivot pin at rod end mounting
from external abuse-espesiall% paint, welded spatter, and similar 2 Remove pritective wrapping from rod and any masking ape
materials that csuld damage the n dfinish anti reitlt in escese frtom cylinder. Do not remove pipe port thread protectors until c%,u
wear of the sealsdaring operat:n. are ready to connect air lines to cylinder. Theseprotectors kec.pout
Tie Rod Top Atatteda- C linders should hr hirld to mounting dirt, chips and other foreign materials that might otherise gti
plate b fastening high strength boili direct] ito the for in. inside tlinder during the mounting process.
ternal tapped holet in-line with tie r s in heador tap. 1. Mount cylinder and carefully check alignment if piston rid
Flatb Moited- Two tapped holes are provided in the edges with machine part while piston rod is in both extended and retra, ted
of both heads for mounting tslinders flush t. a surface. Shear Positions. No side load should be put on either cylinder or rod in
kess are generallt usedto resist the major litad suth as puh normal applications, (In running rod in and out, the pipe p,,ri
n
pull. Again, use high strength Iblts for fastening. thread protectors must be removed.)
Esd Li.e- -These accessories are fastened onto the head and 4. Now connect the air lines to the ports. Make sure their inc,
cap in tapped holes diretthl,in-line with the tie rids End lugs are dean and free of dirt. water and all foreign matter, fr uh
shouldbe tightened into a position where side and bottom are tontaminants can severelydamage the cylinder. Install an air filer
lush with ends of cylinder head. Cylinder tan be mtunted I to keep the lines clean at all times.
high strength bhilis passing through end lugs. Cilinder must be properly lubricated at all times. A lubritacr in
Rectawalar Flatge - Either Lapor head flange is fastened to ,l. the air line is essential to provide proper degree of lubri.ati,,.
inder b cap screws (Svmtlt 29) threaded into four tappedhole, under all operation conditions. If it is desirable to slow speed of
in-line with the tie rods. The four flange mounting holes are then piston strttke in either direction, install either a speedcontrtl salie
available for mounting tlinder. to restrict exhaust in that direction - or an air line pressure rt-
Detachable Cletis or Detachable Eve - Either of these mtunting lator t) reduce inlet pressure.
accessories mat beattached iti the tap b fastening srews (Smbil S. Ctbisou -Tt adjust cushions. (a) loosen needle sahe nui
0) and hiikwashers (Sm)bI 31) direttli into the ftourtapped (Si mlvl 2-I) and (b) rotate cushion adjusting screw (Ssmhol 22) io,
hiles in-line with the tie rods. For this tspeof mounting. tlinder ilesired eiting. Be sure to re-tighten the needle valve niti.
SERVICING THE CUSHIONS REPLACING THE WIPERSEAL

This operation necessitates dis-assembly of cylinder. Disconnect Before installing a new seal, check surface of rod for scratches,
piston rod from its machineattachment and removecylinder from dents. or other damage. A damaged rod surface will quickly damage
its mountings. With a screwdriver, unfasten the four tie rod any sealthrough which it moves. In order to replace viperseal, it is
fasteners (Symbol 1) from the head. making certain to releasethe netessary to dis-assemble the cylinder. See ist paragraph of "Sers.
tension from the tie rods equally. ie., unfastening. by fractional icing the Cushions." Remove old seal (Symbol 10) with a hooked
turns. diagonally opposed fasteners. tool or by hand and simply place a new seal into the gronve in the
head. Re-assemble cylinder and torque tie rods equally to values
INSTALLATION: Simply place cushion bushing with assembled shown below.
seal(Symbols 16 and 20. or 17 and 21) into cavity provided in head
or cap.Be sure that steppedportion of bushing facespiston. After
installation, place snap ring (Symbol 18 or 19) into its groove, thus TIE ROD TORQUE SPECIFICATIONS
holding cushion bushing in place. Re-assemble cylinder and torque
tie rods equally to values shown below. If cushions were addedin An extreme pressure lubricant (such as molybdenum disulphide)
the field to a cylinder originally purchased without cushions. it will should be used ot tie rod threads ind fasteners bearing faces t
be otcsary to removeplug screw and seal (Symbols 42 and 23) contrtl friction and reduce tie rod tmist. Tie rod twist can be elimi-
and inatall a cushion adjusting srew (S)'mbl 22) with a needle nated by chalking a straight line on each tie rod before torquing
valve packing and nut (Symbols 23 and 24) in their place. See and backing off fastener after torquing sothis line is straight again
cushion adjustment instructions under "How To Install" for varying ... very important on long stroke cylinders.
cushion action. Using a drag link toket or a screwdriver bocket, tighten each tie
REMOVAL: Remove soap ring (Symbol I or 19) from head or rod fastener to torque value given in table below. Apply only a
capand position piston rod so that the tapered end of cushion sleeve partial amount of required torque to a tie rod, then tighten a
(Symbol 9) is just inside of cushion bushing (Symbol 16 or 17). diagonall! opposed tie rod to the sameamount. Tightening all four
Replacecylinder body into head and cap but dot not - torque-up on fasteners in this gradually increasing manner will prevent buckling
eic cods.7or cylinders cushioned at cap end on t / and 1%' bore of cylinder body, especially on long stroke cylinders.
sine%spearon end of piston rod is usedinsteadof a cushion sleeve
(Symbol 9). Slight air pressure (about 5 psi) admitted through port Cinder 1 1 1
wi "at' cushion bushing out of its groove and along cushion more IY ly'a 2% 3% 4%
slev from where it can be removed by hand. Never pull cushion To -e'l 1 5 50 20 1.0 20.0
bushin out of its cavity by hand because the nap reng grooves lb f Man 20 2.5 2.5 13.0 25.0
will damage the seal lips.
4HIAkNI1IN CYLINOWN DIVIIOM

PARKS as- MANNI I N COMPOOAIs^ ON l 0i0 Pt,AIN g. II.-LL. OIs. U.S.A.
C-5
SERIES "C" PARTS LS
BASIC CYLINDER-1',4" AND 1Y." BORES DOUBLE ROD CYLINDER

-Sym~bols 4. 10, 14 and 15 comrprise Seal Kit SK (so* table belo,)
IA ii 7 1S 2 ~( j
BASIC CYLINDER-24", 3%" AND 4%-" BORES DOUBLE ROD CYLINDER

-Sym~bols 4. 10 and 15 Comnprse Sear Kit SK (see table belo.)
NAME OF PART nI NAME OF PART

SK' SEAL KIT- inclod.n Symbo..4. 10. 14 & 1S 21 LIPSEAL. Cap End (See Kit CC) - -
H CUS4HIONKIT. Hea Efnd(Regupred tor Cu.nron Cylo. Only)- 22 CUSHION ADJUSTMENT SCREW (See Kts~tCC_&CH)
Includes Symnbol,I . 1. 2022. 23 & 24 ?7NEEDLE VALVE PACKING (See Kits CC & CH)
C CUSHION KIT. Cap End jlNa Orrlid to, Cusin yo Ol) 24 NEEDLE VALVE NUIT-(SeeKbtsCC kCPI__ ___- -
IA Includes Symbol, 17. 1.R1. 22. 23 & 24 AENLUSKT2Lo) 3
Ro RI.tnrg. ymbl
HEADASSMBL-Inooda -26A DETACHABLE EYE KIT Ijnclo-des Synmbci~ O & 31
Rii 9
!CCINDEi --- 27A RECTANGUILA FLANGE KIT- Includes Symbol 2'9
3 CYLNDERBODY28A DETACHABLE CLEVIS KIT Includes SymbsVI 30, 31 & 37
5 !ISTON (SnKnW K 29 MOUNTING SCEW Flang~e See Kit2A
3lONN SCREW. Eye &_Bracilet (See Kits 26A & 28A)
So Typeo~
________________________ 31LOCKWASHER, Bracket (See Kits 26A & 28A1
iE RqD "STENoRdTp
_32 ROD BUTTON
7 JA NTERU TER 33A SHORT CL-EVIS -KIT._Femnale I Ocodes Symnbol35 -
B4-CU'O NU LEEV
9CSON SEEE SK 34A LONG CLEVWSKIT. Femnale Inclurdes Symnbyl36 -
10 WIPEREL(e n K 35 PIVOT PIN. Short Cleon (See Kit 33A)
33 PISTON SPACER. Haad End _ PIVOT PI.LAC~.n(. I3
12 PISTOn, SPACER. cap End 37 - PIVfjPi.De nlag Cov s ISee El 2R4AI -
13 PISTON RETAINING NUT 38 PINRO.
i Dtahbl RodTe Set2A
14 LOCK PIN 3 ITwRD obeRdTp
15 -GASKET.Cyne Tba e KICCCH _39 _PISTON -ROD EXTENSION. Double Rod Typi,
1A CUSHION BUSHING. eaad End (Se Kn11
CHI 40 LOKPIN, Double Rod Type
J1 CUSHIONU a--NCa n Se i C 41 PISTON SPDACER.Rod Eaitenin- End. Dcoobte RodType
18 SNAP IG. ieEd l H 42 PLUG SCRE
I SNAP R ING C s",C 43 FI USHING (See HeadAnnnnOy IA)______
LIPSEAL.Hiid4n0a .IH 44 fj TE O. Dob Rod Type
ACCESSORIES
t -t NEEDLE PONT SEAL IOR I UHO EDO A ARTS

DETCHALE LEVS ED LGSNON-CUSH. H EAD OR CAP IFOR CUSHION ADJUSTMENT
(CAP END) (HEAD AND CAP)
ROD BUTTON
(KYCA EYE RECTANGULAR FLANGE SNORT CLEVIS LOGCEI(FME

(CAP END)(HEAD OR CAP END) (FEMALE) LN LVS(EAE
C-6
APPENDIX D
VENDOR DATA FOR HYDRAULIC EQUIPMENT
TITLE VENDOR PAGE
Axial Piston Pump -

Variable Displacement
with Auxiliary Package Denison o-3
Proportional Actuator Dynex D-32
Pilot Operated Relief Valve Manatrol D-37
Needle Valve Manatrol D-38
Metering Valve Manatrol D-39
Filter Marvel D-40
Hydraulic Cylinder Miller D-42
Heat Exchanger Young D-71
D-1/(D-2 blank)
-IJJ
Bulletin SPP-P6-7P
DENISON SERVICE LITERATURE

Axial Piston Pump - Variable Displacement with
Auxiliary Package
TRIMLINE MODEL P6P

TRIMLINE MODEL P7P
INSTALLATION
AND
OVERHAUL INSTRUCTIONS
D-3
Table of Contents
Section 1 INTRODUCTION Section IV ASSEMBLY TOOL DRAWINGS
General............................ 3 TI, T2............................ 9
Description......................... 3 T3.............................. 10
Table 1 Characteristics................. 3 T4.............................. 10
TS, T6&IIT7....................... 11
Section 11 INSTALLATION
Mounting.......................... 4 Seiction V ASSEMBLY PROCEEDURES
Piping............................. 4 Drive Shaft Assembly................. 12
Service Information................... 4 Barrel & Auxiliary Shaft............... 13
Start Up........................... 4 Rocker Cam & Stroking Assembly ... 14 & 15
Table II Trouble Shooting ........... 5 &6 Barrel & Stroking Assembly to
Mounting Flange.................. 18
Section III DISASSEMBLY Housing SOBearing Assembly............ 17
Valve Cover......................... 7 Port Block Assembly................. 18
Valve Block......................... 7 Gerotor........................... 20
Controls........................... 7 Valve Block........................ 22
Barrel Holddown & Gerotor Assembly . ..7 Shaft & Shaft Seal................... 24
Port Block.......................... 7 Counter Balance Control............... 24
Barrel & Auxiliary Shaft................ 7 Control Cover Assemblies.............. 27
Drive Shaft......................... 8
Housing...........................B8
Cam II Cradle Assembly................B8
Series Model Code

Use these odfas to ideritifystiardard
T-hitn PUMnPSandMOO'rson,, rMdel rnriben TheComnlions of tle Onlystandard
Optionsavailable areShownr onthe tollo~r5 pagel
PUMPS P 6 P .1 R 1 *4 3 1A
PUMPSERIES CONTROL.LOCATION
DISPLACEMENT.
max. (Oloplealert Indkcator onlthe
7 7.25 nreo. W&Coppo~sitedonIsd
with Pon A
OISPLP1(0 UNIT
KVARIABLE a- IlldrA"onN sift
WhPn
SHAFT SAE-Caid
I*Sptined. toatr Ilrdn Control
2. Keyed,rigid Coasltinfations
3. Spltnad.rigid SECONDARY
CONTROLS IffClude snly:
SHAFT ROTATION (vewed Tonge U~i
.
fro arel ed)2. Aux. Replan Port onterline 100 "AS
R-CW;L-CCW 3. Torque LimiterAs, 10x.
I1 4Al
Replen ri~n on Centertlne 102 "A2
FLUID CLASS 103 4A3
with Surta, N
1. comnpatible CORO
PROAARY ONS* 1E0
DESIGNLETTER(Assigned bymtr A- AdIN * maxsGig goe 1152

COSETROLS
MIl inckudeRot.spervo.
PCOR C -AMIt -deel 5
110S 4 0
and
ildiWg.Indacetor D:Bakie a Neuatral
0 3 48
Is"Prt PtueUD s I ny30 B
"'PartPftomE"ORr 303 483
PRIMARYCONTRIOLS*
I -Spring offset to thurmbwheel Max 400 I1CS
0Spt stop.PCORto got screw 401 4C1
mis stop. 402 4C2
3. Rosary sfervoend PCOR(only) 403 AIC3
4'- Spring &pressureto adljbIcenter
0-4
Section I
INTRODUCTION
GENERAL DESCRIPTION
The Danison Trimline 6 and Trimline 7 axial The use of a rocker cam to control the pump
piston pumps feature advance design concepts displacement provides a small package size, reduces
which are time proven and provide for advance wear, and speeds control response. The control
pumping and control concepts. The instructions vane actuator eliminates linkage and backlash in-
contained in this manual cover complete disassem- herent in typical stroking cylinder designs.
bly and reassembly of the unit. Before proceeding Standard controls for the Trimline units are
with the disassembly or reassembly of any unit, Rotary Servo and Compensator Over-Ride. Addi-
this manual should be studied in order to become tional optional controls are also ava;lable.
familiar with proper order and parts nomenclature.
,...CONTROL VALVE BLOCK
DRIVE SHAFT
0 &.-SYSTEM PORTS
MOUNTING FLANGE 0
SERVO CONTROL PI OCK

HOUSING
Table 1
TYPICAL CHARACTERISTICS
Slefiatim TOM Trimlnee Tfrmline 7
in. 3/rev 6.00 7.25
Displtemlnt Ithteoretical) tero PSI mi/rev 98 119
Presure, Pors A & S nmx. continuous PSI 00 B000

bar 345 345
max. Intermnittent
PSI 6000 6000
bar 414 414
Speed, mex. continuous RPM 3000 3000
Flew, PortsA or e 3000 RPM GPM 77.9 $4.2

Iimin. 295 357
Flow, Replenishing pump 3000 RPM GPM 139 13.9

I/rn. 52.6 52.5
Replebhng Pressure PSI 200 200

bar 14 14
Seo Pressure PSI 3M535 33-635
bar 23.37 23-37
Mounting SAE C-2 bolt C-2 bolt
Shaft SAE C Spline C spline

or ke or key
A i
Fluld connection Ports S
SAE 1%'"a00o PSi 1'WA00PSI
4 bolt pod for spitt flwnga
Weightw/rotary 90M lb. 175 175 D-5

3
i __.-
Section II
INSTALLATION
MOUNTING START UP PROCEDURE FOR NEW

The mounting hub and two bolt mounting MACHINE INSTALLATION
flange are based on an SAE-C type configuration. 1. Read and understand the machine instruction
The pump should be mounted on a base or bracket manual. Identify components and their func-
of sufficient strength to support the pump without tion for the hydraulic schematic.
allowing flexing or movement. Close shaft align- 2. Visually inspect components and lines for
ment between the pump unit and prime mover is possible damage.
of utmost importance. 3. Check reservoir for cleanliness and drain and
When installing the pump, the power source clean as required.
drive should be checked for proper alignment with 4. Check fluid level and fill as required with
the mounting pad or bracket that the pump pilots filtered fluid at least as clean as that recom-
into. It is recommended that a dial indicator be mended. Be sure piston rods and rams are in
used when checking alignment. The concentricity the correct position relative to fluid level. Fill
of the pump shaft and power source shaft must not pump cases as necessary.
exceed 0.010 TIR and preferably should be 0.006 5. Check alignment of pump drive.
to 0.008 TIR maximum. The shaft concentricities 6. Check oil cooler and activate it. Check fluid
are particularly important if the pump shaft is temperature.
rigidly connected to the power source without a 7. Reduce pressure settings of relief valves and/
flexible coupling or a coupling that allows only for or compensator. Make sure accurate pressure
minor misalignment, readings can be made at appropriate places.
8. If electric motor drive, check for correct pump
rotation.
9. If solenoids in system, check for actuation.
10. Start pump drives. Make sure pump(s) fill
PIPING properly.
All fluid lines, either pipe, tubing, or flexible 11. Cycle unloaded machine at low pressure and
hose must be of adequate size and strength to as- observe actuation (at low speed if possible).
sure free flow to and from the pump. Note: DO 12. Bleed system of air. Recheck fluid level.
NOT USE GALVANIZED PIPE. Galvanized coat- 13. Gradually increase pressure settings in steps
ing may flake off after continued use. Fluid lines Check for leaks especially in pump inlet lines.
to and from the pump must be of proper size to 14. Make correct pressure adjustments.
prevent restriction of the fluid flow. 15. Gradually increase speed. Be alert for trouble
If rigid pipe or tubing is used, the workmanship as indicated by changes in sounds, system
must be accurate in order to eliminate strain on shocks, and air in fluid.
the pump or the fluid connections. Sharp bends, 16. Machine is operational.
elbows, or reducers in the lines should be elimi-
nated or minimized whenever possible. All system
piping must be clean and free of foreign material
before connecting to the pump. It is recommended
that all piping be cleaned with solvent or equiva-
lent cleaning agent.
SERVICE INFORMATION
These hydraulic products are designed to give
long dependable service when they are properly
applied and their systems properly maintained.
These general instructions apply to typical sys-
tems. Specific instructions for a particular machine
may be developed from them.
D-6
4
Table II
TROUBLE-SHOOTING CHART
TROUBLE SHOOTING
Component problems and circuit problems are failure is the effect. not the cause of the problem.
often inter-related. An improper circuit may oper- This general guide is offered to help in locating
ate with apparent success but will cause failure of and eliminating the cause of problems by studying
a particular component within it. The component their effec.ts:
ROOl of Tmub P-6m Cause F&auWhict Needs Rwm*

Noisy Pump Air in Fluid Leak in suction line
Leak at sheft seal
Low fluid level
Turbulent fluid
Return lines above fluid level
Gas leak from accumulator
Excessive pressure drop in the inlet line
from a pressurized reservoir
Suction line strainer acting as air trap
Cavitation in pump or motor rotating Fluid too cold

group Fluid too viscous
Fluid too heavy
Shaft speed too high
Suction line too small
Suction line collapsed
Suction strainertoo small
Suction strainer too dirty
Operating altitude too high
Boost or replenishment pressure too
low
Replenishment flow too small for
dynamic conditions
Misaligned shaft Faulty installation

Distortion in mounting
Askralinterference
Faulty coupling
Excesssive overhung loads
Mechanical fault in pump Piston and shoe looseness or failure

Bearing failure
Incorrect port plate selection or index
Eroded or worn parts in the displace-
ment control
Eroscri on barrel ports and port plate Air in Flud See abOve
Cavitation Seeabove
High wear in pump and motor Excessive Loads Reduce pressure settings
Reduce sPeeds
Contaminant particleS in fluid Improper filter maintenance

Filters too coarse
Introduction of dirty fluid to System
Reservoir openings
Reservoir breather
Improper fine replacement
Improper fluid Fluid too thin or thick for operating

temperature range
Breakdown of fluid with time/tempera-
ture shearing effects
Incorrect additives in new fluid
Destructon of additive effectiveness
aith Chemical aging
improper repair Incorrect parts

IncOrrect Procedures, dimenSions,
finishes
D-7
TABLE II CONTINUED
EIfect of Trouble Possible Cause Fault Which Needs Remedy

High wear in pump and motor Unwanted water in fluid Condensation
Faulty breather, strainer
Heat exchanger leakage
Faulty clean-up practice
Water in makeup fluid
Pressure shocks Cogging load Mechanical Considerations

Worn relief valve Needed repairs
Worn compensator Needed repairs

Slow response in check valves Replace or relocate
Servo pressure to low to maintain firm Increase pressure and check pressure
control drop through ervo filter
Excessive decompression energy rates Improve decompression control
Excessive line capacitance (line volume. Reduce line size or lengths, Eliminate
line stretch, accumulator effects) hose
Bleed air
Barrel blow-off Recheck pump hold-down rotating

group, drain pressure
Heating of Fluid Excessive pump or motor leakage Recheck case drain flow and repair as
required
Fluid too thin
Improper assembly, port timing
Relief valve Set too low (compared to load or to

compensator)
Instability caused by back pressure,
worn parts
Compensator Set too high (compared to relief)
Worn parts
Pump too large for fluid needs Select smaller pump displacement
Heat exchanger Water turned off or too little flow

Water too hot
Fan clogged or restricted
Efficiency reduced by mud or scale
deposits
Intermittent hydraulic fluid flow
Reservoir Too little fluid

Entrained air in fluid
Improper baffles
Insulating air blanket that prevents heat
rejection
Heat pickup from adjacent equipment
D-8
6
Section III
UNIT DISASSEMBLY
The instructions contained in this section cover 2. Remove seats (8) and (9). Do not remove roll
a complete teardown of the subject pump. Dis- pins (5) and (10) unless replacements are need-
assemble only as far as necessary to replace or re- ed.
pair any worn parts.
CONTROLS
DISASSEMBLY See Figure 11
Position pump unit so that valve block assem- Remove the four screws (14) from the side
bly is on top. A bench or similar suitable surface (16) and remove the input shear sea valve assern-
capable of supporting unit should be used. Disas- bly.
sembly area sould be clean. Remove the four screws (14) from the side cov-
er (15) and remove the counter balance shear seal
assembly.
VALVE BLOCK Remove the two screws (12) and remove the
See Figure 11 servo stem (9) and plate (10).
1, Remove the eight hex head cap screws (17) and
lift the entire block assembly from the port
block. BARREL HOLDDOWN AND
GEROTOR ASSEMBLY
VALVE COVER See Figure 9
1. Remove snap ring (17), end cover (15) and
See Figure 10 "O" ring (16).
1. Remove the four screws (39) to separate the 2. Remove cotter pin (14), holddown nut (13),
cover (21) from the block (11). DO NOT RE- thrust washers (10), bearing (11) and seal ring
MOVE THE CHECK VALVES (19) UNTIL (12).
THE TWO ORIFICES (20) ARE REMOVED. 3. Remove pressure plate (9), Gerotor side plate
2. Remove plugs (43), (36) and pin (40). Remove (5), "0" rings (7) and (8), needle bearing (5b).
the 8-32 nut from the bottom of cover (21) to Do not remove 6-32 screw (6) from side plate
remove filter assembly (34). (Sa) unless the unit is to be reassembled for
3. Remove housing (29). Remove items (30), (31), the opposite rotation.
(32) and (33) as a unit. Insert a small brass rod 4. Remove Gerotor assembly (3), dowel pin (4),
thru the hole in the housing and tap out piston key (2), and side plate (1).
(27) and O-ring (26).
4. Remove spring (25) and cone (24). Remove
seat (23) and 0-ring (22). Note: Seat is made
for hex wrenching. Use '/" 6 point socket with PORT BLOCK
'/." drive. See Figure 8
5. Remove O-rings (38) from bottom of cover. 1. Remove
block (2) four screws
to the (1)(6).
theUse
secure the port
housing caution when
removing screws on valve block side to prevent
marring valve block face.
VALVE BLOCK 2. Remove port block (2) and gasket (5). Remove
1. Remove 0-ring (37) and replenishing relief port plate (4) and face plate pins (3).
valve (41). Inspect orifices (12) visually to in- 3. See Figure 7
sure they are open. Do not remove unless dam- 1. Remove the check valve assemblies (7) from
age or clogging is apparent. the port block.
2. Remove springs (16), (17) and (18). Remove 2. Remove needle bearing (2) from the port
retainer (15) and poppets (13) and (14). block.
3. Remove two screws (5), Iockwashers (6), check
rings (3), and clairrs (4).
RETAINER PLATE
1. Remove the four screws (4) from the plate (6) BARREL AND AUXILIARY SHAFT
and (11. Remove gasket (7). Remove the barrel assembly by grasping the
D-9
auxiliary shaft and lifting the complete assembly with the two tubes (2) in a horizontal position and
out of the housing. located at the top. Mark the cam (24) and cradle
(20) as indicated in Figure 3. These marks will de-
REMOVING DRIVE SHAFT termine positioning of ports during reassembly.
See Figure 11 Carefully remove the small tube lines (3) and
Remove the four screws (8) and gaskets (7). (4) from the cradle.
Remove seal retainer (6), and the stationary part DO NOT BEND THESE LINES
of the shaft seal (4).
See view of item 4. See Figure 3
Carefully remove the carbon ring and the re- Position the assembly in an upright position on
mainder of the shaft seal from the shaft, the flat surface of the cradle (20). Remove the re-
Remove snap ring (3) and the shaft and bearing taining ring (1), thrust washer (2), and bearing
assembly (1). Remove spacer or ring (2). flange (3). Remove the piston and shoe assembly
(4) and the creep plate (5) from the cam (24).
HOUSING REMOVAL Carefully remove the two differential screws (6)
After shaft assembly has been removed, posi- (CAUTION: These must be alternatively removed
tion the unit on end with the mounting flange one turn at a time) from the rocker cam (24), and
turned down. remove the servo input parts (7), (8) and (9).
1. Push the ends of the small tube lines away Remove the four 7/16" screws (10) and eight
from the housing. %/,"screws (11) and (12) from the control covers
2. Lift the housing from the mounting flange, re- (15R) and (15L). Remove the four dowel pins (16)
move the gasket, and dowel pins from the and remove the two chambers (17). Remove the
mounting flange. two special seals (18) and the four steel balls (19).
3. Remove the two Vane Seal Cartridge Assem-
Do not remove the roll pins and the bearing blies and the four holddown vanes (22) from the
from the housing unless the bearing is damaged and rocker cam (24).
must be replaced. (Note: Some units may have thin shims under
the holddown vanes).
ROCKER CAM AND CONTROL Remove the rocker cam (24) from the cradle
STROKING ASSEMBLY (20).
See Figure 4 DO NOT REMOVE THE PLUGS FROM THE
Remove the complete assembiy from the ROCKER CAM OR THE ROLL PiNS iN THE
mounting cap and position on a clean flat surface CRADLE.
D-10
f • • • •
Section IV
ASSEMBLY TOOL DRAWINGS
T1
1.00-6
MATERIAL DIA.
C RS 1' DIA. x2%"
T-2
&&~AConcentric within .005 FIR.
5.265~
DIA DOWEL
(2) 10-24 69 j
FLAT MD.
AlSCREW-- T&
f" 1.750
ea 1.295 DIA. - 1.55 00
mv1.390 &DIA.
13.0
DI.A.
DIA..1 31
.19
MATERIAL 1.25
CRS SECTION A-A

D-11
9
T-3 48
1..310
.0 .MATERIAL BOTH ENDS.

4150 STEEL (HDUN. TO Rc 45-50)
T-4
&.63OIA.
MATERIAL
D-12 CR S 1% 6Y," 01A.
MD. KNURL 4.1
IID
5.62 OI4TS %*DA
Hwdoned Tip RC 5S-62
T-6
2.00-
A s
7 77 7:3150-TYP.
+ - ___ ___ ____ _ DA. 62 DIA.
WALL THICKNS
A MIMIUMYe SECTION A-A
MATERIAL
HRS-CRS
T-7
3%" DRILL go 1.13

DEPTH SHOWN
A
BLEND RADIUS
MATERIAL SECTION A-A
HRS-CRS D-13
Section V
ASSEMBLY PROCEDURES
DRIVE SHAFT ASSEMBLY
FIGURE 1
3
2
S15-41806
S15..41805 Shaft
4=2
;:I Shaft
I. Pass one retaining ring (3)over the internal end Support only the inner race of the bearing and
of drive shaft (1) and install in the groove near press on the coupling end of the shaft.
the shaft seal surface. DO NOT USE EXCESSIVE FORCE AND DIS-
00 NOT PASS THE RING OVER THE SEAL TORT OR DAMAGE "HE RETAINING RING.
SURFACE. 3. Install the other retaining ring (3) in the other
2. Slide the bearing (2) over the same end of the retaining ring groove. Be sure that both rings
shaft and seat against the ring. are fully seated.
PARTS LIST FOR FIGURE 1

S15-41805 #1 Drive shaft assembly (Splinad)
815-41806 #2 Drive shaft assembly (WI Keyway)
Oty. Part
11mm #1 #2 NumberDecito
035. 70567 _1 Drive shaft
_(Spllned)
1. 035-70579 #2W(_W/5/16 KW)Drive shaft
2302140 Shaft bearing MRC&107 K
2 035-70817 Retaining ring
4 ~-EIJj...... 3-71348 Sur e /6 x
D-1 12
BARREL AND AUXILIARY DRIVE SHAFT ASSEMBLY
FIGURE 2
2 -
'~T2
q .. T1
1. Position the barrel (1) in a press with the large and against the barrel (1) face. Insert ring (6)
end turned down and insert tool figure T-1 in around the shaft (2) and in the tool.
the splined shaft hole in the barrel. 5. Position the ring with the gap within 5/8" of
2. Place thrust washer (3) and spring (4) over the notch in the barrel for easy removal.
shaft (2)in the same sequence as shown. 6. Place tool figure T-3 over the shaft (2) with
3. Insert shaft (2) in barrel (1) and rest on tool the small end against ring (6). Press on the
figure T-1. Position the two spring retainers end of the assembly tool and seat the ring (6)
(5) around the shaft (2) and inside of spring in the groove in the barrel (1).
(4). 7. Remove the assembly tools. Check to be sure
4. Carefully place tool figure T-2, with the large that the ring is properly seated. Check barrel
end of the tapered hole up. over the shaft (2) face to be certain it is not marred.

S1543654 POP Complete Barrel &Shaft Assembly
S1I-42316 P Cmlrte Barrel &Shaft Assembly
No. ty. Part Oeealption
1 1 S15-43657 Barrel &i Sleeve Assy. P6P Only

1 S15-41221 Barrel & Sleeve Any. P7P Only
2 1 1 035-70568 Auxiliary Drive Shaft
3 1 1 350-10069 Thrust Washer TRA-.1220
4 1 1 035.70493 Barrel Nolddown Spring
5 2 2 035-70483 Spring Retainer
6 1 1 035-70494 Retaining Ring D-15
13
- - / •j i
FIGURE 3 Install four %-20 screws, two (11) and two
(12), in each side and torgue to 10 ft. lbs.
CRADLE ASSEMBLY Install two 7/16-14 screws (10) in each side
1. Install the four '" roll pins (20b) in the holes and torgue to 45 ft. lbs.
provided in the sides of the cradle (20a). THE Install 0-ring (14) and plug (13) in each cover.
PINS MUST BE 3/16" BELOW THE SUR- Install tubes (25) in reamed holes in each coy-
FACE. er.These tubes must be a tight fit. If tubes are
2. Position the cradle assembly (20) on a clean loose, the ends can be expanded with a tapered
flat surface with the large flat area down. punch. *
Tap the tubes in place with a plastic mallet.
ROCKER CAM ASSEMBLY
Position the rocker cam (24) on the cradle SERVO ASSEMBLY
120). Mark the cradle and cam to indicate top. (See
marks in Figure 3.) Marks will be used for ass(m- Install the 10-32 end of the differential screws
bly reference. (6) in the servo plate (9) from the inside. Allow the
screws to extend 11/64" through the stem.
VANE SEAL CARTRIDGES Install two orifice screws (8) in the servo stem
1. Place 0-ring (23c) around spacer (23d) and in- (7).
sert in the seal vane (23b). Install servo plate with the long end of the dif-
2. Insert check valve (23e) inside of spacer (23d) ferential screws through the servo stem. The
and assemble between the two backup plates orifice screw end of the servo stem must be against
(23a) with the notched V's exposed, the servo plate.
3. Install assembled cartridge in slot in cam as Position the stem and plate on the rocker cam
indicated in Figure 3. Repeat steps 1, 2 and 3 input side (at 9 o'clock on "B" model or 3 o'clock
on other side of cam. on "A" models) with the screws positioned over
4. Insert the four holddown vanes (22) and the 10-24 tapped holes. Hold the assembly against
springs (21) in the slots on each side of the the cam and alternately turn the screws % turn
control vanes (23). each until the stem and plate are firmly attached
to the cam. Torque the screws (6) to 70 in. lbs.
CONTROL CHAMBER
Position both control chambers (17) on a clean WARNING
flat surface with seal grooves turned up. Drop the THE SCREWS MUST NOT PROTRUDE
four steel balls (19) in the four counterbored holes FROM THE SERVO PLATE
at each end of the seal grooves.
Lubricate seals (18) and insert in seal grooves
in control chamber (17). PISTON AND SHOE ASSEMBLY
The tapered side of the seals must be pushed Install creep plate (5) over center post on rocker
into the grooves and the ends must cover the steel cam. Small O.D. of plate must be turned down.
balls. Insert the seven piston and shoes (4b) in the
Install the control chamber (17) with seal (18) shoe retainer (4a). Position the assembly (4) over
and steel balls (19) assembled over the control the center post and against the creep plate.
vane (23). The seal must be against the cam. Ro- Install flange bearing (3) over center post. Place
tate the chamber until it passes over the control thrust washer (2) against bearing.
vane assembly,tionuntl
'Athendowl
rotate in the
th pns (6) opposite direc-
an b puhed ThrThree
washere2)ragain
different retaining ring
rings (1) are available
tion until the '" dowel pins (16) can be pushed for the holddown assembly. Each ring is marked;
through the chamber (17) and into the cradle (20). yellow dot .083 thick, green dot .081 thick, and
Install chamber in the same manner on the other red dot .079. Install the thickest ring (1) with the
side of the cam. dot up, that will fit in the groove on the center
Two sets of chamber covers are available. The post and allow a maximum clearance of .0015 be-
set marked CW tust be installed in the right hand tween the shoe and creep plate.
rotation pump and the set marked CCW must be The piston and shoe assembly (4) should be
used in the left hand rotation pump. (Rotation is free to rotate by hand. (5 ft. lbs. or less).
determined facing the shaft end of pump.) The
covers must be installed with the tubing holes and
the tapped holes at the top of the unit. Install
chamber covers (5r) and (151) on the control
chambers (17) over the dowel pins (16). The
topped holes must be at the top. Refer to the "T"
marked on the rocker cam (24) and cradle (20).
D-16
14
4
, C- 4
to, JM
_.
-~ 44
Qc2 Jl
goil
ill! I "6ii
- -17
ttli ! I - lli
D=17
Position the cradle and cam assembly with the
piston and shoe assembly attached with T marked
on the cradle turned up.
Insert tube line assemblies (3) and (4) in the
holes provided in cradle.
Position the mounting flange (7) with the large
open end up, and install two dowel pins (6) in the
cradle mounting surface of the flange and two
dowel pins (6) in the outer edge of the flange.
Install rocker cam and cradle assembly over the
two dowel pins (6) in the mounting flange. Be cer-
tain that cradle is seated over the pins and against
the flange with the tube lines (3) and (4) in the
grooves in the flange.
Position the mounting flange with the rocker
cam assembly on the top or bottom side and
install two or more 1 -20 x 1%iscrews through the
seal retainer area into the cradle. Be certain the
cradle is fully seated in flange. These screws are
required to hold the rocker cam assembly in place 2
and will -be removed later.
Return the assembly to an upright position
with the mounting flange down.
Tilt the rocker cam to either extreme position SEE
in the cradle. FIGURE
Position the Barrel Assembly with Auxiliary
Shaft (1) directly over the pistons. Start with the
upper-most piston and guide them one at a time
into the barrel. Return the rocker cam to a level
position in the cradle.
No. Cry. ParrNo. Desription
I 1 See Fig. 2 Barrel end Auxiliary Shaft AssV.
1 2 035-70524 Pressure Tube
3 1 S15-42402 Tubing Ashy.(right side)
4 1 S15-42403 Tubing Assy. (left side)
5 1 See Fig. 3 Rocker Carnand Stroking Assembly
6 4 324-22412 Dowel Pin 3/8 x 3/4
7 1 o3570604 Mounting Flange
Fig. 5 S15-42335 HOUSING ASSEMBLY

No y. P
Prt No. ,e/eviption
1 1 035-71284 Housing
1 035-7068o Bearing
3 4 324-21806 Dowel Pin
4 2 325-16280 Roll Pin
5 1 61-00912 -Rilng 90-6290-12
6 1 488-5014 HOllow Me. PlugSAE-12

No. Oty. entNn. Derption
1 2 035-49925 Faca Plate Pins
3
2 1 I 035-71530 BarrelFace Plate in only
3
1 035-71264 Barrel Face Plete 725 on only
3 1 10.5-70576 Housing Gasket
4 1 1 SeeFig. 4 Housing Aaembly
Item2 - Reference only
Arcuate
3
Port Width
6 in is-113/32 FIGURE 4
725 in is 15/32
D-18
16
0
. 1N RIGHT
.. SIDE
LEFT
SIDE
"
p1
FIGURE 5
S15,42335 PORT BLOCK END
HOUSING ASSEMBLY
See Figure 5
1. Position housing (1) on a clean flat surface
with the large open end up.
2. Position bearing (2) in the housing bore. Insert
Pressing Plug tool (figure T-4) in the bearing.
With a smooth and steady force, press the
bearing into the housing bore until seated. DO cr,.'
NOT HAMMER OR BEAT INTO PLACE.
3. Turn housing (1) on side and install roll pin 2
(4) in the 1/" through hole in the control cov-
er pad. The pin must be 3/8" below the pad
surface. THE PIN END MUST NOT INTER- D
FERE WITH THE INTERNAL BEARING
CAGE. Install two dowel pins (3) in the blind
holes in the same pad.
4. Repeat operation 3 on the opposite side of the
housing.
5. Place O-ring (5) on plug (6) and install the
hollow hex plug (5) in bottom of housing (1). See
(Roll pins (4) are in bottom half of housing.) FIg.4
ASSEMBLY FOR PARTS IN FIGURE 6
1. Insert the two face plate pins (1) in the holes
provided in the barrel face.
2. Apply heavy grease to the face of the barrel
and install the face plate (2) over the pins (1)
in the barrel.
Make certain the plote is properly mted on the barrel
and pins.
3. Install gasket (3) over the two dowel pins
(item 6 on Fig. 4) in the mounting flange.
4. Position the Housing assembly (4) over the
Barrel and Auxiliary Shaft assembly and care-
fully guide the pressure tubes and tube lines
(items 2, 3 and 4 on Fig. 4) through the Hous-
ing assembly (4). FIGURE 6-19
17
S15-42386 MOUNTING PORT BLOCK ASSEMBLY
PORT BLOCK ASSEMBLY See Figure 8
Figure 7 Position the pump with the unplugged hole in
1. Position the port block (1) on a clean flat sur- the housing assembly at 12 o'clock.
face with the two open ports up. THE OPPO- Install gasket (5) on the housing assembly (6).
SITE FACE MUST NOT BE SCRATCHED OR Install the two special pins (3) in the face of
DAMAGED. Position needle bearing (2) on the Port Block Assembly. Apply petroleum jelly or
tool (Figure T-5) with the marked end of the heavy grease to the steel side of the port plate (4)
bearing against the shoulder on the tool and and position port plate over the pins (3) on the
press the bearing (2) into the port block. The port block.
bearing must be .010-.025 below the surface. Slide the Port Block Assembly and port plate
2. Compress ring checks (3) and slip into the two over the end of the auxiliary shaft. Be certain that
1.50" ports and align holes in the ring with the tubes 2, 3 and 4 as shown on Fig. 4 are seated and
side holes in the port wall. that the port plate (4) is still on the pins (3).
3. Place lock washers (6) on special screws (5). When the pump is properly assembled, the
Insert (5) through port wall and drilled holes valve mounting surface will be at the top of the
in checks (3) and thread into clamps (4). Tor- unit.
que to 10 ft. lbs. Install the four bolts (1), and torque to 150
4. Thread socket pipe plugs (8) into port block. ft. lbs.
5. Thread two check valve assemblies (7) into
valve face of port block. I I
6. Place O-ring (10) on hollow hex plug (9) and
thread into tapped hole in top of the port USE CARE TO PREVENT DAMAGE TO THE
block. VALVE MOUNTING SURFACE WHILE
INSTALLING AND TORQUING THE TWO
TOP BOLTS
S15-42386 PORT BLOCK ASSEMBLY
No. Oty. Part Number Description

1 1 035-71296 Port block
2 1 230-82146 Needle bearing
3 2 035-70502 Check ring
4 2 035-70489 Clamp
5 2 035-70908 Special screw
6 2 348-10016 No. 10 Lock washer
7 2 S1540266 Check valveay. (3/8-24 ext. thrds.)
8 2 431.90404 1/4" Soc. pipe plugs
9 1 488-35041 Hollow hex plug SAE-6
10 1 691-0006 0-ring 90-6290-6
No. Qty. Part Number Description

1 4 306-40056 Hex head cap screw 5/8-11 x 9
2 1 S15.42386 Port block assembly
3 2 03549825 Port plate pins
3
4 1 035-71526 RH port plate 6 in only
3
1 035-71525 LH port plate 6 in only
3
1 035-71265 RH port plate 7.25 in only
3
1 035-71266 LH port plate 7.25 in only
5 1 035-70577 Housing gasket
6 1 S15-42335 Housing assembly
7 1 See Fig. 4 Mounting flange
D-20
19
6K
00
04 0
D-21
GEROTOR AND BARREL HOLDDOWN
FIGURE 9
Position the unit with the shaft In a horizontal the screw must be located at 8 o'clock. The un-
position and the valve block mounting surface plugged hole in the side plate must be at the
turned up. Rotate the shaft until the small keyway uppermost position.
in the auxiliary shaft Is at 12 o'clock. Place O-rings (7) and (8)on side plate assembly.
If pump is being assembled for right hand rota- Lubricate the 0-rings and slip the pressure plate
tion (facing coupling shaft end) install dowel pin (9) 9ver the O-rings on the side plate assembly.
(4) in hole in port block at the 9 o'clock position; Slip the two plates over the auxiliary shaft and
if left hand pump, Install at 3 o'clock position. position the gerotor side plate over the dowel pin
Install side plate (1), steel side first, over dowel (4).
pin. Insert key (2)in shaft keyway. Install the inner Place seal ring (12) on auxiliary shaft. Position
gear of the gerotor assembly (3b) on the shaft and bearing (11) between the two thrust washers (10)
over the key (2). Install the eccentric ring (3a) on and install around the seal ring. (12). Thread hold-
the dowel pin (4). Install the large outer gear of the down nut (13) on the shaft and tighten. No more
gerotor assembly (3b) inside the eccentric ring than 10 ft. lbs. max. Back off the nut (13) until
(3a) and over the inner gear. second slot is aligned with cotter pin hole in the
Press needle bearing (5b) into gerotor side plate shaft. Insert cotter pin (14) through nut and shaft
(5a) with the marked end of the bearing against and bend one tang over the end of the shaft.
the pressing tool (T-5). Check the main shaft for smooth rotation. If
The marked end of the bearing must be .010 to not smooth, check the gerotor parts for position
.025 below the lapped face of the inside plate and holddown nut for forces.
If the dowel pin hole in the side plate will be Place O-ring (16) on end cover (15) and lubri-
the 9 o'clock oosition, then the 6-32" screw (6) cate. Place end cover over holddown nut (13).
must be at th, , o'clock hole in the plate. If the Depress cover and install snap ring (17). Make
plate 'is installed at the alternate position, then certain that snap ring is properly seated in groove.
No. ty. Part Number Description

1 1 035-71492 Side plate
2 1 211-22034 Square key I1/Bx 9/16
3 S1-43334 Gerotor and eccentric ring assy.
3a 1 035-71501 •Eccentric ring
3b 1 035-71500 - Inner end outer gerotor
4 1 324-21225 Dowel pin 3/16 x 1-9/16
5 1 S15-43384 Gerotor sideplate and bearing my.
5a 1 035-71491 - Sideplate
5b 1 230-82146 •Needle bearing 8H 1212
6 1 311.06030 Soc set screw 6-32 x 3/16
7 1 671.00144 0-rina 70-914.44
8 1 67100129 O-ring 70-914-29
9 1 035-70631 Pressure plate
10 2 350-10065 Thrust washer
11 1 230-82131 Bearing NTA-1625
12 1 035-71490 Seal ring
13 I 035.70496 Holddown nut
14 1 322.03320 Cotter pin 3/32 x 1
15 1 035-70535 Solid cover
1 035-70989 Cover w/SAE.16 inlet
16 1 671.00147 O-ring 70-914-47
17 1 356-65082 Internal snap ring Eaton IN287
D-22
20
0 jl
D-23
S15-45542
VALVE BLOCK ASSEMBLY
FIGURE 10
Lubricate the four orifice plugs (12) and insert Install dowel pin (40) in the hole over the
in the top of valve block (1 1). Servo poppet. Lubricate the four 0-rings (42) and
Check the Pilot valve assembly (41) to be cer- place on the four plugs (43). Install the four plugs.
tain that approximately 1V threads are exposed Lubricate 0-ring (35) and place on plug (36) and
from the small nut on the bottom of the valve as- install.
sembly. This setting will allow the valve to func- Inveri the complete assembly and install roll
tion at about 100 PSI. Each complete right hand pins (5) thru plate (6) and into the valve block.
turn of this screw will increase the pressure about Install 0-rings 1, 2 and 3 in the plate (5).
25 PSI. Thread the check valve (41) into the 3/8-
24 tapped hole into the valve block (11) as shown. PARTS LIST FOR FIGURE 10
Press the two dowel pins (10) into the holes S15-45542 Valve Block Assembly
provided in the bottom of the valve block (11).
The pins (10) must be .12 below the surface. Io I 7rM, O ionx1
Place the two sequence seats (8) in the se- 1 2 671-000 0-ning5-1/4S-21I8
quence ports SB and SA and the four valve seats 2 2 671-00014 0-ringO-914-2
(9) in four remaining ports (RB, RA, RV and 3 2 67100013 0-ringo -914-1
Servo). Position the gasket (7) and retainer plate 4. 353-25023 10-24 x 1/2 Button hd screw
(6) over the seats and insert the four screws (4) 5 2 325-08120 1/8 x 3/4 Roll pin
in the block (1 1). Torque to 10 in. lbs. 6 1 01571322 Retainer plate
Position the valve block and the attached parts 7 1 03-70586 Lower gasket
with four orifices (12) turned up. Insert the two 8 2 0.-70507 Sequenceenat
1-7/16 long springs (17) in the two sequence pop- L 4 035-70500 Vahre sent
pets (13) and install (13) and (17) in the block 10 2 325-12120 3/16x3/4Ronlpin
and over the sequence seats (8) in ports SB and SA. 11 1 035-71324 Valv block
Install the four valve poppets (14) in the ports 12 4 035-13786 .036 Orifice plug
marked RB, RA, RV and Servo. Insert spring re- 13 21 035-70631 Sequence poppet
tainer (15), large end first, in the Servo poppet. 1 4 035-70830 vain poppet
Insert the light weight spring (18) 1%/."long in the 1 1 03-70482 Spring retainer
RV poppet. Insert the three 1" long springs (16) in 16 3 03571086 Spring (IOAL)
poppets RB, RA and Servo. 17 2 035-70512 Spring (1-7/16 OALI
Lubricate the two check valves (19) and in- ie
1
1
2
035-22141
S15-40266
Spring (light weight)
Check caine aerblV
stall in sides of cover (21). Install the two orifice 20 2 .035-13786 plug
.036 Orifice
plugs (20) in the bottom of the cover after the 21 1 035-71323 Valve cover
valves (19) are in place and NOT BEFORE. 22 1 691-00903 0-ring-6290-3
Lubricate 0-ring (22) and place on seat (23) 23 I 035-7060e Seat
and install in valve cover (21). Use a %" 6 point 24 1 035-12288 Cone
%,"drive socket. Lubricate 0-rings (26) and (28) 25 1 035-70832 Spring
and place on parts (27) and (29). Assemble parts 26 1 671-0o12 0-ring 70-6227-7
30, 32 and 33 on (31) and start (31) into housing 27 1 035-21767 Seal piston
(29). Push seal piston (27) and 0-ring (26) into 28 13691-010 0-ring90-6290-10
housing (29) with the small end of the piston ex- 29 1 03-70545 Housing
posed. Place sprirg (25) on cone (24) and insert 30 1
3
333-13100 S/16-24 Hex nut
all these parts in the valve cover (21). Be certain 31 1 312-13200 5/16-24 x 1-1 Soc et screw
that cone (24) enters seat (23). 32 1
3
312.0904 10-32 x 1/4 Soc set screw
Remove the 8-32 nut from Strainer assembly 3 0"-2450 Control knob
(34) Insert the Strainer assembly in the largest 53s r
Samv strainer assembly
_2! 1 S15.43240
hole in cover (21). Push the 8-32 threads thru the 3 6910096 0-ring 90-62906
small drilled hole in bottom and attach the 8-32 36 !- 48,6003 Hex plug SA E-6
nut under the cover. Lubricate 0-rings 37 & 38. In- 3 1 671005 0-ring 5-1/4 a 5-1/8
stall (37) in the block (11) and two of (38) in the 38 2 671-00117 0-ring 70-914-17
cover.______________________
Position the cover (21) over the springs and 30 4 306-40167 Hex hd cap screw10-24 x 1-3/4
1/8 x 3/4dowel pin
poppets and install the four screws (39). BE CER- 40 1 324-20612
41 1 SIS-41219 Pilot relief valve gy.
TAIN THAT THE SPRINGS ARE IN THE RIGHT 42 4 6914004 0-ring 90-62904
POSITION BEFORE TIGHTENING THE 4 4 488-1001 HallowheaplugSAE-4
SCREWS.
D-24
22
36
43 g35
U42 43 3
21 c 4
co ) c o 4 4
442
420 19
0.
32)C.
66 4)
2Q 254:
17
133
SHAFT AND SEAL INSTALLATION COUNTER-BALANCE SERVO
STEM ASSEMBLY
Stand the pump in an upright position with the Place the two spacers (11) on the two screws
port block inlet and outlet pads turned down. (12) and insert through the balance plate (10) and
Remove the two V4-20 x 1/" -rews that were servo stem (9).
temporarily used to hold the cradle in the mounting Insert these parts through the opening in the
flange. Install the Shaft and Bearing (1) assembly side of the housing assembly and position the
in the mounting flange and cradle. Be certain that screws over the two 10-24 tapped holes in the
there are no burrs or sharp edges on shaft seal rocker cam.
area of the shaft. Hold these parts against the cam and alternately
Install the nylon bearing spacer (2) around the tighten the screws (12) to hold the assembly firmly
shaft bearing if the unit is to be used on an appli- in place. Torque screws to (5) ft. lbs.
cation that requires a floating shaft. If the unit is
used on a rigid application, use the metal toler-
ance ring (2) around the bearing.
Install the snap ring (3) in the mounting flange PARTS LIST FOR FIGURE 11
to retain the Shaft Assembly. Be certain that the
ring is fully seated in the groove. ft. oty. Pa.Numbe Deoception
1 1 S15-41805 No. 1 Splined Shaft Auy. See Fig. I
- I S1541806 NO 2 Keyed Shaft Ass See Fia 1
2 1 035-70492 Nylon Bearing Spacer
1 605-10028 Tolerance Ring
3 1 356-30250 Retaining Ring
4 1 62300006 Shaft Seal
SEAL ASSEMBLY s 1 035-70549 Seal Retainer Gasket
6 1 035-70516 Seal Retainer
The seal assembly (4) is available as a complete .2 4 631.46003 Nyltite Gasket
unit only.
u 4 353-25019 %-20 x 11AHex WasherHd Screw
9 1 035.71312 ServoPlate
CAUTION 10 1 O357546 Balance
Plate
(Before installing the seal assembly examine all 11 1 035-71247 Spacer
the parts. The lapped seal seat and the carbon 12 2 358-10300 10-24 x 2-A Soc. Hd CapScrew
ring have a precision finish that must be handled 13 8 63145007 Nvltite Washer
with care. Be certain that both parts are free of 14 8 353-25018 3/e-16 x 1.1, Hex WasherHd Screw
scratches, marks and cracks.) 15
16
1
1
SIS42064
S15.42073
Output Balance Control Any.
input Servo Control Asgy.
Place the spring retainer ( e) over the shaft and 16
l6a 1 S15-2073
S1529S6 ShaftSev
-Input an link
Cntmy.Ay.
against the retaining ring on the shaft assembly. Job 1 671-00012 .o.rilng 704227.7
Place the spring ( d) against the retainer ( e). le 1 679,00004 Glyd ring 12547-013
Apply oil to the inner surface of the rubber friction led 1 035.70625 .Shear el (plt side)
ring ( f) and position the shell containing the rub- lee 2 671.00017 -O-ring 70.814.
ber friction ring ( f) and carbon ring ( c) over the 1F 2 350-10067 .Wavywaher
shaft with the carbon ring exposed. Apply heavy leg 1 035.71371 Sheerseal (cover sidel
grease to the square section rubber seal ( a) and l6 1 23082141 -Thrust bearing NTA-916
install on the cast iron seat ( b). Insert the seat 1lk 1 3564070 .R1tlnng rinPgWldas51U.60
and seal in the seal retainer (8) with the lapped lk 1
161 431.0204
671.00017 -115oc.70-41445
.'-.ring pipeplug
side of the seat In position to contact the carbon Jef I 671.0004e 0-ring 4 x4-7/8
ring. Place the seal retainer assembly and gasket 1n 1 035-70614 Cover
(5) over the shaft with the lapped surface against too 2 325-12120 -3/16 x 3/4 roll pine
the carbon face. Place the four gaskets (7) on the 17 6 3o.4o169 318-16 x 3 lex Nd Cap Screw
four screws (8) and insert in the seal retainer (6).
Depress the seal retainer only far enough to start
the four screws and tighten evenly. Torque to 10
ft. lbs.
D-26
24
coi
,~ ID.
wi CAj
U..
Wil.
~1Z C
~~0
MCA2
INSTRUCTIONS FOR REPLENISHING
CIRCUIT ISOLATION PLUG
CAUTION
The isolation plug enclosed is to be used ONLY if an external filter circuit is pro-
vided. DO NOT operate this unit with the isolation plug installed unless an external
line has been provided.
When the external filter circuit is NOT used discard the isolation plug.
When the external filter circuit IS used install the isolation plug between port G
and H (refer to appropriate installation drawing): use a 3/16 Hex. wrench by 4"
minimum length inserting the isolation plug into port H and tighten to 80 - 120 in.-
lb. torque.
PORTO'G"
0 PORT "H"
o0
WITHOUT FILTER EXTERNAL FILTER

No Plug with Plug
IMPORTANT
Instructions for replenishing
Circuit Isolation Plug
D-28
26
CONTROL COVER ASSEMBLIES tioned between the roll pins (06p)on the input
S15-42073 Input and S15-42064 Output cover or roll pin holes on the output cover.
See Figure 9 Install snap ring (16j) in the groove of the
1. Apply thread sealant and install the 1/8" pipe- servo shaft extending through the cover plate.
plugs (16k) in the cover plates (16n). Install 5. Position the indicator over the servo shaft with
the two roll pins (16p) in the two 3/16" holes the pointer line on the indicator in line with
provided in one cover. (Input cover only.) the scribed line on the shaft and pointing to-
ROLL PINS (16p) ARE NOT REQUIRED IN ward the "FOF" marks on the cover. Support
COVER USED ON THE OUTPUT. SIDE. the opposite end of the shaft and install the
(S15-42064) indicator on the shaft.
2. Position assembly tool (Thimble) Figure T-7 OMIT STEP 5 COMPLETELY ON THE INPUT
over the end (tapped hole end) of the servo COVER ASSEMBLY.
shaft in the Link and Servo Shaft Assembly. 6. Lubricate 0-rings (161) and (16m) and in-
Lubricate 0-ring (16b) and slide over the stall in counterbore and groove in the covers.
Thimble and install in second groove in the 7. Position the Cover Assemblies over the two
servo shaft. Slide glyd ring (16c) over the dowel pins on the housing pads and insert the
Thimble and position on the 0-ring (16b). Re- four screws (14) with the seals (13) on the
move the Thimble and form the glyd ring (16c) screws. Torque to 30 ft. lbs.
on the 0-ring (16b) with Tool Figure T-6.
3. Lubricate the 0-rings (161) and install one in
the groove on each of the four shear seals The Input Cover Assembly must be installed
Install the shear seals and 0-rings in servo on the righthandside of the housing on pumps
stem with the two spring washers (161) posi- with "B" suffix Install the Output Cover As-
tioned between the parts. Be certain that the
shear seals are installed straight and are seated sembly on the right hand side on models with
against servo links, the "A" suffix.
4. Slide thrust bearing (16h) over servo shaft and
against the servo link. Push the servo shaft
through the cover with the shear seals posi-
VALVE BLOCK
RIGHT
INDICATOR
OUTPUT COVER ASSEMBLY INPUT COVER ASSEMBLY
Shaft end view of pump

COVERS ARE SHOWN IN POSITION FOR
STANDARD PUMP
Covers and the internal Servo assemblies must D-29
be reversed for models with "A" suffix.
27
GENERAL SALES OFFICES
CDMIPONmA
Lee Alan SM
54. Nwc.oii 4M2
17YS Ban Ao." Rd
,."I od5734
"S10A
MtM 204
174 W. WOW&* "NE
(041 35-3417
ILuIM
La Gnim., (l.t'y..m d0225
1341 last Awl
(312) 6414134
I"W Tom
Clt.2t 12037
16 141M.St.
ISIS) 3011-1118
pannyI.ANA
Pillow".9 11320
Iola CO.O.... Md. monar 044 1 Bldg
(4171 343-5,313
Tax"S
called 7535)
7914 UkJ Freeway
Park Dom.51 . Suit, M3
(2141 346
6'
Et le" 31 22
(414) 70-040
A4ltd h Lid, 06.4o 0-i,,n
("I 40)4633M
CUSTOMER SERVICE
CENTER
COI.sit. Ohi.o 4321
1201)0"1.- Ad
0.14) 441.72112
(6141 41.7771
(4141do$ -r0
MARINE, OFFSHORE &

GOVERNMENT
DEPARTMENT
mei. 00e.
CA 5.
flS.. 4216
4614) 01.7405
$3620 .49 adn. .to 107

(713144 4
Sm. 0.im. Comerntl, WI12l
(714) 48141
80m susornasvo 04d Oit'.1btili' LOCatedin Maor. In~dustrial AreIS-Look IS. "Abot/OllOofl Hydralaic: EQuipment" in the Yellow Pages
WfNNvAFIO'AL SURS10,AAES AND~ SALES OF."ICES LOCATEDIN-Arg-Imina. A..ut/ai~s A..Ilr. So/pvm. Broa, Canada CS,1, Colonloia
OeinOrk. Easter EuroW. England. Fiand3. Fr.nC.. G&I'mory.0,..,., Holand. India. Ilan. Italy. Jeoon Womr,c0 New4 Zedaland. Nolitril. Peu
SooM Africa. Seamn.Sweal", Switzerland. Turkey.vbmnolawll
= DENW7N£ABU CORPOAION, 011411094 OGISIC. 1160 Dublin oA0d.Columbus. Ohi~o 43216 (614) 461- 7200
D-30
.1A
DYNEX REMOTE PROPORT!ONAL ACTUATOR
REPAIR INSTRUCTIONS
The following instructions will aid in the dis-assenibly, inspectlon of parts

and re-assembly of the Dynex Remote Proportional Actuator.
We suggest reading thc following instructions to bccome familiar with the

correct procedure before proceeding with a repair. For ordering information
refer to the Repair Parts Sheet and Parts List.
Filter
A Filter (22) is provided to protect the Actuator in the event of dirt entering
the Hydraulic System. This is sized only to protect the Actuator and should
not be regarded as the Main System Filter. A 10 micron absolute - non-bypass
external filter should also be provided in the system.
The filter is designed to collapse when the pressure differential across the
element becomes excessive. This prevents the collected particles from being
introduced into the Actuator.
The Filter should be removed and inspected at regula.r intervals and if damage
is evident the element should be renewed.
To remove the Filter, unscrew the Filter Cap (18) allowing the Filter Element
(22) to be removed. When replacing the Filter, make certain the Spring (21)
and Seal (23) are in position.
Dis-Assembl' for Visual Inspection
Remove Actuator from machine, turn ports down to drain oil and place the
Actuator on a clean bench. Proceed carefully, referring to these ,nstruct-ons
to insure against any unnecessary damage to the parts. Parts can only be
removed in the correct sequence.
The position of the Force Motor (1) determines the null position of the Output
Rod (29) , therefore, the motor must be screwed into the same position ")n
re-assembly. Before unscrewing, mark the position of the motor and count
the number of threads exposed. To romove the Force Motor (1) , loosen the
set screw securing it and unscrew the motor from the actuator body.
Remove the following items next. Spring (3) , Piiot Spool (4) , Pilot Sleeve 5)
and Spring (6) . The P iot Spool and Sleeve iust be treated with extreme care
to prevent damage to the lands on the spool and aperture in the sleeve. The
Plug (7) , Spring (8) and Feedback Cone Assembly (9) can now be removec.
D-32
p=EUING E'h~ BL---NO1 rIj---

Next remove the Circlip (17) and Plug (20) . The Plug can be pushed out
using the Output Rod (29) . The Output Rod should only be removed through
the rear cnd of the unit ns there is a lead-in for the Piston Rings (26) to
prevent damage to-the rings.
Circlip (13) can now be removed and Gland (10) complete with seals is
pushed out
Examine all parts and seals for wear and any damaged items should be re-
placed.
Assembly
Clean parts thoroughly and re-assembly as follows.
Replace Plug (20) and insert Circlip (17) . Replace Output Rod (29) through
the front end of the unit and carefully fit the Gland Assembly (10) , complete
with seals, over the output rod. Push the Gland into position and replace
the Circlip (13)
Replace the Feed Cone Assembly (9) , Spring (8) and Plug (7) . Tighten
the Plug.
Next fit the Spring (6) into the Sleeve (5) and cirefully insert the Spool (4)
into the Sleeve. Ensure the Spool is correctly positioned as shown on the
drawing. Insert the Spring (3) and screw the Force Motor (1) into the
Actuator Body to its original factory set position.
Before tightening the set screw securing the Force Motor the Actuator should
be re-connected to the hydraulic circuit to set the precise position of the
Force Motor. With the Actuator in the null position (i.e. no electrical
connection to the Force Motor) the Output Rod should be in the mid stroke
position.
If the Rod is retracted in the null position, the force motor should be slowly
unscrewed from the Actuator Body until the output rod moved forward. By
very careful adjustment of the Force Motor position the point is reached
where the Rod is in mid stroke position.
If the Rod is cxtCldcd in the null position the Porce Motor should bc stow i,
screwed futrtier iote the ActuaItor Body until LhC mid stroke point is ;chcChu.
When the null position ias been set, the Force Motor is loc cd il posILon
by tightening the :!ct screw in the Actuator 11ody. Lectrical connections
are now made to the terminals on the Force Motor.
D-33
PARTS LIST FOR DYNEX REMOTE PROPORTIONAL ACTUATOR
MODEL SA0505-03-00
PART NUMBER QUANTITY DESC RIPTION
I B5044.900 1 Force Motor Assembly

2 B1232.503 1 O'Ring
3 A5007.110 I Spring
4 C5002.617 I Pilot Spool
5 A5022.900 1 Sleeve Assembly
6 A5006.110 1 Spring
7 A1008.006 1 Plug
8 A5008.110 1 Spring
9 A5021.900 1 Feedback Cone Assembly
10 B5006.019 I Gland
11 A5006.476 I Seal
12 B1254.503 I O'Ring
13 A1008.049 1 Retaining Ring
14 ASOO0 476 1 Wiper Ring
is A5006.562 1 Back-up Ring
16 31230.503 1 O'Ring
17 AI008. 049 1 Retaining Ring
18 B5001.098 1 Filter Cap
19 B1908 503 1 O'Ring
20 A5002.006 1 Plug
21 A5009.110 1 Spring
22 A8031.018 1 Filter
23 A5000.037 I Gasket
24 E5001.190 1 Body
25 B1226.503 2 O'Ring
26 Z5007.476 2 Piston Ring
27 A5006.562 1 Back-up Ring
28 81230.503 1 O'Ring
29 C5004.107 I Output Rod
WHEN ORDERING PARTS PLEASE INCLUDE THE ACTUATOR MODEL NO. AND SERIAL NO.
o01"9, !WAYUL WISCONSINSJ1O2. ruOC ,i4i6ai OJO6 o-Slun 0 d APPU(O POWtft NQ.
D-34
ACTUATOR
MODEL SA 0505-03-00
D-35/(D-36 blank)
Section 1 Part 18
File #2259, Issue 3
November, 1969
MILLER FLUID POWER DIVISION

7N015 York Road
Bensenville, Illinois
INSTALLATION AND MAINTENANCE INSTRUCTIONS FOR MILLER

AIR AND HYDRAULIC CYLINDERS
GENERAL PRECAUTIONS: Cylinders which have been in storage for

some time should be lubricated and cycled several times before they
are installed on machines and subjected to actual working loads.
Excessive breakloose and cycling pressures indicate the cylinder may
have been damaged during shipment or storage. Costly installation
and removal time can be eliminated by following this procedure.
Cylinders should be stored in a vertical position with the piston rod up.
A Miller air or hydraulic cylinder is a precision piece of equipment,

and therefore, it is recommended that the cylinder be removed from
the machine and taken to a general repair area where suitable tools,
repair and testing facilities are available.
Dirt protector plugs should be kept in cylinder ports whenever the pipe
fittings are removed or while cylinder is in storage. This prevents
dirt and other foreign material from entering the cylinder and damaging
moving parts.
Be certain that the connecting pipes and fittings are clean before con-
necting to the cylinder. All pipe ends should be deburred and the insides
of the pipe cleaned of scale, rust, dirt, and foreign matter.
Clean oil is essential to long and satisfactory operation of cylinders,

pumps, valves, etc. Keep oil tanks covered as even normal room dust
causes premature failure, sticking of parts, and needless repairs to
hydraulic systems. Provide an adequate oil filter, preferably a micro
filter.
AIR CYLINDER LUBRICATION AND INSTALLATION: Provide an oiler,

filter, and water separator in the air line, and use a light mineral oil
as a lubricant. Use a pressure regulator to conserve air and provide a
smoother action. Save air and obtain a greater speed by installing the
valve as close to the cylinder port as possible. Air cylinders can be
furnished with a grease fitted rod bushing on request. The grease
fitting is threaded into the side of the retainer.
D-43
CAUTION: When cylinders require servicing, an additional set of
seals should be ordered. The original seals may become damaged
in servicing, and this precaution will save time and eliminate costly
delays. Generally, it is best to replace all seals unless the existirng
seals are in excellent condition or this is not economical or possible
due to availability.
Any seal can be damaged if forced over threads or sharp metal parts
of almost the same size. All burrs and damaged areas should be
corrected prior to removing piston rod bushing and rod seal.
Accordingly, care in assembly should be exercised. In the case of a

rod wiper and rod seal, a simple shield of thin wrapping paper around
the threads will permit easy installatluii of the seals without damage.
DIRT WIPERS: To remove a dirt wiper without taking the rod bushing
off, it is necessary to use a pointed tool as the wiper is lodged firmly.
It may be necessary to take the wiper out in pieces. Care should be
exercised so that the piston rod will not be damaged in removal of the
wiper. A new wiper should always be in serted by using a smooth,
blunt tool so that the wiper will not be damaged. Whenever the dirt
wiper has a tendency to be blown out, it is an indication that the rod
seal is leaking, or in the case of a cylinder equipped with a grease-
fitted rod bushing, that an excessive supply of grease has been forced
into the grease fitting.
The following step-by-step outline will be a valuable aid to personnel

qualified to service precision equipment. By exercising only normal
care, which any good workman would accord fine machinery, no undue
difficulty will be encountered.
1. Wipe all external surfaces clean. Drain excess oil from

hydraulic cylinders. Paint or draw a line on one side of the
cylinder running from the cylinder cap to the mounting end of the
piston rod. This will serve as a reference line when inspecting
components and reassembling the cylinder.
2. VISUAL INSPECTION: Visually inspect all exterior surfaces

for evidence of damage, and, in particular, damage to the piston
rod. Evidence of rod seal leakage can usually be traced to nicks
in the piston rod or misalignment. If a slight nick is noticed in the
piston rod, it can often be quickly removed by using a No. 400 grit
D-44
emery cloth. The rod should then be wiped carefully for removal
of any matter. UNDER NO CIRCUMSTANCES SHOULD COMPRESSED
AIR BE USED TO REMOVE FOREIGN MATTER, as this practice
may tend to drive such particles into close clearances. Misalign-
ment can often be detected by observing the condition of the piston
rods for evidence of excessive wear, polishing, burnishing or
scoring on the side of the piston rod. Check carefully the end of
the piston rod and the area around the flats on the end of the rod
for burrs and nicks. If burrs and nicks are present, remove with
a file or emery cloth to avoid damage to the piston rod seal, rod
wiper, and bushing during removal.
3. REMOVAL OF BOLTED BUSHING:

3 a. Loosen and remove the cap screws that hold the bushing
in the cylinder head. Refer to File 4770.
3 b. Lift out the bushing.
3 c. Use step #5 for removal of rod seals.
4. LOOSENING THE CYLINDER TIE RODS:

4 a. Proceed to loosen the four cylinder tie rods, noting if
the tie rods were tightened evenly. It may be necessary,
in some cases, to grip the tie rods with vise grips to
prevent the tie rod from turning.
5. REMOVAL OF ROD SEAL: Normally the rod seal will come out when
bushing is removed. If rod seal remains in cylinder head, raise the
cylinder head approximately one inch, and then lower it back into
original position. This will expose the rod seal for easy removal
(BY NO MEANS USE A TOOL TO PRY OR LIFT OUT THE ROD SEAL
FROM THE CYLINDER HEAD). See attached File 2861 or 2862 for
rod seal arrangement. Refer to File 4770 for Caged Piston Rod
Seal Assembly.
6. REMOVAL OF RETAINER HELD PISTON ROD BUSHING:

6 a. Loosen the cylinder tie rods - NOTE: Refer to step #4.
6 b. Removal of retainer plate: Remove retainer plate, (in
some cases, this may be a flange mounting plate. )
Model "H' cylinders in 8" through 14' bores have a
circular retainer holding the bushing and rod seal
assembly in place. Model 'A" & "J', 8' through 14'
bores have a square retainer holding the bushing and
rod seal assembly in place.
6 c. Lift out the piston rod bushing.
6 d. Remove rod seal; Refer to step #5.
, *e. Refer to File 4770 for Caged Piston Rod Seal Assembly.
D-45
-. -
,t. 1' -
7. REMOVAL OF CYLINDER HEAD: Remove cylinder head from
cylinder. Lift out pressure ring, wave spring and cage. See
File 2861 and 2861 for parts arrangement.
7 a. On air cylinder remove only rod seal, no cage
assembly is used.
8. REMOVAL OF PISTON ROD AND ASSEMBLY: Remove piston

rod and piston assembly from cylinder tubing. (If tubing comes
off from cap pilot, merely slide piston assembly off from cylinder
tubing).
9. REMOVE TIE RODS FROM CYLINDER CAP.
10. INSPECTION OF INTERNAL PARTS: Inspect all cylinder parts

on internal surfaces, noting particularly any evidence of foreign
matter. (Retain all foreign matter for future study if necessary.)
Examine parts for evidence of misalignment as evidenced by ex-
cessive or uneven wear on parts.
11. CONDITION OF PISTON, TUBING, PISTON ROD, ETC.: If

piston, tubing, piston rod, or piston rod bushing is damaged, the
part should be replaced if available: however, correct if necessary,
by removing nicks, burrs and other forms of damage. However,
do not remove enough material to change the diameters, thus
affecting the clearances and fits.
12. REMOVAL OF PISTON ASSEMBLY: Piston assemblies are

staked to prevent the parts from coming loose in operation. If
the piston assembly must be taken apart, first grind or drill out the
stake marks to facilitate disassembly. When removing the upset
material caused by the stake mark, lightly touch the tool being used
to the stake area and remove only the upset material, To disassemble
single end cylinders, you may insert two dowel pins in the spanner
pin holes and use a bar to remove the threaded follower, or in the
case of double end cylinders, remove taper pin or set screw and use
flats on piston rods to disassemble. An alternate method is to clamp
the piston assembly by the faces of the followers in a vise and screw
out the piston rod using the flat on the end of the piston rod for
turning. ( Y NO MEANS CLAMP THE PISTON ON ITS OUTSIDE
DIAMETER.) The vise should be equipped with bronze or brass jaw
protectors if clamping piston rod on chrome plated area.
12 a. 6" bore "H" cylinder and larger have a one-piece
type piston assembly. This piston is removed by
drilling or grinding the stake marks and removing
the piston the same as described in the previous
paragraph.
D-46
Ai
12b. The cup seals are removed by removing the cap
screws from the circular cup retainer ring on
both sides of the piston. NOTE: THERE IS NO
NEED OF REMOVING THE ONE-PIECE PISTON
FROM THE PISTON ROD IF ONLY THE PISTON
CUP SEALS ARE TO BE REMOVED.
RECOMMENDED PRE-STRESS TORQUES

FOR PISTONS AND STYLE NO. 2 PISTON RODS
Cylinder Bores
Models Model Thread Torque
A, J, C H Size Ft. Lbs.
1-1/2, 2, 2-1/2
1-1/2 7/16-20 55
3-1/4, 4, 5 2, 2-I/2 3/4-16 185
6, 8 3-1/4 1-14 375
10 4 1/4-12 690
12 5 1-1/2-12 995
14, 16 6 1-7/8-12 1415
18, 20 7 2-1/4-12 1970
8 2-1/2-12 5050 *
10 3-1/4-12 7940 *
12 4-12 12560 *
14 5-1/2-12 16275 *
NOTE: * When Molycote is used on threads.
13. REASSEMBLY OF PISTON ASSEMBLY: To assemble the

piston cup assembly, first assemble to the rod the piston
and followers only and tighten the piston assembly tight,
metal to metal. Scribe a diametrical line which is com-
mon to both the piston rod and the threaded follower,
remove the threaded follower and piston, and then place
the piston cups into position. In tightening the threaded
follower, it must be tightened to the scribed line on the
rod or slightly beyond. To restake a piston assembly,
use a sharp center punch wherever possible. Stake marks
must be in the thread area to be effective. Staking should
be accomplished at three points which are different from
the original stake marks.
When installing the piston assembly into the cylinder tubing,

the piston assembly should be inserted into the cylinder tube
with the aid of a tapered starting ring or with a piston ring
compressor so as not to damage the lip of the cup.
D-47
13 a. If a tapered ring or compressor is not available,
assemble the piston assembly in the tubing as
follows:
Install only the plain follower, one piston cup and
the piston on to the rod, and insert that portion of
the assembly into the cylinder tube, keeping the
piston rod as parallel to the centerline of the tube
as possible. Push the assembly to the opposite
end of the tube to within approximately 1" from the
end of the tube, and install the second cup and the
threaded follower. The piston assembly is
tightened and staked as indicated above. Assembling
the piston assembly in the tube eliminates the prob-
lem of starting the lip of the cup into the tubing, and
this alternate method of assembly may be preferred.
An ample amount of lubrication should be used when
installing piston into tube.
Step seal piston rings used in Miller hydraulic cylinders are stamped
"UP" on one side. The "UP' side must be installed to face the pres-
sure it is to seal. Double acting pistons must have an equal number
of rings facing both ends of the cylinder. Installation of piston rings
into cylinder tubing can be simplified by using a piston ring com-
pressor. If a compressor is not available, the piston should be
inserted into the tubing until it meets a ring. Pressure should then
be applied to the first ring at positions 90 o from the split in the ring.
When a ring is compressed, the piston can move forward until the
entire piston is completely installed in the tube. Do not use a tool
which will damage the piston ring. A non-metallic tool is suggested
such as wood, plastic, fibre, etc.
Hydraulic cylinders equipped with followers have a small hole drilled

through the follower to the base of the cup seal. This hole permits
pressure balancing the cup hydraulically. Under no circumstances
is the hole to be permanently closed so that it cannot perform its
function.
13 b. If a one-piece piston is used, thread piston on piston

rod per instructions in Section 13. Torque piston
using torque as indicated in Chart. Install cup seals
per Section 13. When cup seal starter is not avail-
able, cup seals will have to be assembled in the tube,
see Section 13 c.
13 c. Assembly of one-piece piston assembly when starter

is not available:
1. Assemble piston to rod with the proper torque
applied.
0-48
2. Insert piston & rod into tube. NOTE: BE SURE TO
GREASE TUBE & PISTON ASSEMBLY.
3. Push Piston Rod to move piston to one end of tube.
Install cup seal in position on piston.
4. Install circular retainer over cup seal and bolt
in place.
5. Tighten Allen screws in circular retainer to proper
torque. Refer to Chart on recommended torque.
6. Push rod through tube to move piston to opposite
end of tube.
7. Assemble cup seal on cap end, using same procedure.
RECOMMENDED TORQUE FOR

STEEL - CUP RETAINER SCREWS
MODEL "H"
Cylinder Bore Dia. SCREW SIZE TORQUE
5" 10-- 32 7.5 ft. - lbs.

6" thru 14" -1 - 28 17.5 ft. - lbs.
16" thru 20" 5/16- 24 35 ft. - lbs.
NOTE: THE ABOVE TORQUE FIGURES ARE FOR STEEL SCREWS

USED IN STANDARD CYLINDERS. IF STAINLESS STEEL SCREWS
ARE USED, SUCH AS, IN WATER SERVICE CYLINDERS, A LOWER
TORQUE FIGURE IS USED BECAUSE OF LOWER STRENGTH OF
STAINLESS STEEL. CONTACT MILLER FLUID POWER CUSTOMER
SERVICE DEPARTMENT FOR THESE TORQUE FIGURES.
14. INSTALLATION OF TUBING END SEAL: Prior to installing

the tube into the cylinder cap or head, install tubing end seal as
follows, dependent on the type of tubing and seal:
A. TEFLON STRIP TUBING END SEAL ("SHEF-SEAL")
For complete instructions for installing Miller

"SHEF-SEAL" tubing end seal, see attached
File No. 2039, Issue 7.
B. CYLINDER "0" RING END SEALS: (HYD. CYLIND ERS

ONLY)
Step I. Install cylinder "0" ring in groove.
Step 2. Grease cylinder "0" ring to facilitate

installation of tubing, without damage
to "0" ring. Make sure end of tubing
does not have nicks on I. D. from im-
proper handling as "0" ring may be
damaged.
D-49
15. INSTALLATION OF WIPER INTO BUSHING: In cases of
single wiper bushings, it is convenient to install the wiper
into the bushing before assembly of the bushing on to the piston
rod. In the case of double wiper bushings, the wipers should
be installed after the cylinder has been completely assembled.
In the case of a double wiper, installation of wipers is recom-
mended after the cylinder has been completely assembled and
tested so that the one oil wiper does not act as a seal in the
event there is a slight leakage of the piston rod seal which
might go undetected. The wiper is not intended as a pressure
seal but only as an oil wiper. The double wiper design has been
discontinued on later models, as the oil wiper is deemed un-
necessary due to Miller's leakproof hydraulic rod seal construction.
16. REASSEMBLY OF THE CYLINDER: After the cylinder has

been assembled in the reverse order of the disassembly, tighten
tie rods snugly with hand wrench and light pressure, and accomplish
final tightening gradually, working from one tie rod to the
diagonally opposite tie rod to insure evenness of tie rod tightening.
DO NOT TIGHTEN ONE TIE ROD COMPLETELY AND THEN THE
OTHERS. THIS WILL RESULT IN IMPROPER TIGHTENING OF
TIE RODS AND IMPROPER ALIGNvIENT OF THE HEAD AND CAP.
TIE ROD PRE-STRESS TABLE

Recommended Torques (Ft. Lbs.)
No Lubrication - 4 Tie Rod Construction
Models A, J, and C Model H

Cyl. Torque Elongation Torque Elongation
Bore Ft. Lbs. in 36" Ft. Lbs. in 36"
1-1/2 8 1/16" 21 1/16"
2 15 1/16" 54 1/16"
Z-1/2 15 1/16' 54 i116"
3-1/4 34 5/64" 95 1/16"
4 34 5/64" 150 3/3Z"
5 62 1/16"- 315 5/64''
6 62 1/16" 465 5/64"
7 690 5/64"
8 110 1/16" 850 5/64"
10 185 1/16" *1340 1/16"
12 230 5/64" '1740 l/16"
14 356 5/64" *2zz00 1/16"
16 373 1/16"
18 550 1/16" I
z0 1680 1/16"
When " dia. multiple tie rods are used on 10", 12", and 14" bore
"H" cyls., equivalent torque is 400 ft. lbs. and elongation in 36"
is 1/16". NOTE: When Molycote is used on threads, use 2/3
of torque shown in table.
0-50
NOTE: WHEN REASSEMBLING CYLINDER, USE THE FOLLOW-
ING TORQUE FIGURES ON BOLTED BUSHING CAP
SCREWS: Please refer to File 4770.
RECOMMENDED TORQUE FOR

STEEL - BOLTED BUSHING CAP SCREWS
PISTON ROD DIA. SCREW SIZE TORQUE

5/8 20 - 32 7 ft. - lbs.
1' thru 31" - 28 15 ft. - lbs.
4" thru 10" 5/16 - 24 30 ft. - lbs.
NOTE: THE ABOVE TORQUE FIGURES ARE FOR STEEL

SCREWS USED IN STANDARD CYLINDERS. IF
STAINLESS STEEL SCREWS ARE USED, SUCH AS,
IN WATER SERVICE CYLINDERS, A LOWER
TORQUE FIGURE 15 USED BECAUSE OF LOWER
STRENGTH OF STAINLESS STEEL. CONTACT
MILLER FLUID POWER CUSTOMER SERVICE DE-
PARTMENT FOR THESE TORQUE FIGURES.
17. TESTING OF CYLINDER: Move rod in and out by hand with

cylinder horizontal to determine freedom of movement, or if
cylinder is very large and long stroke, use approximately 8 to
15 P.S.I., or slightly more air pressure, to check for freedom
of movement of piston assembly. Even small bore cylinders
1-" bore with 3 to 6 foot strokes move at 8 to Z3 P.S.I. Break-
loose pressures on air cylinders should generally be less than
hydraulic cylinders.
Double rod end cylinders and cylinders with oversize rod dia-
meters take more pressure, but in no case more than approxi-
mately 45 P.S. I. should be used. If the stroke is longer than
6 ft. , it may require slightly more pressure, but if the pres-
sure required to cause the piston assembly to move is substan-
tially above 45 P.S. I. , this would indicate improper assembling
and functioning from the standpoint of efficiency and could re-
sult in either mechanical damage to the piston cups, tubing,
bushing, piston rod, etc., or premature seal failure. There-
fore, the cylinder should be disassembled, re-assembled after
corrective action, and rechecked again before installation into
the mechanism.
0-51
It is always advisable to test a cylinder before installation into
a machine. If the cylinder is equipped with piston cup seals, a
short hose should be connected to t:.a head port. The open end
of the hose should be submerged in a small container of water.
Apply airline pressure at the cap port only, and if more than
an occasional bubble appears in the water, the piston assembly
is not sealing properly.
The procedure should be reversed with the short hose at the

cap end inserted into the water, and airline pressure at the
head port. Rod seal leakage may be checked at the same time
by depositing a small quantity of oil around the piston rod in
the clearance between the rod bushing and the piston rod. An
occasional air bubble may appear. If more than an occasional
air bubble appeare, the cylinder may leak under hydraulic pres-
sure. If in doubt, proceed to test under hydraulic static and
cycling conditions to check for rod seal leakage. Hydraulic
leakage at rod seal should be checked without installation of
wipers in the case of a double wiper bushing. (Seals which
will leak an occasional bubble of air are expected to be leak-
proof when tested hydraulically. )
18. REMOUNTING PROCEDURE: The ideal method of mounting

a cylinder to the machine is to have the point of mounting on the
equipment machined to the exact dimensions with proper alignment,
so that bolting the cylinder in place insures perfect alignment. In
many cases this is not practical from a cost and design standpoint.
Therefore, alignment must be secured at the time of installation.
Whenever the piston rod is fastened to the machine which confines
the cylinder in one position, we have found that it frequently is
best to bolt the cylinder down as a last operation of assembly.
Alignment can be secured in other ways, but we believe the fol-
lowing sequence of installation steps is quite effective:
A. Assemble the piston rod to the machinery. The piston

rod must be fastened and held squarely so its centerline
is parallel to the guides of the attached machinery (or
parallel to the line of movement of the attached machinery
in cases of fixed mounted cylinders. )
B. Insert mounting bolts but do not tighten them.
C. In the case of horizontally mounted cylinders, it is

necessary to support the weight of the cylinder body
so as to eliminate strain on the piston rod.
D. Use feeler gauges under the mounting and shim at these

points equal to the space indicated by the feeler gauges.
D-52
L ,
E. Finally, tighten the mounting bolts.
F. If possible, the machine operation should be tested

with low pressure air to insure that cylinder and
attached parts are operating freely. This should be
done without machine operating under load conditions.
NOTE: A little extra care in aligning the cylinder

properly will pay dividends in terms of long.
trouble-free service, and is well worth the
additional time and effort.
GENERAL: Whenever possible, damaged parts, especially seals,

should be sent to the Miller Fluid Power Division along
with a complete report so that a thorough analysis can
be made. Your cooperation in this respect will help us
to help you overcome service difficulties encountered
as a result of adverse operating conditions or improper
application.
CAUTION: SPRING RETURN CYLINDERS--An installed spring can

injure a person if special precautions are not exercised
in removing the tie rods. In some cases, clamps may
be used to contain the cylinder assembly while the tie
rods are being removed. If such is the case, the clamps
should, of course, be designed to permit gradual release
of spring compression to its free length. In other in-
stances, it is desirable to prepare two special tie rods
which are longer than the original tie rods, and which
are threaded for the full additional length over and
above the original tie rod length. The special tie rods
required to disassemble a standard Miller spring should
be 1 -1/2 times the length of the cylinder with the extra
half length threaded. Remove two of the original tie rods,
bringing the tie rod nuts up snug. The other two original
tie rods may then be removed, after which the special
tie rods can be used for final safe disassembly by grad-
ually threading the tie rod nuts off, working alternately
from one tie rod to another. The special tie rods may
be used to reassemble the cylinder as compressing the
spring will be easy, positive, and safe.
CAUTION: CYLINDERS WITH NON-SAG RODS--During disassembly

or reassembly, exercise extreme care to hold piston rod
rigid in position where word stamped "TOP" is facing
upward. Piston rod must be concentric with counterbore
in head while installing rod seal parts and bushing.
D-53
ASSEMBLY INSTRUCTIONS FOR SPRING LOADED TEFLON
PISTON CUPS. See File 4632 B or 4618 A for cross-sectional
drawing on 3-piece Piston Design Cylinder.
The following instructions give a detailed breakdown on the proper

methods to be used when assembling spring loaded teflon piston cups.
These instructions should be followed closely to prevent darage to
the cups during assembly.
1. Make certain that all parts are free from any contami-
nation or foreign material and that the assembly area is clean.
2. Insert piston pressure ring retainer (Spir "0" Lox) into

slot provided in threaded and plain followers. On 1-1/2"
and 2" bores, this operation is deleted.
3. Insert rod end cushion plunger on rod with 45 0 chamfer

toward the follower. This is for rod end cushioned cylinders.
4. Assemble plain follower, piston, and threaded follower

on rod.
5. Tighten assembly hand tight.
6. Scribe a line across the threaded follower and end of the

piston rod. Make certain that the scribed line can be
clearly identified.
7. Remove the threaded follower and piston from the piston

rod.
8. Insert the teflon follower seal over the rod end and against
the plain follower.
9. Place the tube in a vertical position on the bench, if

possible.
NOTE: Extreme caution should be taken when performing

the following operations to prevent damage to cups,
piston, or tube.
10. Position the first cup seal into tube approx. 4" parallel to
top of tube, lip of cup seal down or away from assembler.
11. Position the piston into tube and allow to rest evenly
against cup seal.
D-54
12. Position the Znd cup seal into tube snugly against the piston.
Lip of cup seal up or toward the assembler.
13. Insert one wave spring over plain follower. The plain follower
at this point should be on the piston rod. Make certain that the
teflon follower seal is in place.
14. Insert one piston pressure ring over plain follower angled
side out or to the assembler so that the step side is squarely
against the wave spring.
15. Place the tube with both cups and piston carefully over the
plain follower and over the rod end.
16. Insert the second cup pressure ring into the cup seal so that
the angled side is evenly against the angled side of the cup.
17. Insert the 2nd wave spring over the threaded follower and
evenly against the shoulder of the pressure ring retainer (Spir
"0Q' Lox ring).
18. Carefully assemble the threaded follower to the rod end.
19. Tighten threaded follower using torques as specified on

Page 5 of these instructions. If using the scribed line method,
make certain that the scribed line on threaded follower is
approx. 20 0 to 25 0 beyond that of the scribed line on piston rod.
Occasionally slightly higher torques will permit locating the
scribed lines properly.
CAUTION: Care should be taken when tightening the

follower to make certain that the tube is
not damaged.
20. Stake the threaded follower to the piston rod. Make certain
that three punches are evenly spaced 120 'apart. Peen all sharp
burrs.
21. Proceed with normal assembly of cylinder.
D-55
ASSEMBLY INSTRUCTIONS FOR SPRING LOADED TEFLON
PISTON CUPS ON AN INTERIM TYPE PISTON. See File 4632B
or 4618A for cross-sectional drawing.
1. Make certain that all parts and assembly area are clean,
2. Assemble Interim type piston to rod with the proper torque

applied.
3. Place the tube in a vertical position if possible.
NOTE: Extreme caution should be taken when per-

forming the following operation to prevent
damage to cups, piston, or tube.
4. Insert piston and rod into tube, approximately 2".
NOTE: Be sure t0 grease tube and piston before assembly.
5. Insert teflon cup seal inti tube at rod end on to piston.
6. Insert pressure ring against cup.
7. Insert wave spring flush against pressure ring.
8. Install circular retainer oer spring loaded assembly and

bolt in place.
NOTE: Circular retainers must be machined to

accept spring loaded assembly.
9. Tighten Allen screws in circular retainer to proper torque.
IC. Push rod through tube to cap end approximately 2" from end.
11. Assemble teflon cup and spring loaded assembly. Same

procedure as done on the opposite end.
12. Do not take piston rod and assemibled parts out af the tube
after parts have been assemblecL
13. Proceed with normal assembly of the cylinder.
D-56
ASSEMBLY INSTRUCTIONS
MILLER "BASE-LOK" HYDRAULIC CYLINDER
CAGED PISTON ROD SEAL AND BUSHING ASSEMBLY
This kit contains Miller's new design caged rod seal assembly which includes either a
bolted design bushing or a retainer held bushing, both of Base-Lok design. Please Note:
The complete caged rod seal assembly is interchangeable with all previous design
cylinders. However, the individual parts of the caged rod seal assembly may not be
interchanged with previous design rod seal parts. Please follow the assembly
instructions carefully.
Step If bushing is retainer held, remove tie rod nuts and retainer. Remove all rod
1 seal parts from cylinder and discard. Remove any dirt, chips, etc. from bushing
cavity in bead. Inspect piston rod and polish out any nicks or
scratches in piston rod.
Step For convenience, extend piston

2 rod partially and install the 0ffiZ0m = D"1Extm1pA3,zm '
caged rod seal assembly per LhM.Ek
assembly drawing and in
sequence as follows-.
A. Rod seal cage 1b
B. Rod wave spring 10

C. Rod pressure ring eo
D. Rod Seal
E. Bushing
Step
3
A. After bushing has been put
on piston rod the flange of
piston rod seal should be
-
inserted into the counterbore of the bushing
before inserting bushing into the counterbore of the head. This is to assure
that the piston rod seal is properly mounted in the bushing.
B. The entire caged rod seal assembly and bushing is then inserted into the
bushing cavity of the cylinder head.
C. If the bolted bushing is used socket head cap screws are used to hold the
bushing in the cylinder head. Use the torque figures indicated below when
installing the socket head cap screws.
Piston Rod Diameter Cap Screw Size Torque
5/8" 10-32 x 3/8 76 in/lbs.

I" thru 3-1/2 1/4-28 x 5/8 180 in/lbs.
4" thru 10" 5/16-24 x 1 360 in/lbs.
D. If retainer held bushing is used, reinstall retainer and tie rod nuts.
(retorque tie rod nuts to values shown in catalog.)
E. Install rod wiper in bushing. FILE #4770

REVISED 6-24-70
ASSEMBLY INSTRUCTIONS
MILLER "'BASE-LOK" PNEUMATIC CYLINDER
PISTON ROD SEAL AND BUSHING ASSEMBLY
This kit contains Miller's new design rod seal assembly which includes either a
bolted design bushing or a retainer held bushing, both of Base-Lok design. Please
follow zhe assembly instructions carefully.
Step If bushing is retainer held, remove tie rod nuts and retainer. Remove rod
1 seal parts from cylinder and discard. Remove any dirt, chips, etc. from
bushing cavity in head. Inspect piston rod and polish out any nicks or
scratches in piston rod.
Step For convenience, extend piston

2 rod partially and install the
rod seal assembly per assembly
drawing and in sequence as
follows:
A. Rod Seal .
,I&
B. Bushing "
Step A. After bushing has been put

3 on piston rod the flange
of piston rod seal should ~V
be inserted into the V-1
counterbore of the bushing
before inserting bushing into )%4 -
the counterbore of the head. This -
is to assure that the piston rod seal
is properly mounted in the bushing.
B. The rod seal and bushing is then inserted into the bushing cavity of the
cylinder head.
C. If the bolted bushing is used socket head cap screws are used to hold the
bushing in the cylinder head. Use the torque figures indicated below when
installing the socket head cap screws.
Piston Rod Diameter Cap Screw Size Torque
5/8" 10-32 x 3/8 76 in/lbs.

1" thru 3-1/2" 1/4-28 x 5/8 180 in/lbs.
4" thru 10" 5/16-24 x 1 360 in/lbs.
D. If retainer held bushing is used, reinstall retainer and tie rod nuts.
(retorque tie rod nuts to values shown in catalog.)
E. Install rod wiper in bushing.
FILE #4770A 6-24-70

D-58
Field Installation of Latest Design MILLER "SHEF SEAL" Tubing End Seal
SHEF
of SEAL
Teflon is amaterial
sealing rectangular
supplied~t
strip ...VW--
"/ A -1
already cut to the proper lengths
for the various bore sizes as shown
in table below-or supplied in long
lengths on convenient spools from
which the Teflon strip is easily cut APOX.
with knife or scissors to the re- SECTION A-A
quired lengths (shown In table). SHOWING "S1FSEAL"
Squareness of cut is not critical and TII END UAL
length of cut need only approxi-
mate the lengths shown in table below. Installation of the Teflon strip
is as follows:
Step #1. Apply greose to ite tubing groove of cylinder had or cap.
Step #2. Call the oeon strip an its narrow edge Into the greosd tubing groove.
The strip should make two complete revolutions plus about I/2" overlop.
For convenience of denonstration, the sketch of right oxosgeroes the spocsbetweenthe

shef Seal coils which actually hog octh otherclosely when ited into tubina groove.
SUJGGESTED 0 SHEF-SEA..' LENGTHS IN INCHES

Bore 1-1/2 2 2-1/21 3-1/i 5 6 7 10 12 L
Yodel "A" or "J"lO1-1/ 13-3/8116-1/2 21-1/11 26 32-i 38-i/2 51 63-5/8
/l li'4 77 5
_, "B"
___odel 10-31h_____8_22-_____
8 1 i0- 531 67 791'
Field Installation of Previous Design MILLER "SHEF SEAL" Tubing End Seal
Some earlier Tubing End Seals utilized A m
.070" square 'SHEF SEAL" with the ends
butted together. The new rectangular strip
replaces and is completely interchangeable
with this previous design. Also, some earlier
designs had seal cavities wider than the
groove now being used. SHEF SEAL is used
in the wide groove cavities by spiraling in
"SHEF SEAL", starting from the 0. D. of SECTION A-A
the tubing groove, then making two com- SHOWING "SHIP SEAL"
plete revolutions and zig-zagging in accord- TUSING END SEAL
ance with the sketch at right. The sketch
is exaggerated to more clearly illustrate how "SHEF SEAL" is installed.
Also, if desired, Miller can furnish a metal ring. at extra charge, which
reduces this wide cavity to the narrower dimensions of the new cavity
of the latest design.
If the "SHEF SEAL" material becomes twisted or deformed, we ordinarily
recommend replacement with new "SHEF SEAL" sealing material when
the cylinder is reassembled. However, if a cylinder is disassembled and
there is no new "SHEF SEAL" material available and the "SHEF SEAL"
which came out of the cylinder on disassembly is twisted or distorted, it
can be made more satisfactory for use by simply submerging in boiling +-4
water for 5 to 10 minutes, remove from the water and stretch the material
by hand, exercising care in not pulling too hard. Distorted "SHEF SEAL"
has been successfully reused after reforming in the above described
manner.
"SHEF SEAL" on original equipment is sometimes furnished in a con- (The pos. between thecoils do*% not oeuaIiy .exist
tinuous ring of .070" square material. For field service, it, too, would be as "SHE'SEAL'" is coiled ivusty og ,ist itteit.i
replaced with the rectangular strip.
Advantages of Spoofed Toflon Strip SHEF SEAL

By using Teflon strip "Shet Seal" from sspool, you avoid the stocking of
the many different lengths required for the different bore sises. You lust
cut the length you need from the spool. And on]) one crosssection dimension
of the spooled
Model Teiton strip
-J- Hydraulic Seal
'hef and.
Cylinder AssMiller
dell ill bo'es of Miller
Model "A" AirModel "H"
... and
Cylinder
She Seal design. Thus, the greet expense end confusion of stocking all
of ~ lt R F
[7ILLER UO
FLUID ~ L~
extensive range of seal sizes are completely eliminated. And the field installa.-
tion from the spooled strip provides the quickest, easiest end most effective OF PLCK-•IEPY CO5POOATION
mIVISION
servicing of tubing end Seals. NO15 York Road Bensenvle, tlnois
tl.#2039, iW. 7
D-61
4 9~J3S~'
S
V
-
3!
33 !
3 3 3
!~II ~
4P~ } ~
~
31
LI
--
32
1
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~ ~ h'.
~4.~a Iii:~
-
3r~3
*
mm I.
a A'
~ vi ~ ui~ 3
III,!,:
II.
'~
~
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III~i~
~
-~
6 SI
3
; 3..a
3 t-.
~
4
8
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~
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~ I
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'
~a
t4t
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-'IES
W,
wl
z4--o u
- 405
in
a a t4 I-
I!V, tj
CCc -6
o oit, it
- a
LU £
01~
04
U ',: C'
W L
7L Z
a- w a
Lja: .)O. otaa
oi~co
w- wj
C-4
WHEN ORDERING PARTS 7
OR IN CORRESPONDENCE
MILLER SINGLE ROD CYLINDER SPECIFYPARTNM

SERIAL NO._______
N
Serisi No a stamped on
DOUBLE ACTING - NON-ROTATING N ...epl .. sd Po,, ..d. of H..d
14-BEAD SEE DETAIL F ON REVERSE

13-CAP SEE DETAIL AON REVERSE SIDE SIDE POR BALL CHECK BREATHER PARTS
1S-TUBE FOR ROD BUSHING A REAL PARTS . SEE DETA.L DONREVERSE SIDE FOR
27-SQUARE RETAINER/ CSINCEK&AJTMTPRS
S I
34-TIE ROD NUT
30-T ROD ( RE CYLINDER)

49-TUBING END SEAL (SHEP-SEAL)
131B-SOLTED BUSHING SCREW 315
BSEEDETAIL BON REVERSE
SIDE FOR PISTON ASSEMBLY
PISTON ROD LENGTH TIE ROD LENGTH TUBING LENGTH

ADDITIONAL PARTS (NOT SHOWN) REQUIRED FOR CERTAIN MOUNTING MODELS
MODELS 625
&4 - ADD FLANGE PLATE@CAP END TIE ROD NUTS ARE NOT MODELS 6I 65D WHEN BOLTED BUSHING IS INDICATED ADD FLANGE
REQUIRED. TIE RODS ARE THREADED INTO FLANGE PLATE PLATE@
MODEL 6 - ADD CLEVIS BRACIET®AT CAP END CAP END TIE ROD NUTS -WHEN PULL SQUARE RETALNER IS INDICATED
ARE NOT REQUIRED TIE RODS ARE THREADED INTO BRACKET. SUBSTITUTE FLANGE PLATEFR RETIER®
MODEL 77 - SUBSTITUTE MOUNTING LUGS@ FOR 2 TIE ROD NUTS. EACH END -OMIT ROD END TIE ROD NUTS TIE RODS ARE THREADED
INTO FLANGE PLATE.
12 69
FILE NO. 5138A
D-65
1AU
!EEgg
m 3
Via
T VM
LI.
_r, Q
___ * NR
------
D-66
0
GENERAL PARTS
BREAK DOWN
INSTALLATION AND
SERVICE INSTRUCTIONS
hydrauli1c
1913NO STHAMMON IN
cylinders
6320 " Garlock
D-67
GENERAL PARTS SREAKDOWN
INSTALLATION AND SERVICE INSTRUCTIONS
FOR SERIES 2TH CYLINDER
PAR) S ORAING 49 43 46 40 20 21 4 26 11 33 34 C5 58 61 61 -
28 6 22 19 32 31
15 22
2' 7 6 24
24 25 3 10 1G 9 39 1 42 49 41 53 "1 !; '.3 5 36
PARTS
ITEM PART IAIr ITEM7 PART VA)D ITEM) PAP- "'- USE
7 MrENrD COVER -TT flt ROO IL:7 -Tr
I' ',
Pl STALo:C
0 = "rP
-- O
2 CAP' EID C 18 PISTON OCY SC.rW
3 310CR ''EE PISTOl 19 CAR.. LOC SCREW c PISO
P PLATE o-rIl 2-5D - CUsP. WD
4 SC PSTOl. 20 BLEEDEP SCR-W 41 W7D .10 Ci). 'OSr El'D
5 VE PISTO,' pLATE-WD. 2 B EEDER BALL 4: H'D CUS. A2. I DL 1
)-3c
8 V"E PISTOTI pLATE-A1 22 ROD PYG. POE. I::G 47 7D SAIL Ci)'P SCRErW 57-65- CUSH). CAP
7 PISTON S PPORT BRG. 24 BLOCY V E PIS0O':PEG. 4C 111D sALL ClIF SPRII3 E1D
BCARTRIDGE 25 PIS. 11 PXG. 701EXT E 40, 1.0 Da I. C 9 DALL 1-65 COS.l son:
9 ROD BEARING 26 SCR PIS'O';PFG. 49 11D 'I'DL C-:
1 0-plU:" VDS
20 PISTON ROD 27 VEE P00,70 PKG. ASS'Y, o CCSH. '3OSEr-8I.:G
11 TtBr 23 ROD WIPr 57 CAP CVS. AO. ':'IDLI
12 CART. RT. PLATE 30 VrE ROD PKG. .S'SY. 58 CP BALL C1;:1SCREW
13 TIE PO 3D CART, O-R0'0 02 CAp BALL C.'. SPRIIG
14 CLEVIS P17 ASS'S. 32 CART. 010-EXT. RI-IG C1 CAP BA.L CI P. PiL.
1 CARTRIDGE SLUG 33 END COVE.RO-R11)G C5 CAP :,DL. & Or): O-P.I
KITS
SEAL WITS (KITI
(KIT 7AME) TYPE)4 (ITEM 7)OI8BEMP)
sat PISTO-1 !!!F=, TM) 26. 33(21,3472)
5-V PISTONl SEAL KIT 19 25421, 34'2)
'RT20 27(2). 33)(2), 34) 2)5 36
I QXID SEALK2IT 2 30) 1. 32

,, ).
"I SIXD REPAIR W17 15?
2) 3 31.
t
7|.
3d
:IC KLY
REPAITI 335 3442 4 3726 4)42) 3
C 23 3 1PX 33M, * 3,42). , 2
USH CP RAIR KIT1) -i. 34(2). 327 42) 5
5. 9. 27)2). 25). 3. 3D 3. 2 7') 4
IC WULT it
BtM1
KEP 4 9' 37(2). 25. 30. n32.
5lEE 31)2 4, 14111, 15.
MSE
AIRY CAP
CUIR
PIPTE
AS!
BIT
IT SCR -
T42,i303, 3.
574~ 20 ]a.
R1VJI))
30, RIM. 34182r .BD 470CEI
38.
VIPDCL ~L
*C RED
BI3m. ARI 34
5,8 2
CUSASS
RDIT t,324, 432)434854
3134 1,
CM CAP AID IT 5 3. 34. Ady1 )1 IVS?5TDCL~DB ~L

-2-
D-68
ISTALLAT01 A:iD SrRV1OCr J!jSTRUC'TjOjS
211 CYLI'IDERS
1. GMJERAL: The parts drawing on Page 2 shows a
POCtMDUR FORRrPACKX:IG CYLVIDERS
-Ie listing of
all standard Series parts and is applicable
2TH hydraulic cylinders. to
This parts drwing, when usod in conjunction A. Disconnect cylinder nd drain oil from
with the listed parts and kite, should head and cap end ports.
facilitate the ordering of ay replacement B. Remove the tie rod nuts (161.
parts or kite by specifying: C. RenOwe cap end (2) nd then head end (1).
(1) cylinder Cartridge retainer plate (12) and
Aerial number, As it appears on the name
cartridge (8) will come off with head
plate; and (2) itan number and part name
kit type and nm. or end.
D. Ramove piston and rod assembly free tube
2. I..STAiLATIOv; OF CYLIOOr : Standard cylinders
are furnished with sell anmpatible with E. Remove retainer plate (12) and rod
petroleam base fluids. cartridge (8) from head end (1). Renoval
These seals work best is Simplified by rotating retaining plate
within the temperature range of 00 F.
F. For fluids other than Petroleum base.to 1700 (12) 45 with respect to head snd (i).
different seal material may have to be F. ReMove or loosen cartridge lock screw
used. (19). Cartridge, if desired, may now be
removed from retainer
For the cylinder to perform well, it must be G. Cla, piston rod (10) plate.
in soft 5awsnd
properly installed. Alignment of the cylinder
with load is mst important. Forcing rod. proceed an follows:
1evis pine. or Munting bolts Into position
indicates that the cylinder is not properly (1) SCR Type Piston
aligned, and Permanent damage may result from
euch installation. a. Remove piston lock screw (16).
b. The piston (4) is threaded onto
befove Instcllin
Protective port covers
pipihngo
r shuld no t or
a dirt be other
rmoved
once (10) nd can pe
the piston
backed off rod
eth the piston lock.
foreign particles may enter the cylinder. screw (18) has been removed.
All Lse
pipe nd fittings must be clean before the pin spanner holee provideJ it
final connections. making tsar face Of piston.
c Remoe head end cushion nose (41).
3. P9 E FoR PPLAc~frm7 OF ROD SrALS XD d. Remove piston packing rings (261.
CARTRDGE
(2) Block Vee Type Piston
A. Disconnect cylinder and drain oil from
B heed end
Loos and rti
ort.g okAr.a a 3oc
moc piston
itnlc loch screw
ce (18).
(19). 1)
C. o o cartridge och scrw f b. Turn threaded piston (3) from
the piston rod.
C. (move od cartridge (8) from the retainer eUsthe p n scanner
(12) and slip off the isto holes provided in rear face of
(1v.ntmd iton.
D. Remove retaining ring (22), rod packing
assembly (0), rod bearing (9), and rod c. Remove head end cushion nose (41).
wiper (28). (The wave spring and any d. Remove block wee packinq (24) and
bach-up (non-extrusion) mon (21.
shims are considered part of the rod
pecking assembly.)
E. (3) Vee Type Piston
Remove cartridge 0-ring
non-extrusion ring (32). (31) and csrtridge
a. Rmv pieton plate loch screw (19)
f. Reasemble the cartridge with and turn threaded rear piston
corresponding replacement parts, cleaning plate () from piston rod. inc
a 11parts thoroughly. Swelling, ppa e r ho nrod. Us.
shrinking, weer, nicks, cuts, and
indentations are all signs of defective pistn p lte.
eeals. SUCh seals
G. &&Isshould
Prior tO installation.
G.
t041 Suh!db. replacparts
allberubber d, Renew.
forward piston
niston support(5),
bearing
end cushion noseplate
(41). and head
must be wel coated with lubricant. Remove ee piston pakn
H. Carefully quide cartridge assembly over
assemblies (27) from forWard and
the end of the piston rod (10) and into
rea pton plat.
the retaining plate (12); tighten in place r iton a.
with a wrench,
D-69
5. 4IU: Clean all parte thoroughly. The tube. If this should happen, it cay
pec-9g- and seals in this cylinder are be necessary to assmble the piston
seopetible with hydraulic oils, air, water, within the tube.
and neutral fluids. The cleaning agent most
a1so bs compatible to avoid damaqe to packinge (2) Care must be taken to be sure the rear
and seals, Whenever a pa cular lubricant La plate (6) is tight against the forward
specified for an installation, do not deviate plate (5). Any gap betwen these
from this specification without checking for platea may permit the piston plate
compatibility. 0-ring (36) to extrude. This can lead
to piston bypass.
. 3PECTXOTIIB. Tie rod threads and nut bearing facs
A. Inspect all packinqa, seals, and non- should be well lubricated to allow
extrusion rings for swelling, shrinking, tightening the nuts evenly for proper
wear, nicks, cuts, and Indentations. pre-stre "n9. To void twisting of the
Discard all damaged packings. seals, and tie rods during tightening, hold with viae
non-extrusion rings, grip on dlmp. To assure equal pro-
. Check and inspect bore of tube for stresaing of the tie rods, first turn on
scratchos, excessive wear, and any other nuts even and snug to align assembly; then
defect that might damage piston packing the nuts are to be tightened alternately.
or causs piston bypass. For proper tie rod pro-stressinq, they
C. Inspect piston rod for signs of wear, should be torqued as reccmended:
nicks, dents, scratches, or anything that
rod packing
may damage war or rod bearing. CYLIIDER ? 8
excessive an mne side of piston rod DORE ih 2-1N 1 A-4
or rod bearing usually indicates misalign-
sent in installation and should

orrected.
be K
PT. LB.
iii
26 56 148 282
I
74 150 690
D. Inspect al remaining items for evidence
of damage or wear. In most cases, A 9. TESTING:
little polishing of the various parts will
restore then to like-new condition. A. After the cylinder has been completely
reassembled, it should be tested, either
7. MPLACEPIT, Replace all damaged packings, on a test bench or in the regular
seals, rod wipers, and non-exrusion rings. installation. Watch for the following as
the cylinder is cycled at pressures
S. RASSEMBLYs The procedure for reassembly is ranging from normal operating pressure to
essent-ally the reverse of disassembly. 50 percent oar, depending on the
However, the following exception* and availability of the hiqher pressures:
considerations should be noted: (1) Rod gland leakage.
A. All 0-rings and non-oxtrusion rings should
be well costed with lubricant after they (2) Leakage at end cover 0-rinqs.
are installed in their respective qrooves
and prior to reassembly with the mating (3) Leakage at cushion ad)usting needle.
part. Care must be taken when asnebling
0-rings and packings that they are not (4) Leakage at ball check plug.
damaged, as this will caUs lesakage.
B. Final ad3us tnt of cushion ad)ustlng
(1) Itsi sonetimes difficult to install needle ust be made after cylinder is
assembled vee type pistons into a installed in system.
D-70
YOUNG RADIATOR COMPANY
RACINE, WISCONSIN 53404
INSTALLATION AND MAINTENANCE INSTRUCTIONS

FOR YOUNG HEAT EXCHANGERS
INSTALLATION INSTRUCTIONS SERVICE RECOMMENDATIONS
Young Radiator Company Heat Exchangers are de- The Heat Exchanger, when shipped from the factory,
signed to give the optimum heat transfer rate for is clean and should require no on-the-job cleaning. It
given flow conditions. Ordinarily the most viscous is recommended that the Exchanger be inspected
fluid is piped to the shell side while the least viscous thoroughly on both the shell and tube side making
is piped to the tube side. The shell side of the Ex- sure that no foreign matter entered while in shipment.
changer is baffled and therefore the shell fluid is This inspection can be made without removing the
required to make many changes of direction in its end bonnets of the Exchanger. It is also recommended
travel through the Exchanger. This breaks up the that the bolts holding the end bonnet to the end cast-
surface film which would otherwise prevent the ing be checked and pulled down so as to insure
transfer of heat. The next important consideration in tightness. The Exchanger should be mounted solidly
the piping of the fluids to the Exchanger pertains to in place and the pipe connections made up, being
temperature. A single pass Exchanger should be piped sure that all connections are tight. If the Exchanger
counter flow for greatest heat transfer as this will is to be stored for any length of time before use,
give the greatest mean temperature difference over shell and bonnet openings should be kept sealed to
the entire length of the Exchanger. True counter flow prevent the entry of dirt or other foreign matter.
exists where the two fluids flow in opposite direc-
tions in the Exchanger and is possible in the single When the Exchanger is first installed, sufficient data
pass Exchanger only. should be taken to establish the temperature and
In connecting a multi-pass Exchanger, the shell fluid pressure drops. Similar data recorded at regular in-
tervals by the operator will serve to detect any
should enter the Exchanger at the same end at which accumulation of sediment or scale, and from such data
the tube fluid enters. the proper interval between cleanings can be estab-
lished.
Strainers
In making up the pipe on the tube oil side of a Heat When an Exchanger is disassembled for cleaning, new
Exchanger for lubricating oil cooling it is essential gaskets should be used upon reassembly. This is
to install a strainer on the outlet side of the Heat important in both the Fixed and Removable Tube
Exchanger. This is to collect foreign matter which Bundle Exchangers.
may have entered the Exchanger in shipping and
piping, preventing its entry into the engine. Consult
representative or write Care be ataken
should of when removing or handling the
your f'actory
the directly Company
Young Radiator for strainer recommendations. tube bundle Removable Tube Bundle Exchanger
to protect the baffle plates and tubes from being bent
Water Regulating Valves or damaged. The result of bent baffle plates is by-
passing of fluid with an accompanying decrease in
In the interest of conserving water, a water regulating heat transfer rate.
valve should be installed ahead of the Heat Exchang-
ers in which water is used for cooling another fluid. Corrosive and Scale Forming Fluids
Normally the regulating valve is temperature control-
led and the control bulb for the valve is placed in the In many sections of the country raw water is extreme-
stream of fluid being cooled. Consult Young Radiator ly corrosive or scale forming and should be treated
Company ore reputable manufacturer of this equipment to prevent damage to the Heat Exchanger and to pro-
for recommendations. long periods between cleanings. Before piping fluids
to a Heat Exchanger, they should be analyzed as to
Pressure Relief Valve what action they, will have on the metals in the
Exchanger.
When there is a possibility of surge pressures,above
the design pressure of the Heat Exchangera pressure If salt water is used as a cooling medium, zinc
relief or regulating valve should be installed to pencils should b.- used in the Heat Exchanger on the
protect the Exchanger from bursting pressures. salt water side to prevent corrosion of the Exchanger.
Consult Young Radiator Company factory or a reliable Parts in contact with the salt water should be of
manufacturer of such equipment for recommendations. Admiralty metal, cast iron, or copper-nickel alloys.
-1. D-71
Water Treatment - Closed System be reversed and fresh water-cleaner solution circu-
In a closed water system, such as an engine jacket lated, again for one to three hours. After draining,
system, Young Cooling System Treatment No. 3-1-2 the unit should be thoroughly flushed with freshwater
should be added to prevent corrosion and control and then reconnected for service.
scale deposits. This treatment is effective under Severely fouled tubes can also be cleaned by use of
normal operating conditions for a period of six months, a rotary brush, similar to a shotgun cleaner, in con-
after which the system should be drained and refilled junction with an air or electric rotating tool. This
with a new solution of Young No. 3-1-2. type of equipment is available commercially.
Draining Cleaning Lube Oil Passages

A Heat Exchanger mounted horizontally will not com- Formation of oil sludge and other deposits about the
pletely drain until it is tipped at a slight angle. tubes decreases the efficiency of the Exchanger and
it is important that a cleaning medium be used which
Therefore, in draining, it is important to purge or is suitable for removing such sludge.
blow
Ifowutout the tubes with compressed air.
the etuExcheris irsed wre tBenzol, trichlorethylene and various commercial
If the Heat Exchanger is installed where there is solvents are suitable for this operation. Benzol, and
chance of freezing on shutdown, the water circuit the hydrocarbon derivatives, are inflammable and
should be completely drained or an antifreeze should should be used with due regard for open flames and
be added. the "sparking" of tools.
Cleaning Engine Jacket Water or Raw Water Circuit Benzol and trichlorethylene vapors are also toxic
Young "Cooling System Cleaner" No. 585. in the in "harmful" concentrations. Ample ventilation must
proportion of one pound to six gallons of water, should be provided in the working area, supplying fresh air
be used to remove oil, grease, rust, and scale. The and exhausting all fumes to an outdoor location.
solution should be circulated at normal rate and at The solvent should be circulated through the Ex-
a temperature between 180 to 200 F for a period of changer in the reverse direction to the normal flow
from one to three hours. (Do not allow solution to for approximately fifteen minutes, after first soaking
boil). After this has been done, open drain cocks in for about ten minutes. The length of time of circu-
the water system and flush thoroughly with clean lation depends on the degree of dirt deposit.
water. The Exchanger water connections should then
YOUNG RADIATOR COMPANY
2825 Four Mile Road Racine. Wisconsin 53404

Plants at: Racine, WI, Mattoon, IL and Centerville, IA
:OM NO. 2031C .2- L.TrHO IN U.S.A.

7:
-
PARTS LIST
Young Radiator Company -- Heat Exchanger Assembly

Model F-503-EY-2P-CNT-B
Part Number 264444
Drawing C260499 and Form 3000
ITEM QTY PART NUMBER DESCRIPTION
1 1 NSS *** Tube Bundle & Shell Assemby
2 1 269473 Bonnet Kit, Inlet & Outlet
120015 Bonnet, Brass
67443 ** Gasket
3 1 269472 Bonnet Kit, Return
120016 Bonnet, Brass
67442 ' Gasket
Pipe Plug, Brass
4 1 269428 Anode, Zinc
5 8 5/16-18 x 1-1/4" Capscrew
6 a 5/16-18 x 15/16" Capscrew
7 8 Washer
8 2 67489 Bracket, mounting
• 269441 Anode Kit, box of 12
S* 269448 Gasket Kit, box of 5 each
•* Not Serviced Separately
Recommended spore parts include one or more anode kits and one or more gasket sets.
D-73
cc a
0a 7
31. 3. b
Ic aq
rm.
cc CL~ - d d d
-A
ILi
Z IL Id
a
D- 1114
APPENDIX E
VENDOR DATA FOR ELECTRICAL EQUIPMENT
TITLE VENDOR PAGE
AC Motor Controller Cutler Hammner E-3
Immersion Heater Chromalox E-15
Electric Motor Reliance E-19
E-1I(E-2 blank)
TECHNICAL MANUAL
WATERTIGHT A.C. MAGNETIC
CONTROLLER
SIZE 3'
30H.P. 440V. 3PH. 60CY.
CUTLER-HAMMER, INC.
MILWAUKEE, WISCONSIN
C-H TECHNICAL MANUAL 6862SPI104
E-3
CONTROLLER SECT ION
INDEX
CONTROLLER
SECTION PAGE
SPARE PARTS LIST
DIAGRAM 250455D3
DIMENSION DRAWING G123249A
SIZE 3 CONTACTOR - INSTRUCTION SHEETS CIOE-I
S.IZE 3 OVERLOAD RELAY - INSTRUCTION SHEETS C300E-1
CUTLER-HAMMER, INC.
MILWAUKEE, WISCONSIN
6862SPI104L
E-4
LIST OF MATERIAL & RECOW4ENDED REPAIR PARTS
ado ~aREPAIR PART

NAME OF PART PART DIG.OR PUB.
___ ___
___ ___ _ _ ___ _ NO. ITEM _
1 0 SIZE "3' CONTACTORtCIOE CIOE-I

IA 6 CONTACT STATIONARY 23-4028
IB 3 tONTACT, MOVABLE 23-4029
IC 3 SPRING,.CONTACT 69-2908
0 10 3 RETAINER, SPRING 19-1736-2
- IE 2 SPRING, ARM. FRAME 69-2554
1F I INTER., N.O.-N.C. BASE MTD. C320KB8
Q- IG I COIL, SHUNT (110 VOLT) 9-1891-23
12 1 0 SIZE "3" OVLO.RELAY(C3OEN3)(0L) C300E-I
! ,g!2A 2 HEATER COIL (LATER)

00 !3-i CONTROL DISCONNECT SW. (COS) --
(3A 3 0 CONTACT BLOCK 2N.O. 10250T2
S 3
-
S-C, - ICMLW-KROERING EN
_wO. o- ALWAYS SPECIFY E
A. COMPLETE NAMEEPLAT READING

1 ON
• >4 SIZEMAGNETIC
C.
"3"' C-H ORDER NO. G123991B
ld-H OWG. ,10.RE

INC MLWUKE. ____6__2_____110 ____
0 CUTLER-HAMMER I. LW [,WIS. SHEET ,OF I SHEETS
CONTROLLER SEC'TlI0H PAGE 1
E-5
- .SE
311
E-6-
.250 X 4.00 K S.r.2.
ORAINPLUGREMOVABLE CABLE ENTRANCE
IN BOTTOM PLATE FOR I.S0 X .-
_, CUTOUT IN TOP S, BOTTOM
,I5 MAX.FRONT EXTENSION FOR

DISCONNECT SWITCH PuSUTTON
Oil ANY DOOR MOUN'TED DEVICE
4N
- >
4 FOR
SLOT UDER GASKET AMOUND
112 MTG. SCREWS DOOR AND CABLE
CEPA.
FINISH -ZINC CHIROMATEENR
PIIIMER BAKED GRAY ENAMEL (.
DIMENSIONS OF WATERTIGHT ,Z~c
V CUTLER *HAMMIER-
E-7
PUBLICATION NO. (RP) ClOE-1
368
RENEWAL PARTS AND INSTRUCTION PUBLICATION FOR

NEMA SIZE "3" 2 AND 3 POLE AC CONTACTORS
6. Install the clamp and secure the screws.
7. Install the cover.
RENEWAL OF POWER UNIT
NOTE a The power unit item 1 consists of a factory assem-
bly of all the magnetic parts, movable contacts, and
their carrier assembly. This unit usually permits imine-
diate restoration to service of a device which may have
become inoperative.
Unfasten the two gold colored Hex. Head screws "B",
pull out the power unit, plug-in the new and retighten
the screws "B". A set of stationary contacts is included
with the power unit. It is advisable to install these
stationary contacts at the same time, particularly if
visual inspection indicates that both the movable and
stationary contacts need replacement. Specify coil by
suffix letter selected from the coil table on page 4.
A RENEWAL OF POWER CONTACTS
The power contacts when used within their rating will
provide long trouble free life. They should not be filed
or dressed.
TYPICAL CONTACTOR THREE POLE 1. Remove the power unit assembly by loosening the two
WITH TWO CIRCUIT ELECTRICAL INTERLOCK gold colored slotted hex, head screws "B" and pull the
power unit straight out.
INTRODUCTION
This publication is designed to simplify inspection and MOVABLE CONTACTS
maintenance. It features... 2. Remove the contact bar item 34 by removing the two
1. A publication number keyed to the ordering number of screws and washers items 35 and 36.
the device . . .to simplify filing and fact finding. 3. Refer to sketch "A". Raise the retainer item 12 against
2. A nameplate inscription keyed to the specific renewal the spring to free the contact so it can drop out.
parts publication . .. to eliminate cross referencing. TO REMOVESPRING
3. An exploded view for easy, positive identification of parts TO REMOVE CONTACT ANO RETAINER
with illustrated steps on "how to assemble and dis. 71,41 EFE ROTAE
P IO D
assemble" . . . to conserve time and eliminate guesswork. TO TREE DO
4. Comprehensive maintenance information to provide
maximum performance. This information should be read
carefully.
DESCRIPTION CONTACT
These are 2 and 3 pole A-c contactors for across the line
applications within the ratings shown on the nameplate of SKETCH "A" SKETCH "B"
the equipment. 4. Refer to sketch "B" and "C". Rotate the retainer into
CARE the position shown and push it into the window to hold it.
These A-c contactors require no mechanical maintenance. Lift the spring off the seat with a small screwdriver.
Any maintenance required can be performed with an Push the spring and retainer through the window.
electrician's screwdriver. For continued uninterrupted per-
formance, renew all of the power contacts and springs at MY SPRINGOFF SEAT INSERTCOMPRESSEO
time before
the same renewing the tip material
contactcheck has worn away.
screws to SPR'NG AN
RETAINER
ANAD OV
1I=_I
contacts
theand
Whenthey are tight all terminal OUT
insure secure.
Suggestion - refer to publication 14183 for helpful in-
formation on inspecting and determining when to replace
contacts.
RENEWAL OF OPERATING COIL
The operating coil is epoxy encapsulated and so con- SKETCH "C" SKETCH "D"
structed to provide long service life. Should the coil require
changing, the entire operation can be performed in a few 5. Refer to sketch "D". Place and hold the retainer in the
minutes. position as shown.
1. Unfasten the two pan head cover screws "A" and remove 6. Compress the spring with the thumb and index finger and
the cover item 28 page 2. insert and seat in the cavity above the retainer.
2. Unfasten the four pan head screws item 27 securing 7. Raise the retainer against the spring, insert and position
the clamp item 25 and the armature item 22. Remove the contact. Contact tips must face away from the
the clamp and the armature, retainer.
3. Pull the coil straight out. 8. Install the contact bar to the push bars items 21 and 23
4. Install the new coil with the coil terminal blades engaging with screws and washers items 35 and 36.
the coil terminal clips. Note: The contact bar is not reversible. Match the ends
5. Install the armature (narrow end to the left) into its of the contact bar to fit inside the raised projections
seated operating position. on the push-bars.
(Continuedon Page 4)
Made in U. S.A. CUTLER-HAMMER, Milwaukee, W1is. PAGE 1

E-8
CIOE-i PUBLICATONNO. (RP)
368
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368
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CIOE-1 PUBLICATION NO. (RP)
368
(Continued from Page 1)
STATIONARY CONTACTS ARC CHUTES

Note: Itis not necessary to disconnect any wiring. These seldom require renewal. Some burning and dis-
9. Remove the screws securing the stationary contacts, coloration are normal. When the contacts are renewed, brush
10. Install the new contacts and screws, out any loose accumulations.
MAGNET
ELECTRICAL INTERLOCKS The magnet clamp screws item 33 are accessible when
The electrical interlocks are renewable as a complete the two center arc chutes are removed.
assembly. See illustrations and tables below for the various LUBRICATION
electrical interlocks. Do not lubricate any part of this equipment.
ACCESSORIES
ELECTRICAL INTERLOCKS, TERMINAL BLOCK
AND COIL TABLE
ADD ON TYPE I
BASE MOUNTED FOR MOUNTING ABOVE BASE MOUNTED INTERLOCK TERMINAL
BLOCK
Circuit Catalog No. Circuit Catalog Number
Cat. No.
1 N.O. C320KB7 1 N.O. C320KA1
1 N.C. C320KA2 C320TB1
1 N.O.-1 N.C. C320KB8 1 N.O.-i N.C. C320KA3
Operating Coils Selection Table

Suffix Suffi x
Volts Cycles Part Number Letter Volts Cycles Part Number Letter
120 60 9-1891-1 A 600 60 9-1891.4 D

110 50 550 50
240 60 9.1891-2 B 208 60 9-1891-13 E

220 50
480 60 9-1891-3 C 380 50 9-1891-14 L

440 50 I
required only when power unit is ordered.
*Suffix letter
PAGE4 CUTLER-HAMMER, Milwaukee, WIS. Made in U.S. A.

PUSLICATION NO (RP) C300E.1
368
RENEWAL PARTS AND INSTRUCTIONS FOR 100 AMPERES

STANDARD TRIP EUTECTIC OVERLOAD RELAY
(WHITE BUTTON)
3m 3
4 4
5 5
8 7 8 7
1 Element Overload Relay 2 or 3 Element Overload Relay
RENEWAL PARTS - Information Required

To insure prompt handling of renewal parts orders, please include the following: DESCRIPTION, PART NO.,
AND QUANTITY REQUIRED.
PARTS LIST
Item No. 1 Element No. 3 Element
No. Description of Part Req. I Part No. Req. Part No.
1 I Lug (Copper) ........... ................................ 4 80.2801 6 80-2801
2 -20 x .75 Slotted Hex Head Sems Screw .......................... 4 11-2683 6 11.2683
3 10-32 x.50 Pan Head Sems Screw ................................. 4 11-2537 6 11-2537
4 Connector ........................................................... 1 25-2217-2 1 25-2217-2
5 Screw ................... 4
............................................ 11-2581 6 11-2581
6 Term inal Plate ...................................................... 4 80-3321 6 80-3321
7 Auxiliary Terminal Clamp
Silver (Color) ...................................................... 2 55-1743 2 55-1743
Gold (Color) ....................................................... 2 55-1743-2 2 55-1743-2
Button (White) ...................................................... 1 53-1346-6 1 53-1346-6
6
T2rmal Element ........................................ 1 10-4057 3 10-4057
632x .312 Round Head Sems Screw........................ 3 11-1525 3 11-1525
NOTE: The parts listed and illustrated are available for repairs. Should other parts be required order a complete overload relay by refer-
ring to the identifying number on the mounting plate.
INSTRUCTIONS
This overload relay has two steps HEATER COIL POSITION All coils must be mounted in the same position for a given
of adjustment (low or high) obtain- LOW HIGH overload relay.
ed by POSITIONING THE HEATER
COILS as shown in the adjacent Reset and tripped indication -
illustrations. Note the location of A transparent rectangular window above the reset but-
the pointed terminal on the heater ton provides visual indication.
coil.
The heater coil selection table Relay Reset - Dark Window.
furnished with the starter Illus. Rlay Tripped - Light (silver) Window.
trates the proper mounting position. Do not disassemble this relay.
Made in U. S. A. PAGE
E-12 CUTLER-HAMMER, MIlwaukee, Wis.
PUBLICATION NO. 14183
867
TO ELECTRICAL MAINTENANCE MEN
ARE YOU GETTING FULL SERVICE

FROM THE CONTACTS IN YOUR
CUTLER-HAMMER CONTROLS
Here's a hint that may he HELPFUL. "

... ,1
i/
CONTACT m.
SCONTACT PLATE CORNER OF CONTACT

(13RASS OR COPPER) WORN AWAY
NEW STILL REPLACE
SERVICEABLE
* i .A 7
Are you throwing away contacts before they are worn out? Have you wondered when contacts do need
replacing? Are you making the decision to replace contacts based on your experience with old forged
copper contacts?
Cutler-Hammer's introduction of the cadmium silver oxide contacts, over a decade ago, heralded a new
era of longer contact life. But with longer contact fife came new visual contact inspection means of judging
when contacts need replacement.
This brochure is designed to help you get maximum life from your contacts, yet replace them before a
costly shutdown occurs.
Made*inU. s. A. CU'TLER-,HAMMER, MIlwaukes, Wisl. PAGE I

E-13
14183 PUBLICATION NO.
567
WHAT CAUSES A CONTACT TO WEAR OUT in good condition. If the contacts appear to be questionable,
check the stationary contacts also, and the wear allowance as
In establishing and interrupting motor currents, contacts are described in the next paragraphs. With a little experience, you
subjected to both electrical and mechanical wear. Normally will soon become an expert in judging contacts by their ap.
mechanical wear is insignificant. Electrical wear. caused by pearance and YOU WILL AVOID THE NEEDLESS WASTE OF
arcing, erodes the contacts; and during arcing a small part of THROWING AWAY GOOD USABLE CONTACTS.
each contact Is vaporized and blown away,
Accurate determination of the time to replace contacts should MEASUREMENT OF WEAR ALLOWANCE
actually combine measurement of wear allowance and judg- Wear allowance of a contact is defined as the total thickness
ment regarding the appearance of the contacts, of contact material which may be wcrn away before the con-
VISUAL INSPECTION tact becomes inadequate to carry the rated current. Generally,
a contact is serviceable as long as the remaining wear
allow-
CAUTION: Contacts should never be Inspected without first anace is not less than a specified minimum value. Usually this
disconnecting the power at the branch circuit disconnecting minimum value is in the order of 0.015 inch.
device. In starters provided with a separate low voltage power On a contactor, the means of determining how much wear
supply, the separate control source should also be discon- allowance an arrangement of contacts has remaining is to in-
nected. sert a 1/32" feeler gage between the armature and the mag-
As contacts continually make and interrupt a current, the sur. net frame, and move the armature toward the sealed position
face of the contact will change in color, contour, in smooth- until it comes to rest against the feeler gage. At this point, if
ness. resulting in discolorations, irregularity of surface, and the contacts are touching, the wear allowance has not been
pitting. Normally a new contact has a uniform silver color, exceeded, and the contacts are still usable.
As electrical wear occurs, the silver color may change to blue, In many instances, visual observation of the contacts during
brown, or black. The black color is primarily a result of silver measurement of wear allowance, may be difficult. A more
oxidation which is beneficial to contact operation. The pres- reliable method of determining whether the contacts are or
ence of small black embedded granules in the contacts indi- are not touching is to use a continuity checker. There should
cates the presence of cadmium oxide which is also an excel- be continuity with the armature closed against the 1/32"
lent electrical conductor. feeler gage. It is advisable to use a wide feeler gage to avoid
Irregularity of contour is caused by uneven electrical wear. the possibility of tilting the armature while holding it closed.
Su.h wear does not necessarily indicate that a contact is worn If the continuity checker indicates continuity, the contacts
out. Considerable silver is built into the contact to provide for have sufficient wear allowance to still be usable. If there is
wear allowance. no continuity, the contacts should be replaced. Be sure to
Irregularity of contour usually involves a slantwise type of check the continuity checker to make sure that it is working
wear. As en example, one corner of a contact may wear more properly.
quickly than the other three corners wear away. This type of
wear is normal. Even though the wear allowance of the con- WHEN TO REPLACE CONTACTS
tact may not be exceeded, contacts should be replaced if it is Determination of when to replace contacts should combine
noted that one contact is nearing the condition in which it both visual inspection and measurement of wear allowance.
will be making direct contact with the plate. The plate is the If there is extreme pitting and curling of the corners, or if the
material on which the contact tips are fastened. If the plate contact has eroded at the corners to a point where the con-
material is contacted, welding of the contacts may occur, tact bridge is beginning to show, the contacts should be
Pitting is caused by melting and vaporization of the material, replaced. Even with contacts whose appearance is good, how.
The pitted surface has high spots and low spots, and tests ever, they should be replaced if they do not check out satis
indicate that such a surface provides a better contact than a factorily on measurement of wear allowance.
smooth surface. The size of a pit mark, or crater, is propor. DO NOT FILE silver contacts, as all you are doing Is removing
tional to the amperes of the arcing current. On a high amper- useful life. Filing of the contacts will neither improve the per.
age contact, then, the pit marks will be larger than on a low formance, nor extend the life of the contact.
amperage contact. Pitting of a contact that is wearing well
will show a uniform texture. When it appears that chunks are REPLACEMENT OF CONTACTS
being torn away from the arcing surface, it is advisable to CAUTION: Contacts should never be Inspected or replaced
replace the contact. without first disconnectIng the power at the motor branch cir-
Curling of a contact is a condition in which the corners of the cult disconnecting device. In starters provided with a separate
contact separate from the plate to which the contact is fas- low voltage supply, the separate control source should also be
tened. If such separation is occurring, the contact should be disconnected.
replaced. Curling is usually a result of service that produces When you have determ;ned that the contacts should be re-
very high heat. An example of such service is severe inching placed, it is advisable to replace the STATIONARY CONTACT,
or jogging of the contactor. or when the device is subjected MOVABLE CONTACT, AND THE MOVABLE CONTACT SPRING.
to fault conditions that occur from short circuits or grounds Also, if a device is used to control a three-phase motor, it is
in the system. If the condition continues lo exist with each advisable to replace all of the power pole contacts whenever
replacement of contacts, the application should be carefully any one pole needs replacement. Contact kits are readily avail-
checked to determine if the contactor is properly rated for the able containing all of the necessary contacts and springs to
application, and whether other associated equipment is oper. make this replacement readily. The contact kit part number
sting properly. providing all the necessary parts for replacement of the con-
Inspection of contacts is a simple maintenance operation. tacts is included on the nameplate of the contactor.
Merely remove the contact block cover and slide out the mov.
able contact bar. Where periodic maintenance is performed
regularly, inspection of the movable contacts alone will tell Remember, DO NOT REPLACE CONTACTS UNNECESSARILY;
the story. If the movable contacts are in reasonably good but when it is necessary, replace all of the power contacts
condition, chances are that the stationary contacts are also in that device.
PAGE2 CUTLER-HAMMER, Milwaukee, Wis. Made in U.S. A.

E-14
Chromalox"
Installation, Operation bIV 4 SEC.ARMTO JI.UMBEE 01
and RENEWAL PARTS IDENTIFICATION -It.-111i PD41164 PD406-5
(Supersedes
1 161-"6231401O
Chromalox Screw Plug Oil immersion Heaters - Type ARMYC

Constructed of Steel Sheathed Elemntsf with Steel Screw Plus%
Celluloe Numale.wLsated "u P.O. 4
REMOVABLE SCREW
ST7EEL PLUG COLDLENGTH5" fOr SerieS%
cHROSTAT I
'NT it Seres 3 i ISA CONTROL
CHARACTERISTICS
OF
IN STANOAR
USED0 0 EATERS
COLDHOT Ot'." for Series2sUt -.- oible Doltt~e Otg"i'.
21 "forS~A&
JUNCION acton bceak ott tiroeitr t.....
Maximumn
35ttc A.C. Atime
____ 3-Prs 4 375 XWat 125 Y.11,
Ampst A 25 AWat 250 cots
0sd.5
.S, :,, Conct :"l ntosX!ardirecty to
G LEENS . wire t-lr05tt Into hiold", -1.

L HAHSTEEL WELL FOR cciii of sortable,cortacroc IS". Pgs
THEInMOSTAT
BULB I t1ni IT tot
et c loeoacte greatet
FOR2 CNDIeater
CO3CO . ThreeDuehetrChstcti
s
tot 3 "Themosettes Ihc
FIGURE A 3,o seroce' Dni Ct mag"'
'.t
NATE:
Serles 2 Nesters AllCat.Mos. starting with 2; EerIll$3 Nesters Alli Cat.*ft. stMEarig
ort c.ntactot 050 na, wtoltau
Soo page 4 flat Specifications.
INSTALLATION CAUTIONS-
OUTLET
I. He wrLit neIrt I '(ihai' is the sai(c as that smamped onT:
lsalr tIametie. ±
0t
2. IDo nol rcvIr Iloheaters in series whose element Isatraives DRIPLOOP
HECOMMENOED
TOmrtINOM12t
PASSAGE OF
are uneven. MOISTUREALONGWIRING
Note- Heaters of same Ici/yaveo andilvattai' can he connect. MINAL WIRING
INTOTEB
ANDCONNECTIONS
ed tso Or Motre in series across a suppl) voltage equal in
value to the sum of the heater voltages. tIHL
3Install heaters above maximum expected sludge level. WIRIN-1G ILE
iee Fig 1.. . . . .
4,. Do not bend the heating elements, If bending is EclL-
sarI.- chbeckthe factor). I M.AMU SLUDGE LEVEL
_______________________________________________LOCATE DHAINPIPE ISALL
s' HEATERABOVE
ABOVE115010
OFHEATER
THSPORTIONt AT BOTTOMOP THIS LEVELBUTAS
T[V N EiS O 1RWILLA HEATERO
YSSLUDGE NEARTO ITAS
N SOSE
LEE
TOPREMArURE rAIWLLED
StELEMENT
BRNOrIUT ECtELO
LEVELOF LIQUID DEPOSI T Of
REMOVESTHROUGH A~iNPiPE
POSSIBLE
H4EATED
PURMAXIMUM
WATERSTORAGE CAPACITY
FIGUE 2 - CLOSED
TANKIN VERTICAL
POSITION
- - -d.-- - If application requires beater be installed thru top of
(O)WRONG Vertical tank, it is IMPORTANT to locate tank outlet
I PECTED RGTpipe location higher than hot-cold junction of heater
RIG~MUt (See Fig A).
INi H FORCED
lOI Ltat lt Rtie
A,.~t hen. oa..OUTETINLET
0 HoatO~tibt SYSTEM
star". cooante HoI otrs nBt tisOIN%
Bowamird
tomul-1..
.W. get, 81Him
heaed . .iINLET usE PUMPIN
O$-bi
r SD
FlouIR I - OMI TANKBRNSTAUWO'IOi HEATER =ILE IDE
5Protect terminal end of heaters from drippings. conden-

sation. spray or direct sptllover
heater below expected low liquid level in open PR~ LSDTN eNQZHTA POSITION4
tankIn"Itall
6 installations (See (DL Fig I I Entire heated length of
heater must be immersed at all times e. When installed 'et a hortzontal plane (See Fig. 3 1. posi-
7 When used in a HoarId folesk as a i'trration heater: lion outlet and inlet in a vertical plane. facing upward
a, Place heater at an elevatios No that natural circulation to prevent air pockets in the heate,
can take place f, Keep the heater housing filled with liquid at all times.
It Important teat should never he located at the highs S. Use only in solutions which will not corrode copper.
point in the *aler Byslem. Provide expansion lank, eif, 9. Insulated copper
0
wire may be used where temperatures
iseceuar will not exceed SO F.
rInstall heater in, slidewall of tank (Customer furnished)I 10. Use explosion resistant terminal housings in hazard-
Intall in a verticall Poson ESeeFigl 2) ous locations. E-15
Am
4 1ARMTO' 3o001
EI
PD406-5
OPERATION CAUTIONS - 6. Replace thermostat cover.

1.Be sure all trapped air is removed from theclosed tank. 7. Replace thermostat knob.
Bleed the air out of the liquid piping system and heater 8. Set thermostat knob to the desired liquid temperature
housing prior to operation, setting.
a. The heater hoiisin in closed tank systems must he kept
filled with liquid at all times. MAINTENANCE INSTRUCTIONS -
2. Do not operate an) section of the heating element in air
Never allow the
in open tank installations (See B. Fig. 1). I. Remove heating element, periodicalls (disconnect power
liquid lcsel to fall below the heating elements or any parn %uppls) to inspect and remove scale deposits.
of same. 2. Remose sludge deposits from heater tank.drain thru
3. Disconnect powser to the heater before removing heater drain pipe. if asailable
from thelank. -3. Clean terminal end (disconnect power supply) of all
4. Disconnect the power to thehealer in case of tank contaminiation.
drainage or failure of water supply.
a. Do not operate heater if dry.
5. Keep heating element, abose sludge deposits. FIELD CALIBRATION OF THERMOSTAT
6. Do not allow excessive coatings to form on heating ele- Thermostals are carefully calibrated to the temperature of
ments or heater burnouts will occur, thesensing bulb atthe factory. However. they should be
recalibrated to the actual working temperature of the load
INSTALLATION INSTRUCTIONS - for themost satisfactory operation.
I. Pull off thermostat knob ion some knobs,. first loosen

set screw I
2. Remove thermostat cover.
3. Screw heater directl> through threaded opening in the
tank wall. (See Fig. 41.
a. Use a standard high quality pipe sealing compound on
thethreads la',ailable local)l.
h. Screw heater into threaded opening-tighten sufficientl.
with proper w.rench applied on heA portion(ofs, rew plu.,.
4. Rough-in suitable wiring (BX. flexible or rigid conduit)
tlhruknockout an thermostat housing. Rigid conduit is nor-
mall. used with heaters equipped with moisture-resistant or A. Alloywbulb to adjust to known temperature (boiling
explosion-resistant terminal housings. (See , .Fig. 21. See water 212cF.i or place bulb in material to be heated and
appropriate wiring diagram and also Renewal Parts Table. measure temperature with thermometer reading when con-
Line Current Data as a guide in determining branch circuit trol "clicks" off.
wiring and control equipment requirements.
Note: All wiring should be done in accordance with local THERMOMETER
and/or national electric codes.
5. Wire asperproper wiring diagrams (Page 3).
SCREW-PLUG
TYPE
VAT,DIE.OR PLATEN)
LOAD(TANA.
STANDARD
PiPETHREAD
/ ELEMENT a. ',,
6.I. Calibrate to correspond with thermometer.

2. Recalibrate to "load" characteristics if necessary.
C. To set Calibration adjustment screw:
plpE
COUPLING TANK
- - 0 Remove knob.
Heaot Tati. WallsMw be iledta Ipied
17g. 1w of threats.
L1TV alissn
s eippeldill
"Ider
If ti
okkINS€lftCHi*5
is
afti@ PipeCouptin.
use nt
alterN
turstiles upto NOP.S.I,
t o
F ) Remove cover.
Loosen outer shaft set
screw - Use V1"Allen
wrench.
MGM 4 - UPOHO VKWW SCItIWPWOMOfUN"ING
E-16
page2
14 1,,MTo[ 300,. ]
7 0 Replace knob and without turning shaft set knob at

. -r a Loosen stop set screw. same temperature reading as thermometer or known value.
Use 1.." Allen wrench. Tighten stop set screw and outer shaft screw. SeeI and G).
If necessary. to reach shaft set scre,. rotate shaft slightly.
Be sure stop set screw is tight.
0 Pull off outer shaft. 0 Move knob to the "OFF" position.
0 Loosen knob screw and remove knob.
0 Replace cover.
0 Replace knob. Tighten knob screw.
0 Turn adjusting screw 0 Recheck calibration and repeat process if closer calibra-
until contacts click open. lion is required.
WIRING DIAGRAMS -
Broken line indicates customer-furnished equipment and
field siring by User or Contractor.
WIRING DIAGRAMS
1 2 OR 3 HEATINGELEMENTS
1, 2 OR 3 HEATING 2 POLECONTACTOR 1N PARALLEL
INTEGRAL ELEMENTS
ILINE
THERMOSTAT
- -- -
LINE OR
120VOR 240V
INTEGRAL
THERMOSTAT
A
F11111111 1
FIBUR[
2 OR 3 HEATING
2 POLECONTACTOR ELEMENTS IN SERIES
3 POLECONTACTOR ELEMENTS
3 HEATING
LINE -------- LINEAIOV

1250. 2405 I-
OftC 1EMTTI
-- - - - -- 'V 1,EMOTA
INTEGRAL 12O00 INEGRAL

11"
/ VOLTS
CONTROL
1200ON 2ASH
THERMOSTAT 240V THERMOSTAT
VUUU CFIslIl 0
E-17
_- . . - --
-f. - - L ... 3
. Post - -a .- - -- -
-
PD4"-SRENEWAL PARTS I DENT IF ICATION
thermostat SPECIAL
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028 l56
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40 A664T0.2605 300-017108-027 A6RMT0-26057 300.01710602 30007802 156-505-00 N.
480 8 1 0M02405
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73-110-2
1560-5050 7 :02 0 1 09 0
50 466402 65 300-017108027 A 66M T0 2 05 300 017108025 300-0 17108028
240 8664AR70.2705 300-017108-027 866470-27057 300-017108025 300-017108-028 56 050507.021 29.16 A
480 1 A:0 T :702705 300:017108-027 A66MT0-2505T300 017108025 300.017108.028 156:0 507:022 64% 40% 104
550 866M702705 300-017108"027 866470-2757 300,017108 025 300 017108026 a
156-050 0 -23 1 0
2 ARM,70:2605 300-017108-027 066470-3305 3001108-:021 300-017108-:028 156-0505076-24 25.
434 081470.33205 300-017108-0207 0664700-05 300-0 708- 300-0170-2 5-556011.
240 3RT 68 6305 300-017108-027 A6M470-33057 300-017106-0,5 300 017108 026 156-05050?-002 120-5 D
34 70305 300-017108-027
A6664O 0664O70357 3.01101:021 100.01710028 156-050507-0027 22 B
401 0664O70305 300-017108-027 06640-05 3007108-2 3-1710 8-028 156-050507-028 53 6.25
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3.d 6664703375 300-01710.027 0664T0-3305T 300 017108025 300-0)17106
028 156-050506-001 14.1 C
240 3.7 2 A64Y0.3305 300-017108-027 A6R470-3375T 300 017108025 30G01710B-02: 156 OOC0502 24o 1 1 5
34 866M70.3375 300-017108-027 866M70-33757 300 017108025 300-017108-028 156-050506-002 9.00 C
480 1, 666470.3375 300 017109027 066470-30T 1 300 017108025 1300 017108028 156-050506-012 7.6 6
124 666470.3375 300 017108027 666470-3375T 300 017108025 300 017108028 1S6-050506003 31.51 A
320 ARM6470.45 3G0-017108
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34 T 33670.45300-017108-027 ARMT70335T 300 017108-025 300-017108-028 156-050)506-005 2175 C
40 ARM086470.45 300-017109-027 066M70-3357T 300 017108025 30D-017108 028 156-050506-006 16.75 6
AR3MT6370.45 300-017108027 1666470.335T7 300-017108-025 300-017108 028 156-050506-006 1085 C
120 2 ARMT703455 300-017108-027 A6647O.34557 300-017108-025 300-017108.028 156-050506-003 38 8
34 666470.3455 300.0:7:0:-027 AR6470-2455T 300 017109-025 300-017108-028 156-050506-005 5.43 C
20 300-0170 -027 ARMT70-36055 300-017108-025 300-017108-028 156-050506.006

066470AMTO3305 1 0 1800 8
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E-18 fCHOROMALOX SERVICE ADMINISTRATION

F EMERSON ELECTRIC CO.
11110111111011 MILE IGHBWAY
1140GOLDEN PENN.15146 - PHONW:
- MONRO11EVILLE 1412)327-4074* TELEX:
U-172
NOVEMBER, 1967 INSTRUCTION MANUAL B-3620-3
INSTALLATION, OPERATION AND CARE OF
RELIANCE
STANDARD INTEGRAL HORSEPOWER INDUCTION MOTORS
VMPORtTANT: It is important that these instructions be studied by the men installing and operating this equip-
ment. Read thoroughly before starting. Keep these Instructions for future reference.
RELIANCE 53
ELECTRIC COMPANY W E-19
TABLE OF CONTENTS
Page
RECEIVING AND HANDLING
Acceptance . ............................... .. ... 3

Unpacking ......................................... 3
Warranty ....................................... 3
INSTALLATION
Inspection ......................................... 3
Location ..... .................................... 3
Mounting ........................................ 3
Drive ............................................ 3
W iring .................... ....................... 4
Starting ............... .......... ................ 4
Drain Plugs ............... ...... ........... 4
R otation ........ ...... ........................... 4
Temperature Rise ................................ 4
Test For General Condition ........................ 4
O PER A T IO N ................................................. 4
MAINTENANCE
Disassem bly ....................................... 5

Reassem bly ....................................... 6
Lubrication ........................................ 6
RECOMMENDED WIRE SIZES ................................ 7
GENERAL ................................................. 7
E-20
Y,
RECEIVING AND HANDLING
ACCEPTANCE time prior to installation, the area storage should
be clean and dry, protected from low temperature,
Thoroughly inspect this equipmentbefore accept- rapid or extreme changes in humidity, oil, dirt
tg shipment from the transportation company. If and similar adverse conditions. Equipment stor-
any of the goods called for in the bill of lading or age should be inspected periodically and the shaft
express receipt are damaged or the quantity is rotated approximately every six months.
short, do not accept them until the freight or ex-
press agent makes an appropriate notation on your
freight bill or express receipt. f any concealed UNPACKING
loss or damage is discovered later, notify your After unpacking and inspection to see that all
freight or express agent at once and request him parts are in good condition, turn the shaft by hand
to make an inspection. We will be very happy to to be sure there are no obstructions to free rota-
assist you in collecting claims for loss or damage tion. Equipment which has been in storage for
in shipment; howeverthis willingness on our part sometime should be testedand relubricated prior
does not remove the transportation company's to being put into service. Refer to "Test for Gen-
responsibility in reimbursing you for collection of eral Condition" and "Lubrication" for procedure
claims or replacement of material. Claims for
loss or damage in shipment must not be deducted
from the Reliance invoice, nor should payment of Equipment with roller bearings is shipped with
the Reliance invoice be withheld awaiting adjust- a shaft block at the opposite pulley end. In remov-
ment of such claims, as the carrier guarantees ing the shaft block, be sure to replace the bolts
safe delivery, which are used to hold the shaft block in place
during shipment.
If considerable damage has been incurred and
the situation is urgent, contact the nearestReliance WARRANTY
District Office for assistance. Please keep a
written record of all communications. The Reliance Electric Company warrants work-
manship and materials on this motor for a period of
STORAGE one year from date of shipment from thc Reliance
factory. In every case concerning warranty,
Equipment which is not going tobe used immed- contactthe nearest Reliance Sales Office or auth-
lately, should not be unpacked until ready for use. orized Reliance Service Shop.
If this equipment is to be stored for any period of
INSTALLATION
INSPECTION motors maybe mounted with the feet at any angle.
Alter the motor is unpacked, examine the name- After carefully aligning the motor with the driven
plate data to see that it agrees with the power cir- unit, bolt securely in place.
cuit to which it is to be connected. The motor is
guaranteed to operate successfully with frequency
not more than 5% and voltage not more than 10% The pulley, sprocket, or gear used in the drive
above or below the nameplate data, or combined should be located on the shaft as close to the shaft
variation of voltage and frequency of not more than shoulder as possible. Heat to install. Driving a
10% above or below nameplate data. Efficiency, unit on the shaft will damage the bearings.
power factor and current may vary from name- Belt Drive: Align the pulleys so that the belt
plate data. will run true; tighten the belt just enough to pre-
vent slippage, any tighter will cause premature
LOCATION bearing failure. If possible, the lower side of the
belt should be the driving side.
The motor should be installed in a location com-
patible with the motor enclosure and specified Chain Drive: Mount the sprocket on the shaft
ambient. as close to the bracket as possible. Align the
sprockets so that the chain will run true. Avoid
excessive chain tension.
MOUNTING
Gear Drive and Direct Connection: Accurate
Mount the motor on a foundation sufficiently alignment is very essential. Secure the motor
rigid to prevmntexcesslve vibration. Ball-bearing and driven unit rigidly to the base.
-3 E-21
INSTALLATION (Cont'd)
WIRING TEMPERATURE RISE
Connect the motor to the power supply accord- Under normal operating conditions, with the
ing to the diagram on the motor nameplate. For motor applied in accordance with the nameplate
most 230 and 460 volt motors, nine leads are rating, the temperature rise will not exceed the
brought out from the stator windings so that the proper limits. Always use a thermometer to de-
motormay be connected for either230or460volts. termine the heating of a motor. The hand is not
reliable in determining whether or not the motor
STARTING is too hot.
When starting the motor, check the following TEST FOR GENERAL CONDITION
items:
1. The rotor should turn freely when discon- If the motor has been in storage for an exten-
nected from the load. sive period or has been subjected to adverse
moisture conditions, it is best to check the in-
2.iDrin acinthe shod hn sulation resistance of the stator winding with
first starting the motor.amehetr
a megohmeter.
The motor should run smoothly with little noise.
If the motor should fail to start and produces a If the resistance is lower than one megohm the
decided hum, it may be that the load is too great windings should be dried in one of the two follow-
for the motor or that it has been connected im- ing ways:
properly. Shut down immediately and investigate 1. Bake in oven at temperatures not exceeding
for trouble.1.Bkinoeattmeauenoexedg
900C. until insulation resistance
becomes
DRAIN PLUGS constant.
If motor is totally enclosed fan-cooled or non- 2. With rotor locked, apply low voltage and
ventilated it is recommended that condensation gradually increase current through wind-
drain plugs be removed. These are located in the ings until temperature measured with ther-
lower portion of the end shields. mometer reaches 1940F. Do not exceed
this temperature.
ROTATION
INITIAL LUBRICATION
inter-
To reverse the direction of rotation,
change any two of the three line leads for three "Reliance motors are shipped from the factory
phase motors, for two phase four wire, inter- with the bearings properly packed withgrease and
change the line leads on any one phase. For two ready to operate. Where the unit has been sub-
phase three wire, interchange phase one and phase jected to extended storage (6 months or more) the
two line leads. bearings should be relubricated prior to starting."
OPERATION
Due tothe inherent characteristics of insulating ing and ultimate failure. It requires only a slight
materials, abnormally high temperatures shorten unbalance of voltage applied to a polyphase motor
the operating life of electrical apparatus. The to cause large unbalanced currents and resultant
total temperature, not the temperature rise, should overheating.
be the measure of safe operation. The class of
insulation determines the maximum safe operating Periodic checks of phase voltage, frequency and
temperature. Aging of insulation occurs at an ac- power consumption of a motor while in operation
celerated rate at abnormally high temperatures. are recommended; such checks assure the cor-
A general rule for gauging the effect of excessive rectness of frequency and voltage applied to the
heat is that for each 100C. rise in temperature motor and yield an indication of the load offered by
above the maximum limit for the insulation, the the apparatus which the motor drives. Compari-
life of the insulation is halved. sons of this data with previous no-load and full-
load power demands will give an indication of the
Unbalanced voltage or single-phase operation performance of the complete machine. Any serious
of polyphase machines may cause excessive heat- deviations should be investigated and corrected.
-4-
E-22
OPERATION (Cont'd)
Stator troubles can usually be traced to one of Squirrel-cage rotors are rugged and, in
the following causes: general, give little trouble. The first symptom
of a defective rotor is lack of torque. This may
Worn bearings Operating single phase cause a slowing down in speed accompanied
Moisture Poor insulation by a growling noise or perhaps failure to start
Overloading Oil and dirt the load.
Dust and dirt are usually contributing factors.

Some forms of dust are highly conductive and con-
tribute materially to insulation breakdown. The This is caused by an open or high resistance
effect of dust on the motor temperature through joint in the rotor bar circuit. Such a condition can
restriction of ventilation is a principal reason generally be detected by looking for evidence of
for keeping the windings clean, localized heating.
MAINTENANCE
The fundamental principle of electrical main- motor, care should be taken not to damage the
tenance is - KEEP THE APPARATUS CLEAN stator windings as the insulation may be injured
AND DRY. This requires periodic inspection of by improper or rough handling. Precautions to
the motor, the frequency depending upon the type keep bearings clean should be exercised.
of motor and the service.
Before removing either end shield:
at regular
The following should be checked
intervals. 1. Disconnect motor from power source. Tag
1. Windings should be dry and free of dust, the leads to insure proper reconnection.
grease, oil, and dirt. Windings may be
cleaned by suction cleaners or by wiping. 2. Remove motor from mounting base.
Nozzles on suction type cleaners should be
non-metallic. Gummy deposits of dirt and 3. Mark end brackets relative to position on
grease may be removed by using a corn- frame so they can be easily replaced.
mercially available low volatile solvent.
Do not use gasoline or other inflammable REMOVING BRACKETS AND ROTOR -
solvents.
4. Remove bearing cartridge nuts or screws.
2. Terminal connections, assembly screws,
bolts and nuts should be tight. They may 5. Remove front end bracket bolts.
loosen if motor is not securely bolted and
tends to vibrate. 6. Pull bracket.
3. Insulation resistance of motors in service 7. Remove back end bracket in same manner.
should be checked periodically at approx- B. Remove rotor.
imately the same temperature and humidity
conditions to determine possible deterior- REMOVING AND REPLACING BALL BEARINGS-
ation of the insulation. When such measure-
ments at regular intervals indicate a wide Bearings should not be removed unless they
variation, the cause should be determined, are to be replaced. When removal is necessary,
Motor should be reconditioned if the motor use a bearing puller if possible. If a puller is
has been subjected to excessive moisture, not accessible and a hammer must be used, the
or by re-winding or re-insulating if neces- blows should be transmitted through a hard wood
sary. Enclosed motors require very little or fibre block. A bearing puller may be rigged
attention. Be sure that external air chain- by using a metal plate, with holes drilled to
ber of fan-cooled motors does not become match the tapped holes in the inner cap. Use
clogged with foreign material which will care to keepthe pressure equal to prevent break-
restrict passage of air. ing the cap.
DISASSEMBLY To install a bearing, use a steady pressure on

the inner race. One method is to use a piece of
If it becomes necessary to disassemble the pipe of the correct size to slip over the shaft. If a
E-23
MAINTENANCE (Cont'd)
hammer is used, the blows should be transmitted to Instruction Manual A-3611.
through a block of wood or fibre. All bearings
must be replaced with the identical part used by REASSEMBLY
Reliance. In many cases special bearings are used
which cannot be identified by markings on bearing. Follow reverse procedure as outlined for Dis-
assembly. Having marked the brackets in the
For precautions in handling ball bearings, refer original position, replace as marked.
LUBRICATION
INITIAL LUBRICATION For motors operating in ambients between OOF.
and 1200F., use the following lubricants or their
Grease lubricated motors are properly lubi- equal:
cated at the time of manufacture and It Is not
necessary to lubricate at time of installation. If
the motor has been in storage for a period of six Standard Oil Co. of Indiana - Stanobar No. 2
months or greater, lubricate before starting. Standard Oil Co. of New Jersey - Andok C*and B
Below is a list of recommended types of grease. Master Lubricants Co. - Lubriko M-6. M-21,
These have all been tested and should be used and M-32
whenever possible. New York and New Jersey Lubricant Co. - F-925,
S-58, and S-58-M
RELUBRICATION Gulf Refining Co. - Precision No. 2 and No. 3
To lubricate, remove fillerplugand with motor The Texas Co. - Starfak H, M, and No. 2
running or at rest grease with clean lubricant Sinclair Refining Co. - A.F. No. 2
until grease appears at drain hole or along shaft. Tidewater Associated Oil Co. - Tycol Armitage 0
1/2 to 1 cu. inch of grease is sufficient in small Union Oil Co. of California - Strona HT-1
sizes, proportionatly more In large HP motors. Shell Oil Co. - Alvania No. 2
Standard Oil Co. of California - Chevron 0. H.T.
RELUBRICATION PERIOD Socony Mobil Oil Co. - Mobilux Grease No. 2
For relubricat~on period, follow instruction *Not recommended for roller bearings.
plate on motor.
cate per table:is provided, relubri-
If no plate
the following For operation in other ambient temperatures.
______perthefollowingtable:_ refer to motor tag 162214 or nearest Reliance
Sales Office.
Standard Severe Extreme
HP at 1800
RPM or Less Conditions Conditions Conditions SLEEVE BEARINGS (FRAMES D-5000)
1/8 - 7-1/2 3 years 1 year 6 months Motors with sleeve bearings are shipped from
the factory without oil. Fill the reservoirs to the
10 - 40 1-3 years 6mo.-lyear 3 months center of the oil level gauge (minimum) to 3/8
above center (maximum) with a good grade of
5 0- 150 1 year 6 months 3 months turbine oil as recommended for electric motor
and generator use by a reputable oil manufacturer.
200 & Up 1 year 6 months 3 n'-nths
THESE OILS MAY BE USED
All AllMotrs
Motors 6 months 3 months 3 months
Over 1800 RPM Mobil DTE Light or Heavy Medium
Texaco Regal A or PC
Standard Conditions: Eight hours per day, normal
0
or light loading, clean 100 F. Use Oil of the viscosity range indicated in the
maximum ambient, following table:
Severe Conditions: Twenty-four hours per day, Recommended

shock loading, vibration: Speed Range Viscosity Range
dirt or dust 100-1500 F, RMP SSU @ 100F.
ambient.
Extreme Conditions: Heavy shock or vibration, 1500 and below 250-350
dirt or dust. 1800 and over 100-200
E-24 -6-
LUBRICATION (Cont'd)
Watch oil rings when first starting to see that CONSTANT LEVEL OILER
they revolve.
Change oil every six months or more often un- When supplied, refer to instructions accom-
der severe operation conditions. panying the constant level oiler.
RECOMMENDED WIRE SIZE

Motor Horsepower
Volts 1-3 5 7-1/2 10 15 20 25 30 40 50 60 75
230 14 12 10 8 6 4 3 1 0 000 0000 300
460 14 14 14 12 10 8 6 6 4 3 2 0
575 14 14 14 14 12 10 8 6 6 4 3 2
Volts 100 125 150 200 250 300 350 400 450 500 600 700
230 500
460 000 0000 300 500 700 900 1500 600* 750* 900* 1750* --
575 0 000 0000 250 500 600 800 1000 1500 600* 900* 1500*
**2300 6 4 3 2 1 1 0 00
* Parallel
**Use high voltage cable.
GENERAL
For special motors for use by United States master plans, etc., refer to the applicable mas-
Government including special specifications, ter plans and specifications involved.
7 E-25/(E-26 blank)

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00

CABLE LAYING SYSTEM

Waso 42816 DECEMBER 1982

THIS DOCUMENT IS BEST QUALITY

2a. SECURITY CLASSIFICATION AUTHORITY 3. DISTRIBUTION AVAILABILITY OF REP.

4. PERFORMING ORGANIZATION REPORT NUMBER 5. MONITORING ORGANIZATION REPORT #

11. TITLE (Including Security Classification) 0

17. COSATI CODES 18. SUBJECT TERMS (Continue on reverse if nee.

19. ABSTRACT (Continue on reverse if necessary & identify by block number)

2a. SECURITY CLASSIFICATION AUTHORITY 3. DISTRIBUTION AVAILABILITY OF REP.

4. PERFORMING ORGANIZATION REPORT NUMBER 5. MONITORING ORGANIZATION REPORT #

Western Gear Machinery Co. has taken every reasonable pre-

Direct discharge of high pressure air can seriously injure

When performing maintenance operations, tag the equipment con-

Make certain work area is safe and clear of unnecessary per-

1-2. This manual provides description, installation, operation, troubleshoot-

1-3. EQUIPMENT PURPOSE.

1-5. EQUIPMENT SUPPLIED.

Table 1-1. Equipment Supplied

I DOHB Tension Machine 0316127 8,500 64.8* 127.8 75.4

1 DOHB Power Unit D316128 3,500 48.0 59.4 44.8

1-7. EQUIPMENT SPECIFICATIONS.

Figure 1i-1. Outline and General Arrangement (Sheet 2 of 3)

SERVO FILTER SUCTION FILTER

'-.69 DIA LIFTING EYE

.I I ,.J POWER UNIT

Figure 1-1. Outline and General Arrangement (Sheet 3 of 3)

DOHB Tension Machine

Low Gear Tension 2,250 pounds at 315 fpm

1-9. GENERAL DESCRIPTION.

1-10. The DOHB tension machine is a hydraulically powered, pneumatically oper-

4. A main pressure (lift and squeeze) cylinder. See figure 6-1.

1. One 120 gallon tank.

3. One variable delivery pump with integral replenishing pump.

5. One heat exchanger.

7. One bypass and brake control valve. See figure 6-10.

OUTBOARD PROFILE ma CUT41

,N........ -\ .......... /./.

cofgrain adterfr exat loain/o themDH tensioner c hine aen

Due to the multipurpose design of SEACON, its inventory of equipment includes

Figure 1-2. Shipboard Locations

Use extreme care when handling, moving or lifting to avoid

Use a sling to lift the tension machine at all four lifting

Failure to install the machinery properly can cause compo-

5 to 15 8.000 16.000 32.000 64,000 128.000 256.000 512.000 1.024,000

25 to 50 253 506 1.012 2.025 4.050 8,100 16.200 32.400

Over 100 8 16 32 64 128 256 512 1.024

Pickle all piping and flanges in accordance with the proce-

SEE DETAIL I 00i I_

32DRAIN PLUG .38NPT

Figure 2-1. outline and General

DETAIL 1 2-3/(2-4 blank)

.56 DtA THRU

PUMP .00 8) HOLES

HETR1.00 SECTION AmA

MOTOR CONTROLLER PLAN VIEW

4LO ,;12 1 F/ (DHOSE

460.69 DIA LIFTING EYE 3- NTEI

1. POWER UNIT SPECIFICATIONS:

_ _ ____

,, L2 WHT PIN 2 440 VAC PHASE 2