ARCTURUS MARINE TRAC 1280 Guide

35989
THRUSTERS
•
DIGITAL STABILIZERS
•
INTEGRATED HYDRAULICS
Hydraulic Thruster
Installation & Operation

Arcturus Marine / American Bow Thruster
Standard Installation and Operating Instructions
Version 6.99.1_c
Hydraulic TRAC Table of Contents
Prefix: Gearbox Installation Drawings (all TRAC sizes):
List of Graphics & Tables:
Section 1 – Before Starting Installation; ………………………………………. 1-1
Technical Assistance 1-1
Section 2 – Basic Component Installation: ………………………………………. 2-1
Tunnel Installation 2-1
Thruster Installation 2-4
Thruster Safety Wiring 2-5
Propeller Mounting 2-6
Motor Bell Housing Mounting (splined shaft) 2-7
Hydraulic Motor Mounting (splined shaft) 2-8
Header Tank Mounting / Lubrication Requirements 2-9
Electrical Component Installation 2-10
Hydraulic Pump Installation 2-11
Engine PTO Location 2-12
Centa-flex Coupling Installation 2-13
Centa-flex Alignment Suggestions 2-14
Spicer Coupling Installation 2-16
Miscellaneous Pump Information 2-16
Reservoir Installation 2-18
Cooling Pump Installation 2-18
Direction Control Valve Installation 2-19
Section 3 – Plumbing: ……………………………………… 3-1
Generic Hydraulic System Schematic 3-2
Section 4 – Electrical Wiring: ……………………………………… 4-1
Generic Wiring Diagram 4-1
Section 5 – Miscellaneous Pre-start-up Notes: ……………………………………… 5-1
Section 6 – Final Check List: ……………………………………… 6-1
Section 7 – Start-up Tuning & Operation : ……………………………………… 7-1
Hydraulic Check 7-1
Tuning 7-3
Arcturus Marine
517-A Martin Avenue
Rohnert Park, CA 94928
U.S.A.
Tel:[phone]
Fax: [phone]
www.thrusters.com

PROPELLER
COTTER PIN
NUT. COAT SHAFT THREADS
WITH HIGH STRENGTH LOCKING
COMPOUND AND TIGHTEN TO
55 FT-LBS
FSCM NO. REV.
ENGINEER
CONTRACT NO.
SCALE:
SUFACES:
ANGLES: ± 2°
DONOT SCALE DRAWING
TOLERANCES ARE: 63
.XX ±.01
.XXX ± .005
DEBUROUTSIDE EDGES R.015 MAX
FILLET INSIDE EDGES R.015 MAX
SIZE
THIS DRAWING, DESIGN AND ALL INFORMATION IS THE
EXCLUSIVE PROPERTY OF ARCTURUS MARINE SYSTEMS.
REPRODUCTION IN WHOLE OR PART WITHOUT THE
CONSENT OF ARCTURUS MARINE SYSTEMS IS EXPRESSLY
FORBIDDEN. ALL APPLICABLE COPYRIGHT LAWS APPLY.
FINISH: SHEET
APRVD
A division of Arcturus
American Bow Thruster
REVISIONS
DRFTRDATE DESCRIPTIONZONEREV.
C
DIMENSIONS AND TOLERANCES ARE PER ANSI Y14.5
A
C
DRAWN
MATERIALS
ISSUED
UNLESSOTHERWISE SPECIFIED DIMENSIONS ARE
ININCHES
DWG.NO.
B
D
QTY DESCRIPTIONPART NOITEM NO
BILL OF MATERIAL
517-A MARTINAVENUE
ROHNERT PARK CA94928
[phone]
CHECKED
123
123
C
D
B
A
REMOVE SET-
SCREW BEFORE
INSTALLING
BELLHOUSING
KEY
8" TRAC HYDRAULIC
THRUSTER INSTALLATION
GENERAL UPDATE
ER
ER
10/30/02B
1:5
ER
B
INM8TRACHYD
1of 1
THERE ARE A TOTAL OF SIX THRUSTER
MOUNTING BOLTS. USE ANTI-SEIZING
COMPOUND, AND SAFETY WIRE.
TIGHTEN TO:
3/8"= 24 FT-LBS
HYDRAULIC
MOTOR
LEAVE 0.050" GAP
IN COUPLING
ASSEMBLY
BELL HOUSING MOUNTING
BOLTS (QTY. 7) USE HIGH
STRENGTH LOCKING
COMPOUND. TIGHTEN TO
24 FT-LBS EVENLY!
MAKE SURE O-RING
IS IN PLACE BEFORE
INSTALLING
BELLHOUSING
MOTOR MOUNTING BOLTS (QTY. 2
OR 4) USE MEDIUM STRENGTH
LOCKING COMPOUND. TIGHTEN
TO 40 FT-LBS
COUPLING
INSERT
MOUNTING GASKET.
COAT WITH RTV
SILICONE BOTH SIDES.
TUNNEL
MOUNTING
BOLTS
BREATHER
FITTING
BELL
HOUSING
KEY
MAGNALOY
COUPLING
KEY
BELL HOUSING,
TOP VIEW
GEARBOX OIL
BREATHER
FITTING PORT

THRUSTER MOUNTING BOLTS. TOTAL OF
SIX BOLTS IN TWO DIAMETERS. USE ANTI-
SEIZING COMPOUNDAND SAFETY WIRE.
TIGHTEN TO:
3/8" =24 FT-LBS
1/2" =50 FT-LBS
MOUNTING
GASKET.
COAT WITH RTV
SILICONE.
FSCM NO. REV.
ENGINEER
CONTRACTNO.
SCALE:
SUFACES:
ANGLES: ± 2°
DONOT SCALE DRAWING
TOLERANCES ARE: 63
.XX±.01
.XXX ±.005
DEBUROUTSIDE EDGES R.015 MAX
FILLET INSIDE EDGES R.015 MAX
SIZE
THIS DRAWING, DESIGN AND ALL INFORMATION IS THE
EXCLUSIVE PROPERTY OF ARCTURUS MARINE SYSTEMS.
REPRODUCTION IN WHOLE OR PART WITHOUT THE
CONSENT OF ARCTURUS MARINE SYSTEMS IS EXPRESSLY
FORBIDDEN. ALL APPLICABLE COPYRIGHT LAWS APPLY.
FINISH: SHEET
APRVD
A division of Arcturus
American Bow Thruster
REVISIONS
DRFTRDATE DESCRIPTIONZONEREV.
C
DIMENSIONS AND TOLERANCES ARE PER ANSI Y14.5
A
C
DRAWN
MATERIALS
ISSUED
UNLESS OTHERWISE SPECIFIED DIMENSIONS ARE
ININCHES
DWG. NO.
B
D
QTY DESCRIPTIONPART NO ITEM NO
BILL OF MATERIAL
517-A MARTINAVENUE
ROHNERT PARK CA 94928
[phone]
CHECKED
123
123
C
D
B
A
KEY
REMOVE SET-
SCREW
BEFORE
INSTALLING
BELLHOUSING
FASTENERS. COAT WITH
MEDIUM STRENGTH
LOCKING COMPOUND AND
TIGHTEN TO 7FT-LBS
10" AND 12" TRAC HYDRAULIC
THRUSTER INSTALLATION
GENERAL UPDATE10/30/02
ER
ER
1:5
B
B
1of 1
INM1012TRACHYD
PROPELLER
COTTER PIN
NUT. COAT SHAFT
THREADS WITH HIGH
STRENGTH LOCKING
COMPOUND AND TIGHTEN
TO 80 FT-LBS
NOSE CONE
.
BELL HOUSING MOUNTING
BOLTS (QTY. 7) USE HIGH
STRENGTH LOCKING
COMPOUND. TIGHTEN TO
24 FT-LBS EVENLY!
MOTOR MOUNTING BOLTS (QTY. 2) USE
MEDIUM STRENGTH LOCKING COMPOUND.
TIGHTEN TO 50 FT-LBS FOR 1/2"
MAKE SURE O-RING IS IN
PLACE BEFORE INSTALLING
BELLHOUSING
SPLINE
COUPLING
BELL
HOUSING
BREATHER
FITTING
MOUNTING
BOLTS
TUNNEL
HYDRAULIC
MOTOR
BELL HOUSING
TOP VIEW

PROPELLER
NUT. COAT SHAFT THREADS
WITH HIGH STRENGTH LOCKING
COMPOUND AND TIGHTEN TO
100 FT- LBS
NOSE CONE
THERE ARE SIX THRUSTER MOUNTING
BOLTS IN TWO SIZES. USE ANTI-
SEIZING COMPOUND AND SAFETY
WIRE. TIGHTEN TO:
3/4" =100 FT-LBS
3/8" = 24 FT-LBS
FINISH:
THIS DRAWING, DESIGN AND ALL INFORMATION IS THE
EXCLUSIVE PROPERTY OF ARCTURUS MARINE SYSTEMS.
REPRODUCTION IN WHOLE OR PART WITHOUT THE
CONSENT OF ARCTURUS MARINE SYSTEMS IS EXPRESSLY
FORBIDDEN. ALL APPLICABLE COPYRIGHT LAWS APPLY.
TOLERANCES ARE: 63
.XX ±.01
.XXX ± .005
DEBUROUTSIDE EDGES R.015 MAX
FILLET INSIDE EDGES R.015 MAX
DONOT SCALE DRAWING
SUFACES:
ANGLES: ± 2°
DIMENSIONS AND TOLERANCES ARE PER ANSI Y14.5
UNLESSOTHERWISE SPECIFIED DIMENSIONS ARE
ININCHES
3
A
2
REMOVE SET
SCREW
BEFORE
INSTALLING
BELLHOUSING
B
KEY
COTTER
PIN
FSCM NO.
DESCRIPTION
REVISIONS
A division of Arcturus
American Bow Thruster
COTTER PIN ADDED
16" TRAC HYDRAULIC
THRUSTER INSTALLATION
GENERAL UPDATE
DRAWN
ER
ER ENGINEER
ISSUED
MATERIALS
CHECKED
SIZE
SCALE:
C
1:5
11/5/05
DATE
10/30/02
CONTRACT NO.
REV. ZONE
C
B
SHEET
DWG.NO.
INM16TRACHYD
1of 1
1
REV.
C
A
DRFTR APRVD
517-A MARTIN AVENUE
ROHNERT PARKCA94928
[phone]
JP
ER
COAT FASTENERS WITH
MEDIUM STRENGTH LOCKING
COMPOUND AND TIGHTEN TO
7FT-LBS
B
2
BELL HOUSING MOUNTING
BOLTS (QTY. 7) USE HIGH
STRENGTH LOCKING
COMPOUND. TIGHTEN TO
24 FT-LBS EVENLY!
GEARBOX OIL
BREATHER FITTING
BELL HOUSING
STABILIZER BOLTS
USE HIGH STRENGTH
LOCKING COMPOUND
AND TIGHTEN TO ONLY
5FT-LBS
HYDRAULIC MOTOR
MOTOR MOUNTING BOLTS (QTY. 2 OR
4) USE MEDIUM STRENGTH LOCKING
COMPOUND. TIGHTEN TO 50 FT-LBS
BELL HOUSING
C
MOUNTING
BOLTS
MOUNTING
GASKET.
COAT WITH
RTV SILICONE.
TUNNEL
SPLINE
COUPLING
SAE SPLINE
ADAPTER
(IF APPLICABLE)
D
3
PLACE PROVIDED O-RING
IN GROOVE BEFORE
INSTALLING BELLHOUSING
BELL HOUSING,
BOTTOM VIEW
C
DESCRIPTION
BILL OF MATERIAL
PART NO
ITEM NO QTY
D
1

PROPELLER
WASHER(IF PROVIDED)
COTTER PIN
NUT. COAT SHAFT THREADS
WITH HIGH STRENGTH LOCKING
COMPOUND AND TIGHTEN TO
125 FT-LBS
NOSE CONE
.
FSCMNO. REV.
ENGINEER
CONTRACT NO.
SCALE:
SUFACES:
ANGLES: ±2°
DONOTSCALE DRAWING
TOLERANCES ARE: 63
.XX ±.01
.XXX±.005
DEBUR OUTSIDE EDGES R.015 MAX
FILLET INSIDE EDGES R.015MAX
SIZE
THIS DRAWING, DESIGN AND ALL INFORMATION IS THE
EXCLUSIVE PROPERTY OF ARCTURUS MARINE SYSTEMS.
REPRODUCTION IN WHOLE OR PART WITHOUT THE
CONSENT OF ARCTURUS MARINE SYSTEMS IS EXPRESSLY
FORBIDDEN. ALL APPLICABLE COPYRIGHT LAWS APPLY.
FINISH: SHEET
APRVD
A division of Arcturus
American Bow Thruster
REVISIONS
DRFTRDATE DESCRIPTION
ZONEREV.
C
DIMENSIONS AND TOLERANCES ARE PER ANSI Y14.5
A
C
DRAWN
MATERIALS
ISSUED
UNLESS OTHERWISE SPECIFIED DIMENSIONS ARE
ININCHES
DWG.NO.
B
D
QTY DESCRIPTIONPART NOITEM NO
BILL OF MATERIAL
517-A MARTINAVENUE
ROHNERT PARK CA 94928
[phone]
CHECKED
123
123
C
D
B
A
KEY
20" TRAC HYDRAULIC
THRUSTER INSTALLATION
ORIGINAL DRAWING RELEASE
1:5
B10/30/02
ER
ER
ER
B
1 of 1
INM20TRACHYD
COAT FASTENERS WITH
MEDIUM STRENGTH
LOCKING COMPOUND AND
TIGHTEN TO 7 FT-LBS
HYDRAULIC MOTOR
THERE ARE SIX THRUSTER MOUNTING
BOLTS. USE ANTI-SEIZING COMPOUND
AND SAFETY WIRE.
TIGHTEN TO: 3/4" = 100 FT-LBS
BELL HOUSING MOUNTING
BOLTS (QTY. 7) USE HIGH
STRENGTH LOCKING
COMPOUND. TIGHTEN TO
50 FT-LBS EVENLY!
NOTE ENLARGED HOLE
FOR GEARBOX OIL
BREATHER FITTING
MOTOR MOUNTING BOLTS (QTY. 2
OR 4) USE MEDIUM STRENGTH
LOCKING COMPOUND. TIGHTEN TO
80 FT-LB. FOR 5/8" AND 50 FT-LBS.
FOR 1/2"
SAE SPLINE ADAPTER
(WHERE APPLICABLE)
SPLINE COUPLING
BELL HOUSING
MOUNTING GASKET.
COAT WITH RTV
SILICONE.
BELL HOUSING
STABILIZER BOLTS
USE HIGH STRENGTH
LOCKING COMPOUND
AND TIGHTEN TO
ONLY 5FT-LBS
MOUNTING BOLTS
TUNNEL
GEARBOX OIL
BREATHER FITTING
BELL HOUSING,
TOP VIEW

REMOVE SET
SCREW BEFORE
INSTALLING
BELLHOUSING
PROPELLER
WASHER(IF PROVIDED)
COTTER PIN
NUT. COAT SHAFT
THREADS WITH HIGH
STRENGTH LOCKING
COMPOUND AND TIGHTEN
TO 150 FT-LBS
NOSE CONE
.
FSCM NO. REV.
ENGINEER
CONTRACT NO.
SCALE:
SUFACES:
ANGLES: ± 2°
DONOT SCALE DRAWING
TOLERANCES ARE: 63
.XX ±.01
.XXX ± .005
DEBUROUTSIDE EDGES R.015 MAX
FILLET INSIDE EDGES R.015 MAX
SIZE
THIS DRAWING, DESIGN AND ALL INFORMATION IS THE
EXCLUSIVE PROPERTY OF ARCTURUS MARINE SYSTEMS.
REPRODUCTION IN WHOLE OR PART WITHOUT THE
CONSENT OF ARCTURUS MARINE SYSTEMS IS EXPRESSLY
FORBIDDEN. ALL APPLICABLE COPYRIGHT LAWS APPLY.
FINISH: SHEET
APRVD
A division of Arcturus
American Bow Thruster
REVISIONS
DRFTRDATE DESCRIPTIONZONEREV.
C
DIMENSIONS AND TOLERANCES ARE PER ANSI Y14.5
A
C
DRAWN
MATERIALS
ISSUED
UNLESSOTHERWISE SPECIFIED DIMENSIONS ARE
ININCHES
DWG.NO.
B
D
QTY DESCRIPTIONPART NOITEM NO
BILL OF MATERIAL
517-A MARTIN AVENUE
ROHNERT PARKCA94928
[phone]
CHECKED
123
123
C
D
B
A
KEY
COAT FASTENERS WITH
MEDIUM STRENGTH
LOCKING COMPOUND AND
TIGHTEN TO 7FT-LBS
24" &28" TRAC HYDRAULIC
THRUSTER INSTALLATION
ORIGINAL DRAWING RELEASE
ER
1:5
ER
10/30/02B
B
1of 1
INM2428TRACHYD
ER
HYDRAULIC MOTOR
THRUSTER MOUNTING BOLTS. TOTAL OF
SIX BOLTS IN TWO DIAMETERS. USE ANTI-
SEIZING COMPOUND. AND SAFETY WIRE.
TIGHTEN TO:
3/4" = 135 FT-LBS
7/8" = 225 FT-LBS
BELL HOUSING MOUNTING
BOLTS (QTY. 7) USE HIGH
STRENGTH LOCKING
COMPOUND. TIGHTEN TO
50 FT-LB. EVENLY!
MOTOR MOUNTING BOLTS (QTY. 2
OR 4) USE MEDIUM STRENGTH
LOCKING COMPOUND. TIGHTEN
TO 80 FT-LBS
SPLINE COUPLING
TUNNEL
MOUNTING GASKET.
COAT WITH RTV
SILICONE.
MOUNTING BOLTS
BELL HOUSING
STABILIZER BOLTS
USE HIGH STRENGTH
LOCKING COMPOUND
AND TIGHTEN TO
ONLY 5FT-LBS
SAE SPLINE ADAPTER
(WHERE APPLICABLE)
BELL HOUSING
BELL HOUSING,
TOP VIEW
GEARBOX OIL
BREATHER
FITTING
ALIGN HOLE FOR GEARBOX
OIL BREATHER FITTING WITH
CORRESPONDING HOLE ON
TOP OF THRUSTER. MAKE
SURE O-RING IS IN PLACE
BEFORE FINAL INSTALLATION
OF BELLHOUSING.

Graphics, Pictures, Diagrams and Tables:
Figure 1: Tunnel Positioning 2-1
Figure 2: Marking The Tunnel Cutout 2-1
Figure 3: Marking The Tunnel Cutout 2-1
Figure 4: Tunnel / Hull Joint Radius 2-2
Figure 5: The “Eyebrow” 2-2
Figure 6: The “Scallop” 2-3
Figure 7: Tunnel Gratings 2-3
Figure 8: Thruster Mounting 2-4
Figure 9: Safety Wiring Example 2-5
Figure 10: Propeller Mounting 2-6
Figure 11: Bell Housing Top View 2-7
Figure 12: Installing Hydraulic Motor (Splined Shaft) 2-8
Figure 13: Header Tank Mounting 2-9
Figure 14: Thruster Control Stations (TCS) 2-10
Figure 15: PLC / Switch Board 2-10
Figure 16: Engine Rotation 2-11
Figure 17: Gear Pump Rotation 2-11
Figure 18: Hydraulic Pump PTO 2-12
Figure 19: CENTAFLEX Coupling, Clutch, Bracket 2-12
Figure 20: CENTAFLEX Coupling 2-13
Figure 21: CENTAFLEX Alignment 2-14
Figure 22: CENTAFLEX Orientation 2-15
Figure 23: SPICER Parallel Alignment 2-16
Figure 24: SPICER Coupling 2-16
Figure 25: Extra Long Pumps Support 2-17
Figure 26: Reservoir 2-18
Figure 27: Cooling Pump Installation 2-18
Figure 28: D03 Directional Control Valve (DCV) 2-19
Figure 29: D05 Directional Control Valve (DCV) 2-19
Figure 30: D08 Directional Control Valve (DCV) 2-19
Figure 31: Hydraulic Diagram 3-2
Figure 32: Electrical Diagram 4-1
Figure 33: Reservoir Outlet Valve 7-1
Figure 34: Thruster Control Stations (TCS) 7-2
Figure 35: Reservoir Oil Level Gage 7-2
Figure 36: TCS Adjustments 7-3
TABLE 1: Thruster Assembly Torque Requirements 2-8
TABLE 2: CENTAFLEX Data 2-14
TABLE 3: SPICER Short Coupled Drive Data 2-16
I

Section 1 - Before Starting Installation:
Please read this manual in its entirety before starting installation! It will save you money!
Technical Assistance:
Listed below are several numbers you can call in case you have any questions about your system, or if you
need technical assistance. Please call us at:
[phone] or
[phone] or
[phone] or
We want to help!
Protect Against Contamination
Hydraulic system contamination prior to initial start-up is, by far, the biggest problem experienced in the field.
We define contamination as any substance other than hydraulic fluid that has penetrated and possibly de-
graded the hydraulic lines. Contaminants include, but are not limited to, dirt, metal shavings, grinding grit,
water, grease, rags, etc. Keep hydraulic reservoirs, pumps, valves, and plumbing lines closed, capped, and
sealed prior to final hookup.
Remember, system failure or damage due to contamination can be very costly to repair. Protect your invest-
ment! Talk about the need for system cleanliness with your workers.
1-1

Section 2 - Basic Component Installation
Tunnel Installation:
WARNING! Thruster tunnel becomes an integral part of the hull. Installation of thruster tunnel
should be undertaken only by professionals with certified competency in the fabrica-
tion and repair of the hull material in question. Proper mechanical bonding of the
tunnel to the hull and support of the tunnel must be confirmed and certified with your
naval architect.
Tunnel Positioning:
Priority 1 - Locate top of tunnel at least 1/2 diameter below the waterline. It is strongly recommended that
this distance be at least 1 diameter whenever possible. Deeper is better.
Priority 2 - Locate the tunnel as far forward as possible while maintaining adequate tunnel length. At a
minimum, the tunnel must be long enough so that no part of the thruster protrudes. (See page
2-3, “propeller free wheeling” and “tunnel gratings”)
Marking the Tunnel Cutout:
1- Measure and re-measure to exactly pinpoint the center of the tunnel on the inside of the hull on both sides.
Be sure that the location is square in all directions.
2- Drill a horizontal 3/16" diameter hole through the hull at each center point.
3 - Fabricate a scribing tool from 1/8" steel rod as shown. Bend the end of the rod into a hook shape having a
diameter equal to the tunnels O.D. radius. Pass the scribing tool through the holes in the hull as shown
and scribe the tunnel openings on both sides of the hull.
4 - Cut holes in both sides of hull at scribe mark. Try to hold cutting device parallel to the ground.
2-1
waterline
Position tunnel as far forward and deep as
possible without making tunnel too short.
Preferred submergence is 1
diameter or more.
Figure 1
Figure 2 Figure 3