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

2-2
Tunnel/Hull Joint Radius:
To minimize inlet turbulence, which can reduce thrust, it is best if the tunnel/hull joint radius be not more or
less than 1/10 the tunnel diameter. It is recognized that fabrication of such a radius can be quite time con-
suming and expensive. It should be noted that this recommendation is made in the pursuit of an ideal situa-
tion and that in practice is not often achieved.
On steel and aluminum tunnels, where such a radius is most difficult, but where performance is critical, a 45
degree chamfer, also 1/10 the tunnel diameter in dimension, can be fabricated at the tunnel/hull joint.
Other Tunnel/Hull Joint Treatments:
The "eyebrow":
This treatment was very common 5-10 years ago. An "eyebrow" would be built up at the leading edge of the
tunnel. The theory was that the eyebrow would deflect water from "tripping" on the trailing edge of the tunnel
and thus reducing turbulence drag. It is our opinion that this theory is not technically supportable. However, it
is acknowledged that an eyebrow may have some benefit in deflecting larger debris from hitting the trailing
edge of the tunnel although damage to a vessel from this type of impact has never been reported. Eyebrows
have also been used successfully in the reduction of propeller freewheeling while underway. (See page 2-3)
Optimum radius or chamfer =
1/10 tunnel diameter.
Figure 4
Figure 5

2-3
The "scallop":
A few builders have gone to the expense of scalloping out the trailing edge of the tunnel so as to soften or
eliminate the corner of the trailing edge of the tunnel. The theory behind this approach is that, if left un-
treated, the trailing edge corner will cause turbulence and hull drag.
In recent tank tests some builders have sought to determine what type of tunnel opening treatment is best.
Tests have shown that with or without tunnel opening treatments, drag from thruster tunnels is so little that it
cannot be measured.
Propeller Free Wheeling:
In some hull shapes while a vessel is underway water flow through a tunnel can cause the thruster propeller
and motor to spin at very high rpm in certain sea conditions. In some cases considerable noise can be
generated.
Thruster free wheeling has been solved in the past in two ways. The first is to install a tunnel eyebrow as
described above. It is not clearly understood why this works, but it does!
The second fix is through the use of a special hydraulic valve sandwich that would be installed in your existing
directional valve.
All thruster propellers free wheel to a certain extent while underway. It is only those that free wheel to a
degree resulting in significant noise that are a problem and require the measure stated above.
Only a very, very few vessels experience this problem, but all installations had two similar characteristics:
1 - the tunnels were extremely short
2 - the hulls had very fine entry at the bow
Tunnel gratings:
Tunnel gratings are installed to keep people and large debris out of thruster tunnels. We recommend the use
of tunnel gratings.
We suggest placing bars 3.5 - 5 inches apart. Usually bars made of 1/4" x 2" stainless flat stock are used.
The size of material can be varied according to thruster diameter. The bars should be located perpendicular
to the normal water flow past the tunnel opening while the vessel is underway. This means that the bars will
be approximately vertical in position, not horizontal as might be expected.
yes no
It is believed that placing the gratings in this position helps to maintain laminar flow past the tunnel opening
which should reduce tunnel drag. Tunnel gratings are also believed to reduce the potential for excess propel-
ler free wheeling.
Figure 6
Figure 7

Thruster Installation:
• The thruster is held in the tunnel by 6 socket head cap screws. The diameter of the screws vary with
thruster size and material. Use only screws supplied by American Bow Thruster. A gasket is usually used
between the strut (thruster mounting surface) and the inside of the tunnel. Because some tunnels may be
slightly undersized, oversized, or out of round, it is acceptable to:
- use the gasket provided
- eliminate the gasket See Enclosed Thruster Mounting Instruction Sheet
- use two gaskets
Please read the following instructions for more details.
Checking propeller tip clearance:
• Test mount the thruster in the tunnel. Use the single gasket provided. Pull the thruster up tight with the
screws provided. Slide both propellers on their respective shafts and check for adequate tip clearance.
Aluminum tunnels warp considerably during installation and give the most trouble in so far as tip clearance
is concerned.
Because the thruster strut is machined with the same radius as the inside of the tunnel it tends to nest
squarely in the tunnel. The result is propeller shafts that are well centered. However, by loosening the
mounting screws the thruster can be twisted to a small degree in order to improve propeller tip clearance.
You may add an extra gasket or remove the gasket entirely to aid in propeller positioning.
Once it has been established that the propeller tip clearance is acceptable, remove the propellers and dis-
mount the thruster.
2-4
MOUNTING BOLTS
TUNNEL
REMOVE SET
SCREW BEFORE
INSTALLING
BELLHOUSING
MOUNTING
GASKET.
COAT WITH
RTV SILICONE.
Figure 8

Final Thruster Mounting:
• Carefully clean the mounting surfaces on the thruster strut and the inside of the tunnel.
• Apply RTV silicone to both sides of the gasket. (If a gasket is not being used, coat the thruster mounting
surface with an underwater gasket material such as Sikaflex.)
• With gasket in place, fasten thruster in tunnel with the screws provided. Screw threads should be coated
with an anti-seizing compound.
• Before torquing fasteners, slide props in place to be sure that thruster is centered properly.
• Torque fasteners to the values listed in Table 1 or on the Assembly drawing.
• Safety wire the thruster mounting screws so that they cannot loosen with vibration.
2-5
Thruster Safety Wiring :
• After Installing the thruster in the tunnel, (see Thruster Assembly drawing) the six mounting bolts must be
safety wired. The mounting bolts supplied by American Bow Thruster come predrilled to accept the safety
wire. There will be a length of stainless safety wire included in the mounting kit that must be used. Refer
to the diagram for proper wiring technique.
MOUNTING BOLTS
WASHERS
TUNNEL
GASKET
THRUSTER
Safety Wire
EXAMPLE
Figure 9

Propeller Mounting:
• Clean the propeller shaft and the inside of the propeller hub. Fit key into shaft key way and test fit the
propeller. Propeller should make up on the shaft cleanly. If propeller does not fit snug and clean, remove
propeller and correct problem.
• For final mounting fit key into shaft keyway. Coat both propeller shafts with anti-seizing compound. Slide
propeller onto shaft, making sure that key does not “cock up”. Propeller should make up on the shaft
cleanly.
• Slide prop nut washer onto shaft end (when provided).
• Coat prop shaft threads with high strength locking compound.
• Tighten prop nuts to torque listed on Assembly drawing.
Nut materials : Bronze thrusters must use Monel nuts. These nuts are usually marked “NICU”.
Aluminum thrusters must use 316 stainless nuts. These nuts are usually marked 316.
• Check to see that propeller rotates freely and is not binding up on the face of the thruster gearbox.
• Insert cotter pin in the hole provided in the end of the prop shaft and bend ends around shaft.
• All TRAC thrusters 10" and up will have propeller nose cones.
• Install nose cone by fastening to face of propeller with the screws provided. Coat screws with medium
strength locking compound. Tighten to 7ft. lbs. ( see table 1 )
Nose cone screw materials : Bronze thrusters must use Monel screws. These screws are
usually marked “NICU”.
Aluminum thrusters must use 316 stainless nuts. These nuts are
usually marked 316.
2-6
FASTENERS. COAT WITH
MEDIUM STRENGTH LOCKING
COMPOUND
KEY
CHECK FOR PROPELLER CLEARANCE.
SHOULD NOT BE BINDING UP ON
FACE OF GEARBOX.
PROPELLER
WASHER(IF PROVIDED)
COTTER PIN
NUT. COAT SHAFT THREADS
WITH HIGH STRENGTH
LOCKING COMPOUND
NOSE CONE
.
Figure 10

2-7
Motor Bell Housing Mounting (Splined Shaft):
• The bell housing is designed to slide onto a boss on the pinion shaft seal housing. This aligns the bell
housing perfectly with the pinion shaft. The bell housing fastens through the seal housing into the top of the
thruster strut. Some bell housings have stabilizer screws for added motor support. It is important that the
bell housing remain square with the top of the thruster. This will ensure that the motor shaft is in perfect
alignment with the thruster pinion shaft.
• Clean the mating surfaces on the bottom of the bell housing. Apply a light coat of medium to heavy weight
grease. Also clean the pinion shaft seal housing on the top of the thruster.
• Locate the bell housing onto the top of the pinion shaft seal housing. Be sure that the bell housing seats
squarely on the seal housing. The bell housing must not touch the tunnel. It may be necessary to use
a grinder to smooth out any rough spots on the outside of the tunnel that interfere with bell housing mount-
ing.
• It is apparent that there are 7 mounting holes that must align and one port for the gearbox oil breather. The
clearance hole for this breather is smaller than the clearance holes for the fasteners. Be sure that the port
and fastener holes are aligned properly.
• Remove the set screw from the pinion seal housing and install the o-ring.
• Coat the seven fasteners with high strength locking compound and tighten to the correct torque. (refer to
Thruster Assembly drawing or table 1)
• Install case drain fitting to side of motor bell housing and cap or cover until header tank hose is attached
• Coat bell housing stabilizer screws (where provided) with high strength locking compound and tighten evenly
by hand, until the end of the screws come into contact with the tunnel. Do not over tighten!
Note: On fiberglass tunnels place stainless pressure pads underneath bell housing stabilizer screw tips.
These pads can be bedded with Sikaflex or 5200.
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.
Figure 11

Table 1 - Thruster Assembly Torque Requirements
2-8
Hydraulic Motor Mounting (Splined Shaft):
• Apply heavy grease to pinion shaft spline and install spline coupling.
• Where applicable, install Spline Sizing adapter.
• Apply heavy grease to hydraulic motor shaft spline and fit onto bell housing.
Note: Bell housing heights vary. Be sure that your bell housing is not too short. There should be .100" -
.350" clearance between the ends of the two shafts.
• Coat motor mounting bolts with medium strength locking compound and install through motor flange into bell
housing top flange. Tighten to appropriate torque. ( See table 1 or assembly drawing )
Thruster mounting bolts Propeller Nut Nose Cone Screws Bell Housing Bolts Hydr. Motor BoltsThruster mounting bolts Propeller Nut Nose Cone Screws Bell Housing Bolts Hydr. Motor Bolts
Thruster mounting bolts Propeller Nut Nose Cone Screws Bell Housing Bolts Hydr. Motor BoltsThruster mounting bolts Propeller Nut Nose Cone Screws Bell Housing Bolts Hydr. Motor Bolts
Thruster mounting bolts Propeller Nut Nose Cone Screws Bell Housing Bolts Hydr. Motor Bolts
3/8"
TRAC 8TRAC 8
TRAC 8TRAC 8
TRAC 8 24 Ft.lbs 55 Ft.lbs N/A 24 Ft.lbs 40 Ft.lbs
3/8" 1/2"
TRAC 10TRAC 10
TRAC 10TRAC 10
TRAC 10 24 Ft.lbs 50 Ft.lbs 80 Ft.lbs 7 Ft.lbs 24 Ft.lb 50 Ft.lbs
3/8" 1/2"
TRAC 12TRAC 12
TRAC 12TRAC 12
TRAC 12 24 Ft.lbs 50 Ft.lbs 80 Ft.lbs 7 Ft.lbs 24 Ft.lbs 50 Ft.lbs
3/8" 3/4"
TRAC 16TRAC 16
TRAC 16TRAC 16
TRAC 16 24 Ft.lbs 100 Ft.lbs 100 Ft.lbs 7 Ft.lbs 24 Ft.lbs 50 Ft.lbs
3/4 1/2" 5/8"
TRAC 20TRAC 20
TRAC 20TRAC 20
TRAC 20 100 Ft.lbs 125 Ft.lbs 7Ft.lbs 50 Ft.lbs 50 Ft.lbs 80 Ft.lbs
3/4" 7/8"
TRAC 24TRAC 24
TRAC 24TRAC 24
TRAC 24 135 Ft.lbs 225 Ft.lbs 150 Ft.lbs 7 Ft.lbs 50 Ft.lbs 80 Ft.lbs
3/4" 7/8"
TRAC 28TRAC 28
TRAC 28TRAC 28
TRAC 28 135 Ft.lbs 225 Ft.lbs 150 ft.lbs 7 Ft.lbs 50 Ft.lbs 80 Ft.lbs
SPLINE COUPLING
HYDRAULIC MOTOR
BELL HOUSING
MOUNTING BOLTS
TUNNEL
SAE SPLINE ADAPTER
(WHERE APPLICABLE)
MOTOR MOUNTING BOLTS (QTY. 2
OR 4) USE MEDIUM STRENGTH
LOCKING COMPOUND.
BELL HOUSING MOUNTING
BOLTS (QTY. 7) USE HIGH
STRENGTH LOCKING
COMPOUND.
BELL HOUSING
STABILIZER BOLTS
USE HIGH STRENGTH
LOCKING COMPOUND.
Figure 12

2-9
Header Tank Mounting/Lubrication Requirements:
WARNING! On some systems, the header tank fitting and plumbing must be connected before the
driveline or motor are installed, or they cannot be reached.
The header tank maintains positive fluid pressure inside the thruster gearbox to prevent water
intrusion in the unlikely event of a leak. Although rare, the most probable source of a leak in the thruster is
through the shaft seals.
In the event of a leak, case fluid will slowly seep out of the thruster gearbox, rather than water seeping in.
The fluid level in the header tank should be monitored on a regular basis, and must be kept 1/2 full.
1- Using the brackets provided, mount the header tank in any convenient location near the thruster. The
header tank should be mounted at least 30" above the waterline.
2- Connect the header tank hose to the supplied fitting on the thruster with the 3/8" diameter, oil resistant,
low pressure hose. The fittings on the header tank and the thruster are -6 male JIC.
3- Fasten the hose along its route to the hull or bulkhead with nylon straps or clamps.
NOTE: Be sure that the hose cannot be pinched or become crimped at a later date by stowed gear or
equipment.
4- Remove the breather cap on the header tank and begin filling with the gear oil supplied.
NOTE: Use ONLY Chevron Delo Gear Lubricant SAE 80-90.
Thruster is shipped pre-filled with gear oil.
5- Fill the header tank approximately 1/2 full. Store remaining fluid for future use.
MOTOR BELLHOUSING
WATERLINE
HEADER TANK
A/C, DC OR HYDRAULIC MOTOR
Figure 13

Thruster Control Station (TCS):
Thruster Control Stations (TCS's) should be located at steering stations near main engine throttle and shift
controls. A console cutout template and gasket is provided with each TCS. Make the console cutout as
shown and drill the four mounting holes. The TCS mounts with four pre-installed stainless 10-32 studs. Extra
long coupling nuts are provided for tightening.
Note: On variable speed TCS's there are three electronic adjustments (pots) that will need to be adjusted at
start-up (see pg. 7-3 and 7-4). Keep this in mind when locating the TCS and before tightening in
place.
The portion of the TCS that extends below the console is NOT weather resistant. In situations where the area
below the mounting surface is open to the environment, a protective cover for the bottom of the TCS must be
fabricated.
Relay Box or Switch Box:
The relay box should be mounted in the engine room in a dry, central location, where the ambient tempera-
ture will not exceed 120 degrees F. Access to the relay box is key in troubleshooting.
Nearly all control wiring leads to the relay box. Run all wires in the sizes indicated on the accompanying
wiring diagram.
2-10
Thruster Control Station
Remote Start Stop Station
Bow / Stern Thruster Control Station
PLC / Switch Board
PLC Micro Controller
Wiring Terminal Strip
Glass Fuses
Control Relays
Electrical Component Installation:
Figure 14
Figure 15

For pumps driven from the front end of the engine:
Right Hand Pumps Left Hand Pumps
Right Hand Pumps Left Hand Pumps
For assistance determining rotation on hydraulic pumps other than GEAR pumps, contact factory.
Hydraulic Pump Installation:
WARNING! Operation of a hydraulic pump having the wrong rotation will cause serious damage to
the pump. Confirmation of proper pump rotation is the responsibility of the installer!
WARNING! Operation of a hydraulic pump having inlet and outlet plumbing accidently reversed will
cause serious damage to the pump. Confirmation of proper port location is the respon-
sibility of the installer! Do not rely on pictorial plumbing diagrams for determination of
proper port location.
DETERMINING ROTATION OF GEAR PUMPS, ALL MAKES:
DRIVE SHAFT IN LOWER POSITION AND BELLY OF PUMP UP:
DRIVE SHAFT IN HIGH POSITION AND BELLY OF PUMP DOWN:
2-11
IF ENGINE ROTATION IS
COUNTER CLOCKWISE AS
VIEWED FROM FRONT OF
ENGINE, USE A RIGHT
HAND PUMP.
IF ENGINE ROTATION IS
CLOCKWISE AS VIEWED
FROM FRONT OF ENGINE,
USE A LEFT HAND PUMP.
for gear pumps driven from the front of the engine
Figure 16
Figure 17