BW350 PSRU Installation Manual

Transcription

GEARED DRIVES
BW350 PSRU Installation
Manual
Version 1.0 Chevrolet V8 Engines
By Phyllis Ridings
11/1/2010
A step by step instructional manual on the proper installation of the Geared Drives PSRU for Chevrolet
V8 engines, including lubrication and maintenance recommendations.
Geared Drives Installation Manual for the
BW350 PSRU Version 1.0 for Chevy V8 Engines
Table of Contents
Getting Started--------------------------------------------------------------------------------------------------------------------3
Assemble these items before you get started-----------------------------------------------------------------------------3
Your shipment includes---------------------------------------------------------------------------------------------------------3
Step 1 – Install Bronze Bushing------------------------------------------------------------------------------------------------4
Step 2- Install Flywheel----------------------------------------------------------------------------------------------------------4
Step 3 Install the Clutch---------------------------------------------------------------------------------------------------------5
Step 4 Install the Counter Weights-------------------------------------------------------------------------------------------6
Step 5 Align and Bolt the Gearbox to the Engine--------------------------------------------------------------------------8
Step 6 Bolt the Gearbox to the Engine---------------------------------------------------------------------------------------9
Step 7 Add Lubricants ----------------------------------------------------------------------------------------------------------10
Step 8 Prime the Oil Pump----------------------------------------------------------------------------------------------------10
Step 9 Install the Hydraulic Prop Governor-------------------------------------------------------------------------------11
Step 10 Set the Prop Governor-----------------------------------------------------------------------------------------------12
Step 11 Check Oil Levels-------------------------------------------------------------------------------------------------------13
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Getting Started
The Geared Drives BW350 Propeller Speed
Reduction Unit (PSRU) is shipped with the clutch and
flywheel unit already assembled. Take note of how
the clutch assembly is bolted together as you will
need to disassemble the clutch and flywheel
assembly for installation on your engine. Do not
remove the AN bolts, washers or spacers as shown
in the photo to the right. They are already installed
with thread locker and there is no need to remove
them.
Remove the flywheel or flex plate from your engine so that the end of the crankshaft is
exposed.
Assemble the items listed below before you get started.
Loc-Tite or other thread lock liquid (medium)
Small amount of wheel bearing grease, white lithium, or other to lubricate bronze bushing
RTV to seal threads on air-oil separator for final installation
Two Quarts of 85-140 mineral type (non synthetic) limited slip gear lubricant
labeled for make up or refill, GL5 or better
Limited Slip Differential Anti Foaming Additive (any brand)
One bottle Polydyn TX-7 Manual Transmission Anti Friction Treatment (no substitutions)
Two 5/16” bolts 2” long or longer for ease of assembly
Two M10 x 1.5 x several inches long with heads removed to use for ease of assembly
Torque wrench with adapter for allen head socket cap screws
1/4” allen head adapter for torque wrench
5/16” allen head adapter for torque wrench
15 mm socket to fit crankshaft flange bolts
Your shipment includes:
Gearbox assembly with oil pump and
filtration system
Centrifugal clutch assembly
Bronze pilot bushing and installation tool
9/16” drive socket
1 – M10 x 1.5 x 30 socket head cap screw
4 – M10 x 1.5 x 50 socket head cap screw
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Step 1- Install Bronze Bushing
Using the installation tool provided, gently tap the bronze bushing into place in the end of the
crankshaft. Tap very gently until you feel the bushing just bottom out.
DO NOT TAP hard or continue to tap the bushing once you feel it bottom out as there is an
internal oil plug within the crankshaft that could be damaged. Clean off the end of the
crankshaft and polish off any burrs or rough places
Step 2 – Install Flywheel
Bolt the flywheel on the crankshaft flange with the machined pockets facing outward. Install
two bolts 180° apart and tighten just to pull the flywheel down snuggly on the end of the
crankshaft. Remove one bolt at a time, add a small amount of medium thread locker, and
screw each in just to hand tight. Continue to add the bolts with thread locker applied until they
are all installed and hand tight. Torque incrementally, using the standard alternating method,
until each bolt is torqued to 45 ft. lbs.
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Step 3 – Install the Clutch
Slip each of the six springs supplied with your clutch assembly into the six holes on the outside
edge of the flywheel as shown in the photo below. Place the assembly tool into the bushing
and slide the clutch disc onto it as a temporary way to hold the clutch disc for assembly. Orient
the disc so that the encapsulated springs are visible as shown below.
To assist in assembly, use one of the two 5/16” bolts that we mentioned on page one to draw
the pressure plate into position by placing the bolt through a hole, through a spring, and screw
it into the threaded hole on the flywheel. Repeat this at 180 ° as a way to hold the assembly
together. You will remove the two 5/16” bolts once all counterweights are installed.
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Step 4 – Install the Counter Weights
Orient the first counter weight so that the angled surface is facing outward. Place the
counterweight along the counter weight finger as shown in the photo below. The end of the
counter weight will fit underneath the washer bolted into the pressure plate as shown. Holding
the assembly together in your hand, place the base of the finger into the machined pocket
being sure to seat it flatly against the bottom of the pocket. Apply thread locker to the bolt
threads and coming in from behind the flywheel, install the bolt to secure the finger in place.
Be sure that the base of the counter weight finger is flat, square, and properly seated into the
machined pocket before you tighten the bolt. To rotate the flywheel assembly to the next
position for installation, use a large screw driver leveraged against the alignment pin on the
engine block to move the flywheel 180° and repeat the steps to install the second counter
weight assembly. With two counter weight assemblies installed the pressure plate will be
drawn into proper position and the remainder of the counter weights will be easier to install.
You may now use an adjustable wrench as you wish to make it easier to rotate the flywheel
assembly as you install the remainder of the counter weight assemblies.
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You may now remove the two temporary 5/16” bolts. Check each counter weight for proper
seating into the machined pockets and be sure that all are installed properly. Be particularly
sure to use thread locker on these bolts as you will not want these bolts to ever back out.
NOTE: If you are using a Geared Drives engine mount, you will need to dress an edge of a
casting tab on the engine in order to create clearance for the engine mounting assemblies.
We generally take around ¼” off the top corner of the casting in this area and polish it smooth.
See the photo for clarification.
There is a square casting boss with a hole in it just to the right and slightly below the area you
just ground and polished to create clearance for the mounting flanges for the PSRU. This boss
will be in the way of your starter, so now is a good time to cut or grind it off flush with the edge
of the oil pan.
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Step 5 – Align and bolt the Gearbox to the Engine
Screw the two long M10 x 1.5 studs that you made into two of the lower bell housing holes on
the engine just to hand tight. These will be used to help support the gearbox as you are mating
it to the engine. Lightly coat the end of the input shaft on the inside of the gearbox housing
with grease. Do not over lubricate as excess grease may contaminate the clutch disc.
You are now ready to mount the gearbox onto the engine. Align the end of the input shaft with
the crankshaft and the two long studs you installed to help and gently push the gear box into
place. Unless you are really lucky, the gearbox will not draw up completely and will look a lot
like the photo below on the right. Do not force it.
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To get the components to align property,
simply grasp the prop flange firmly and slowly
turn it while gently pressing against the
gearbox just until the gearbox mounting
flange pulls up flush with the engine. It is now
ready to bolt into place.
Step 6 – Bolt the Gearbox to the Engine
The first bolt to install is the M10 x 1.5 x 30 into the top bolt hole on the co-pilot side of the
engine, just underneath the oil pump. Use medium thread locker on all of the mounting bolts.
If you are using the Geared Drives engine mount, or the mounting ears from the mounting
assembly, use the four M10 x 1.5 x 50 bolts with medium thread locker applied to bolt the two
aluminum mounting blocks through the gearbox flange and into the engine block.
Tighten alternately, and torque these four bolts no more than 35 ft. lbs. Any higher than that
and there is a risk of pulling the threads out of the engine casting. See photos for clarification.
PSRU Mounting Bolts
1 - Use one M10 x 1.5 x 30 socket head cap screw on copilot side. On the pilot side no bolt hole
is supplied on LS series engines blocks. The bolt hole in the PSRU is there for use on early model
Chevrolet engines only.
2 - Two small holes on either side are alignment holes for manufacturing and are not used.
3 - Use a M10 x 1.5 x 50 socket head cap screw in each of these four places to secure the PSRU
mounting blocks through the PSRU flange and into the engine block.
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Step 7 – Add Lubricants
The only additive other than the anti-foaming agent we discuss in Step 11
that is recommended for use in Geared Drives gearbox products is Polydyn
TX-7 from Polydyn in Houston, Texas. It contains TFE Fluoropolymer Resin.
It is the only additive we have found that has particles fine enough to survive
in the filtration system. In addition it is the only additive we have ever found
that actually contributes to cooling and we have tried them all. You will only
a couple of ounces as needed to eliminate foaming up. Using more than this will only serve to
dilute the gear lube. If we are shipping overseas to you we will include this in the gearbox but
will not be shipped with gear lubricant already added.
Remove the air-oil separator on the front of the gearbox case by spinning it off of the blue AN
elbow on the front of the gearbox case. Using an extra #8 oil line, press it onto the threaded
elbow as a way to assist filling the reservoir. Attach a funnel and add the TX-7 if you choose to
use it, followed by two quarts of 85-140 Limited Slip Gear Lube, rated GL 5 or better. This
should be labeled for “make-up” or fill. This will indicate that it will have more anti-foaming
additive in it than other labels will. This will not indicate that you will not have to add more, as
there is a wide variance from brand to brand,
region to region. Carefully remove the oil filler
line and verify that you can see the oil level in the
elbow after you have added two quarts.
Once lubricants are all added, use RTV on the
threads of the air-oil separator and spin it back
onto the elbow. Add a long piece of oil line to the
barb on top of the air-oil separator and route it
down and into a catch can for any oil overflow.
In the event that the gearbox is over filled, the
excess will be expelled through the air-oil separator into the catch can.
Note: Make sure that neither the air-oil separator and overflow line ever become plugged up
for any reason, as operating the gearbox in this situation will cause the hydraulic pressure to
back up in the case and blow out the oil seals in the gearbox.
Step 8 –Prime the Oil Pump
Remove the oil filter, fill it with gear lube, lubricate the rubber seal on the top of the filter, and
spin it back on to hand tight, plus one quarter turn. Remove the plug in the top of the oil filter
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manifold and add gear lube through this hole until full. This will prime the oil pump. Replace the
plug snugly.
The oil filter we recommend for this unit is FRAM PH4967.
Step 9 – Install the Hydraulic Prop Governor
Locate the 9/16” socket supplied with your shipment and plug the drive end onto the square
drive in the prop governor port of the PSRU case. This will couple the prop governor to the
accessory drive shaft.
Be sure the prop governor pad on the PSRU is clean and smooth. Before you bolt the governor
on, test fit checking the fit without a gasket. If the prop governor will sit flush against the
surface of the governor mounting pad then the shaft lengths are correct. The prop governor
can’t handle any end thrust so if there isn’t just a little clearance it will destroy your prop
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governor. If it is tight, the easiest fix would be to simply grind or machine off just enough of the
length of the 9/16 socket to remove the tension and then reinstall.
Using the gasket supplied with your hydraulic governor, place it against the prop governor and
verify that the oil holes in the gasket line up with the oil chambers on the governor before you
use it. Your gasket will have one flat side and the other side with the screen protruding. Place
the flat side of the gasket facing the mounting pad, and the side of the gasket with the screen
protruding goes toward the prop governor. Place the governor onto the studs and check for fit.
To get the splines to align, firmly turn the prop shaft until it pops into place with no binding or
having to force it. Use nuts and washers to secure the prop governor on the studs.
Step 10 – Set the Prop Governor:
If you purchased your prop governor through Geared Drives, we will have ordered it with the
coarse adjustments already made. In this case you will only need to make fine adjustments to
set your max engine RPMs. The photo on the right illustrates the adjustment screw location
and direction of turn required to increase or decrease engine RPM max settings.
Prop settings: Push for fine pitch
Pull for coarse pitch
We recommend that you anchor the airplane to
something secure and have a pilot at the controls
and on the brakes. Start the engine and have
your pilot set the prop for fine pitch by pushing in
on the prop control cable. Carefully have the
pilot bring the engine RPM’s up and check to
determine the engine RPM the prop governor will
limit the engine to. No matter how much throttle
you add, the prop governor should not allow the engine to exceed 4000 RPM. If it does, shut
the engine down, and make the adjustments, start the engine and repeat the process until you
have determined that the prop governor will not allow the engine RPMs to exceed 4000.
You may find that fine adjustments are not enough to obtain the 4000 RPM. If not, you will
need to re-index the control arm so that its travel is longer. Do this by marking the current
position of the control arm on the shaft as a point of reference. Next, remove the control arm
and move it two splines in which ever direction is required in order for the shaft to travel
further on the same movement, and tighten it back in place. Test run again, repeating the
above processes as necessary.
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Note: Geared Drives advocates the use of a hydraulic prop governor as a way to achieve better
performance from your airplane without over revving the engine. Engine RPMs that exceed
what we have recommended stand a chance of damaging our prop. Once you have become
experienced with this system and feel confident you may choose to adjust your prop governor
for additional engine RPM, but we never recommend exceeding 4300. UNDER NO
CIRCUMSTANCES EVER EXCEED 4300 ENGINE RPM. IF YOU DO SO IT WILL BE AT YOUR OWN
RISK.
Step 11 – Check Oil Levels:
Check the lubricant level in the gearbox after you have completed prop governor adjustments.
You may find that the gear lube level might need to be topped off due to the prop hub
requirements.
It is important to be sure that the gear lube in the gearbox does not foam up since the air in the
gear lube will prohibit the proper operation of the prop governor, will not allow proper
lubrication of the components, and could possibly damage the PSRU, prop, or prop governor.
To avoid this, visibly check the appearance of the gear lube after first run up. If
it gear lube appears grayish or milky, add a couple more ounces of the anti
foaming additive, test run again and visibly check the appearance of the gear
lube again. Continue to add anti foaming additive an ounce or two at a time
just until the fluid runs clear to achieve proper lubrication. The photo to the
right is just a sample of one of the brands we have used. Any brand available to
you will do. Most will be labeled “limited slip gear oil additive” and mention
that it helps eliminate “slipping, chattering and jerking”.
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BW350 PSRU Installation Manual

Transcription

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