0

John Crane-Lips
Marine Propulsion Systems

MANUAL
Transverse Thruster, Mechanical
Type: FT300

GENERAL

Lips order number(s) B02363

Shipyard

Newbuilding number(s) W/D "FAIRWAY"

Owner Baggermaatschappij Boskalis

Type of ship Trailing Suction Hopper Dredger

DOCUMENT HISTORY

Revision Date Comment

John Crane-Lips
Marine Propulsion Systems

Phone : +31 416 388424

Fax :+31416379140

eMail : [email protected]

http : //www.lips-propulsion.com

John Crane-Lips

Marine Propulsion Systems

P.O. Box 6

5150 BB Drunen

The Netherlands
 BTF-AILI PS-OO
John Crane-Lips
Marine Propulsion Systems

Contents

Table of Contents Page

Chapter 00 Front Matter

Transverse Thruster System - Introduction BTF-A-OO-OO-OO-OOA-OO 1 A-A
Transverse Thruster System - Warnings and Cautions BTF-A-OO-OO-OO-OOA-01 2A-A
Transverse Thruster System - Symbols BTF-A-01 -OO-OO-OOA-01 3A-B
Transverse Thruster System - Abbreviations BTF-A-01 -OO-OO-OOA-01 4A-B
Transverse Thruster System - Classification/Technical Data BTF-A-O 1 -OO-OO-OOA-030A-C

Chapter 01 General
Transverse Thruster System - Description BTF-A-O 1 -OO-OO-OOA-O 11 A-A
Transverse Thruster System - Component Location BTF-A-01-OO-OO-OOA-055A-A
Procedures, General - Scheduled Inspections BTF-A-O 1 -OO-OO-OOA-28 1 A-B
Procedures, General - Removal Procedures BTF-A-01-OO-OO-OOA-520A-B
Procedures, General - Disassembly Procedures BTF-A-O 1 -OO-OO-OOA-530A-C
Procedures, General - Assembly Procedures BTF-A-O 1 -OO-OO-OOA-7 1 OA-C
Procedures, General - Installation Procedures BTF-A-O 1 -OO-OO-OOA-720A-B
Procedures, General - Change Procedures BTF-A-O 1 -OO-OO-OOA-921 A-B

Chapter 02 Propulsion System

Propulsion System - Description BTF-A-02-OO-OO-OOA-01 lA-A
Propeller - Removal BTF-A-02-1 O-OO-OOA-520A-B
Propeller - Installation BTF-A-02-1 O-OO-OOA-720A-B

Chapter 03 Transmission System

Transmission System - Description BTF-A-03-OO-OO-OOA-O 11 A-A
Gear System - Description BTF-A-03-1 O-OO-OOA-042A-C
Lower Gearbox - Description BTF-A-03-20-OO-OOA-042A-C
Lower Gearbox, Gearset - Adjustment/Test BTF-A-03-20-OO-OOA-27 lA-C
Lower Gearbox - Removal BTF-A-03-20-OO-OOA-520A-B
Lower Gearbox - Disassembly BTF-A-03-20-OO-OOA-530A-C
Lower Gearbox - Assembly BTF-A-03-20-OO-OOA-7 1 OA-C
Lower Gearbox - Installation BTF-A-03-20-OO-OOA-720A-B
Lower Gearbox, Propeller Shaft - Disassembly BTF-A-03-21 -OO-OOA-530A-C
Lower Gearbox, Propeller Shaft - Assembly BTF-A-03-21 -OO-OOA-71 OA-C
Lower Gearbox, Input Shaft - Disassembly BTF-A-03-22-OO-OOA-530A-C
Lower Gearbox, Input Shaft - Assembly BTF-A-03-22-OO-OOA-7 1 OA-C

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Lower Gearbox, Propeller Shaft SèaI, Oil 'Seals - Change BTF-A-O3-23-OO-OÖA-9iA-C

Flexible Shaft Coupling - Removal BTF-A-03-60-OO-OOA-520A-B
Flexible Shaft Coupling - Installation BTF-A-03-60-OO-OOA-720A-B

Chapter 04 Pitch Control System (Not Applicable)

Chapter 05 Structure
Structure - Description BTF-A-05-OO-OO-OOA-O 11 A-A
Outer Rope Guard Assembly - Removal BTF-A-05-1O-OO-OOA-520A-B
Outer Rope Guard Assembly - Installation BTF-A-05-1O-OO-OOA-720A-B
Tunnel Assembly - Removal BTF-A-05-20-OO-OOA-520A-B
Tunnel Assembly - Installation BTF-A-05-20-OO-OOA-720A-B
Sacrificial Anodes - Change BTF-A-05-21-OO-OOA-921A-B

Chapter 06 Steering System (Not Applicable)

Chapter 07 Hydraulic Power System (Not Applicable)

Chapter 08 Lubrication System

Lubrication System - Description BTF-A-08-OO-OO-OOA-O 11 A-A
Lubrication System - Filling BTF-A-08-OO-OO-OOA-2 1 2A-B
Lubrication System - Draining BTF-A-08-OO-OO-OOA-222A-B
Lubrication System - Flushing BTF-A-08-OO-OO-OOA-230A-B
Oil-Pressure Filter-Cartridge - Change BTF-A-08-2 I -OO-OOA-92 lA-A

Chapter 09 Auxiliary Systems

Auxiliary Systems - Description BTF-A-09-OO-OO-OOA-01 lA-A
Auxiliary Systems, Shaft Brake - Description BTF-A-09-1 O-OO-OOA-Ol 1 A-A
Auxiliary Systems, Shaft Brake, Pads - Change BTF-A-09-1 1 -OO-OOA-921 A-B

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Transverse Thruster System - Introduction

References
Table 1 References

Data Module! Technical Publication Title

BTF-A-OO-OO-OO-OOA-033A-A Table of Contents

BTF-A-OO-OO-OO-OOA-OO1 A-A Introduction
BTF-A-OO-OO-OO-OOA-01 2A-A General Warnings and Cautions
BTF-A-OO-OO-OO-OOA-01 3A-A List of Symbols
BTF-A-OO-OO-OO-OOA-01 4A-A List of Abbreviations
BTF-A-OO-OO-OO-OOA-030A-A Classification and Technical
Data

Description
Purpose
The Maintenance Manual gives the information necessary to maintain and service the mechanical
parts of your Transverse Thruster System. It also gives the technical information on the systems
the Transverse Thruster requires for normal operation.

2 Structure
The Maintenance Manual consists of these parts:
- the front matter;
- the technical content.
The two parts contain data modules. Each data module has a Data Module Code (DMC), which
lets you identify its content (Ref. Para 2.3).

2.1 Front Matter

The front matter contains these data modules:
- Table of Contents (Ref. BTF-A-OO-OO-OO-OOA-000A-A).
Introduction (Ref. BTF-A-OO-OO-OO-OOA-OO 1 A-A);
- General Warnings and Cautions (Ref. BTF-A-OO-OO-OO-OOA-012A-A);
- List of Symbols (Ref. BTF-A-OO-OO-OO-OOA-01 3A-A);
- List of Abbreviations (Ref. BTF-A-OO-OO-OO-OOA-O 1 4A-A);
- Classification and Technical Data (Ref. BTF-A-OO-OO-OO-OOA-030A-A);

2.2 Technical Content

The technical content divides into a number of chapters and the appendix. Each chapter contains
data modules that have a relation with the systems and the sub-systems of the Transverse
Thruster System. The Appendix contains the information and the drawings used during the
manufacturing process.

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Transverse Thruster System - Introduction

References
Table 1 References

Data Module! Technical Publication Title

BTF-A-OO-OO-OO-OOA-OO1 A-A Introduction

BTF-A-OO-OO-OO-OOA-01 2A-A General Warnings and Cautions
BTF-A-OO-OO-OO-OOA-01 3A-A List of Symbols
BTF-A-OO-OO-OO-OOA-01 4A-A List of Abbreviations
BTF-A-OO-OO-OO-OOA-030A-A Classification and Technical
Data
BTF-A-OO-OO-OO-OOA-033A-A Table of Contents

Description
1 Purpose
The Maintenance Manual gives the information necessary to maintain and service the mechanical
parts of your Transverse Thruster System. It also gives the technical information on the systems
the Transverse Thruster requires for normal operation.

2 Structure
The Maintenance Manual consists of these parts:
- the front matter;
- the technical content.
The two parts contain data modules. Each data module has a Data Module Code (DMC), which
lets you identify its content (Ref. Para 2.3).

Front Matter
The front matter contains these data modules:
- Introduction (Ref. BTF-A-OO-OO-OO-OOA-OO1A-A);
- General Warnings and Cautions (Ref. BTF-A-OO-OO-OO-OOA-012A-A);
- List of Symbols (Ref. BTF-A-OO-OO-OO-OOA-01 3A-A);
- List of Abbreviations (Ref. BTF-A-OO-OO-OO-OOA-01 4A-A);
- Classification and Technical Data (Ref. BTF-A-OO-OO-OO-OOA-030A-A);
- Table of Contents (Ref. BTF-A-OO-OO-OO-OOA-033A-A).

2.2 Technical Content

The technical content divides into a number of chapters and the appendix. Each chapter contains
data modules that have a relation with the systems and the sub-systems of the Transverse
Thruster System. The Appendix contains the information and the drawings used during the
manufacturing process.

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These chapters make up the technical content:

- Chapter 01 General;
- Chapter 02 Propulsion System;
- Chapter 03 Transmission System;
- Chapter 05 Structure;
- Chapter 08 Lubrication System;
- Chapter 09 Auxiliary System(s).

2.3 Data Module Code

The Data Module Code (DMC) gives an indication of the position of the data module within the
contents of the manual. You will find the DMC in the right-hand corner of each page. The DMC
contains this information:
the code for the product group;
- the code for the variant of the product group;
- the number of the chapter or the system;
- the number of the section or the sub-system;
- the subject or the title of the data module;
the codes for the level of disassembly and the variant;
the code for the type of information and the variant the data module contains;
the code for the location of the component or the assembly part to which the data module
applies.
For example, in this manual the DMC "BTF-A-03-20-0O-OOA-720A-B" gives this information:
- BTF Transverse Thruster;
-A Fixed Pitch Propeller;
- 03 Chapter 03 (Transmission System);
- 20 Section 20 (Lower Gearbox);
- 00 Subject 00 (Installation of the Lower Gearbox);
- OOA Not applicable to this data module;
- 720A Installation procedure for the Lower Gearbox;
-B the ship is in dry dock.
The location code defines the location of the component or assembly part before you start the
procedure. This manual contains data modules with these location codes:
-A the ship is afloat;
-B the ship is in dry dock;
-C the component or the assembly part is in the workshop.

3 How to Use the Manaul

Do these steps to use the manual:
1 Look at the Table of Contents (TOC) for the manual (Ref. BTF-A-00-00-00-OOA-033A-A).
2 Select the chapter you require from the TOC.
3 Go to the TOC fôr the chapter.
4 Select the data module you require from the TOC.
For an overview of the contents of each chapter, refer to Para 3.2.

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3.1 Maintenance
This manual contains the technical information to let you do the maintenance on the Transverse
Thruster System. Go to the data module that contains the procedure you require. Follow the steps
to remove/install or change component of the Transverse Thruster System.

3.2 Chapter Contents

Chapter 1 contains these data modules:
- the description of the Transverse Thruster System;
- the component location for the Transverse Thruster System;
- the lists of procedures for the Transverse Thruster System
Chapter 2 contains the data modules that relate to the Propulsion System.
Chapter 3 contains the data modules that relate to the Transmission System.
Chapter 4 is not applicable to the Transverse Thruster System.
Chapter 5 contains the data modules that relate to the Structure.
Chapter 6 is not applicable to the Transverse Thruster System.
Chapter 7 is not applicable to the Transverse Thruster System.
Chapter 8 contains the data modules that relate to the Lubrication System.
Chapter 9 contains the data modules that relate to the Auxiliary System(s). The Transverse
Thruster System has the Shaft Brake System only.

4 Service Contact Information

If you have a query on the function or repair of theTransverse Thruster System, please give this
information:
- the LIPS order number (See title page of the manual);
- the Lloyds registration number.
Make a report of your query. Give these details:
- the symptom(s) of the malfunction:
- how it occurred;
- when it occurred.
Send the report to the Service Department at this address:
LIPS B.V.
PROPELLER WORKS
P.O. BOX 6
5150 BB DRUNEN
THE NETHERLANDS
Phone:+31 416 388115
Fax:+31 416379140
E-mail:info @ lips-propulsion.nl
Website:www.johncrane-lips.com
If you speak to the Service Department by telephone, please confirm your conversation by letter
or fax.

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4.1 How to Order Spare Parts

John Crane-Lips issues a cross-reference list of all the components supplied under the terms of
the order contract. The cross-reference list lets you find the parts you require. It gives a numerical
list of the article numbers with the cross-reference to these lists:
- the assembly drawing number;
- the parts list numbers;
- the item numbers.
When you order spare parts you must give this information:
- the LIPS order number (See title page of the manual);
the title of the assembly drawing;
the list number;
the drawing number;
the item number of the part you require;
the name of the part you require;
- the article number;
- the quantity of the part you require.
Please confirm your order in writing with the official order number and the customer VAT number.

5 Disclaimer
5.1 Liability
JC-L does not accept any liability for defects due to or connected with: (i) any materials or
components or design provided by or on behalf of the Customer, (ii) the negligence or other
improper act or omissions of the Customer, its employees or agents or other third parties, (iii)
improper installation and alterations carried out without JC-L's consent in writing. In particular, any
defects that are caused or connected with normal wear and tear, the use of unsuitable materials
or which are caused by any use, maintenance, service or operation of the Equipment or any part
thereof which 's not in conformity with JC-L's manuals, instructions, or Technical Specifications or
which is otherwise not in accordance with good engineering practice.
JC-L's liability, both contractual and non-contractual, is strictly limited to performing the warranty
obligations.
JC-L's liability is explicitly excluded with respect to any economic loss and consequential damage,
including -but not limited to- environmental pollution, docking costs and mounting and demounting
costs.
JC-L's liability shall in no event exceed the lesser of (1) the amount of the Price, calculated at an
average use of manpower and facilities, and (2) the amount which is paid out under JC-L's liability
policy in the matter concerned.

5.2 Copyright
All rights reserved. Nothing from this publication may be reproduced, or transmitted in any form
or by any means, electronic or mechanical, including photocopying, recording or any information
storage or retrieval system without prior written approval of John Crane-Lips.
Also for using one or more parts of this publication in papers, readers and other collected works,
you should contact John Crane-Lips, P.O. Box 6, 5150 BB Drunen, the Netherlands.

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Warnings and Cautions - General

References
Table 1 References

Data Module! Technical Publication Title

None

Description
Introduction
This data module lists all the warnings and cautions found throughout the complete set of data
modules for the Transverse Thruster System. All the warnings relate to the general safety of
maintenance personnel. All the cautions relate to the general safety of the components within the
Transverse Thruster System.

2 Warnings
WARNINGS
DO NOT COMPLETELY REMOVE THE SCREWS THAT FASTEN THE ADJUSTING
PLATE TO THE PROPELLER SHAFT. THE PROPELLER COULD SPRING OFF AND
CAUSE INJURY OR LOSS OF LIFE DUE TO THE TENSION BETWEEN THE
PROPELLER AND THE PROPELLER SHAFT.
TAKE CARE WHEN YOU WORK NEAR EQUIPMENT WITH COMPONENTS THAT
ROTATE. CARRY OUT FREQUENT CHECKS ON THE EQUIPMENT FOR POSSIBLE
DANGEROUS CONDITIONS TO PREVENT INJURY OR LOSS OF LIFE.
ALWAYS WEAR PROTECTIVE CLOTHING AND GLASSES WHEN YOU WORK ON
EQUIPMENT.
ALWAYS USE APPROVED LIFTING POINTS AND CERTIFIED LIFTING
EQUIPMENT. MAKE SURE EQUIPMENT CANNOT TILT OR MOVE DURING
LIFTING.
MAKE SURE THAT WHEN YOU USE LIFTING EQUIPMENT THE FOLLOWING
APPLIES:
- SUFFICIENT SPACE EXISTS FOR THE EQUIPMENT TO MOVE IN.
- PERSONNEL ARE IN SAFE POSITIONS.
MAKE SURE THAT WHEN YOU WORK ON EQUIPMENT, YOU DO THE
FOLLOWING:
- PUT UP WARNING SIGNS.
- SHUT OFF DRIVE MOTORS AND ALL PUMPS.
- DISCONNECT THE ELECTRICAL POWER SUPPLY.
- CLOSE ALL RELEVANT VALVES.
MAKE SURE THAT YOU DISENGAGE THE DRIVE MOTOR BEFORE YOU
PROCEED. THIS PREVENTS IT FROM BEING STARTED ACCIDENTALLY.

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MAKE SURE THAT BEFORE YOU START THE PRIME MOVER NO ONE IS
WORKING ON THE EQUIPMENT.
DO NOT START THE PRIME MOVER OR OPERATE EQUIPMENT WHEN YOU SEE
A WARNING SIGN.
INSTALL PROTECTIVE GUARDS, WHERE NECESSARY, TO PREVENT OIL LEAKS
WHEN THE EQUIPMENT BECOMES PRESSURISED.
MAKE SURE THAT YOU INSTALL ALL PROTECTIVE GUARDS AND COVERS IN
THE CORRECT MANNER.
MAKE SURE THAT WHEN YOU WORK ON THE REMOTE CONTROL SYSTEM, YOU
DO THE FOLLOWING:
- DISCONNECT THE MAINS AND THE BACK-UP POWER SUPPLIES.
- PUT UP WARNING SIGNS.
DISCONNECT INTERFACE CIRCUITS FROM THE POWER SUPPLIES BEFORE
YOU START WORK ON THE EQUIPMENT.
MAKE SURE THAT WHEN YOU CONNECT WELDING EQUIPMENT YOU ALWAYS
USE AN EARTH CONNECTION. CONNECT THE EARTH CONNECTION AS CLOSE
AS POSSIBLE TO THE WELD POINT TO PREVENT INJURY OR DAMAGE TO
EQUIPMENT.
MAKE SURE THAT YOU SECURE THE HUB AND PROPELLER SHAFT DURING
THE LAUNCHING AND OUTFITTING PERIOD TO PREVENT ANY FREE
MOVEMENT.
TAKE CARE THAT YOU SELECT A FASTENER OF THE CORRECT STANDARD. IF
YOU ATTEMPT TO USE A FASTENER OF ANOTHER STANDARD, IT COULD
CAUSE EQUIPMENT TO MALFUNCTION AND RESULT IN INJURY TO
PERSONNEL.
TAKE CARE WHEN YOU WORK NEAR EQUIPMENT WITH PRESSURIZED OIL.
CARRY OUT FREQUENT CHECKS ON THE EQUIPMENT FOR POSSIBLE
DANGEROUS CONDITIONS TO PREVENT INJURY OR LOSS OF LIFE.
TAKE CARE WHEN YOU REMOVE A PROPELLER. WHEN YOU USE A HIGH
PRESSURE OIL PUMP IT CAN CAUSE THE PROPELLER TO SPRING OFF THE
PROPELLER SHAFT AND CAUSE INJURY OR LOSS OF LIFE.
DO NOT OPERATE THE TRANSVERSE THRUSTER FOR LONG PERIODS S
WITHOUT RUNNING THE LUBRICATION-OIL CIRCULATION-PUMP. THIS CAN
REDUCE THE LIFE EXPECTANCY OF THE BEARINGS IN THE LOWER GEARBOX.

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S
3 Cautions

DO NOT ATTACH LIFTING EQUIPMENT TO MACHINED SURFACES, SHAFT ENDS,

PIPING WORK OR OTHER EXTERNALLY MOUNTED EQUIPMENT.
MAKE SURE THAT WHEN USING LIFTING EQUIPMENT YOU ALWAYS USE
SHACKLES OR SLINGS TO ATTACH TO KNOWN AND APPROVED LIFTING POINTS
AS INDICATED ON (TRANSPORT) DRAWINGS.
MAKE SURE YOU MEET THE MANDATORY REQUIREMENTS BEFORE YOU DO
THE THRUSTER ALIGNMENT, AS FOLLOWS:
- ENSURE THE VESSEL IS AFLOAT AND NOT IN CONTACT WITH THE SEA BED.
- ENSURE THE PROPELLER IS BELOW THE WATER LINE.
- ENSURE THE ASSEMBLY OF THE HULL STRUCTURE IS COMPLETE.
- ENSURE ALL THE MACHINERY IN THE VESSEL.
MAKE SURE THAT YOU DRAIN SYSTEM OIL OR FLUID BEFORE EQUIPMENT
DISASSEMBLY.
MAKE SURE THE CATCH TANK(S) YOU USE TO DRAIN OIL OR FLUID FROM
EQUIPMENT ARE LARGE ENOUGH TO CONTAIN THE OIL OR FLUID. IF YOU SPILL
OIL OR FLUID DURING A REMOVAL OR INSTALLATION PROCEDURE, ALWAYS
COLLECT AND REMOVE THE OIL OR FLUID.
MAKE SURE THAT YOU USE CLEAN TEMPORARY PIPES AND COUPLINGS. DIRT
OR FOREIGN MATERIALS CAN CONTAMINATE THE OIL OR FLUID IN THE
LUBRICATION OR CIRCULATION SYSTEMS. THIS CAN CAUSE DAMAGE TO
EQUIPMENT.
MAKE SURE THAT NO DIRT OR FOREIGN MATERIALS CONTAMINATES THE OIL
OR FLUID IN THE HYDRAULIC OR CIRCULATION SYSTEMS. THIS CAN CAUSE
DAMAGE TO EQUIPMENT.
DO NOT USE ALKALINE CHEMICAL CLEANERS. THEY CAN CAUSE MATERIAL
DAMAGE TO SYNTHETIC PARTS.
DO NOT USE CHEMICAL DETERGENTS TO CLEAN RUBBER OR SYNTHETIC
PARTS. WIPE WITH A DRY CLOTH ONLY.
MAKE SURE THAT BEFORE YOU RUN PRESSURE PUMPS OF A HYDRAULIC
SYSTEM INSTALLED IN PARALLEL, THE DESIGN ALLOWS THE PUMPS TO RUN
AT THE SAME TIME. IF NOT, THIS CAN CAUSE SERIOUS DAMAGE TO
EQUIPMENT.
DO NOT USE CONTROL PANELS OR ELECTRICAL CABINETS FOR AN EARTH
CONNECTION POINT WHEN WELDING, AS THIS CAN CAUSE DAMAGE TO
ELECTRICAL COMPONENTS.
ALWAYS DISCONNECT THE MAINS AND BACK UP POWER SUPPLY FROM
ELECTRICAL CABINETS OR COMPONENTS CLOSE TO A WELDING AREA.
ELECTRIC WELDING CREATES POWER SPIKES WHICH CAN DAMAGE
ELECTROSTATIC SENSITIVE DEVICES.
ALWAYS PROTECT THE SURROUNDING AREA FROM WELDING SPLATTER
WHEN WELDING.

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ALWAYS DO THE FOLLOWING DURING REMOVAL AND INSTALLATION

PROCEDURES:
- DISCONNECT THE MAINS AND BACK UP POWER SUPPLIES.
- SWITCH OFF ALL CIRCUIT BREAKERS.
ALWAYS CONNECT THE SCREEN OF SCREENED CABLES ON THE SIDE OF THE
CABINET AND NEVER ON A PANEL OR THE SIDE OF A COMPONENT.
MAKE SURE YOU DO NOT WELD THE HOISTING EYES TO THE STAINLESS STEEL
RING.
BE CAREFUL WHEN YOU USE A PIPE-WRENCH. MAKE SURE THAT YOU DO NOT
CAUSE DAMAGE TO THE TOP PART OF THE SUCTION-LINE.
DO NOT LIFT THE LOWER GEARBOX FROM THE INPUT SHAFT. THE THREADED
HOLE FOR THE HOISTING EYE-BOLT WILL NOT TAKE THE WEIGHT OF THE
LOWER GEARBOX.
KEEP THE TUNNEL AS COOL AS POSSIBLE TO PREVENT DAMAGE WHEN
WELDING.

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Transverse Thruster System - Symbols

References
Table 1 References

Data Module! Technical Publication Title

None

Description
1 General
The table below contains the symbols from the schematics of the Transverse Thruster System.
The adjacent columns give the term and the functional description of the symbol.

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Table 2 Symbol Descriptions

Symbol Term Function Symbol Term Function

AB Filler/Breather NRV Non-Return Valve

0
DS Dip Stick SOV Shut-off Valve
(NO) (Normally Open)
2 3

EM Electric Motor SOV Shut-off Valve

(NC) (Normally Closed)
2 3

LLS Low Level Switch SOV Shut-off Valve (2 way)

23
P Pump Flow Restrictor

PF Pressure Filter Variable Flow

Restrictor

PG Pressure Gauge DCV Directional Control

Valve 3/2
'v/It .

W Temperature Gauge PRS Pressure Switch

ED
PSV Pressure Safety PC Pressure Cylinder
Valve

- lyli

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S
Transverse Thruster System - Abbreviations

References
Table 1 References

Data Module! Technical Publication Title

None

Description

1 General
The table below contains a description of all the abbreviations you will find in the documentation

4 of the Transverse Thruster System.

Table 2 Abbreviation Descriptions

Abbreviation Name
3WVEL Pressure Control Valve, 3 way
AIR As required
AB Filler/Breather
DS Dip Stick
EM Electric Motor
LLS Low Level Switch
P Pump
PC Pressure Cylinder
PF Pressure Filter
PG Pressure Gauge
PRS Pressure Switch
PSV Pressure Safety Valve
SOV Shut-off Valve
TNRV Throttle/Non-return Valve

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Classification and Technical Data - General

References
Table 1 References

Data Module/Technical Publication Title

Classification Data Sheet

Description
1 General
The classification and technical data contains the general and technical information that applies
to the Transverse Thruster System.

1.1 Classification Data

LIPS records the classification data on the classification data sheet, refer to the Appendix. The
information includes:
- thedateof issue;
- the order number;
- the class bureau;
- the class notation;
- the area of operation;
- the name and the address of the vessel owner;
- the vessel details;
- the shipyard;
- the thruster details;
- the prime mover details.

1.2 Technical Data

The technical data gives the specifications of the Transverse Thruster System.

Table 2 Transverse Thruster Type FT300

Part Description Specification
Transverse Thruster without Mass (kg) 30000
Propeller Drive Motor

Tunnel Inside diameter (mm) 2895

Length (mm) 2581
Wall thickness (mm) 30
Mass (kg) 18000

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Part Description Specification

Cover Mass (kg) 3150

Propeller Diameter (mm) 2850

Speed (rpm) 223
Blades 4
Material Cunial
Mass (kg) 2180

Lower Gearbox Housing material GS2OMn5

Gear reatio 750:223
Gear module 15.5
Mass without propeller (kg) 8300

Lubrication Oil System Pump capacity (litre/mm) 10

Operating pressure (bar) 0.5

Power (kW) 0.4
Pump speed (rpm) 1800
Supply voltage (V) 440
Frequency (Hz) 60

Propeller Drive Motor Manufacturer HMA

Type WK238VB-08
Speed (rpm) 750
Power (kW) 2650
Mass (kg) 12000

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Chapter 1 - General
Table of Contents Page

Title Data Module No.

Procedures, General - Description BTF-A-01 -OO-OO-OOA-01 1 A-A

Procedures, General - Component Location BTF-A-01 -OO-OO-OOA-055A-A
Procedures, General - Scheduled Inspections BTF-A-01 -OO-OO-OOA-281 A-B
Procedures, General - Removal Procedures BTF-A-01 -OO-OO-OOA-520A-B
Procedures, General - Disassembly Procedures BTF-A-01 -OO-OO-OOA-530A-C
Procedures, General - Assembly Procedures BTF-A-01 -OO-OO-OOA-71 OA-C
Procedures, General - Installation Procedures BTF-A-01 -OO-OO-OOA-720A-B
Procedures, General - Change Procedures BTF-A-01 -OO-OO-OOA-921 A-B

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 BTF-AJLI PS-01
John Crane-Lips
Marine Propulsion Sys ferns

Transverse Thruster System - Description

References
Table I References

Data Module! Technical Publication Title

BTF-A-02-OO-OO-OOA-01 1 A-A Description of the Propulsion

System
BTF-A-03-OO-OO-OOA-01 1 A-A Description of the Transmission
System
BTF-A-05-OO-OO-OOA-01 1 A-A Description of the Structure
BTF-A-08-OO-OO-OOA-01 1 A-A Description of the Lubrication
System
BTF-A-09-OO-OO-OOA-01 1 A-A Description of the Auxiliary
System(s)

Description
I General
The transverse thruster system provides the vessel with the force necessary to give the ship side-
movement.

Physical Description
Refer to Fig 1

The transverse thruster system fits into the support structure in the hull of the vessel. The tunnel
assembly forms the platform for the primary components of the installation.
For a new installation, the yard aligns and welds the alignment frame to the support structure of
the vessel. Then the yard lowers the tunnel assembly onto the alignment frame via the access
shaft. The mounting flange of the tunnel assembly fastens to the alignment frame with bolts.
The yard welds two thrust blocks, made from stainless steel, at the bottom of the tunnel. The thrust
blocks have these functions:
- prevent movement of the tunnel from side to side during normal operation;
- transmit the thrust to the vessel.
The vessel can remain afloat when it becomes necessary to carry out maintenance on the thruster
system. You trim the vessel so that the level of the water remains below the height of the
alignment frame. You can remove the tunnel assembly via the access shaft.

2.1 Sub-Systems
The transverse thruster system has these sub-systems:
the propulsion system (Ref. BTF-A-02-OO-OO-OOA-01 lA-A);
the transmission system (Ref. BTF-A-03-OO-OO-OOA-01 lA-A);
- the structure (Ref. BTF-A-05-OO-OO-OOA-01 lA-A);
the lubrication system (Ref. BTF-A-08-OO-OO-OOA-01 lA-A);
- the auxiliary systems (shaft brake) (Ref. BTF-A-09-OO-OO-OOA-01 lA-A).

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2.1.1
Marine Propulsion Systems

Propulsion
I
The propulsion system comprises the propeller.
The propeller fits on the propeller shaft, which gives a taper interference fit.

2.1.2 Transmission
The transmission system comprises;
- The torque-protection device;
- The flexible-shaft coupling;
- The lower gearbox.
The torque-protection device connects the shaft of the propeller drive motor to the flexible-shaft
coupling.
The flexible-shaft coupling connects the torque-protection device to the input shaft of the lower
gearbox.
Bolts fasten the pod of the lower gearbox assembly to the tunnel assembly.

2.1.3 Structure
The structure comprises:
- The outer rope guard assembly;
- The tunnel assembly.
The outer rope guard assembly fastens to the rear of the the propeller hub with bolts. The outer
rope guard assembly prevents rope or debris from fouling the propeller shaft.
The tunnel assembly fits into the bow of the vessel and fastens to the structure with bolts. The
tunnel assembly lets you remove the transverse thruster with the ship still afloat.

2.1.4 Lubrication
The lubrication system comprises:
- The headertank;
- The lubrication-pump set.
The header tank contains the lubrication oil for the lubrication system. The mounting platform in
the hull holds the header tank above the waterline of the vessel.
The yard installs the lubrication-pump set on the structure of the ship near the upper part of the
tunnel assembly. The lubrication-pump set comprises:
- the lubrication-oil circulation pump;
- the lubrication-oil pressure gauge;
the thermometer;
the oil-pressure filter;
- the electric motor;
- the shut-off valves.

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Marine Propulsion Systems

Fig 1 Transverse Thruster System - Installation Diagram

BTF00000000AO11M1

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Marine Propulsion Systems

2.1.5 Auxiliary
The auxiliary systems include the systems that are optional to the transverse thruster system. The
shaft brake system comprises:
- the brake control panel;
- the disk-brake caliper.
The yard installs the brake control panel near to the tunnel assembly.

3 Functional Description
3.1 Transmission
The transmission system transmits the drive from the propeller drive motor to the propeller. The
drive shaft of the propeller drive motor connects to the following components:
- The torque protection device;
- The flexible shaft coupling;
- The input and propeller shafts of the lower gearbox;
- The propeller.

3.2 Propulsion
As soon as the propeller starts to rotate the water starts to flow in the tunnel. The difference in the
pressure between the upstream and the downstream sides of the propeller cause the thrust-force
to develop. The thrust-force causes the vessel to move sideways through the water.
The water that flows in and out of the tunnel meets the water that passes the vessel.This creates
fields of pressure around the bow of the vessel, which increases the thrust-force.

3.3 Lubrication
The lubrication system provides a constant supply of lubrication oil to the lower gearbox.
The lubrication oil floods the lower gearbox. The height of the header tank maintains the oil at a
constant pressure.
When the lubrication oil pump gets electrical power, it causes the oil to circulate. The lubrication
oil passes through the pressure filter, which removes contamination.

3.4 Auxiliary
The shaft brake system prevents the propeller from turning when the thruster is not in operation.

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I
Marine Propulsion Systems

Transverse Thruster System - Component Location

References
Table 1 References

Data Module! Technical Publication Title

BTF-A-02-OO-OO-OOA-01 1 A-A Description of the Propulsion

System
BTF-A-03-OO-OO-OOA-01 1 A-A Description of the Transmission
System
BTF-A-05-OO-OO-OOA-01 1 A-A Description of the Structure
BTF-A-08-OO-OO-OOA-01 1 A-A Description of the Lubrication
System
BTF-A-09-OO-OO-OOA-01 1 A-A Description of the Auxiliary
System(s)

Description
1 General
The component location gives the location of the major parts within the Transverse Thruster
System.

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S
Fig. Component Remarks
Item
1 Access Shaft Yard supply.
2 Propeller Drive Motor Yard supply.
3 Alignment Frame See Structure (BTF-A-05-00-00-OOA-01 1 A-A).
4 Tunnel Assembly See Structure (BTF-A-05-00-00-OOA-01 1 A-A).
5 Torque Protection See Transmission System (Ref. BTF-A-03-00-00-OOA-01 1 A-A)
Device
6 Flexible-Shaft Coupling See Transmission System (Ref.BTF-A-03-00-00-OOA-01 1 A-A)
7 Oil Pipe See Lubrication System (Ref.BTF-A-08-00-00-OOA-01 1 A-A)
8 Lower Gearbox See Transmission System (Ref.BTF-A-03-00-00-OOA-01 lA-A)
9 Outer Rope Guard See Structure (BTF-A-05-00-00-OOA-01 1 A-A).
Assembly
10 Propeller See Propulsion System (Ref. BTF-A-02-00-00-OOA-01 1 A-A)
11 Thruster Blocks See Structure (BTF-A-05-00-00-OOA-01 1 A-A).
12 Disc-Brake See Auxiliary Systems (Ref.BTF-A-009-00-00-OOA-01 lA-A)
13 Sacrificial Anodes See Structure (BTF-A-05-00-00-OOA-01 1 A-A).

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Marine Propulsion Systems

Fig 1 Transverse Thruster FT 300

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Marine Propulsion Systems

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 BTF-A/LI PS-01
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Marine Propulsion Systems

Procedures, General - Inspections

References
Table 1 References

Data Module! Technical Publication Title

BTF-A-03-20-OO-OOA-271 A-C Adjustment/Test of the Lower

Gearbox
BTF-A-05-21 -OO-OOA-921 A-B Change sacrificial anode
BTF-A-08-OO-OO-OOA-21 2A-A Lubrication oil filling
BTF-A-08-OO-OO-OOA-222A-A Lubrication oil draining
BTF-A-08-OO-OO-OOA-230A-A Lubrication oil flushing
BTF-A-08-21 -OO-OOA-271 A-B Change oil-pressure filter-
cartridge

Preliminary Requirements

Required Conditions
Table 2 Required Conditions

Condition Data Module

None

Required Persons
Table 3 Required Persons

Number of Persons Category

2 Mech

Support Equipment
Table 4 Support Equipment

Nomenclature Identification No. Qty

None

Consumables, Materials and Expendables

Table 5 Supplies

Nomenclature Identification No. Qty

None

Note
Obey the safety conditions given in the removal procedure.

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 BTF-NLI PS-01
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Marine Propulsion Systems

Procedure
Do these steps each day:

1 .1 Do a check for the level of lubrication oil in the header tank regularly. Fill the header tank,
if necessary (Ref. BTF-A-08-OO-OO-OOA-21 2A-A).

1.2 Do a check for the signs of contamination in bowl of the oil-pressure filter-cartridge.
Change the oil-pressure filter-cartridge, if necessary (Ref. BTF-A-08-21 -OO-OOA-271 A-
B).

1 .3 Do a check for the signs of contamination in a sample of the lubriation oil.

1.3.1 Change the oil-pressure filter-cartridge regularly (Ref. BTF-A-08-21-OO-OOA-

271 A-B).

1.3.2 Change the oil regularly if the Transverse Thruster operates for a large number of
hours. If the Transverse Thruster operates for a lower number of hours change the
oil after 1-2 years. For the procedures you require, refer to these data modules:
- Flushing (Ref. BTF-A-08-OO-OO-OOA-230A-A);
- Draining (Ref. BTF-A-08-OO-OO-OOA-222A-A);
- Filling (Ref. BTF-A-08-OO-OO-OOA-21 2A-A).

1.4 Do a check for the signs of a leakage from these items of the lubrication system:
- the header tank;
- the lubrication pump set;
- the pipe connections.

1.5 Do a check during the normal operation of the Transverse Thruster for these signs:
- too much noise;
- too much vibration.

1.6 Do a check for the thickness of the brake pads. If the thickness you measure is less than
2 mm replace the brake pad assemblies (Ref. BTF-A-09-1 1 -OO-OOA-921 A-B).

2 Do these steps in dry dock:

2.1 Do a check for the signs of a leakage from these items of the lower gearbox:
- the oil seals of the propeller shaft;
- the oil seals of the input shaft;
- the pipe connections.

2.2 Do a check for the signs of damage to the propeller. Make sure you apply the treatment
to the blades of the propeller that LIPS recommends. For more information speak with
the Service Department at LIPS, Drunen.

2.3 Do a check for the signs of damage to the sacrificial anodes. Replace as necessary (Ref.
BTF-A-05-21 -OO-OOA-921 A-B).

2.4 Do a check for the signs of damage to the surface of the pod. Paint the surface of the
pod, where necessary. For more information on the paint you require, refer to the Coating
Specification for the pod in the Appendix.

2.5 Do a check of the gear backlash (Ref. BTF-A-03-20-OO-OOA-271A-C).

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Marine Propulsion Systems

Requirements After Job Completion

1 None

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 BTF-A/LI PS-01
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Marine Propulsion Systems

Procedures, General - Removals

References
Table 1 References

Data Module/Technical Publication Title

BTF-A-02-1 O-OO-OOA-520A-B Removal of the Propeller

Assembly
BTF-A-03-20-OO-OOA-520A-B Removal of the Lower Gearbox
BTF-A-03-60-OO-OOA-520A-B Removal of the Flexible Shaft
Coupling
BTF-A-05-1 O-OO-OOA-520A-B Removal of the Outer Rope
Guard Assembly
BTF-A-05-20-OO-OOA-520A-B Removal of the Tunnel
Assembly

Preliminary Requirements

Required Conditions
Table 2 Required Conditions

Condition Data Module

AIR

Required Persons
Table 3 Required Persons

Number of Persons Category

S As Required Mech

Consumables, Materials and Expendables

Table 5 Supplies

Nomenclature Identification No. Qty

AIR

Note
Obey the safety conditions given in the removal procedure.

. Effectivity:
All
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 BTF-A/LIPS-01
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Marine Propulsion Systems

Procedure
1 Clean all the components you remove during the change procedure. Use the instructions of
the supplier to apply the degreasing agent(s).

2 Use boxes to store the components you remove during the removal procedure. Put labels on
the boxes to identify where the components come from. For example, the label for a gearbox
gives these details:
- the name of the ship;
- the order number;
- the position of the component in the ship (port or starboard).

3 Use protective material to protect the components you remove during the removal procedure,
where necessary. Use wooden blocks to protect heavy components such as the lower
bearbox. Use the preservation procedures to protect the components, where necessary.

4 Discard contaminated, worn or damaged components you remove during the removal
procedure. For example, discard the 0-rings, the oil seals and the screws or the bolts you
tighten with a torque load during the installation procedure.

5 Take care not to damage the input shaft or the propeller shaft when you remove one or more
of the bearings. Always discard the bearing(s).

6 When you apply heat to a component with the torch cutter, make sure you:
- apply the heat evenly in the "spreading" mode;
- cover adjacent components, such as seals, to protect them from the heat;
- cool the component with compressed air immediately after installation.

Requirements After Job Completion

1 Comply with the requirements given in the removal procedure.

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 BTF-A/LIPS-01
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Marine Propulsion Systems

Procedures, General - Disassembly

References
Table 1 References

Data Module! Technical Publication Title

BTF-A-03-20-OO-OOA-530A-C Disassembly of the Lower

Gearbox
BTF-A-03-21 -OO-OOA-530A-C Disassembly of the Lower
Gearbox Propeller Shaft
BTF-A-03-22-OO-OOA-530A-C Disassembly of the Lower
Gearbox Input Shaft

S Preliminary Requirements

Required Conditions
Table 2 Required Conditions

Condition Data Module

NR

Required Persons
Table 3 Required Persons

Number of Persons Category

As Required Mech

Consumables, Materials and Expendables

Table 5 Supplies

Nomenclature Identification No. Oty

NR
Note
Obey the safety conditions given in the disassembly procedure.

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 BTF-A/LIPS-01
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Marine Propulsion Systems

Procedure
1 Clean all the components you remove during the disassembly procedure. Use the
instructions of the supplier to apply the degreasing agent(s).

2 Use boxes to store the components you remove during the disassembly procedure. Put
labels on the boxes to identify where the components come from. For example, the label for
a gearbox gives these details:
- the name of the ship;
- the order number;
- the position of the component in the ship (port or starboard).

3 Use protective material to protect the components you remove during the disassembly
procedure, where necessary. Use wooden blocks to protect heavy components such as the
lower bearbox. Use the preservation procedures to protect the components, where necessary
(Ref. BTF-A-01 -1 O-OO-OOA-81 OA-C).

4 Discard contaminated, worn or damaged components you remove during the disassembly
procedure. For example, discard the 0-rings, the oil seals and the screws or the bolts you
tighten with a torque load during the assembly procedure.

5 Take care not to damage the input shaft or the propeller shaft when you remove one or more
of the bearings. Always discard the bearing(s).

6 When you apply heat to a component with the blow torch, observe the following:
- Apply the heat evenly in the "spreading" mode;
- Cover adjacent components such as seals to protect them from the heat;
- Cool the component with compressed air immediately after assembly.

Requirements After Job Completion

1 Obey the requirements given in the disassembly procedure.

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S
Procedures, General - Assembly

References
Table 1 References

Data Module! Technical Publication Title

BTF-A-03-20-OO-OOA-71 OA-C Assembly of the Lower Gearbox

BTF-A-03-21 -OO-OOA-71 OA-C Assembly of the LGB Propeller
Shaft
BTF-A-03-22-OO-OOA-71 OA-C Assembly of the LGB Input Shaft

Preliminary Requirements

Required Conditions
Table 2 Required Conditions

Condition Data Module

NR

Required Persons
Table 3 Required Persons

Number of Persons Category

As Required Mech

Consumables, Materials and Expendables

Table 5 Supplies

Nomenclature Identification No. Qty

NR

Safety Conditions

Note
Obey the safety conditions given in the assembly procedure.

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 BTF-NLI PS-O 1
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Marine Propulsion Systems

Procedure
1 Do these steps before you begin the assembly procedure:

1.1 Make sure you thoroughly clean all the components

1.2 Make sure you use component(s) which have a date of expiry within their storage life.

1.3 Make sure you use equipment which has a date of expiry within the recommended
calibration period.

2 Do these steps during the assembly procedure:

2.1 Use protective material such as plastic sheeting and adhesive tape to prevent
contamination, where necessary.

2.2 Use the instructions of the supplier to apply the degreasing agent(s).

Requirements After Job Completion

1 Obey the requirements given in the assembly procedure.

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 BTF-AILI PS-01
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Marine Propulsion Systems

Procedures, General - Installations

References
Table 1 References

Data Modulel Technical Publication Title

BTF-A-02-1 O-OO-OOA-720A-B Installation of the Propeller

BTF-A-03-20-OO-OOA-720A-B Installation of the Lower
Gearbox
BTF-A-03-60-OO-OOA-720A-B Installation of the Flexible Shaft
Coupling
BTF-A-05-1 O-OO-OOA-720A-B Installation of the Outer Rope
Guard Assembly
BTF-A-05-20-OO-OOA-720A-B Installation of the Tunnel
Assembly

Preliminary Requirements

Required Conditions
Table 2 Required Conditions

Condition Data Module

AIR

Required Persons
Table 3 Required Persons

Number of Persons Category

S As Required Mech

Consumables, Materials and Expendables

Table 5 Supplies

Nomenclature Identification No. Qty

AIR

Note
Obey the safety conditions given in the installation procedure.

S Effectivity:
All
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 BTF-AILIPS-01
John Crane-Lips
Marine Propulsion Systems

Procedure
Do these steps before you begin the installation procedure:

1.1 Make sure you thoroughly clean all the components

1.2 Make sure you use components which have a date of expiry within the storage life.

1.3 Make sure you use equipment which has a date of expiry within the recommended
calibration period.

2 Do these steps during the assembly procedure:

2.1 Use protective material such as plastic sheeting and adhesive tape to prevent
contamination, where necessary.

2.2 Use the instructions of the supplier to apply the degreasing agent(s).

Requirements After Job Completion

1 Obey the requirements given in the installation procedure.

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 BTF-NLIPS-01
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Marine Propulsion Systems

Procedures, General - Changes

References
Table 1 References

Data Module/ Technical Publication Title

BTF-A-03-23-OO-OOA-921 A-B Change of the Lower Gearbox,

Propeller Shaft, Oil Seals
BTF-A-05-21 -OO-OOA-921 A-B Change of the Sacrificial
Anodes
BTF-A-08-21 -OO-OOA-921 A-A Change of the Oil Pressure
Filter
BTF-A-09-1 1 -OO-OOA-921 A-B Change of the Shaft Brake Pad
Assemblies

Preliminary Requirements

Required Conditions
Table 2 Required Conditions

Condition Data Module

AIR

Required Persons
Table 3 Required Persons

Number of Persons Category

As Required Mech

Consumables, Materials and Expendables

Table 5 Supplies

Nomenclature Identification No. Qty

AIR

Note
Obey the safety conditions given in the change procedure.

Effectivity: BTF-A-01 -OO-OO-OOA-921 A-B

All

2002-02-01 Page 1
 BTF-NLI PS-01
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Marine Propulsion Systems

Procedure
1 Clean all the components you remove during the change procedure. Use the instructions of
the supplier to apply the degreasing agent(s).

2 Discard contaminated, worn or damaged components you remove during the change
procedure. For example, discard the 0-rings, the oil seals and the screws or the bolts you
tighten with a torque load.

Requirements After Job Completion

1 Obey the requirements given in the change procedure.

Effectivity: BTF-A-01 -OO-OO-OOA-921 A-B

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 CHAPTER 2

PROPULSION SYSTEM
 BTF-AILIPS-02
John Crane-Lips
Marine Propulsion Systems

S
Chapter 2- Propulsion System
Table of Contents Page

Title Data Module No.

Propulsion System - Description BTF-A-02-OO-OO-OOA-01 1 A-A

Propeller - Removal BTF-A-02-1 O-OO-OOA-520A-B
Propeller - Installation BTF-A-02-1 O-OO-OOA-720A-B

S Effectivity:
All
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 BTF-NLI PS-02
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Marine Propulsion Systems

Effectivity: BTF-A-02-00-00-OOA-000A-A
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 BTF-NLIPS-02
John Crane-Lips
Marine Propuision Systems

Propulsion System - Description

References
Table 1 References

Data Module! Technical Publication Title

None

Description
1 General
The propulsion system provides side-thrust for the vessel.

2 Physical Description
The propulsion system comprises the propeller (2).
The factory casts the propeller (2) into a monobloc from a bronze alloy of nickel and aluminum.
The propeller (2) has four blades and a hub, which fits on the taper end of the propeller shaft. As
a result of the extreme force the hub receives during the installation procedure, the propeller (2)
remains on the propeller shaft.
The adjusting plate (1) fastens to the end-face of the propeller shaft with screws. The adjusting
plate (1) has these functions:
- lets you install again with minimum requirement.
- seals the end of the propeller shaft;
- prevents the propeller (2) from springing off the shaft after initial installation.

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Marine Propulsion Systems

Fig 1 Propulsion System - Component Location

Fig 2 OlAdjusting Plate

O2Propeller

3 Functional Description
The transmission system transmits the drive from the propeller drive motor to the propeller. The
propeller generates the thrust necessary to push the vessel sideways in the water.

Effectivity: BTF-A-02-OO-OO-OOA-01 1 A-A

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Marina Propulsion Systems

S
Propeller - Removal

References
Table 1 References

Data Module! Technical Publication Title

BTF-A-05-1 O-OO-OOA-520A-B Removal of the Outer Rope

Guard Assembly
BTF-A-08-OO-OO-OOA-222A-B Draining the Lubrication Oil

Preliminary Requirements

S Required Conditions
Table 2 Required Conditions

Condition Data Module

Remove the Outer Rope Guard Assembly BTF-A-05-1 O-OO-OOA-520A-B

Drain the Lubrication Oil BTF-A-08-1 O-OO-OOA-222A-B

Required Persons
Table 3 Required Persons

Number of Persons Category

2 Mech

Support Equipment
Table 4 Support Equipment

Nomenclature Identification No. Qty

Electric Welding Tool 1

Chain Hoist 1

Chain Block 1

High pressure oil pump set 'B' 1

Hoisting Eyes 2
Sling 1

Consumables, Materials and Expendables

Table 5 Supplies

Nomenclature Identification No. Qty

None

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Marine Propulsion Systems

Safety Conditions
WARNINGS
ALWAYS WEAR PROTECTIVE CLOTHING AND GLASSES WHEN YOU WORK ON
EQUIPMENT.

MAKE SURE THAT WHEN YOU USE LIFTING EQUIPMENT THE FOLLOWING APPLIES:
- SUFFICIENT SPACE EXISTS FOR THE EQUIPMENT TO MOVE IN;
- PERSONNEL ARE IN SAFE POSITIONS.

'MAKE SURE THAT THE PROPELLER HUB OR SHAFT CANNOT ROTATE BEFORE YOU
REMOVE THE PROPELLER.

DO NOT COMPLETELY REMOVE THE SCREWS THAT SECURE THE ADJUSTING PLATE
TO THE PROPELLER SHAFT. DUE TO THE TENSION BETWEEN THE PROPELLER AND
THE PROPELLER SHAFT THE PROPELLER COULD SPRING OFF AND CAUSE INJURY OR
LOSS OF LIFE.

sTAKE CARE WHEN YOU REMOVE A PROPELLER. WHEN YOU USE A HIGH PRESSURE
OIL PUMP IT CAN CAUSE THE PROPELLER TO SPRING OFF THE PROPELLER SHAFT
AND CAUSE INJURY OR LOSS OF LIFE.

MAKE SURE THAT WHEN YOU CONNECT WELDING EQUIPMENT YOU ALWAYS USE AN
EARTH CONNECTION. CONNECT THE EARTH CONNECTION AS CLOSE AS POSSIBLE TO
THE WELD POINT TO PREVENT INJURY OR DAMAGE TO EQUIPMENT.

CAUTIONS
'MAKE SURE YOU DO NOT WELD THE HOISTING EYES TO THE STAINLESS STEEL RING.

Procedure
1 Do the following steps to prepare for the removal of the propeller:

WARNINGS
ALWAYS WEAR PROTECTIVE CLOTHING AND GLASSES WHEN YOU WORK ON
EQUIPMENT.

MAKE SURE THAT WHEN YOU CONNECT WELDING EQUIPMENT YOU ALWAYS
USE AN EARTH CONNECTION. CONNECT THE EARTH CONNECTION AS CLOSE
AS POSSIBLE TO THE WELD POINT TO PREVENT INJURY OR DAMAGE TO
EQUIPMENT.

CAUTION
MAKE SURE YOU DO NOT WELD THE HOISTING EYES TO THE STAINLESS STEEL
RING.

1.1 Use the electric welding tool to weld the hoisting eyes to the top of the tunnel (Ref. Fig 1).

Effectivity: BTF-A-02-1 O-OO-OOA-520A-B

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Marine Propulsion Systems

Fig 1 Tunnel - Position of Hoisting Eyes

To be issued later

1.2 Remove the outer rope guard assembly (Ref. BTF-A-05-1 O-OO-OOA-520A-B).

WARNING
MAKE SURE THAT WHEN YOU USE LIFTING EQUIPMENT THE FOLLOWING APPLIES:

- SUFFICIENT SPACE EXISTS FOR THE EQUIPMENT TO MOVE IN;

- PERSONNEL ARE IN SAFE POSITIONS.

1.3 Put the sling over the blades of the propeller in a safe position for hoisting.

2 RefertoFig2
Do the following to remove the propeller (9) from the propeller shaft (11):

2.1 Remove the screws that fasten the liner of the propeller shaft seal to the hub of the
propeller (9).

Effectivity: BTF-A-02-1 O-OO-OOA-520A-B

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Marine Propulsion Systems

WARNING
DO NOT COMPLETELY REMOVE THE SCREWS THAT FASTEN THE ADJUSTING
PLATE TO THE PROPELLER SHAFT. THE PROPELLER COULD SPRING OFF AND
CAUSE INJURY OR LOSS OF LIFE DUE TO THE TENSION BETWEEN THE PROPELLER
AND THE PROPELLER SHAFT.

2.2 Loosen the screws (1) that fasten the adjusting plate (3) to the propeller shaft (11). Make
sure you undo each screw until approximately 10mm (0.4 in) of the thread shows.

2.3 Remove the screw plug (5) and the sealing ring (6) to open plug hole A.

2.4 Remove the screw plug (7) and the sealing ring (8) to open plug hole B.

2.5 Connect the hydraulic hose of the high pressure oil pump to the plug hole A in the
propeller hub.

2.6 Tighten the connection of the hydraulic hose.

WARNING
TAKE CARE WHEN YOU WORK NEAR EQUIPMENT WITH PRESSURIZED OIL. CARRY
OUT FREQUENT CHECKS ON THE EQUIPMENT FOR POSSIBLE DANGEROUS
CONDITIONS TO PREVENT INJURY OR LOSS OF LIFE.

2.7 Operate the high pressure oil pump until oil comes out of the plug hole B.

2.8 Install the screw plug (7) and the sealing ring (8) to close plug hole B.

2.9 Operate the high pressure oil pump until the oil pressure reaches maximum.
Note
If the propeller fails to move immediately, maintain the pressure at maximum until it does.

WARNING
TAKE CARE WHEN YOU REMOVE A PROPELLER. WHEN YOU USE A HIGH
PRESSURE OIL PUMP IT CAN CAUSE THE PROPELLER TO SPRING OFF THE
PROPELLER SHAFT AND CAUSE INJURY OR LOSS OF LIFE.

2.loContinue to operate the high pressure oil pump until the propeller (9) moves to the
adjusting plate (3).

2.11 Remove the screws (1) and the sealing rings (2) that fasten the adjusting plate (3) to the
propeller shaft (11). Discard the sealing rings (2).

2.l2Remove the adjusting plate (3) and the 0-ring (4). Discard the 0-ring (4).
2.1 3Make sure the identification marks on the adjusting plate (3) match the identification
marks on the propeller (9). Apply the identification marks with a permanent -ink felt-tip
pen, if necessary.

2.l4Disconnect the hydraulic hose from plug holes A. Remove the high pressure oil pump.

Effectivity: BTF-A-02-1 O-OO-OOA-520A-B

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Marine Propulsion Systems

Fig 2 Propeller - Removal

TI-IRAO21 00000A52OAA

S Effectivity:
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Marine Propulsion Systems

2.1 5Carefully pull the propeller (9) off the propeller shaft (11).

2.1 6Put the propeller (9) in the safe position.

2.1 7Put protective material over these items to prevent possible damage:
- the hub of the propeller (9)
- the propeller shaft (11).

2.l8Remove the sling from the propeller (9).

2.19 Remove the 0-ring (10) from the liner on the propeller shaft (11). Discard the 0-ring (10).

Requirements After Job Completion

Make sure that there are no tools or equipment in the work area and that the work area is
clean.

Effectivity:
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BTF-A-02-1 O-OO-OOA-520A-B S
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 BTF-A/LIPS-02
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Marine Propulsion Systems

S
Propeller - Installation

References
Table 1 References

Data Module! Techncal Publication Title

Mounting Instructions No. 3004029

References
Table 1 References

Data Module! Technical Publication Title

S BTF-A-05-1 0-00-OOA-720A-B Installation of the Outer Rope

Guard Assembly
BTF-A-08-00-00-OOA-21 2A-B Filling Lubrication Oil

Preliminary Requirements

Required Conditions
Table 2 Required Conditions

Condition Data Module

None

Required Persons
Table 3 Required Persons

S Number of Persons Category

2 Mech

Support Equipment
Table 4 Support Equipment

Nomenclature Identification No. Qty

Chain Hoist 1

Chain Block 1

Dial Guage 1

High pressure oil pump set 'B' 1

Hoisting Eyes 2
Hydraulic Nut HMV 44/A101 1

Sling 1

Electric Welding Tool 1

Effectivity: BTF-A-02-1 O-OO-OOA-720A-B

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Marine Propulsion Systems

Consumables, Materials and Expendables

Table 5 Supplies

Nomenclature Identification No. Qty

0-ring 10 1

0-ring 4 1

Sealing ring 2 8
Sealing ring 6 and 8 2
Molykote 44 T002006754 AIR
Loctite 270 T002005540 AIR
Loctite 275 W005903954 AIR
Super Clean 706 T00300506 AIR

Safety Conditions
WARNINGS
ALWAYS WEAR PROTECTIVE CLOTHING AND GLASSES WHEN YOU WORK ON
EQUIPMENT.

MAKE SURE THAT WHEN YOU USE LIFTING EQUIPMENT THE FOLLOWING APPLIES:
- SUFFICIENT SPACE EXISTS FOR THE EQUIPMENT TO MOVE IN;
- PERSONNEL ARE IN SAFE POSITIONS.

MAKE SURE THAT THE HUB OR SHAFT CANNOT ROTATE WHEN YOU INSTALL THE
PROPELLER.

TAKE CARE WHEN YOU REMOVE THE PROPELLER. WHEN YOU USE A HIGH PRESSURE
OIL PUMP IT CAN CAUSE THE PROPELLER TO SPRING OFF THE PROPELLER SHAFT
AND CAUSE INJURY OR LOSS OF LIFE.

Procedure
Note 1
This procedure applies to the propeller from a transverse thruster system that you have to
install again.

Note 2
Use the LTD form (2016527) in compliance with classification regulations.

Note 3
Use Super Clean 706 to clean both fasteners and surfaces before applying a Loctite product.

1 Make sure that the propeller shaft (11) cannot rotate.

2 Make sure the propeller (9) matches with the propeller shaft (11). Check for these
identification marks on the propeller hub:
- Class stamps;
- Alignment mark;
- Order number.

3 Put the propeller (9) in a safe position near the pod (12) for a period of time. Let the propeller
(9) reach the same temperature as the propeller shaft (11) before you begin the installation.

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Marine Propulsion Systems

S 4 Clean the propeller shaft (11) and the inner surface of the propeller hub. Make sure that all
surfaces are free from damage. Smooth all rough surfaces as necessary.

5 Apply lightly the grease Molykote 44 to the 0-ring (10).

6 Install the 0-ring (10) into the groove on the liner of the propeller shaft (11).

WARNING
MAKE SURE THAT WHEN YOU USE LIFTING EQUIPMENT THE FOLLOWING APPLIES:

- SUFFICIENT SPACE EXISTS FOR THE EQUIPMENT TO MOVE IN;

- PERSONNEL ARE IN SAFE POSITIONS.

7 Put the sling over the blades of the propeller (9) in a safe position for hoisting.

8 Slowly lift the propeller (9) into position over the end of the propeller shaft (11).

9 Carefully put the propeller (9) on the propeller shaft (11).

10 Install the studs (14) to attach the hydraulic nut (13) on the end of the propeller shaft (11).

11 Install the adjusting plate (3), the hydraulic nut (13) and the mounting plate on the studs (14).

12 Install the washers (16) and the nuts (15) on the studs (14). Tighten the nuts (15) until
fingertight.

13 Do these steps to align the propeller (10) on the propeller shaft (11):

13.1 Connect the pump to the hydraulic nut (13).

WARNING
TAKE CARE WHEN YOU WORK NEAR EQUIPMENT WITH PRESSURIZED OIL. CARRY
OUT FREQUENT CHECKS ON THE EQUIPMENT FOR POSSIBLE DANGEROUS
CONDITIONS TO PREVENT INJURY OR LOSS OF LIFE.

1 3.2BIeed the air from the hydraulic nut (13).

S 13.3operate the pump until the pressure reaches the value for the "START LOAD POINT"
given on the drawing titled Propeller Mounting (Ref. Appendix).

Note
Do not put oil in the propeller hub at this stage of the procedure.

WARNING
TAKE CARE WHEN YOU WORK NEAR EQUIPMENT WITH PRESSURIZED OIL. CARRY
OUT FREQUENT CHECKS ON THE EQUIPMENT FOR POSSIBLE DANGEROUS
CONDITIONS TO PREVENT INJURY OR LOSS OF LIFE.

1 3.4Remove the screw plug (5) and the sealing ring (6) to open plug hole A.

13.5Remove the screw plug (7) and the sealing ring (8) to open plug hole B.

Effectivity: BTF-A-02-1 O-OO-OOA-720A-B

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13.6Connect the hydraulic hose of the high pressure oil pump to the plug hole A in the
propeller hub.

13.7Tighten the connection of the hydraulic hose.

WARNING
TAKE CARE WHEN YOU WORK NEAR EQUIPMENT WITH PRESSURIZED OIL. CARRY
OUT FREQUENT CHECKS ON THE EQUIPMENT FOR POSSIBLE DANGEROUS
CONDITIONS TO PREVENT INJURY OR LOSS OF LIFE.

13.8Operate the high pressure oil pump until oil comes out of the plug hole B.

13.9Install the screw plug (7) and the sealing ring (8) to close plug hole B.
13.lO0perate the high pressure oil pump until.

WARNING
TAKE CARE WHEN YOU WORK NEAR EQUIPMENT WITH PRESSURIZED OIL. CARRY
OUT FREQUENT CHECKS ON THE EQUIPMENT FOR POSSIBLE DANGEROUS
CONDITIONS TO PREVENT INJURY OR LOSS OF LIFE.

13.11Operate the high-pressure oil pump until these conditions occur:

- the oil pressure reaches maximum;
- the oil comes out between the propeller hub and the propeller shaft (11).

13.l2Operate the pump on the hydraulic nut (13) to move the propeller (9) on the propeller
shaft (11).

13.l3Continue with the pump until the adjusting plate (3) makes a firm contact with the end
of the propeller shaft (11). At this point the hydraulic nut (13) reaches the maximum
extension.

13.l4Stop the operation of the pump. Maintain the pressure on the hydraulic nut (13) for a
minimum period of 15 minutes.

13.l5Disconnect the hydraulic hose from plug hole A.

13.l6lnstall screw plug (5) and sealing ring (6).

14 Disconnect the pump from the hydraulic nut.

15 Remove the adjusting plate (3), the hydraulic nut and the mounting plate from the studs.

16 Remove the studs from end of the propeller shaft (11).

17 Apply lightly the grease Molykote 44 to the 0-ring (4).

18 Install the 0-ring (4) in the groove of the propeller hub.

19 Apply Loctite 275 to the thread of the screws (1).

20 Install the adjusting plate (3) using the screws (1) and the sealing rings (2). Tighten the
screws (1) to a torque value of 610 Nm.

21 Apply Loctite 270 to the thread of the set screw.

Effectivity: BTF-A-02-1 O-OO-OOA-720A-B

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Marine Propulsion Systems

S Fig 1 Propeller - Installation

16

THRAO2I00000A72OAA

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22 Install the set screw in the centre of the adjusting plate (3).

23 Make sure the propeller (9) and the propeller shaft (11) moves freely.
24 Install the outer rope guard assembly (Ref. BTF-A-05-1 O-OO-OOA-720A-A).

Requirements After Job Completion

1 Make sure that there are no tools or equipment in the work area and that the work area is
clean.

Effectivity: BTF-A-02-1 OOO-OOA-72OA-B

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 CHAPTER 3

TRANSMISSION SYSTEM
 BTF-AILIPS-03
John Crane-Lips
Marine Propulsion Systems

Chapter 3- Transmission System

Table of Contents Page

Title Data Module No.

Transmission System - Description BTF-A-03-OO-OO-OOA-011A-A

Gear System - Description BTF-A-03-1 O-OO-OOA-042A-C
Lower Gearbox - Description BTF-A-03-20-OO-OOA-042A-C
Lower Gearbox, Gearset - Adjustment/Test BTF-A-03-20-OO-OOA-271 A-C
Lower Gearbox - Removal BTF-A-03-20-OO-OOA-520A-B
Lower Gearbox - Disassembly BTF-A-03-20-OO-OOA-530A-C
Lower Gearbox - Assembly BTF-A-03-20-OO-OOA-71 OA-C
Lower Gearbox - Installation BTF-A-03-20-OO-OOA-720A-B
Lower Gearbox, Propeller Shaft - Disassembly BTF-A-03-21 -OO-OOA-530A-C
Lower Gearbox, Propeller Shaft - Assembly BTF-A-03-21 -OO-OOA-71 OA-C
Lower Gearbox, Input Shaft - Disassembly BTF-A-03-22-OO-OOA-530A-C
Lower Gearbox, Input Shaft - Assembly BTF-A-03-22-OO-OOA-71 OA-C
Lower Gearbox, Propeller Shaft Seal, Oil Seals - Change BTF-A-03-23-OO-OOA-921 A-C
Flexible Shaft Coupling - Removal BTF-A-03-60-OO-OOA-520A-B
Flexible Shaft Coupling - Installation BTF-A-03-60-OO-OOA-720A-B

Effectivity: BTF-A-03-OO-OO-OOA-000A-A
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Marine Propulsion Systems

Effectivity: BTF-A-03-00-00-OOA-000A-A
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 BTF-AILI PS-03
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Marine Propulsion Systems

Gear System - Description

References
Table 1 References

Data Module/ Technical Publication Title

BTF-A-03-20-OO-OOA-042A-C Description of the Lower

Gearbox
BTF-A-08-OO-OO-OOA-042A-A Description of the Lubrication
System

Description
1 General
The gear system forms a part of the transmission system. The drive from the prime mover passes
through the gear system to turn the propeller.

2 Physical Description
The gear system consists of the input shaft (1) and the propeller shaft (2), which form a set. The
lower gearbox (3) contains the gearset (Ref.BTF-A-03-20-OO-OOA-042A-C).
The input shaft (1) connects to the flexible-shaft coupling and makes a right-angle with the
propeller shaft (3). Bearings support the shafts and the lubrication system provides the lubrication
oil (Ref.BTF-A-08-OO-OO-OOA-042A-A).

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Fig 1 Gear System - Component Location

Fig2 Olinput Shaft

O2Propeller Shaft
O3Lower Gearbox

3 Functional Description
The lower gearbox contains the gear system. For more information, refer to Lower Gearbox -
Description (Ref .BTF-A-03-20-OO-OOA-042A-C).

Effectivity: BTF-A-03-1 O-OO-OOA-042A-C

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Marine Propulsion Systems

S
Transmission System - Description

References
Table 1 References

Data Module! Technical Publication Title

BTF-A-03-20-OO-OOA-042A-C Description of the lower gearbox

Description
General
The Transverse Thruster Transmission System connects the drive from the prime mover to the
propeller.

2 Physical Description
The Transverse Thruster Transmission System consists of these components:
- the Torque Protection Device (1);
- the Flexible-Shaft Coupling (2);
- the Gear System (Ref. BTF-A-03-1 O-OO-OOA-042A-C).

2.1 Torque Protection Device

The torque protection device (1) connects the prime mover to the flexible coupling (2).

2.2 Flexible-Shaft Coupling

The flexible-shaft coupling (2) comprises:
- the upper and lower flanges;
- the intermediate shaft.
The flexible-shaft coupling (2) connects the torque protection device (1) to the input shaft of the
lower gearbox (3) (Ref. BTF-A-03-20-OO-OOA-042A-C).

2.3 Gear System

The gear system comprises the lower gearbox (3) (Ref. BTF-A-03-20-OO-OOA-042A-C).
The lower gearbox (3) connects the flexible coupling (2) through the right-angle drive of the
gearset to the propeller.

Effectivity: BTF-A-03-OO-OO-OOA-01 1 A-A

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 BTF-NLI PS-03
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Marine Propulsion Systems

Fig 1 Transmission System - Component Location

Fig 2 01 Torque Protection Device

O2Flexible-Shaft Coupling
O3Lower Gearbox

3 Functional Description
When the drive shaft of the prime mover starts to turn the input shaft of the lower gearbox turns.
The gearset of the lower gearbox transfers the drive to the propeller shaft, which turns the
propeller.
The flexible-shaft coupling joins the drive shaft of the prime mover to the input shaft of the lower
gearbox (Ref.BTF-A-03-20-OO-OOA-042A-A).
The torque protection device limits the amount of torque from the prime mover, If the transmission
system jams the torque protection device disconnects the drive from the prime mover.

Effectivity: BTF-A-03-OO-OO-OOA-01 1 A-A

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 BTF-NLIPS-03
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Marine Propulsion Systems

Lower Gearbox - Description

References
Table 1 References

Data Module! Technical Publication Title

BTF-A-OO-OO-OO-OOA-01 1 A-A Description of the Transverse

Thruster
BTF-A-08-OO-OO-OOA-01 1 A-A Description of the Lubrication
System

Description
1 General
The lower gearbox transfers the drive from the propeller drive motor through the gearset to the
propeller.

2 Physical Description
Referto Fig 1
The lower gearbox has a gearset, which comprises these sub-assemblies:
- the input shaft (1) (Ref. Para 3.1);
- the propeller shaft (6) (Ref. Para 3.2).
The gearset conforms to the Klingelnberg HPG specifications. The teeth of the gearset form into
a Cyclo-Palloid type. The factory machine finishes the teeth of the pinion and the crown-wheel
after the hardening process.
The input shaft (1) and the propeller shaft (6) get support from the sets of roller bearings. In
accordance with the LIPS recommendations the adjustment rings allow you to set:
- the bearing clearances;
- the gear pattern;
- the gear backlash.
The input shaft seal (2) prevents the leakage of the lubrication oil.
The pod (3) is a distortion-free housing for the input shaft (1) and the propeller shaft (6). The input
shaft (1) forms a right-angle with the propeller shaft (6) through the single-stage gearset. The pod
flange has holes with threads. Bolts attach the lower gearbox to the mounting bracket in the tunnel
(Ref. BTF-A-OO-OO-OO-OOA-01 1 A-A).

The pod cap (4) provides access to the rear of the propeller shaft (6). A cord ring seal prevents
the ingress of water into the pod (4).
The attachment points (5) on the pod casing form the bases for welding the spoke plates (Ref.
BTF-A-OO-OO-OO-OOA-01 1 A-A).

The propeller shaft seal (2) prevents:

- the ingress of water;
- the leakage of lubrication oil.

Effectivity: BTF-A-03-20-OO-OOA-042A-C
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The suction line (9) connects to the oil pump of the lubrication system (Ref. BTF-A-08-OO-OO-OOA-
O11A-A).

Fig 1 Lower Gearbox - Component Location

Fig 2
01 Input Shaft
02 Input Shaft Seal
03 Pod
04 Pod Cap
05 Attachment Points (Spoke Plates)
06 Propeller Shaft
07 Propeller Shaft Seal
08 Suction Line(Lubrication Oil)

Effectivity: BTF-A-03-20-OO-OOA-042A-C
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3 Functional Description
Refer to Fig 2
When the input shaft (1) turns the spiral-bevel gearset transfers the drive to the propeller shaft
(21).
The lower gearbox floods with lubrication oil from the header tank of the lubrication system (Ref.
BTF-A-08-00-00-OOA-01 1 A-A). The height of the header tank ensures that the pod remains full of
oil due to gravity. The oil keeps the inside of the pod free from condensation and corrosion.
The oil pump sucks the oil through the suction line (25). The oil passes to the oil filter of the
lubrication system (Ref. BTF-A-08-00-00-OOA-01 1 A-A).

3.1 Input Shaft

Refer to Fig 2
The input shaft (1) stands vertical in the lower gearbox. The pinion of the gearset forms an integral
part of the input shaft (1).
The locking nut (2) holds the liner (4) in position on the input shaft (1). The seals in the seal
housing (5) and the liner (4) prevent theleakage of the lubrication oil from around the input shaft
(1). The screws of the seal housing (5) fasten the bearing housing (12) to the pod.
The spherical-roller thrust-bearings (9, 11) hold the upper part of the input shaft (1) in the lower
gearbox. They absorb the forces due to the axial components of the tooth load.
The distance bush (10) keeps the spherical-roller thrust-bearings (9, 11) at the correct distance
apart on the input shaft (1).
The spherical-roller bearings (14, 17) form double rows on the input shaft (1). They have these
functions:
- hold the lower part of the input shaft (1) in the lower gearbox;
- absorb the radial and tangential components of the forces the tooth load generates.
The retaining ring (12) holds the spherical-roller bearing (14) on the input shaft (1) in the bearing
support (15). The bearing locking device (16) does not let the outer race of the spherical-roller
bearing (14) turn.
The retaining ring (19) holds the spherical-roller bearing (17) on the input shaft (1) in the bearing
support (18). The bearing locking-device (20) does not let the outer race of the spherical-roller
bearing (17) turn. S
The compression spring (23) keeps the tension on the spherical-roller thrust-bearings (9, 11). This
ensures that the spherical-rollers move smoothly inside the cages. The screw plug (22) puts
tension on the compression spring (23).

3.1.1 Bearing Adjustment

The adjusting ring (6) lets you set the amount of play on the spherical-roller thrust-bearings (9, 11).
The hardened pin (6) does not let the adjusting ring (7) turn in the bearing housing (12).

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Fig 3 Lower Gearbox - Input Shaft

Fig 4
01 Input Shaft
02 Lock Nut
03 V-ring
04 Liner
05 Seal Housing
06 Hardened Pin
07 Compression Ring
08 Adjusting Ring
09 Spherical-Roller Thrust-Bearing

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10 Distance Bush
11 Spherical-Roller Thrust -Bearing
12 Bearing Housing
13 Retaining Ring
14 Spherical Roller-Bearing (Double row)
15 Bearing Support
16 Bearing Locking-Device
17 Spherical Roller-Bearing (Double row)
18 Bearing Support
19 Retaining Ring
20 Bearing Locking-Device
21 Propeller Shaft
22 Screw Plug
23 Compression Ring
24 0-Ring
25 Suction Line
26 0-ring

3.2 Propeller Shaft

Refer to Fig 3
The propeller shaft (1) lays horizontal in the lower gearbox. The crown wheel (9) fastens on to the
flange of the propeller shaft (1) with bolts.
The spherical-roller bearings (3) in a double row hold the end of the propeller shaft (1) with the
crown wheel (9). They absorb the forces due to the radial and tangential components the tooth
load generates. The bearing flange (4) holds the spherical-roller bearings (3). The retaining ring
(2) keeps the spherical-roller bearings (3) in position on the propeller shaft (1).
The seamless 0-ring (8) provides an oil seal for the bearing flange (4). The bolts (7) fasten the
bearing flange (4) to the pod. The factory welds lengths of lockwire on the tops of the bolts (7).
The lockwire prevents the bolts (7) from becoming loose due to vibration. The seamless 0-ring (6)
has these functions:
- prevents the leakage of the lubrication oil out of the pod;
- stops the entrance of the water into the pod.
The bearing housing (12) contains the spherical-roller thrust bearing (13) and the taper roller-
bearing (14). These bearings hold the end of the propeller shaft (1) with the propeller. They
absorb:
- the loads from the gearset;
- the forces due to the radial and axial components from the propeller.
The lock nut (15) holds the spherical-roller thrust bearing (13) and the taper roller-bearing (14) in
position on the propeller shaft (1).
The compression spring (11) keeps the spherical-roller thrust-bearings (13, 15) under tension.
This ensures that the spherical-rollers move smoothly inside the cages. The screw plug (10) puts
tension on the compression spring (11).

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Fig 5 Lower Gearbox - Propeller Shaft

Fig 6 OlPropeller Shaft

02 Retaining Ring
03 Spherical Roller-Bearing (Double row)
04 Bearing Flange
05 Pod Cap
06 Seamless 0-ring
O7Bolt(s)
08 Seamless 0-ring

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09 Crown Wheel
10 Screw Plug
11 Compression Spring
12 Bearing Housing
13 Taper Roller-Bearing
l4Spherical-Roller Thrust-Bearing
15 Lock Nut
16 Propeller Shaft-Seal
17 Liner
18 Adjusting Ring
190-ring
20 Hardened Pin

The propeller shaft seal housing (16) contains three radial lip-seals, which run on the liner (17).
The liner (17) is corrosion-free. The three radial lip-seals prevent:
- the leakage of the lubrication oil from around the propeller shaft (1);
- the entrance of the water around the propeller shaft (1).

3.2.1 Bearing Adjustment

The adjusting ring (18) lets you set the amount of play on the spherical-roller thrust-bearings (13,
15).
The hardened pin (20) does not let the adjusting ring (7) turn in the bearing housing (12).

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S
Lower Gearbox, Gearset - AdjustmentRest

References
Table 1 References

Data Module! Technical Publication Title

BTF-A-03-20-OO-OOA-520A-B Removal of the Lower Gearbox

BTF-A-03-20-OO-OOA-71 OA-C Assembly of the Lower Gearbox

Preliminary Requirements

Required Conditions
S Table 2 Required Conditions

Condition Data Module

Remove the lower gearbox BTF-A-03-20-OO-OOA-520A-B

Required Persons
Table 3 Required Persons

Number of Persons Category

2 Mech

Support Equipment
Table 4 Support Equipment

Nomenclature Identification No. Qty

Dial Guage 1

Hoisting Eye-bolts AIR

Chain Hoist 1

Consumables, Materials and Expendables

Table 5 Supplies

Nomenclature Identification No. Qty

Dye paste (Engineers Blue) 1

Soft brush 1

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Safety Conditions
WARNINGS
MAKE SURE THAT WHEN YOU USE LIFTING EQUIPMENT THE FOLLOWING APPLIES:
- SUFFICIENT SPACE EXISTS FOR THE EQUIPMENT TO MOVE IN;
- PERSONNEL ARE IN SAFE POSITIONS.

MAKE SURE THE LOWER GEARBOX IS SECURE AND CANNOT FALL OVER.

ALWAYS WEAR PROTECTIVE CLOTHING AND GLASSES WHEN YOU WORK ON

EQUIPMENT.

TAKE CARE WHEN YOU WORK NEAR EQUIPMENT WITH COMPONENTS THAT ROTATE.
CARRY OUT FREQUENT CHECKS ON THE EQUIPMENT FOR POSSIBLE DANGEROUS
CONDITIONS TO PREVENT INJURY OR LOSS OF LIFE.

Procedure
Do these steps to adjust the BEARING CLEARANCE for the bearings of the INPUT SHAFT:

1 .1 Install a hoisting eye-bolt in the end of the input shaft.

WARNING
MAKE SURE THAT WHEN YOU USE LIFTING EQUIPMENT THE FOLLOWING APPLIES:

- SUFFICIENT SPACE EXISTS FOR THE EQUIPMENT TO MOVE IN;

- PERSONNEL ARE IN SAFE POSITIONS.

1.2 Attach the chain hoist to the hoisting eye-bolt. Use the chain hoist to tighten the chain.

1.3 Use a magnetic support to mount the dial guage on the pod casing. Make sure the ball
of the plunger touches the uppermost face of the input shaft.

1.4 Set the dial gauge to zero.

WARNING
MAKE SURE THAT WHEN YOU USE LIFTING EQUIPMENT THE FOLLOWING APPLIES:

- SUFFICIENT SPACE EXISTS FOR THE EQUIPMENT TO MOVE IN;

- PERSONNEL ARE IN SAFE POSITIONS.

1.5 Use the chain hoist to carefully lift the input shaft with a force of approximately 10 kN
(1.02 if).

1.6 Make a note of the reading shown on the dial gauge.

1.7 Use the chain hoist to carefully lower the gearbox.
1.8 Compare the reading shown on the dial gauge from step 1.6 with the bearing clearances
given in Table 6. Do these steps to get the correct bearing clearance:

1.8.1 Replace the undersized precision blocks with thicker precision blocks.

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1.8.2 Repeat step 1.4 thru step 1 .8 until the bearing clearance is within the limits given
in Table 6.

Table 6 Input Shaft Bearing Clearances

Pod Type Axial Clearance (pm)
(CT/FT/C/F)
125 20-50
150 40-70
175 50-80
200 50-80
225 50-80
250 50-80
275 60-90
300 60-90

1 .9 Machine the adjusting ring to the thickness you require using the measurement for the
correct bearing clearance from step 1.8.

1.loReplace the precision blocks with the adjusting ring of the correct thickness. Do NOT
install the compression springs in this procedure (Ref. BTF-A-03-20-00-OOA-71 OA-C).

1.11 Repeat step 1.4 thru step 1.7. Make sure the bearing clearance is within the limits given
in Table 6. Write the bearing clearance on the Gear Transmission Data Sheet (GTDS).

1.l2Remove the dial gauge.

1.l3Remove the chain hoist and the hoisting eye-bolt from the end of the input shaft.

1 .l4Complete the assembly procedure for the lower gearbox (Ref. BTF-A-03-20-00-OOA-
71 OA-C).

2 Do these steps to adjust the BEARING CLEARANCE for the PROPELLER SHAFT:

2.1 Install a hoisting eye-bolt in the end of the propeller shaft.

WARNING
MAKE SURE THAT WHEN YOU USE LIFTING EQUIPMENT THE FOLLOWING APPLIES:

- SUFFICIENT SPACE EXISTS FOR THE EQUIPMENT TO MOVE IN;

- PERSONNEL ARE IN SAFE POSITIONS.

2.2 Attach the chain hoist to the hoisting eye-bolt. Use the chain hoist to tighten the chain.

2.3 Use a magnetic support to mount the dial gauge on the pod casing. Make sure the ball
of the plunger touches the highest face of the propeller shaft.

2.4 Set the dial gauge to zero.

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WARNING
S
MAKE SURE THAT WHEN YOU USE LIFTING EQUIPMENT THE FOLLOWING APPLIES:

- SUFFICIENT SPACE EXISTS FOR THE EQUIPMENT TO MOVE IN;

- PERSONNEL ARE IN SAFE POSITIONS.

2.5 Use the chain hoist to carefully lift the propeller shaft with a force of approximately 10 kN
(1.O2tf).

2.6 Make a note of the reading shown on the dial gauge.

2.7 Use the chain hoist to carefully lower the gearbox.

2.8 Compare the reading shown on the dial gauge from step 2.6 with the bearing clearances
given in Table 7. Do these steps to get the correct bearing clearance:

2.8.1 Replace the undersized precision blocks with thicker precision blocks.

2.8.2 Repeat step 2.4 thru step 2.8 until the bearing clearance is within the limits given
in Table 7.

Table 7 Propeller Shaft Bearing Clearances

Pod Type Axial Clearance (pm)

(CT/FT/C/F)
125 30-70
150 30-70
175 30-70
200 40-80
225 40-80
250 50-100
275 50-100
300 60-120

2.9 Machine the adjusting ring to the thickness you require using the measurement for the
correct bearing clearance from step 2.8.

2.loReplace the precision blocks with the adjusting ring of the correct thickness. Do NOT
install the compression springs.

2.11 Repeat step 2.4 thru step 2.7. Make sure the bearing clearance is within the limits given
in Table 7. Write the bearing clearance on the Gear Transmission Data Sheet (GTDS).

2.l2Remove the dial gauge.

2.l3Remove the chain hoist and the hoisting eye-bolt from the end of the propeller shaft.
2.l4Complete the assembly procedure for the lower gearbox (Ref. BTF-A-03-20-00-OOA-
710A-C).

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3 Do these steps to adjust the GEAR PATTERN:

3.1 Make sure the gear backlash is within the tolerance given in Table 10.

3.2 Select a minimum of two sets of meshing teeth adjacent to each other.

3.3 Apply the dye paste with the soft brush on the flanks (mating surfaces) of the meshing
teeth.

Note
Make sure you apply only a thin coating of the dye paste. If the coating is too thick it can distort
the image of the gear pattern.

3.4 Turn the pinion shaft in a clockwise direction for approximately 20 to 30 revolutions.

3.5 Turn the pinion shaft in an anti-clockwise direction for approximately 20 to 30 revolutions.

3.6 Look at the mating surfaces (convex and concave flanks) for each set of meshing teeth:

3.6.1 Compare the contact patterns with those shown in the documentation the gearset
manufacturer provides, if available.

3.6.2 Compare with the typical views of contact patterns shown in Fig 1 and Table 9.

3.7 Do these steps to get the correct gear backlash:

3.7.1 Replace the undersized precision blocks between the bearing housing of the input
shaft and the flange of the pod casing with thicker precision blocks.

3.7.2 Repeat step 3.2 thru step 3.7 until you get the satisfactory contact pattern.

3.8 Machine the adjusting ring to the thickness you require using:
- the thickness of the precision blocks, which gave you the satisfactory contact pattern;
- the measurement for the temperature compensation from Table 8.

Table 8 Input Shaft Adapter Ring - Temperature Compensation

Pod Type Temperature

(CT/FT/C/F) Compensation (pm)
125 100
150 100
175 100
200 150
225 150
250 200
275 200
300 200

3.9 Replace the precision blocks with the adjusting ring of the correct thickness. Do NOT
install the compression springs (Ref. BTF-A-03-20-00-OOA-71 OA-C).

3.loRepeat step 3.2 thru step 3.6. Make sure you get the satisfactory contact pattern.

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3.11 Use the digital camera to take a photo of the contact pattern on the convex and concave
flanks (mating surfaces) of the meshing teeth.

3.1 2 Insert the photo into the Gear Transmission Data Sheet (GTDS).

3.1 3Complete the assembly procedure for the lower gearbox (Ref. BTF-A-03-20-OO-OOA-
710A-C).

Fig 1 Crown Wheel - Typical Contact Patterns on Convex and Concave Flanks of Teeth

Note 1
Fig 1 shows typical contact patterns on the teeth of a crown wheel. The photo on the left-hand
side shows the convex flanks. The photo on the right-hand side shows the concave flanks.
Both sets of contact patterns show that the gearset is in the correct position.

Note 2
Table 9 gives typical contact patterns on the teeth of the gearset (pinion). The Gearset
column shows the view of the contact pattern to which the condition relates. The figures

.
represent the contact patterns from gearsets that require an amount of adjustment. The
Adjustment column gives an indication to the possible cause and a cross-reference to an
adjustment procedure.

Condition
Contact pattern shows the
Table 9 Typical Gearset Conditions with Adjustments
Gearset Adjustment
Requires no adjustment.
a
gearset in the correct position
under NO load condition. r

I
BTFAO3I00000A271AA2

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Condition Gearset Adjustment

Contact pattern shows the Requires no adjustment.
gearset in the correct position
under load condition.

n
BTIAO3I00000A271AAI

Contact pattern shows the Increase the mounting distance of

gearset NOT in the correct the pinion shaft (Ref. step 1).
position.

iIc
BTFAO3100000A271AA3

Contact pattern shows the Decrease the mounting distance

gearset NOT in the correct of the pinion shaft (Ref. step 1).
position. V

BTFAO3I00000A271kA4

Contact pattern shows the (a) Measure the gear backlash,

gearset NOT in the correct refer to step 4 of this procedure.
position. (b) Check the mounting distances
of the pinion crown

BTFAO3I 00000A271AA5

Contact pattern shows the (a) Measure the gear backlash.

gearset NOT in the correct (b) Check the mounting distances
position. of the pinion shaft and the crown

cust as necessary.

BTFAO3I 00000A271AA6

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4 Do these steps to adjust the GEAR BACKLASH:

Refer to Fig 2

4.1 Check the crown wheel for the measurement of the gear backlash, if present.
Note
The gearset manufacturer inscribes the measurement of the gear backlash on the crown
wheel. This occurs during production before the final stage of assembly.
4.2 Fasten the input shaft to prevent it from turning.

4.3 Use a magnetic support to mount the dial gauge. Make sure that the plunger:
- points at a convex flank and is perpendicular to the surface of the tooth;
- touches the convex flank at a point two thirds the distance from the root of the tooth;
- touches the convex flank at a point towards the outer edge of the tooth.

4.4 Set the dial gauge to zero.

4.5 Turn the crown wheel clockwise and then anti-clockwise several times. Make sure the
readings on the dial gauge do not exceed these deviations:
- 0.01 mm when the diameter of crown wheel is less than 1 meter;
- 0.02 mm when the diameter of crown wheel is greater than 1 meter.

4.6 Note the final reading on the dial gauge.

4.7 Do these steps to get the correct gear backlash:

4.7.1 Replace the undersized precision blocks between the bearing housing of the
propeller shaft and the flange of the pod casing with thicker precision blocks.

4.7.2 Repeat step 4.4 thru step 4.7 until the gear backlash is within the limits given in
Table 10.

4.8 Machine the adjusting ring to the thickness of the precision blocks, which gave you the
correct gear backlash.

4.9 Cut the adjusting ring in half across the middle of two adjacent screw holes.

4.loReplace the precision blocks with the two halves of the adjusting ring. (Ref. BTF-A-03-
20-00-OOA-71 OA-C).

4.11 Repeat step 3.2 thru step 3.6. Make sure you get the correct gear backlash.

4.1 2Write the measurement of the backlash on the Gear Transmission Data Sheet (GTDS).
4.l3Remove the dial gauge.

4.l4Complete the assembly procedure for the lower gearbox (Ref. BTF-A-03-20-00-OOA-
710A-C).

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Table 10 Gearset Backlash

Pod Type Gearset Teeth (Z) Modulus Backlash Tolerance (pm)
Pinion Crown Wheel
125H 13 44 9.66 0.20 - 0.25
150H 13 53 9.91 0.20 - 0.25
175H 11 51 8.16 0.20-0.25
175M 13 41 9.77 0.20 - 0.25
200H 11 49 9.72 0.20 - 0.25
200M 13 47 9.68 0.20 - 0.25
225H 12 49 10.72 0.25 - 0.30
225M 14 37 13.80 0.30 - 0.35
250H 12 53 11.07 0.25-0.30
250M 13 49 11.54 0.25 - 0.30
275H 12 49 12.53 0.30-0.35
275M 13 48 19.58 0.45-0.50
300H 13 53 19.62 0.45-0.50
300M 13 46 22.13 0.50 -0.55

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Fig 2 Gear Backlash Test Setup

Requirements After Job Completion

1 Make sure that there are no tools or equipment in the work area and that the work area is
clean.

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Lower Gearbox - Removal

References
Table 1 References

Data Module! Technical Publication Title

BTF-A-02-1 O-OO-OOA-520A-B Propeller Removal

BTF-A-03-60-OO-OOA-520A-B Intermediate Shaft Removal
BTF-A-05-1 O-OO-OOA-520A-B Outer Rope Guard Assembly
Removal
BTF-A-08-OO-OO-OOA-222A-B Lubrication Oil Draining
BTF-A-09-1 1 -OO-OOA-921 A-B Brake Pads Change

Preliminary Requirements

Required Conditions
Table 2 Required Conditions

Condition Data Module

Remove the Propeller BTF-A-02-1 O-OO-OOA-520A-B

Remove the Intermediate Shaft BTF-A-03-60-OO-OOA-520A-B
Remove the Outer Rope Guard Assembly BTF-A-05-1 O-OO-OOA-520A-B
Drain the Lubrication Oil BTF-A-08-OO-OO-OOA-222A-B
Remove the Brake Pads BTF-A-09-1 1 -OO-OOA-921 A-B
Hot Work Permit N!A

Required Persons
Table 3 Required Persons

S Number of Persons Category

4 Mech

Required Persons
Table 3 Required Persons

Number of Persons Category

1 Welder

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Support Equipment
Table 4 Support Equipment

Nomenclature Identification No. Qty

Chain Hoist 1

Electric Welding Tool 1

Eye-Bolts 2
Grinding Wheel 1

Slings 2

Consumables, Materials and Expendables

Table 5 Supplies

Nomenclature Identification No. Qty

None

Safety Conditions
WARNINGS
'ALWAYS WEAR PROTECTIVE CLOTHING AND GLASSES WHEN YOU WORK ON
EQUIPMENT.

'MAKE SURE THAT WHEN YOU CONNECT WELDING EQUIPMENT YOU ALWAYS USE AN
EARTH CONNECTION. CONNECT THE EARTH CONNECTION AS CLOSE AS POSSIBLE TO
THE WELD POINT TO PREVENT INJURY OR DAMAGE TO EQUIPMENT.

'MAKE SURE THAT WHEN YOU USE LIFTING EQUIPMENT THE FOLLOWING APPLIES:
- SUFFICIENT SPACE EXISTS FOR THE EQUIPMENT TO MOVE IN;
- PERSONNEL ARE IN SAFE POSITIONS.

CAUTIONS
ALWAYS PROTECT THE SURROUNDING AREA FROM WELDING SPLATTER WHEN
WELDING.

DO NOT ATTACH LIFTING EQUIPMENT TO MACHINED SURFACES, SHAFT ENDS, PIPING

WORK OR OTHER EXTERNALLY MOUNTED EQUIPMENT.

MAKE SURE THE CATCH TANK(S) YOU USE TO DRAIN OIL OR FLUID FROM EQUIPMENT
ARE LARGE ENOUGH TO CONTAIN THE OIL OR FLUID. IF YOU SPILL OIL OR FLUID
DURING A REMOVAL OR INSTALLATION PROCEDURE, ALWAYS COLLECT AND REMOVE
THE OIL OR FLUID.

MAKE SURE YOU DO NOT WELD THE HOISTING EYES TO THE STAINLESS STEEL RING.

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Procedure
WARNING
CAUTION
MAKE SURE THE CATCH TANK(S) YOU USE TO DRAIN OIL OR FLUID FROM
EQUIPMENT ARE LARGE ENOUGH TO CONTAIN THE OIL OR FLUID. IF YOU SPILL OIL
OR FLUID DURING A REMOVAL OR INSTALLATION PROCEDURE, ALWAYS COLLECT
AND REMOVE THE OIL OR FLUID.

1 Drain the lubrication oil from the the lower gearbox (Ref. BTF-A-08-OO-OO-OOA-222A-B).

2 Disconnect the oil-pipe connections LT, ST and VT from the top of the lower gearbox. Put the
covers on the open connections.

3 Remove the outer rope guard assembly (Ref. BTF-A-05-1 O-OO-OOA-520A-B).

4 Remove the bolts that fasten the liner of the propeller shaft seal to the propeller (Ref. BTF-A-
03-20-OO-OOA-530A-B).

5 Remove the propeller (Ref. BTF-A-02-1 O-OO-OOA-520A-B).

WARNING
MAKE SURE THAT WHEN YOU CONNECT WELDING EQUIPMENT YOU ALWAYS USE
AN EARTH CONNECTION. CONNECT THE EARTH CONNECTION AS CLOSE AS
POSSIBLE TO THE WELD POINT TO PREVENT INJURY OR DAMAGE TO EQUIPMENT.

CAUTIONS
ALWAYS PROTECT THE SURROUNDING AREA FROM WELDING SPLATTER
WHEN WELDING.

MAKE SURE YOU DO NOT WELD THE HOISTING EYES TO THE STAINLESS STEEL
RING.

Refer to Fig 1

6 Use the electric welding tool to install the hoisting eyes (1, 6) in the tunnel as shown in Fig 1.

7 Use the torch cutter to cut the spoke plates (3, 4) in the vertical plane. Make sure you cut the
spoke plates (3, 4) to give sufficient clearance for the sides of the lower gearbox.

8 Remove the brake pads from the disc-brake caliper (Ref. BTF-A-09-1 1 -OO-OOA-921 A-B).

9 Remove the intermediate shaft from the flexible shaft coupling (Ref. BTF-A-03-60-OO-OOA-
520A-B).

10 Remove the two screws that cover the threaded holes for the eye-bolts in the top face of the
lower gearbox.

11 Install the eye-bolts in the threaded holes.

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WARNING
ALWAYS WEAR PROTECTIVE CLOTHING AND GLASSES WHEN YOU WORK ON
EQUIPMENT.

12 Use the grinding wheel to remove the lockwire from the bolts that fasten the flange of the pod
to the tunnel assembly. Discard the lockwire.

Fig 1 Hoisting Arrangement for the Lower Gearbox

WARNING

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CAUTION
DO NOT ATTACH LIFTING EQUIPMENT TO MACHINED SURFACES, SHAFT ENDS,
PIPING WORK OR OTHER EXTERNALLY MOUNTED EQUIPMENT.

13 Put the sling (2) around the part of the spoke plate (3) on the lower gearbox and fasten to the
hoisting eye (1). Make sure the sling cannot slip off the spoke plate (3).

14 Put the sling (5) around the part of the spoke plate 4) on the lower gearbox and fasten to the
hoisting eye (6). Make sure the sling cannot slip off the spoke plate (4).

WARNING
MAKE SURE THAT WHEN YOU USE LIFTING EQUIPMENT THE FOLLOWING APPLIES:

- SUFFICIENT SPACE EXISTS FOR THE EQUIPMENT TO MOVE IN;

- PERSONNEL ARE IN SAFE POSITIONS.

15 Use the chain hoist to support the load of the lower gearbox.
Refer to Fig 2

16 Remove the bolts that fasten the flange of the pod to the mounting bracket in the tunnel
assembly.

WARNING
MAKE SURE THE LOWER GEARBOX IS SECURE AND CANNOT FALL OVER.

17 Carefully lower the lower gearbox until it reaches the floor of the tunnel.

18 Remove the slings (2, 5) from between the spoke plates (3, 4) and the hoisting eyes (1, 6).

19 Remove the lower gearbox from the tunnel.

20 Put the lower gearbox in a safe position.

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Fig 2 Lower Gearbox in Lowered Position

Requirements After Job Completion

1 Make sure that there are no tools or equipment in the work area and that the work area is
clean.

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Lower Gearbox - Disassembly

References
Table 1 References

Data Module! Technical Publication Title

BTF-A-03-20-OO-OOA-520A-B Lower gearbox removal

BTF-A-08-OO-OO-OOA-222A-B Lubrication oil draining

Preliminary Requirements

Required Conditions
S Table 2 Required Conditions

Condition Data Module

Remove the lower gearbox BTF-A-03-20-OO-OOA-520A-B

Drain lubrication oil BTF-A-08-OO-OO-OOA-222A-B

Required Persons
Table 3 Required Persons

Number of Persons Category

2 Mech

Support Equipment
Table 4 Support Equipment

Nomenclature Identification No. Qty

Chain Hoist 1

Grinding Wheel 1

Hoisting Eye-bolts AIR

Induction Heater 1

Ring Spanner W08482567 and W08482568 1

Hydraulic Jack 1

Consumables, Materials and Expendables

Table 5 Supplies

Nomenclature Identification No. Qty

None

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Safety Conditions
WARNINGS
ALWAYS WEAR PROTECTIVE CLOTHING AND GLASSES WHEN YOU WORK ON
EQUIPMENT.

MAKE SURE THAT WHEN YOU USE LIFTING EQUIPMENT THE FOLLOWING APPLIES:
- SUFFICIENT SPACE EXISTS FOR THE EQUIPMENT TO MOVE IN;
- PERSONNEL ARE IN SAFE POSITIONS.

MAKE SURE THE LOWER GEARBOX IS SECURE AND CANNOT FALL OVER.

CAUTIONS
MAKE SURE THAT YOU DRAIN SYSTEM OIL OR FLUID BEFORE EQUIPMENT
DISASSEMBLY.

Procedure
1 Do the job preparation in accordance with the Maintenance Disassembly Procedures (Ref.
BTF-A-01 -1 0-00-OOA-530A-C).

2 Do the following steps to remove the propeller shaft (20) from the lower gearbox:

WARNING
ALWAYS WEAR PROTECTIVE CLOTHING AND GLASSES WHEN YOU WORK ON
EQUIPMENT.

2.1 Use the grinding wheel to cut and remove the lockwire from the bolts (15) securing.
Discard the lockwire.

2.2 Remove the bolts (15) that fasten the pod cap (14) to the pod casing (10).

2.3 Remove the pod cap (14) and the seamless 0-ring (13). Discard the seamless 0-ring
(13).

WARNING
ALWAYS WEAR PROTECTIVE CLOTHING AND GLASSES WHEN YOU WORK ON
EQUIPMENT.

2.4 Use the grinding wheel to cut and remove the Iockwire from the bolts (12) securing the
bearing flange (11) to the pod casing (10). Discard the lockwire.

2.5 Loosen the bolts (12).

Note
Do NOT remove the bolts (12) at this stage.

Effectivity: BTF-A-03-20-OO-OOA-530A-C
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Fig 1 Lower Gearbox Propeller Shaft - Removal

1314 15 16

BTFAO3200000A53OAC1

WARNING
MAKE SURE THE LOWER GEARBOX IS SECURE AND CANNOT FALL OVER.

2.6 Put the pod on blocks with the propeller shaft (20) vertical and facing upwards.

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2.7 Remove the bolts (1) securing the propeller shaft seal (2) to the bearing housing (7).

2.8 Remove the propeller shaft seal (2), the 0-ring (3) and the adjusting ring (28). Discard the
0-ring (3).

WARNING
ALWAYS WEAR PROTECTIVE CLOTHING AND GLASSES WHEN YOU WORK ON
EQUIPMENT.

2.9 Loosen the grub screws (25) that prevent the lock nut (24) from turning.

WARNING
MAKE SURE THAT WHEN YOU USE LIFTING EQUIPMENT THE FOLLOWING APPLIES:

- SUFFICIENT SPACE EXISTS FOR THE EQUIPMENT TO MOVE IN;

- PERSONNEL ARE IN SAFE POSITIONS.

2.1 OUse the chain hoist and the LIPS ring spanner to remove the lock nut (24).

2.11 Remove the adjusting ring (27).

2.l2Remove the bolts (4) and the dubo retaining rings (5) covering the threaded holes in the
bearing housing (7).

2.1 3Remove the bolts (6) securing the bearing housing (7) to the pod casing (10).

2.l4Use the hydraulic jack and the special tools to release these components from the
propeller shaft (20):
- the roller-bearings (21, 23);
- the liner (22);
- the bearing housing (7).

Note
Remove the bearing housing (7) with the distance bush (26) and the roller-bearings (21, 23).

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WARNING
MAKE SURE THE LOWER GEARBOX IS SECURE AND CANNOT FALL OVER.

2.l5Turn the pod on the blocks with the propeller shaft (20) vertical and facing down.

2.l6Remove the bolts (12) securing the bearing flange (11) to the pod casing (10).
2.l7Remove the bearing flange (11) and the 0-ring (16) from the pod housing (10). Discard
the 0-ring (16).

2.l8Remove the retaining ring (17) holding the spherical roller-bearing (18) onto the propeller
shaft (20).

WARNING
ALWAYS WEAR PROTECTIVE CLOTHING AND GLASSES WHEN YOU WORK ON
EQUIPMENT.

2.l9Use the hydraulic jack and the special tools to release the roller-bearing (18). Remove
the roller-bearing (18).

WARNING
MAKE SURE THAT WHEN YOU USE LIFTING EQUIPMENT THE FOLLOWING APPLIES:

- SUFFICIENT SPACE EXISTS FOR THE EQUIPMENT TO MOVE IN;

- PERSONNEL ARE IN SAFE POSITIONS.

2.2OUse the chain hoist with the eye-bolt (28) to lift the propeller shaft (20) out of the pod
casing (10).

2.21 Put the propeller shaft (20) in a safe position.

2.22 Remove the eye-bolt (28) from the end of the propeller shaft (20).

Effectivity: BTF-A-03-20-OO-OOA-530A-C
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3 Do the following steps to remove the input shaft (3) from the lower gearbox:
Note
Remove the propeller shaft before you proceed with these steps.

3.1 Remove the screws (1) that fastens the seal housing (2) and the bearing housing to the
pod flange (5).

3.2 Install the eye-bolt (7) in the top of the input shaft (3).

WARNING
MAKE SURE THAT WHEN YOU USE LIFTING EQUIPMENT THE FOLLOWING APPLIES:

- SUFFICIENT SPACE EXISTS FOR THE EQUIPMENT TO MOVE IN;

- PERSONNEL ARE IN SAFE POSITIONS.

3.3 Use the chain hoist with the eye-bolt (7) to carefully lift the input shaft (3) out from the
I
pod casing (6).

3.4 Put the input shaft (3) in an assembly stand.

3.5 Remove the chain hoist from the eye-bolt (7).

3.6 Remove the eye-bolt (7) from the top of the input shaft (3).
3.7 Remove the adjusting ring (4) from the pod flange (5).

Effectivity: BTF-A-03-20-00-OOA-530A-C
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Fig 2 Lower Gearbox Input Shaft - Removal

BTFAO3200000A53OAC2

Requirements After Job Completion

1 Make sure that there are no tools or equipment in the work area and that the work area is
clean.

Effectivity: BTF-A-03-20-OO-OOA-530A-C
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Lower Gearbox - Assembly

References
Table 1 References

Data Module! Technical Publication Title

BTF-A-03-20-OO-OOA-271 A-C Lower Gearbox, Gearset

Adjustment/Test
BTF-A-03-21 -OO-OOA-71 OA-C Lower Gearbox, Propeller Shaft
Assembly
BTF-A-03-22-OO-OOA-71 OA-C Lower Gearbox, Input Shaft
Assembly
BTF-A-03-23-OO-OOA-71 OA-C Lower Gearbox, Propeller Shaft
Seal Assembly
BTF-A-08-OO-OO-OOA-21 2A-A Lubrication oil filling

Preliminary Requirements

Required Conditions
Table 2 Required Conditions

Condition Data Module

Assemble the propeller shaft BTF-A-03-21 -OO-OOA-71 OA-C

Assemble the input shaft BTF-A-03-22-OO-OOA-71 OA-C
Assemble the propeller shaft seal BTF-A-03-23-OO-OOA-71 OA-C

Required Persons
Table 3 Required Persons

Number of Persons Category

2 Mech

Required Persons
Table 3 Required Persons

Number of Persons Category

1 Welder

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Support Equipment
Table 4 Support Equipment

Nomenclature Identification No. Qty

Chain Hoist 1

Dummy Seal Housing 1

Chain Hoist 1

Electric Welding Tool 1

Hoisting Eye-bolts AIR

Hydraulic Jack 1

Hydraulic Nut HMV 60 1

Induction Heater 1

Plastic Cap 1

Ring Spanner W08482567 and W08482568 1

Consumables, Materials and Expendables

Table 5 Supplies S
Nomenclature Identification No. Qty

Copaslip T003000768 AIR

Loctite 243 TOOl 048197 AIR
Loctite 270 T002005540 AIR
Loctite 577 T0020071 14 AIR
Lockwire W007550008 AIR
Molykote 44 T002000754 AIR
0-rings AIR
Super Clean 706 T003000506 AIR
Welding consumable AVESTA P5 AIR

Safety Conditions
WARNINGS
'MAKE SURE THAT WHEN YOU CONNECT WELDING EQUIPMENT YOU ALWAYS USE AN
EARTH CONNECTION. CONNECT THE EARTH CONNECTION AS CLOSE AS POSSIBLE TO
THE WELD POINT TO PREVENT INJURY OR DAMAGE TO EQUIPMENT.

'MAKE SURE THE LOWER GEARBOX IS SECURE AND CANNOT FALL OVER.

'MAKE SURE THAT WHEN YOU USE LIFTING EQUIPMENT THE FOLLOWING APPLIES:
- SUFFICIENT SPACE EXISTS FOR THE EQUIPMENT TO MOVE IN;
- PERSONNEL ARE IN SAFE POSITIONS.

'ALWAYS WEAR PROTECTIVE CLOTHING AND GLASSES WHEN YOU WORK ON

EQUIPMENT.

CAUTIONS
BE CAREFUL WHEN YOU USE A PIPE-WRENCH. MAKE SURE THAT YOU DO NOT CAUSE
DAMAGE TO THE TOP PART OF THE SUCTION-LINE.

'WHEN YOU APPLY HEAT TO THE ASSEMBLY PARTS DO NOT EXCEED A MAXIMUM
TEMPERATURE OF 125 DEG. C (255 DEG. F) UNLESS OTHERWISE STATED.

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Procedure
Table 6 Sequence of Assembly

Step Component Description Reference

1 Suction Line Install in the pod casing.

2 Input Shaft Assemble with the undersized precision BTF-A-03-22-00-OOA-71 OA-C

blocks in the bearing housing.
3 Input Shaft Install in the lower gearbox.

4 Input Shaft Adjust the bearing clearance. BTF-A-03-20-00-OOA-271 A-C

5 Input Shaft Install the adjustment ring of the correct

thickness in the bearing housing.
6 Input Shaft Make sure the bearing clearance is BTF-A-03-20-00-OOA-271 A-C
within the permitted limits.
7 Input Shaft Install the compression springs in the
bearing housing.
8 Input Shaft Install the compression springs under
the bearing housing.
9 Propeller Shaft Assemble with the crown wheel. BTF-A-03-21 -00-OOA-271 A-C

10 Propeller Shaft Install in the lower gearbox.

11 Propeller Shaft Install the bearings in the bearing

housing and the precision blocks.
12 Propeller Shaft Adjust the bearing clearance. BTF-A-03-20-00-OOA-271 A-C

13 Propeller Shaft Install the adjustment ring of the correct

thickness in the bearing housing.
14 Propeller Shaft Check the adjustment for the bearing
clearance.
15 Gearset Adjust the gear pattern. BTF-A-03-20-00-OOA-271 A-C

16 Input Shaft Install the adjusting ring.

17 Gearset Adjust the gear backlash. BTF-A-03-20-00-OOA-271 A-C

18 Propeller Shaft Install the adjusting ring.

19 Pod Cap Install the pod cap.

20 Inspection Cover Install the inspection cover.

Effectivity: BTF-A-03-20-OO-OOA-71 OA-C

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Step Component Description Reference

21 Lower Gearbox Do the spin test.

Note
Use Super Clean 706 to clean both fasteners and surfaces before applying a Loctite
product.

Do these steps to install the suction line:

1.1 Connect these parts together:

- the suction-line (6) with the bend;
- the angle connection (5) with the 45 degree bend.

1.2 Seal the joint between the suction-line (6) and the angle connection (5) with Loctite 577.

1.3 Install loosely the pipe-clamps (8) onto the suction-line (6). For the position of the pipe-
clamps (8), refer to the LIPS drawing "Assembly of the Pod" in the Appendix.

1.4 Put the suction-line (6) with the bend into the pod casing (3).

1.5 Put the suction-line (4) through the hole in the top of the pod casing (3) into the angle
connection (5). Make sure the joint between the suction-line (4) and the angle connection
(5) is a satisfactory fit.

1 .6 Install these items over the suction-line (4) into the pod casing (3):
- the copper sealing-ring (2);
- the stud-coupling (1).
Tighten the stud-coupling (1) until finger tight.

1.7 Put the support brackets (8) in the pod casing (3).

1.7.1 Adapt the shape and the dimensions of each support bracket (8) to hold the pipe-
clamps (7).

1.7.2 Make a mark on the pod casing (3) for the position of each support bracket (8).

1.7.3 Make a mark on the support bracket (8) for the position of the pipe-clamps (7).
1.8 Loosen the stud-coupling (1).

1.9 Release the suction-line (4) and pull it up approximately 10 cm.

1.loRemove the support brackets (8) from the pod casing (3).
1.11 Disassemble the pipe-clamps (7) from the suction-line (6).

1.l2Remove the pipe-clamps (7) and the suction-line (6) from the pod casing (3).

Effectivity: BTF-A-03-20-00-OOA-71 OA-C

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Fig 1 Lower Gearbox - Installation of the Suction Line

WARNING
MAKE SURE THAT WHEN YOU CONNECT WELDING EQUIPMENT YOU ALWAYS USE
AN EARTH CONNECTION. CONNECT THE EARTH CONNECTION AS CLOSE AS
POSSIBLE TO THE WELD POINT TO PREVENT INJURY OR DAMAGE TO EQUIPMENT.

CAUTION
ALWAYS PROTECT THE SURROUNDING AREA FROM WELDING SPLATTER WHEN
WELDING.

1 .1 3Use the electric welding tool to weld the pipe-clamps (7) to the support brackets (8).

1.l4Install the support bracket (8) in the pod casing (3).

Effectivity: BTF-A-03-20-OO-OOA-71 OA-C

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WARNING
S
MAKE SURE THAT WHEN YOU CONNECT WELDING EQUIPMENT YOU ALWAYS USE
AN EARTH CONNECTION. CONNECT THE EARTH CONNECTION AS CLOSE AS
POSSIBLE TO THE WELD POINT TO PREVENT INJURY OR DAMAGE TO EQUIPMENT.

CAUTION
ALWAYS PROTECT THE SURROUNDING AREA FROM WELDING SPLATTER WHEN
WELDING.

1.1 5Use the electric welding tool to weld the support bracket (8) to the pod casing (3).

1 .l6Clean the joints of the support bracket (8) to the pod casing (3).

1.l7Paint the joints of the support bracket (8) to the pod casing (3) and the area on all sides
of the joints. For more information on the paint you require, refer to the Hempel Coating
Specification for Tunnel Thrusters in the Appendix.

1.l8Put the suction-line (6) with the bend into the pod casing (3).

1.1 9Assemble the pipe-clamps (7) on the suction-line (6).

1 .2Olnstall the suction-line (4) into the angle connection (5). Make sure the joint between the
suction-line (4) and the angle connection (5) is a satisfactory fit.

1.21 Use Loctite 577 to seal the joint between the suction-line (4) and the angle connection
(5).

WARNING
CAUTION
BE CAREFUL WHEN YOU USE A PIPE-WRENCH. MAKE SURE THAT YOU DO NOT
CAUSE DAMAGE TO THE TOP PART OF THE SUCTION-LINE.

1 .22Use a pipe-wrench to tighten the stud-coupling (1).

1.23 Put a plastic cap on the top of the suction-line (4).

Effectivity: BTF-A-03-20-OO-OOA-71 OA-C

AH

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2 Assemble the input shaft with the undersized precision blocks in the bearing housing (Ref.
BTF-A-03-22-OO-OOA-71 OA-C).

3 Do these steps to install the input shaft in the lower gearbox:

Refer to Fig 2

3.1 Use the chain hoist to put the pod casing (9) on the wooden blocks. Make sure the flange
the input shaft (4) extends from faces up.

3.2 Clean thoroughly these parts:

- the mating face of the bearing housing (3).
- the input shaft (4);
- the mating faces of the roller-bearings (5, 6);

WARNING
MAKE SURE THE LOWER GEARBOX IS SECURE AND CANNOT FALL OVER.

3.3 Install the eye-bolt into the top of the input shaft (4).

WARNING
MAKE SURE THAT WHEN YOU USE LIFTING EQUIPMENT THE FOLLOWING APPLIES:

- SUFFICIENT SPACE EXISTS FOR THE EQUIPMENT TO MOVE IN;

- PERSONNEL ARE IN SAFE POSITIONS.

3.4 Use the chain hoist with the eye-bolt to carefully lift the input shaft (4) over the opening
for the input shaft (4). Align the outer rings of the bearings (5, 6) with the input shaft (4).

3.5 Lower carefully the input shaft (4) into the pod casing (9). Make sure the outer rings of
the bearings (5, 6) remain in line with the input shaft (4). Help the bearings (5, 6) go into
their supports.

3.6 Put the precision blocks (7) between the flange of the bearing housing (3) and the flange
(8) of the pod casing (9). Use precision blocks (7) of the same thickness given for the
adjusting ring (Refer to the list of parts in the Appendix). You install the precision blocks
temporarily to obtain the correct gear pattern (Ref. BTF-A-03-20-OO-OOA-271A-C).

3.7 Use a minimum of four screws (1) to fasten the input shaft (4) to the flange (8) of the pod
casing (9). Install the screws (1) through the seal housing (2) and the bearing housing
(3). Tighten the screws (1) to a torque value of 265 Nm (195 lb/ft).

Effectivity: BTF-A-03-20-00-OOA-71 OA-C

AU

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Fig 2 Input Shaft - Installation of the Precision Blocks for the Gear Pattern Adjustment

Effectivity: BTF-A-03-20-OO-OOA-71 OA-C

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 BTF-NLI PS-03
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4 Adjust the bearing clearance for the input shaft (Ref. BTF-A-03-20-OO-OOA-271A-C).

5 Do these steps to install the adjustment ring of the correct thickness in the bearing housing
of the input shaft:
Refer to Fig 3

5.1 Remove the screws (1) that fasten the seal housing (2) to the bearing housing (8).
5.2 Remove the seal housing (2) from the bearing housing (8).

5.3 Use the grease Molykote 44 to fill half of the space inside the seal housing (2).
5.4 Remove the precision blocks from the bearing housing (8).

5.5 Install the adjusting ring (6) of the correct thickness in the bearing housing (8).

5.6 Apply lightly the grease Molykote 44 to the supporting ring (3) and the oil seal (4). Make
sure you use the correct items. Compare the mould numbers.

5.7 Install the supporting ring (3) and the oil seal (4) in the seal housing (2).

5.8 Apply lightly the grease Molykote 44 to the 0-ring (5).

5.9 Install the 0-ring (5) in the groove in the flange of the bearing housing (8).

5.lOUse the screws (1)to install the seal housing (2) on the bearing housing (8). Make sure
the vent connections in the seal housing (2) point in the correct direction.

6 Make sure the bearing clearance is within the permitted limits (Ref. BTF-A-03-20-OO-OOA-
271 A-C).

Effectivity: BTF-A-03-20-00-OOA-71 OA-C

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Fig 3 Input Shaft - Installation of the Adjustment Ring in the Bearing Housing

Effectivity: BTF-A-03-20-OO-OOA-71 OA-C

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7 Do these steps to install the compression springs in the bearing housing of the input shaft:
Refer to Fig 4

7.1 Remove the screws (1) that fasten the seal housing (2)to the bearing housing (9).

7.2 Remove the seal housing (2) from the bearing housing (9).

7.3 Use the grease Molykote 44 to fill half of the space inside the seal housing (2).
7.4 Apply lightly the grease Molykote 44 to the supporting ring (3) and the oil seal (4).

7.5 Install the supporting ring (3) and the oil seal (4) in the seal housing (2).
7.6 Install the spring dowel (5) in the seal housing (2).

7.7 Apply lightly the grease Molykote 44 to the 0-ring (6).

7.8 Install the 0-ring (6) in the groove in the flange of the bearing housing (9).

7.9 Install the compression springs (7) in the holes of the adjusting ring in the bearing
housing (9).

7.1 OUse the screws (1) to install the seal housing (2) on the bearing housing (9). Make sure:
- the vent connections in the seal housing (2) point in the correct direction;
- the compression springs (7) remain in position in the holes of the adjusting ring;
- the spring dowel (5) aligns with the centre of the compression spring (7).

Effectivity:
All
BTF-A-03-20-00-OOA-71 OA-C S
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I
- Marine Propulsion Systems

Fig 4 Input Shaft - Installation of the Compression Springs in the Bearing Housing

Effectivity: BTF-A-03-20-OO-OOA-71 OA-C

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8 Do these steps to install the compression springs under the bearing housing of the input shaft:
Refer to Fig 5

8.1 Remove the screws (2) that fasten the input shaft (3) to the flange (12) of the pod casing
(13).

WARNING
MAKE SURE THAT WHEN YOU USE LIFTING EQUIPMENT THE FOLLOWING APPLIES:

- SUFFICIENT SPACE EXISTS FOR THE EQUIPMENT TO MOVE IN;

- PERSONNEL ARE IN SAFE POSITIONS.

8.2 Use the chain hoist to lift the input shaft (3) from the pod casing (13).

8.3 Install the compression springs (7) in the bearing housing (6) using the screw plugs (8).
8.4 Apply lightly the grease Molykote 44 to the 0-ring (5).

8.5 Install the 0-ring (5) in the groove in the flange of the bearing housing (6).

WARNING
MAKE SURE THAT WHEN YOU USE LIFTING EQUIPMENT THE FOLLOWING APPLIES:

- SUFFICIENT SPACE EXISTS FOR THE EQUIPMENT TO MOVE IN;

- PERSONNEL ARE IN SAFE POSITIONS.

8.6 Use the chain hoist to lower carefully the input shaft (3) into the pod casing (13). Help
the bearings (9, 10) go into their supports. Make sure:
- the outer rings of the bearings (9, 10) remain in line with the input shaft (3);
- the groove in the outer ring of the bearings (9, 10) align with the hardened pins (Ref.
View A).

8.7 Install the V-ring (1) over the liner on the input shaft (3).

8.8 Install the screws and dubo retaining-rings in the vacant threaded holes of the seal
housing (4).

8.9 Install the vent plug and the copper sealing-ring in the top of the seal housing (4).

8.1 OInstaIl the plug in the vent connection of the seal housing (4) to keep the dirt out.

8.11 Apply Loctite 243 to the thread of the screw (1).

8.l2Use the screw (14) to fasten the block (15) with the hardened pin (16) to the lower
bearing support inside the pod casing (13). Tighten the screw (14) to a torque value of
47 Nm (35 lb/ft).

8.l3Use the screw (17) to fasten the block (18) with the hardened pin (19) to the upper
bearing support inside the pod casing (13). Tighten the screw (17) to a torque value of
47 Nm (35 lb/ft).

Effectivity: BTF-A-03-20-OO-OOA-71 OA-C

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Fig 5 Input Shaft - Installation of the Compression Springs under the Bearing Housing

BTFAO3200000A71 OAC3

Effectivity: BTF-A-03-20-00-OOA-71 OA-C

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9 Assemble the propeller shaft (17) (Ref. BTF-A-03-21 -00-OOA-71 OA-C).

10 Do these steps to install the propeller shaft in the lower gearbox:

Refer to Fig 6

10.1 Clean thoroughly the propeller shaft (3).

WARNING
MAKE SURE THAT WHEN YOU USE LIFTING EQUIPMENT THE FOLLOWING APPLIES:

- SUFFICIENT SPACE EXISTS FOR THE EQUIPMENT TO MOVE IN;

- PERSONNEL ARE IN SAFE POSITIONS.

10.2 Use the chain hoist to put the propeller shaft (3) in a vertical position. Make sure the end
with the crown-wheel (4) points up.

WARNING
ALWAYS WEAR PROTECTIVE CLOTHING AND GLASSES WHEN YOU WORK ON
EQUIPMENT.

1 0.3Apply heat to the roller-bearing (5). Make sure the temperature is approximately 80 deg.
C (176 deg. F) greater than the temperature of the propeller shaft (3).

10.4Install the roller-bearing (5) onto the propeller shaft (3).

10.5Install the retaining ring (6) on the propeller shaft (3).

1 0.6Let the hot roller-bearing (5) cool sufficiently before you proceed to step 10.7.

1 0.7Apply lightly the grease Molykote 44 to the 0-ring (7).

10.8lnstall the 0-ring (7) in the groove of the bearing flange (8).

10.9Put the bearing flange (8) on the wooden blocks. Make sure:
- the end with the crown-wheel (4) points down;
- the height is sufficient to install the screws (9).

WARNING
MAKE SURE THAT WHEN YOU USE LIFTING EQUIPMENT THE FOLLOWING APPLIES:

- SUFFICIENT SPACE EXISTS FOR THE EQUIPMENT TO MOVE IN;

- PERSONNEL ARE IN SAFE POSITIONS.

10.lOUse the chain hoist to lower the propeller shaft (3) onto the bearing flange (4). Make
sure that the end of the propeller shaft (3) is on the wooden block.

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BTF-AILIPS-03

Fig 6 Propeller Shaft - Installation of the Propeller Shaft in the Lower Gearbox

10.11 Install the hardened pins (2) in the pod casing (1).

10.l2lnstall the hoisting eye-bolts in the pod casing (1).

WARNING
MAKE SURE THAT WHEN YOU USE LIFTING EQUIPMENT THE FOLLOWING APPLIES:

- SUFFICIENT SPACE EXISTS FOR THE EQUIPMENT TO MOVE IN;

- PERSONNEL ARE IN SAFE POSITIONS.

10.1 3Use the chain hoist to lower the pod casing (1) on the bearing flange (8). Make sure the
hardened pins (2) align with the holes in the bearing flange (8).

10.l4Apply Loctite 270 to the threads of the bolts (9).

10.l5Use the bolts (9) to fasten the bearing flange (8) to the pod casing (1). Tighten the bolts
(9) to a torque value of 610 Nm (450 lb/ft).

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11 Do these steps to install the bearings in the bearing housing and the precision blocks:
S
Refer to Fig 7

11.1 Install the hardened pin (14) in the bearing housing (13).

11 .2 Install the outer race of the thrust bearing (9) in the bearing housing (13).

11.3 Use the feeler gauge to make sure these items touch:
- the outer race of the thrust bearing (9);
- the inner surface of the bearing housing (13).

11 .4Adjust the hardened pin (14) to make the items in step 11.3 touch, if applicable.

11.5 Remove the outer race of the thrust bearing (9) from the bearing housing (13).

11.6 Use the electric welding tool to weld the hardened pin (14) to the rear of the bearing
housing (13).

11 .7AppIy lightly the grease Molykote 44 to the 0-ring (11).

11 .8lnstall the 0-ring (11) around the outer edge of the flange of the bearing housing (13). S
11 .9Apply lightly the grease Molykote 44 to the 0-ring (12).

11.1 Olnstall the 0-ring (12) in the groove of the bearing housing (13).

WARNING
MAKE SURE THAT WHEN YOU USE LIFTING EQUIPMENT THE FOLLOWING APPLIES:

- SUFFICIENT SPACE EXISTS FOR THE EQUIPMENT TO MOVE IN;

- PERSONNEL ARE IN SAFE POSITIONS.

11.11 Use the chain hoist and the hoisting eye-bolts to put the bearing housing (13) over the
propeller shaft (17).

11.l2Put the precision blocks (15) between the flange of the bearing housing (13) and the
face of the pod casing (16). Use precision blocks (15) of the same thickness given for the
adjusting ring (Refer to the list of parts in the Appendix). You install the precision blocks
temporarily to obtain the correct backlash (Ref. BTF-A-03-20-O0-OOA-271A-C).

11.1 3Use the screws (1) to fasten the bearing housing (13) to the pod casing (16). Use a
minimum of four screws (1) adjacent to each precision block (15). Tighten the screws (1)
to a torque value of 350 Nm (260 lb/fl).

11.1 4lnstall the outer race of the thrust bearing (9) in the bearing housing (13).

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Fig 7 Propeller Shaft - Installation of the Precision Blocks in the Lower Gearbox

WARNING
ALWAYS WEAR PROTECTIVE CLOTHING AND GLASSES WHEN YOU WORK ON
EQUIPMENT.

CAUTION
WHEN YOU APPLY HEAT TO THE ASSEMBLY PARTS DO NOT EXCEED A MAXIMUM
TEMPERATURE OF 125 DEG. C (255 DEG. F) UNLESS OTHERWISE STATED.

11 .l5AppIy heat to these items. Make them approximately 80 deg. C (176 deg. F) greater
than the temperature of the propeller shaft (17):
- the inner ring of the thrust-bearing (9) including the roller and cage assembly;
- the reducing bush (8);
- the inner ring of the tapered-roller bearing (7) including the roller and cage assembly.

11 .1 6lnstall the inner ring of the thrust-bearing (9) on the propeller shaft (17).

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11.l7Install the reducing bush (8) on the propeller shaft (17).

11 .l8lnstaII the inner ring of the tapered-roller bearing (7) on the propeller shaft (17).

11.1 9Let the hot items cool sufficiently before you proceed to step 11.20.

11 .2OUse the hydraulic nut to press the roller bearing (7) and the thrust-bearing (9) into
position in the bearing housing (13). Set the pressure of the hydraulic pump to 250 bar.
11 .21 Remove the hydraulic nut.

11 .22lnstall the outer race of the roller bearing (7) and the distance ring (4) in the bearing
housing (13).

11 .23Apply lightly the grease Molykote 44 to the thread of the lock nut (5).

WARNING
CAUTION
TAKE CARE NOT TO DAMAGE THE PROPELLER SHAFT WHEN YOU TIGHTEN THE
LOCK NUT.

11.24lnstall the lock nut (5) on the propeller shaft (17). Tighten the lock nut (5) as far as
possible.

11 .25lnstall the dummy seal housing (2) over the propeller shaft (17) to keep the bearing set
together.

11.26 Use a minimum of four screws (1) to fasten the dummy seal housing (2) to the bearing
housing (13). Tighten the screws (1) to a torque value of 350 Nm (260 lb/ft).

WARNING
CAUTION
TAKE CARE NOT TO DAMAGE THE PROPELLER SHAFT WHEN YOU TIGHTEN THE
LOCK NUT.

11 .27Use the LIPS ring spanner with the chain hoist to tighten the lock nut (5) to a torque
value between 22,000 Nm (16250 lb/ft) and 26,600 Nm (19150 lb/ft).
11 .28Tighten the grub screws (6) to a torque value of 35 Nm (25.8 lb/ft).

11 .29Remove the chain hoist and the LIPS ring spanner from the lock nut (5).

11.30 Remove the screws (1) that fasten the dummy seal housing (2) to the bearing housing
(13).

11.31 Remove the dummy seal housing (2) from the propeller shaft (17).

11 .32Put four undersized precision blocks (3) on the distance ring (4) in the bearing housing
(13). Use precision blocks (3) that are thinner than the adjusting ring (Refer to the parts
list in the Appendix for the dimensions of the adjusting ring).
Note
You install the precision blocks (3) temporarily to obtain the bearing clearance for an oversize
adjusting ring.

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______________

11 .33lnstall the seal housing (2) over the propeller shaft (17).

11 .34Use the screws (1) to fasten the seal housing (2) to the bearing housing (13). Use a
minimum of four screws (1) adjacent to each precision block (3). Tighten the screws (1)
to a torque value of 350 Nm (260 lb/ft).

12 Adjust the bearing clearance for the propeller shaft (Ref. BTF-A-03-20-O0-OOA-271 A-C).

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13 Do these steps to install the adjusting ring in the bearing housing after the adjustment for the
bearing clearance:
Refer to Fig 8

13.1 Remove the bolts (1)that fasten the seal housing (2) to the bearing housing (6).
13.2 Remove the seal housing (2) from the propeller shaft (5).

13.3Remove the precision blocks from the bearing housing (6).

13.4lnstall the adjusting ring (4) in the bearing housing (6).

1 3.5Apply Molykote 111 to the 0-ring (3) and the groove in the propeller shaft seal (2).

13.6Put the 0-ring (3) in the groove on the propeller shaft seal (2).

13.7lnstall the liner and the propeller shaft seal (2) on the propeller shaft (5). Make sure the
position of the oil inlet and vent plugs are at the 'TOP".

1 3.8Apply Loctite 270 to the threads of the bolts (1).

13.9 Install the bolts (1) in the propeller shaft seal (2) and the bearing housing (6). Tighten the
bolts (1) to a torque value of 350 Nm (260 lb/ft).

Fig 8 Propeller Shaft - Installation of the Adjustment Ring in the Bearing Housing

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14 Make sure the bearing clearance is within the permitted limits (Ref. BTF-A-03-20-00-OOA-
271 A-C).

15 Do the adjustment procedure for the gear pattern (Ref. BTF-A-03-20-00-OOA-271 A-C).

16 Do these steps to install the adjusting ring for the input shaft:
Refer to Fig 9 and Fig 10

WARNING
MAKE SURE THAT WHEN YOU USE LIFTING EQUIPMENT THE FOLLOWING APPLIES:

- SUFFICIENT SPACE EXISTS FOR THE EQUIPMENT TO MOVE IN;

- PERSONNEL ARE IN SAFE POSITIONS.

16.1 Use the chain hoist to turn the lower gearbox on the wooden blocks. Make sure the
opening from which the input shaft (2) extends points up.

1 6.2Cut the adjusting ring (4) in half across the middle of two adjacent screw holes.

Fig 9 Input Shaft - Adjusting Ring

16.3 Remove the screws (1) that fasten the seal housing and the bearing housing (3) to the
flange (5) of the pod casing (6).

WARNING
MAKE SURE THAT WHEN YOU USE LIFTING EQUIPMENT THE FOLLOWING APPLIES:

- SUFFICIENT SPACE EXISTS FOR THE EQUIPMENT TO MOVE IN;

- PERSONNEL ARE IN SAFE POSITIONS.

16.4Use the chain hoist to sufficiently lift the input shaft (2) from the flange (5) of the pod
casing (6) to gain access to the precision blocks.

1 6.5Replace two precision blocks with one half of the adjusting ring (4). Make sure the screw
holes in the adjusting ring (4) align with the threaded holes in the pod casing (6).

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I
Marine Propulsion Systems

16.6Replace the remaining two precision blocks with the other halt of the adjusting ring (4).
Make sure the screw holes in the adjusting ring (4) align with the threaded holes in the
pod casing (6).

1 6.7Lower carefully the input shaft (2) onto the adjusting ring (4). Make sure the screw holes
in the adjusting ring (4) remain aligned.

16.BApply Loctite 243 to the threads of the screws (1).

1 6.9Use the screws (1) to fasten the input shaft (2) and the adjusting ring (4) to the flange (5)
of the pod casing (6). Tighten the screws (1) to a torque value of 195 Nm (145 lb/ft).

Fig 10 Input Shaft - Installation of the Adjusting Ring

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17 Do the adjustment procedure for the gear backlash (Ref. BTF-A-03-20-OO-OOA-271 A-C).

18 Do these steps to install the adjusting ring for the propeller shaft:

WARNING
MAKE SURE THAT WHEN YOU USE LIFTING EQUIPMENT THE FOLLOWING APPLIES:

- SUFFICIENT SPACE EXISTS FOR THE EQUIPMENT TO MOVE IN;

- PERSONNEL ARE IN SAFE POSITIONS.

Refer to Fig 11 and Fig 12

18.1 Use the chain hoist to turn the lower gearbox on the wooden blocks. Make sure the
opening from which the propeller shaft (2) extends points up.

18.2lnstall two hoisting eyes (1) in the flange of the bearing housing (5).

1 8.3Cut the adjusting ring in two halves (4) across the middle of two adjacent screw holes.

Fig 11 Propeller Shaft - Adjusting Ring

18.4 Loosen the screws (3) that fasten the bearing housing (5) to the flange of the pod casing
(6).

WARNING
MAKE SURE THAT WHEN YOU USE LIFTING EQUIPMENT THE FOLLOWING APPLIES:

- SUFFICIENT SPACE EXISTS FOR THE EQUIPMENT TO MOVE IN;

- PERSONNEL ARE IN SAFE POSITIONS.

1 8.5Use the chain hoist to sufficiently lift the propeller shaft (2) to gain access to the precision
blocks.

1 8.6Replace two precision blocks with one half of the adjusting ring (4). Make sure the screw
holes in the adjusting ring (4) align with the threaded holes in the pod casing (6).

18.7Replace the remaining two precision blocks with the other half of the adjusting ring (4).
Make sure the screw holes in the adjusting ring (4) align with the threaded holes in the
pod casing (6).

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18.8Lower carefully the propeller shaft (2) onto the adjusting ring (4). Make sure the screw
holes in the adjusting ring (4) remain aligned with the threaded holes in the pod casing
(6).

1 8.9Apply Loctite 243 to the threads of the screws (3).

18.101nstall the remaining screws (3) to fasten the propeller shaft (2) and the adjusting ring
(4) to the flange of the pod casing (6). Tighten the screws (3) to a torque value of 195 Nm
(145 lblft).

18.11 Remove the two hoisting eyes (1) from the flange of the bearing housing (5).

18.l2Apply Loctite 270 to the threads of the bolts that seal the remaining threaded holes in
the bearing housing (5).

18.l3lnstall the bolts and the dubo retaining rings in the threaded holes of the bearing
housing (5). Tighten the bolts to a torque value of 350 Nm (260 lb/ft).

Fig 12 Propeller Shaft - Installation of the Adjusting Ring

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19 Do these steps to install the pod cap:

Refer to Fig 13

WARNING
MAKE SURE THAT WHEN YOU USE LIFTING EQUIPMENT THE FOLLOWING APPLIES:

- SUFFICIENT SPACE EXISTS FOR THE EQUIPMENT TO MOVE IN;

- PERSONNEL ARE IN SAFE POSITIONS.

19.1 Use the chain hoist to turn the lower gearbox on the wooden blocks. Make sure:
- the opening from which the propeller shaft (1) extends points down;
- the opening which you install the pod cap (6) points up;
- the input shaft (3) is horizontal.

WARNING
ALWAYS WEAR PROTECTIVE CLOTHING AND GLASSES WHEN YOU WORK ON
EQUIPMENT.

19.2Use the electric welding tool to install the lockwire on the bolts that fasten the bearing
flange (4) to the pod casing (3).

1 9.3Fill the holes of the three locators in the bearing flange (4) with Molykote 111.

1 9.4Apply Molykote 111 to the 0-ring (5).

19.5lnstall the 0-ring (5) on the bearing flange (4).

1 9.6Apply Loctite 270 to the threads of the bolts (7).

19.7lnstall the bolts (7) in the pod cap (6) and the bearing flange (4). Tighten the bolts (7) to
a torque value of 610 Nm (450 lb/ft).

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Fig 13 Lower Gearbox - Installation of the Pod Cap

20 Do these steps to install the inspection cover:

20.1 Install the compression springs and the plugs in the bearing housing of the propeller
shaft.

20.2Apply Molykote 111 to the 0-ring.

20.3lnstall the 0-ring on the inspection cover.

20.4 Put the inspection cover on the pod casing.

20.5AppIy Loctite 270 to the threads of the screws that fasten the inspection cover to the pod
casing.

20.6 Install the screws to fasten the inspection cover to the pod casing. Tighten the screws to
a torque value of 185 Nm (135 Ib/ft)

20.7lnstall the seal plug and the bonded seal in the inspection cover.

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WARNING
MAKE SURE THAT WHEN YOU USE LIFTING EQUIPMENT THE FOLLOWING APPLIES:

- SUFFICIENT SPACE EXISTS FOR THE EQUIPMENT TO MOVE IN;

- PERSONNEL ARE IN SAFE POSITIONS.

20.8Put the lower gearbox in a safe position.

21 Do a spin test of the lower gearbox.

Requirements After Job Completion

1 Cover these parts of the lower gearbox with protective material:
- the input shaft and the input shaft seal;
- the propeller shaft and the propeller shaft seal.

2 Make sure that there are no tools or equipment in the work area and that the work area is
clean.

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Lower Gearbox - Installation

References
Table 1 References

Data Module! Technical Publication Title

BTF-A-02-1 O-OO-OOA-720A-A Propeller Installation

BTF-A-05-1 0-OO-OOA-520A-B Outer Rope Guard Assembly
Removal
BTF-A-08-OO-0O-OOA-21 2A-A Lubrication Oil Filling
BTF-A-09-1 1 -OO-OOA-921 A-B Brake Pads Change

Preliminary Requirements

Required Conditions
Table 2 Required Conditions

Condition Data Module

Hot Work Permit N/A

Required Persons
Table 3 Required Persons

Number of Persons Category

4 Mech

Required Persons
Table 3 Required Persons

Number of Persons Category

1 Welder

Support Equipment
Table 4 Support Equipment

Nomenclature Identification No. Qty

Chain Hoist
Electric Welding Tool
Feeler gauge - 0.03 mm
Grinding Wheel
Hoisting Eye-bolt
Shackles 4
Slings NR

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Consumables, Materials and Expendables

Table 5 Supplies

Nomenclature Identification No. Qty

Electrode 3.5 mm 36 D FILARC (Philips) AIR

Electrode 4.0 mm C 23 S (Philips) AIR
Electrode 5.0 mm 36 D FILARC (Philips) AIR
Loctite 275 W005903954 AIR
Loctite 574 T00201 4948 AIR
Lockwire W007550008 AIR
0-rings AIR
Super Clean 706 T003000506 AIR
Welding consumable AVESTA P5 AIR

Safety Conditions
WARNINGS
'MAKE SURE THAT WHEN YOU CONNECT WELDING EQUIPMENT YOU ALWAYS USE AN
EARTH CONNECTION. CONNECT THE EARTH CONNECTION AS CLOSE AS POSSIBLE TO
THE WELD POINT TO PREVENT INJURY OR DAMAGE TO EQUIPMENT.

'ALWAYS WEAR PROTECTIVE CLOTHING AND GLASSES WHEN YOU WORK ON

EQUIPMENT.
CAUTIONS
'DO NOT ATTACH LIFTING EQUIPMENT TO MACHINED SURFACES, SHAFT ENDS, PIPING
WORK OR OTHER EXTERNALLY MOUNTED EQUIPMENT.

ALWAYS PROTECT THE SURROUNDING AREA FROM WELDING SPLATTER WHEN

WELDING.

KEEP THE TUNNEL AS COOL AS POSSIBLE TO PREVENT DAMAGE WHEN WELDING.

'DO NOT LIFT THE LOWER GEARBOX FROM THE INPUT SHAFT. THE THREADED HOLE
FOR THE HOISTING EYE-BOLT WILL NOT TAKE THE WEIGHT OF THE LOWER GEARBOX.

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Procedure
Note
Use Super Clean 706 to clean both fasteners and surfaces before applying a Loctite
product.

Do these steps to prepare the lower gearbox:

Refer to Fig 1

1.1 Clean these parts of the transverse thruster:

- the top flange of the lower gearbox;
- the lower surface of the mounting flange for the lower gearbox in the tunnel assembly.

WARNING
ALWAYS WEAR PROTECTIVE CLOTHING AND GLASSES WHEN YOU WORK ON
EQUIPMENT.
S
1.2 Use the grinding wheel to grind chamfers on the edges which will join these parts:
- the spokes plates (3, 6);
- the parts of the spoke plates (4, 5) on the tower gearbox.
Make sure that you grind the chamfers at an angle of 30 degrees.

WARNING
MAKE SURE THAT WHEN YOU USE LIFTING EQUIPMENT THE FOLLOWING APPLIES:

- SUFFICIENT SPACE EXISTS FOR THE EQUIPMENT TO MOVE IN;

- PERSONNEL ARE IN SAFE POSITIONS.

CAUTION
DO NOT ATTACH LIFTING EQUIPMENT TO MACHINED SURFACES, SHAFT ENDS,
PIPING WORK OR OTHER EXTERNALLY MOUNTED EQUIPMENT.

1.3 Put carefully the lower gearbox (8300 kg/8.3 tons) in the tunnel of the tunnel assembly.
Make sure:
- the position of the input shaft is directly below the mounting flange for the lower
gearbox;
- the propeller shaft points in the correct direction.

1 .4 Put hoisting tackles on the hoisting eyes (1, 8).

1.5 Put the sling (2) between the part of the spoke plate (4) on the lower gearbox and the
hoisting tackle at hoisting eye (1). Make sure the sling cannot slip off the part of the spoke
plate (4).

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Fig 1 Lower Gearbox - Preparation

1.6 Put the sling (7) between the part of the spoke plate (5) on the lower gearbox and the
hoisting tackle at the hoisting eye (8). Make sure the sling cannot slip off the part of the
spoke plate (5).

1.7 Put the hoisting eye-bolt (9) in the top of the pinion shaft.

1 .8 Put the hoisting tackle on the hoisting eye-bolt (9).

1.9 Put the chain between the hoisting tackle and the hoisting eye-bolt (9).

1.1 OApply loctite 574 to these parts of the transverse thruster:

- the top flange of the lower gearbox;
- the lower surface of the mounting flange for the lower gearbox in the tunnel assembly.
Make sure the top flange of the lower gearbox is clean.

1.11 Apply lightly the grease Molykote 111 to the 0-ring.

1.l2lnstall the 0-ring in the groove on the top flange of the lower gearbox.

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2 Do these steps to install the lower gearbox:

Refer to Fig 2 and Fig 3

WARNING
MAKE SURE THAT WHEN YOU USE LIFTING EQUIPMENT THE FOLLOWING APPLIES:

- SUFFICIENT SPACE EXISTS FOR THE EQUIPMENT TO MOVE IN;

- PERSONNEL ARE IN SAFE POSITIONS.

CAUTION
DO NOT LIFT THE LOWER GEARBOX FROM THE INPUT SHAFT. THE THREADED HOLE
FOR THE HOISTING EYE-BOLT WILL NOT TAKE THE WEIGHT OF THE LOWER
GEARBOX.

2.1 Use the hoisting tackles at the hoisting eyes (1, 8) to lift the lower gearbox to the
mounting flange of the tunnel assembly.

2.2 Use the hoisting tackle at the hoisting eye-bolt (9) to help you align the lower gearbox
with the two spring dowels in the mounting flange of the tunnel assembly.

2.3 Apply Copaslip to the threads of the bolts that fasten the lower gearbox to the mounting
flange of the tunnel assembly.

2.4 Install loosely the bolts in the flange of the lower gearbox.

2.5 Do these steps to align the centre of the propeller shaft with the centre of the tunnel:

2.5.1 Measure the distance from the propeller shaft to the wall of the tunnel.

2.5.2 Adjust the position of the lower gearbox as necessary. Make sure the propeller
shaft is aligned with the centre of the tunnel.

2.6 Do these steps to align the centre of the input shaft with the spigot of the drive motor:

2.6.1 Use a dial gauge to measure the distance between the pinion shaft and the spigot
of the drive motor.

2.6.2 Adjust the position of the lower gearbox as necessary. Make sure input shaft is
aligned with the spigot of the drive motor.

2.7 Tighten the bolts in the flange of the lower gearbox to a torque value of 1300 Nm (950
lb/ft).

2.8 Use the feeler gauge to make sure the flange of the lower gearbox touches correctly the
mounting flange of the tunnel assembly.

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Fig 2 Lower Gearbox - Installation

I
A

J
II

BTFAO3200000A72OAB2

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WARNINGS
MAKE SURE THAT WHEN YOU CONNECT WELDING EQUIPMENT YOU ALWAYS
USE AN EARTH CONNECTION. CONNECT THE EARTH CONNECTION AS CLOSE
AS POSSIBLE TO THE WELD POINT TO PREVENT INJURY OR DAMAGE TO
EQUIPMENT.

ALWAYS WEAR PROTECTIVE CLOTHING AND GLASSES WHEN YOU WORK ON

EQUIPMENT.

CAUTION
ALWAYS PROTECT THE SURROUNDING AREA FROM WELDING SPLATTER WHEN
WELDING.

2.9 Use the electric welding tool to install the lock wire on the bolts that fasten the lower
gearbox to the mounting flange of the tunnel assembly. Do not install the lock wire on the
edges of the heads of the bolts.

Note
It is important that you keep the tunnel as cool as possible to prevent damage. When you weld
the spoke plates you must obey the sequence shown in Table 6

2.1 OClean the joints of the spoke plates (4, 5) to the part of the spoke plate (3, 6).

2.11 Paint the joints between the spoke plates (4, 5) and the parts of the spoke plates (3, 6).
For more information on the paint you require, refer to the Hempel Coating Specification
for Tunnel Thrusters in the Appendix.

Table 6 Spoke Plate Weld Sequence

No. Spoke Plate Surface From To Fig Ref

1 Left Upper left Centre-line Right edge View A
2 Right Upper left Centre-line Right edge View C
3 Left Lower left Centre-line Right edge View B
4 Right Lower left Centre-line Right edge View D
5 Left Upper right Centre-line Left edge View A
6 Right Upper right Centre-line Left edge View C
7 Left Lower right Centre-line Left edge View B
8 Right Lower right Centre-line Left edge View D
9 Left Upper left Left Side Centre-line View A
10 Right Upper left Left Side Centre-line View C
11 Left Lower left Left Side Centre-line View B
12 Right Lower left Left Side Centre-line View D
13 Left Upper right Right Side Centre-line View A
14 Right Upper right Right Side Centre-line View C

Effectivity: BTF-A-03-20-OO-OOA-720A-B
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 BTF-AILI PS-03
John Crane-Lips
Marine Propulsion Systems

No. Spoke Plate Surface From To Fig Ref

15 Left Lower right Right Side Centre-line View B

16 Right Lower right Right Side Centre-line View D

Fig 3 Spoke Plates - Installation

3 Connect the pipes of the lubrication system, refer to the drawing 'tub. oil connections" in the
Appendix.

Requirements After Job Completion

1 Make sure that there are no tools or equipment in the work area and that the work area is
clean.

Effectivity: BTF-A-03-20-OO-OOA-720A-B
All

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 BTF-NLI PS-03
John Crane-Lips
Marine Propulsion Systems

Effectivity: BTF-A-03-20-00-OOA-720A-B
All

2002-02-0 1 Page 10
 BTF-AILI PS-03
John Crane-Lips
Marine Propulsion Systems

Lower Gearbox, Propeller Shaft - Disassembly

References
Table 1 References

Data Module! Technical Publication Title

BTF-A-03-20-OO-OOA-530A-C Removal of the propeller shaft

Preliminary Requirements

Required Conditions
5 Table 2 Required Conditions

Condition Data Module

Remove the LGB propeller shaft BTF-A-03-20-OO-OOA-530A-C

Required Persons
Table 3 Required Persons

Number of Persons Category

2 Mech

Support Equipment
Table 4 Support Equipment

Nomenclature Identification No. Qty

Blow Torch 1

S Chain Hoist
Hoisting Eye-bolt
1

Consumables, Materials and Expendables

Table 5 Supplies

Nomenclature Identification No. Qty

None

Effectivity: BTF-A-03-21 -OO-OOA-530A-C

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2002-02-01 Page 1
 BTF-A/LI PS-03
John Crane-Lips
Marine Propulsion Systems

Safety Conditions
WARNINGS
ALWAYS WEAR PROTECTIVE CLOTHING AND GLASSES WHEN YOU WORK ON
EQUIPMENT.

MAKE SURE THAT WHEN YOU USE LIFTING EQUIPMENT THE FOLLOWING APPLIES:
- SUFFICIENT SPACE EXISTS FOR THE EQUIPMENT TO MOVE IN;
- PERSONNEL ARE IN SAFE POSITIONS.

CAUTIONS
'WHEN YOU APPLY HEAT TO THE ASSEMBLY PARTS DO NOT EXCEED A MAXIMUM
TEMPERATURE OF 125 DEG. C (255 DEG. F) UNLESS OTHERWISE STATED.

Procedure
WARNING
MAKE SURE THAT WHEN YOU USE LIFTING EQUIPMENT THE FOLLOWING APPLIES:

- SUFFICIENT SPACE EXISTS FOR THE EQUIPMENT TO MOVE IN;

- PERSONNEL ARE IN SAFE POSITIONS.

1 Remove the lower gearbox propeller shaft (Ref. BTF-A-03-20-00-OOA-530A-B).

2 Remove the screws (1) and the washers (2) securing the crown wheel (4) to the flange (3) of
the shaft (5). Discard the screws (1).

WARNING
ALWAYS WEAR PROTECTIVE CLOTHING AND GLASSES WHEN YOU WORK ON
EQUIPMENT.

CAUTION
WHEN YOU APPLY HEAT TO THE ASSEMBLY PARTS DO NOT EXCEED A MAXIMUM
TEMPERATURE OF 125 DEG. C (255 DEG. F) UNLESS OTHERWISE STATED.

3 Apply heat to the crown wheel (4). Make the temperature approximately 40 deg. C (104 deg.
F). more than the temperature of the shaft (5).

WARNING
MAKE SURE THAT WHEN YOU USE LIFTING EQUIPMENT THE FOLLOWING APPLIES:

- SUFFICIENT SPACE EXISTS FOR THE EQUIPMENT TO MOVE IN;

- PERSONNEL ARE IN SAFE POSITIONS.

4 Use the chain hoist to lift the crown wheel (4) off the flange (3) of the shaft (5).

5 Put the crown wheel (4) on wooden blocks in a sate position.

Effectivity: BTF-A-03-21 -OO-OOA-530A-C

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2002-02-01 Page 2
 BTF-AILI PS-03
John Crane-Lips
Marine Propulsion Systems

Fig 1 Lower Gearbox Propeller Shaft - Disassembly

Requirements After Job Completion

1 Make sure that there are no tools or equipment in the work area and that the work area is
clean.

Effectivity: BTF-A-03-21 -OO-OOA-530A-C

All

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 BTF-A/LI PS-03
John Crane-Lips
Marine Propulsion Systems

Effectivity: BTF-A-03-21 -OO-OOA-530A-C

All

2002-02-01 Page 4
 BTF-AILI PS-03
John Crane-Lips
Marine Propulsion Systems

Lower Gearbox, Propeller Shaft - Assembly

References
Table 1 References

Data Module! Technical Publication Title

BTF-A-03-20-00-OOA-71 OA-C Assembly of Lower Gearbox

Preliminary Requirements

Required Conditions
Table 2 Required Conditions

Condition Data Module

None

Required Persons
Table 3 Required Persons

Number of Persons Category

2 Mech

Support Equipment
Table 4 Support Equipment

Nomenclature Identification No. Qty

Chain Hoist 1

Hoisting Eye-bolt 1

Induction Heater 1

Long Rod 1

Consumables, Materials and Expendables

Table 5 Supplies

Nomenclature Identification No. Qty

Loctite 243 T001048197 AIR

Super Clean 706 T003000506 AIR

Effectivity: BTF-A-03-21 -OO-OOA-71 OA-C

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2002-02-01 Page 1
 BTF-A/LI PS-03
John Crane-Lips
Marine Propulsion Systems

Safety Conditions
WARNINGS
ALWAYS WEAR PROTECTIVE CLOTHING AND GLASSES WHEN YOU WORK ON
EQUIPMENT.

MAKE SURE THAT WHEN YOU USE LIFTING EQUIPMENT THE FOLLOWING APPLIES:
- SUFFICIENT SPACE EXISTS FOR THE EQUIPMENT TO MOVE IN;
- PERSONNEL ARE IN SAFE POSITIONS.
CAUTIONS
WHEN YOU APPLY HEAT TO THE ASSEMBLY PARTS DO NOT EXCEED A MAXIMUM
TEMPERATURE OF 125 DEG. C (255 DEG. F) UNLESS OTHERWISE STATED.

Procedure
Note
Use Super Clean 706 to clean both fasteners and surfaces before applying a Loctite
product.

1 Thoroughly clean the shaft (5) and the crown wheel (4). Make sure you remove the burrs, if
applicable.

WARNING
MAKE SURE THAT WHEN YOU USE LIFTING EQUIPMENT THE FOLLOWING APPLIES:

- SUFFICIENT SPACE EXISTS FOR THE EQUIPMENT TO MOVE IN;

- PERSONNEL ARE IN SAFE POSITIONS.

2 Use the chain hoist to put the propeller shaft in a vertical position. Make sure the end of the
shaft, which takes the propeller, points up.

WARNING
ALWAYS WEAR PROTECTIVE CLOTHING AND GLASSES WHEN YOU WORK ON
EQUIPMENT.

CAUTION
WHEN YOU APPLY HEAT TO THE ASSEMBLY PARTS DO NOT EXCEED A MAXIMUM
TEMPERATURE OF 125 DEG. C (255 DEG. F) UNLESS OTHERWISE STATED.

3 Apply heat to the crown wheel (4). Make the temperature is approximately 40 deg. C (104
deg. F). more than the temperature of the shaft (5).

Effectivity: BTF-A-03-21 -0O-OOA-71 OA-C

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 BTF-NLIPS-03
John Crane-Lips
Marine Propulsion Systems

Fig 1 Lower Gearbox Propeller Shaft - Assembly

BTFAO3210000A71 OAC

WARNING
MAKE SURE THAT WHEN YOU USE LIFTING EQUIPMENT THE FOLLOWING APPLIES:

- SUFFICIENT SPACE EXISTS FOR THE EQUIPMENT TO MOVE IN;

- PERSONNEL ARE IN SAFE POSITIONS.

4 Use the chain hoist to lift the crown wheel (4) onto the flange (3) of the shaft (5).

5 Install loosely the screws (1) and the washers (2) in the flange (3) and the crown wheel (4).

6 Let the shaft (5) and the crown wheel (4) cool sufficiently before you proceed to step 7.

Eftectivity: BTF-A-03-21 -OO-OOA-71 OA-C

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 BTF-NLIPS-03
John Crane-Lips
Marine Propulsion Systems

WARNING
MAKE SURE THAT WHEN YOU USE LIFTING EQUIPMENT THE FOLLOWING APPLIES:

- SUFFICIENT SPACE EXISTS FOR THE EQUIPMENT TO MOVE IN;

- PERSONNEL ARE IN SAFE POSITIONS.

7 Use the chain hoist to put the shaft (5) in a horizontal position.

8 Install a long rod on the end of the shaft (5). The rod compensates for the torque you apply
on the screws.

9 Remove the four screws (1) shown in View A of Fig 1.

10 Apply Loctite 243 to the threads of the four screws (1).

11 Install the screws (1) and the washers (2) to fasten the crown wheel (4) to the flange (3).
Tighten the screws to a torque value of 690 Nm (500 Ib/ft).

12 Remove the remaining screws (1).

13 Apply Loctite 243 to the threads of the remaining screws (1).

14 Install the screws (1) and the washers (2) in the crown wheel (4). Tighten the screws to a
torque value of 690 Nm (500 lb/ft).

15 Install the propeller shaft in the lower gearbox (Ref. BTF-A-03-20-00-OOA-71 OA-C).

Requirements After Job Completion

1 Make sure that there are no tools or equipment in the work area and that the work area is
clean.

Effectivity: BTF-A-03-21 -OO-OOA-71 OA-C

All

2002-02-01 Page 4
 BTF-NLI PS-03
John Crane-Lips
Marine Propulsion Systems

Lower Gearbox, Input Shaft - Disassembly

References
Table 1 References

Data Module! Technical Publication Title

BTF-A-03-20-OO-OOA-530A-C Removal of LGB input shaft

Preliminary Requirements

Required Conditions
Table 2 Required Conditions

Condition Data Module

Remove the LGB input shaft BTF-A-03-20-OO-OOA-530A-C

Required Persons
Table 3 Required Persons

Number of Persons Category

2 Mech

Support Equipment
Table 4 Support Equipment

Nomenclature Identification No. Qty

Induction Heater 1

Ring Spanner W08482567 and W08482568 1

Hydraulic Jack 1

Threaded Rods 2
Circular Plate 1

Chain Hoist 1

Hoisting Eye-bolts 2

Consumables, Materials and Expendables

Table 5 Supplies

Nomenclature Identification No. Qty

None

Effectivity: BTF-A-03-22-OO-OOA-530A-C
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2002-02-01 Page 1
 BTF-A/LI PS-03
John Crane-Lips
Marine Propulsion Systems

Safety Conditions
WARNINGS
'ALWAYS WEAR PROTECTIVE CLOTHING AND GLASSES WHEN YOU WORK ON
EQUIPMENT.

Procedure
1 Remove the screw plugs (18) and the compression springs (17) from the bearing housing
(16).

2 Remove the screws (1) securing the seal housing (3) to the bearing housing (16).

3 Remove the V-ring (2) from the input shaft (21).

4 Remove the seal housing (3) from the input shaft (23).

5 Remove the spring-dowel pin (4) from the seal housing (3), if applicable.

6 Remove the supporting ring (5) and the oil seal (6) from the seal housing (3). Discard the oil
seal (6).

7 Remove the compression springs (7) and the adjusting ring (8) from the input shaft (23).

8 Loosen the grub screws (9) that prevent the lock nut (10) from turning.

9 Use the chain hoist and the LIPS ring spanner to loosen the lock nut (10).

10 Remove the lock nut (10) from the input shaft (23).
11 Remove the liner (11) from the input shaft (23).

12 Remove the 0-ring (12) from the input shaft (23). Discard the 0-ring (12).
13 Use the hydraulic jack, threaded rods and the circular plate to release the bearing housing
(17). This process releases these items:
- the thrust bearings (13, 15);
- the distance bush (14).

14 Use the chain hoist and the hoisting eye-bolts to remove the items you released in step 13.
15 Remove the 0-ring (16) from the flange of the bearing housing (17). Discard the 0-ring (16).

16 Remove the 0-ring (18) from below the flange of the bearing housing (17). Discard the 0-ring
(18).

17 Remove the retaining ring (21) that fastens the roller-bearing (22) to the input shaft (23).
WARNING
ALWAYS WEAR PROTECTIVE CLOTHING AND GLASSES WHEN YOU WORK ON
EQUIPMENT.

18 Remove the roller-bearing (22) from the input shaft (23). Apply heat to release the roller-
bearing (22), if necessary.

19 Remove the retaining ring (25) that fastens the roller-bearing (24) to the input shaft (23).

Effectivity: BTF-A-03-22-OO-OOA-530A-C
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 BTF-AILI PS-03
John Crane-Lips
Marine Propulsion Systems

20 Remove the roller-bearing (24) from the input shaft (23). Apply heat to release the roller-
bearing (24), if necessary.

Fig 1 Lower Gearbox Input Shaft - Disassembly

Effectivity: BTF-A-03-22-OO-OOA-530A-C
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 BTF-NLI PS-03
John Crane-Lips
Marine Propulsion Systems

Requirements After Job Completion

1 Make sure that there are no tools or equipment in the work area and that the work area is
clean.

Effectivity: BTF-A-03-22-OO-OOA-530A-C
All

2002-02-01 Page 4
 BTF-AILI PS-03
John Crane-Lips
Marine Propulsion Systems

Lower Gearbox, Input Shaft - Assembly

References
Table 1 References

Data Module! Technical Publication Title

BTF-A-03-20-OO-OOA-71 OA-C Installation of the LGB Input

Shaft
BTF-A-03-20-OO-OOA-530A-C Removal of the LGB Input Shaft
BTF-A-03-22-OO-OOA-27 1 A-C Bearing Clearance for the LGB
Input Shaft

Preliminary Requirements

Required Conditions
Table 2 Required Conditions

Condition Data Module

None

Required Persons
Table 3 Required Persons

Number of Persons Category

2 Mech

Support Equipment
Table 4 Support Equipment

Nomenclature Identification No. Oty

Assembly Stand
Induction Heater
Hydraulic Nut HMV 34
Chain Hoist 1
Hoisting Eye-bolts 2
LIPS Ring Spanner (for lock nut)
Precision Blocks AIR

Effectivity: BTF-A-03-22-OO-OOA-71 OA-C

2002-02-01 Page 1
 BTF-AILIPS-03
John Crane-Lips
Marine Propulsion Systems

Consumables, Materials and Expendables

Table 5 Supplies

Nomenclature Identification No. Qty

V-ring M730030039 1

0-ring W007000730 1

Oil Seal W007065208 1

Loctite 243 T001048197 AIR

Copaslip T003000768 AIR
Super Clean 706 T003000506 A/R
Molykotel 11 T00201 46931 A/R

Safety Conditions
WARNINGS
ALWAYS WEAR PROTECTIVE CLOTHING AND GLASSES WHEN YOU WORK ON
EQUIPMENT.

MAKE SURE THAT WHEN YOU USE LIFTING EQUIPMENT THE FOLLOWING APPLIES:
- SUFFICIENT SPACE EXISTS FOR THE EQUIPMENT TO MOVE IN;
- PERSONNEL ARE IN SAFE POSITIONS.

CAUTIONS
'NEVER ALLOW THE BEARING TO BECOME TOO HOT OR APPLY HEAT TO THE BEARING
USING AN OPEN FLAME. THIS MAY RESULT IN PERMANENT DAMAGE TO THE BEARING.

'WHEN YOU APPLY HEAT TO THE ASSEMBLY PARTS DO NOT EXCEED A MAXIMUM
TEMPERATURE OF 125 DEG. C (255 DEG. F) UNLESS OTHERWISE STATED.

Procedure
Note
Use Super Clean 706 to clean both fasteners and surlaces before applying a Loctite product.

1 Clean thoroughly all the assembly parts.

2 Make sure the thread of the lock nut fits on the thread of the input shaft.

Effectivity: BTF-A-03-22-OO-OOA-71 OA-C

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2002-02-01 Page 2
 BTF-A/LI PS-03
John Crane-Lips
Marine Propulsion Systems

3 Do these steps to install the lower roller-bearing:

Refer to Fig 1

WARNING
ALWAYS WEAR PROTECTIVE CLOTHING AND GLASSES WHEN YOU WORK ON
EQUIPMENT.

CAUTIONS
NEVER ALLOW THE BEARING TO BECOME TOO HOT OR APPLY HEAT TO THE
BEARING USING AN OPEN FLAME. THIS MAY RESULT IN PERMANENT DAMAGE
TO THE BEARING.

WHEN YOU APPLY HEAT TO THE ASSEMBLY PARTS DO NOT EXCEED A

MAXIMUM TEMPERATURE OF 125 DEG. C (255 DEG. F) UNLESS OTHERWISE
STATED.

3.1 Apply heat to the roller-bearing (2). Make sure the temperature is approximately 80 deg.
C (176 deg. F) greater than the temperature of the input shaft (1).
3.2 Install the roller-bearing (2) on the input shaft (1).

3.3 Install the retaining ring (3) on the input shaft (1).

Fig 1 Input Shaft - Installation of the Lower Roller-Bearing

Effectivity: BTF-A-03-22-OO-OOA-71 OA-C

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 BTF-A/LIPS-03
John Crane-Lips
Marine Propulsion Systems

4 Do these steps to install the upper roller-bearing:

Refer to Fig 2

WARNING
ALWAYS WEAR PROTECTIVE CLOTHING AND GLASSES WHEN YOU WORK ON
EQUIPMENT.

CAUTIONS
NEVER ALLOW THE BEARING TO BECOME TOO HOT OR APPLY HEAT TO THE
BEARING USING AN OPEN FLAME. THIS MAY RESULT IN PERMANENT DAMAGE
TO THE BEARING.

WHEN YOU APPLY HEAT TO THE ASSEMBLY PARTS DO NOT EXCEED A

MAXIMUM TEMPERATURE OF 125 DEG. C (255 DEG. F) UNLESS OTHERWISE
STATED.

4.1 Apply heat to the roller-bearing (2). Make sure the temperature is approximately 80 deg.
C (176 deg. F) greater than the temperature of the input shaft (3).

4.2 Install the roller-bearing (2) on the input shaft (3).

4.3 Install the retaining ring (1) on the input shaft (3).

Fig 2 Input Shaft - Installation of the Upper Roller-Bearing

Effectivity: BTF-A-03-22-OO-OOA-71 OA-C

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 BTF-AILI PS-03
John Crane-Lips
Marine Propulsion Systems

This page intentionally left blank.

Effectivity: BTF-A-03-22-OO-OOA-71 OA-C

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 BTF-NLIPS-03
John Crane-Lips
Marine Propulsion Systems

5 Do these steps to install the upper and lower thrust-bearings:

Referto Fig 3

WARNING
ALWAYS WEAR PROTECTIVE CLOTHING AND GLASSES WHEN YOU WORK ON
EQUIPMENT.

CAUTIONS
NEVER ALLOW THE BEARING TO BECOME TOO HOT OR APPLY HEAT TO THE
BEARING USING AN OPEN FLAME. THIS MAY RESULT IN PERMANENT DAMAGE
TO THE BEARING.

WHEN YOU APPLY HEAT TO THE ASSEMBLY PARTS DO NOT EXCEED A

MAXIMUM TEMPERATURE OF 125 DEG. C (255 DEG. F) UNLESS OTHERWISE
STATED.

5.1 Put the input shaft (7) in a vertical position. Make sure the input end points upwards.

5.2 Put the outer ring of the lower thrust-bearing (5) in the bearing housing (6). Do NOT
install the compression springs or the screw plugs in the bearing housing (6).

WARNING
MAKE SURE THAT WHEN YOU USE LIFTING EQUIPMENT THE FOLLOWING APPLIES:

- SUFFICIENT SPACE EXISTS FOR THE EQUIPMENT TO MOVE IN;

- PERSONNEL ARE IN SAFE POSITIONS.

5.3 Use the chain hoist and the hoisting eye-bolts to put the bearing housing (6) and the
outer ring of the lower thrust-bearing (5) on the input shaft (7). Let the upper roller-
bearing support the bearing housing (6) and the outer ring of the lower thrust-bearing (5).

WARNING
CAUTION
S
WHEN YOU APPLY HEAT TO THE ASSEMBLY PARTS DO NOT EXCEED A MAXIMUM
TEMPERATURE OF 125 DEG. C (255 DEG. F) UNLESS OTHERWISE STATED.

5.4 Apply heat to these items to approximately 50 deg. C (110 deg. F) greater than the
temperature of the input shaft (7):
- the inner ring of the lower thrust-bearing (5) including the roller and cage assembly;
- the distance bush (4);
- the inner ring of the upper thrust-bearing (3) including the roller and cage assembly.

5.5 Install the inner ring of the lower thrust-bearing (5) including the roller and cage assembly
on the input shaft (7).

5.6 Install the distance bush (4) on the input shaft (7).

Effectivity: BTF-A-03-22-OO-OOA-71 OA-C

2002-02-01 Page 6
 BTF-NLI PS-03
John Crane-Lips
Marine Propulsion Systems

Fig 3 Input Shaft - Installation of the Upper and Lower Thrust-Bearings

5.7 Install the inner ring of the upper thrust-bearing (3) including the roller and cage
assembly on the input shaft (7).

5.8 Let the hot items cool sufficiently before you proceed to step 5.9.

5.9 Install the 0-ring (2) on the input shaft (7).

5.101nstall the liner (1) on the input shaft (7).

5.11 Install the outer ring of the upper thrust-bearing (3).

Effectivity: BTF-A-03-22-OO-OOA-71 OA-C

2002-02-01 Page 7
 BTF-NLI PS-03
John Crane-Lips
Marine Propulsion Systems

WARNING
MAKE SURE THAT WHEN YOU USE LIFTING EQUIPMENT THE FOLLOWING APPLIES:

- SUFFICIENT SPACE EXISTS FOR THE EQUIPMENT TO MOVE IN;

- PERSONNEL ARE IN SAFE POSITIONS.

5.l2Use the chain hoist to lift the bearing housing (6) over the upper and lower thrust-
bearings (3, 5) and the distance bush (4).

6 Do these steps to install the oversized precision blocks in the bearing housing:
Refer to Fig 4

6.1 Put the precision blocks (5) on the face of the upper thrust-bearing inside the bearing
housing (7). Use four precision blocks (5) that are larger than the size given for the
adjusting ring (Refer to the parts list of the Appendix). You install the precision blocks to
keep the bearing package in position.

6.2 Use the screws (1) to install the seal housing (4) on the bearing housing (7). Do NOT
install the supporting ring or the oil seal in the seal housing (4).

6.3 Use the hydraulic nut to press the upper and lower thrust-bearings into position in the
bearing housing (7). Set the pressure of the hydraulic pump to 300 bar.

6.4 Remove the hydraulic nut.

6.5 Apply Copaslip to the thread of the lock nut (3).

WARNING
CAUTION
TAKE CARE NOT TO DAMAGE THE INPUT SHAFT WHEN YOU TIGHTEN THE LOCK
NUT.

6.6 Install the lock nut (3) on the input shaft (7). Tighten the lock nut (3) as far as possible.

6.7 Put the input shaft (6) in a stand. Make sure you lock the input shaft (6) so that it cannot
turn.

WARNING
CAUTION
TAKE CARE NOT TO DAMAGE THE INPUT SHAFT WHEN YOU TIGHTEN THE LOCK
N UT.

6.8 Use the LIPS ring spanner with the chain hoist to tighten the lock nut (3) to a torque value
of 9800 Nm + 2000 Nm maximum (7232 + 1476 lb/ft).
6.9 Remove the chain hoist and the LIPS ring spanner from the lock nut (3).

6.l0lnstall the grub screws (2) in the lock nut (3). Tighten the grub screws (2) to a torque
value of 35 Nm.

Eftectivity: BTF-A-03-22-OO-OOA-71 OA-C

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2002-02-01 Page 8
 BTF-A/LIPS-03
John Crane-Lips
Marine Propulsion Systems

Fig 4 Input Shaft - Installation of the Precision Blocks in the Bearing Housing

7 Do these steps to prepare for the adjustment of the bearing clearance:

Refer to Fig 4

7.1 Remove the screws (1) that fasten the seal housing (4) to the bearing housing (7).
7.2 Remove the seal housing (4).

7.3 Remove the oversized precision blocks (5) from the face of the thrust bearing inside the
bearing housing (7).

7.4 Put the undersized precision blocks (5) on the face of the thrust bearing inside the
bearing housing (7). Use four precision blocks (5) that are smaller than the size given for
the adjusting ring (Refer to the parts list).

7.5 Use the screws (1) to install the seal housing (4) on the bearing housing (7). Do NOT
install the supporting ring or the oil seal in the seal housing (4).

8 Install the input shaft in the lower gearbox (Ref. BTF-A-03-20-OO-OOA-71 OA-C).

Requirements After Job Completion

Make sure that there are no tools or equipment in the work area and that the work area is
clean.

Effectivity: BTF-A-03-22-OO-OOA-71 OA-C

All

2002-02-01 Page 9
 BTF-AILI PS-03
John Crane-Lips
Marine Propulsion Systems

Effectivity: BTF-A-03-22-00-OOA-71 OA-C

All

2002-02-01 Page 10
 BTF-NLIPS-03
John Crane-Lips
Marine Propulsion Systems

Lower Gearbox, Propeller Shaft Seal, Oil Seals - Change

References
Table 1 References

Data Module/ Technical Publication Title

Preliminary Requirements

Required Conditions
Table 2 Required Conditions

Condition Data Module

None

Required Persons
Table 3 Required Persons

Number of Persons Category

1 Mech

Support Equipment
Table 4 Support Equipment

Nomenclature Identification No. Oty

None

Consumables, Materials and Expendables

Table 5 Supplies

Nomenclature Identification No. Qty

None

Safety Conditions
No Safety Conditions

Effectivity: BTF-A-03-23-OO-OOA-921 A-C

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2002-02-01 Page 1
 BTF-A/LIPS-03
John Crane-Lips
Marine Propulsion Systems

Procedure
Note
It is not necessary to remove the propeller shaft seal to replace the oil seals. For more
information contact the Service Department at LIPS, Drunen.

1 Do these steps to disassemble the propeller shaft seal:

1.1 Remove the screws (3) that fasten the cover (2) to the casing flange (9).

1.2 Remove the casing flange (9) from the liner (1).
1.3 Remove these items:
- the seal ring (8);
- the intermediate ring (7);
- the seal ring (6);
- the intermediate ring (5);
- the seal ring (4).
Discard the seal rings (4, 6, 8).

1.4 Remove the cover (2) from the liner (1).

2 Do these steps to assemble the propeller shaft seal:

2.1 Install the cover (2) on the liner (1).

2.2 Install these items on the liner (1):

- the seal ring (4);
- the intermediate ring (5);
- the seal ring (6);
- the intermediate ring (7);
- the seal ring (8).

2.3 Install the casing flange (9) on the liner (1).

2.4 Install the screws that fasten the cover (2) to the casing flange (9).

Fig 1 Typical Propeller Shaft Seal

BTFAO3230000Aa3OAC1

Effectivity:
All
BTF-A-03-23-OO-OOA-921 A-C S
2002-02-01 Page 2
 BTF-AILIPS-03
John Crane-Lips
Marine Propulsion Systems

S Requirements After Job Completion

1 Make sure that there are no tools or equipment in the work area and that the work area is
clean.

Effectivity: BTF-A-03-23-OO-OOA-921 A-C

All

2002-02-01 Page 3
 BTF-NLI PS-03
John Crane-Lips
Marine Propulsion Systems

Effectivity:
All
BTF-A-03-23-OO-OOA-921 A-C S
2002-02-01 Page 4
 BTF-A/LI PS-03
John Crane-Lips
Marine Propulsion Systems

Flexible Shaft Coupling - Removal

References
Table 1 References

Data Module! Technical Publication Title

Torque Protection Device Installation and Maintenance Instruction (Safeset ST-B 180)

Preliminary Requirements

Required Conditions
Table 2 Required Conditions

Condition Data Module

None

Required Persons
Table 3 Required Persons

Number of Persons Category

2 Mech

Support Equipment
Table 4 Support Equipment

Nomenclature Identification No. Oty

Hydraulic Jack 1

Induction Heater 1

Consumables, Materials and Expendables

Table 5 Supplies

Nomenclature Identification No. Qty

None

Safety Conditions
WARNINGS
MAKE SURE THAT YOU DISENGAGE THE DRIVE MOTOR BEFORE YOU PROCEED. THIS
PREVENTS IT FROM BEING STARTED ACCIDENTALLY.

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Procedure
1 Do the following steps to remove the intermediate shaft (6) from the flexible shaft coupling in
the tunnel assembly:

WARNING
MAKE SURE THAT YOU DISENGAGE THE DRIVE MOTOR BEFORE YOU PROCEED.
THIS PREVENTS IT FROM BEING STARTED ACCIDENTALLY.

1.1 Gain access to the flexible shaft coupling in the tunnel assembly.
1.2 Remove the screws (5) that fasten the intermediate shaft (6) to the upper flexible
coupling (4).

1.3 Remove the screws (7) that fasten the intermediate shaft (6) to the lower flexible coupling
(8).

1.4 Remove carefully the intermediate shaft (6) from between the flexible coupling (4) and
the flexible coupling (8).

2 Do the following to remove the flexible shaft couplings:

2.1 Remove the screws (1) that fasten the upper flexible coupling (4) and the spacer (3) to
the intermediate shaft (6).

2.2 Remove the upper flexible coupling (4) and the spacer (3) from the flexible shaft
coupling.

2.3 Remove the screws (11) that fasten the lower flexible coupling (10) and the brake disc
(9) to the intermediate shaft (6).

2.4 Remove the lower flexible coupling (4) and the brake disc (9) from the flexible shaft
coupling.

WARNING
ALWAYS WEAR PROTECTIVE CLOTHING AND GLASSES WHEN YOU WORK ON
EQUIPMENT.

Use the hydraulic jack to remove the upper hub (2) from the torque protection device (Ref.
Torque Protection Device Installation and Maintenance Instruction for Safeset ST-B 180).

3 Use the hydraulic jack to remove the lower hub (10) from the input shaft of the lower gearbox.

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Marine Propulsion Systems

S Fig 1 Flexible Shaft Coupling with Intermediate Shaft

BTFO36OOOOOA52OAC

Requirements After Job Completion

1 Make sure that there are no tools or equipment in the work area and that the work area is
clean.

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Marine Propulsion Systems

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 BTF-AILI PS-03
John Crane-Lips
Marine Propulsion Systems

Flexible Shaft Coupling - Installation

References
Table 1 References

Data Module! Technical Publication Title

Torque Protection Device Installation and Maintenance Instruction (Safeset ST-B 180)

Preliminary Requirements

Required Conditions
Table 2 Required Conditions

Condition Data Module

None

Required Persons
Table 3 Required Persons

Number of Persons Category

2 Mech

Support Equipment
Table 4 Support Equipment

Nomenclature Identification No. Oty

Induction Heater 1

Vernier Caliper 1

Dial Gauge 1

Consumables, Materials and Expendables

Table 5 Supplies

Nomenclature Identification No. Qty

None

Safety Conditions
WARNINGS
'ALWAYS WEAR PROTECTIVE CLOTHING AND GLASSES WHEN YOU WORK ON
EQUIPMENT.

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Marine Propulsion Systems

Procedure
Note 1
This procedure contains the instructions to put back the flexible shaft coupling with the
intermediate shaft after a removal. For the instructions on how to do the initial installation of
the flexible shaft coupling with the intermediate shaft, refer to the Rexnord document
"Instruction No. 92900 1 E" in the Appendix.

Note 2
For the installation of the torque protection device, refer to the manufacturers documentation
(Ref. Torque Protection Device Installation and Maintenance Instruction for Safeset ST-B
180).

Do the following steps to install the upper hub (2) of the flexible shaft coupling to the torque
protection device:

1.1 Clean these parts:

- the outer surface of the torque protection device;
- the inner surface of the upper hub (2).

1.2 Install the upper hub (2) on the torque protection device (Ref. Torque Protection Device
Installation and Maintenance Instruction for Safeset ST-B 180).

1.3 Install the spacer (3) on the upper hub (1), if applicable.

1.4 Use the screws (1) to fasten the upper flexible coupling (4) and the spacer (3) to the
upper hub (2). Tighten the screws (1) to a torque value of 1422 Nm (1050 Ib/ft).

2 Do the following steps to install the lower hub (10) of the flexible shaft coupling on the input
shaft of the lower gearbox:

2.1 Clean these parts:

- the inner surface of the lower hub (10);
- the input shaft of the lower gearbox.

WARNING
ALWAYS WEAR PROTECTIVE CLOTHING AND GLASSES WHEN YOU WORK ON
EQUIPMENT.

2.2 Use the induction heater to heat the lower hub (10) to 200 deg.0 (392 deg.F) above the
ambient temperature.

2.3 Install the lower hub (10) on the input shaft of the lower gearbox. Make sure you put the
lower hub (10) in position as quickly as possible.

2.4 Install the brake disc (9) on the lower hub (10).

2.5 Use the screws (11) to fasten the lower flexible coupling (8) and the brake disc (9) to the
lower hub (10). Tighten the screws (11) to a torque value of 1422 Nm (1050 lb/ft).

3 Do the following steps to install the intermediate shaft (6):

3.1 Put the intermediate shaft (6) between the upper flexible coupling (4) and the lower
flexible coupling (8). Make sure you align the screw holes.

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Marine Propulsion Systems

3.2 Use the screws (5, 7) to attach the intermediate shaft (6) to the flexible coupling (4) and
the flexible coupling (8). Tighten the screws (5, 7) to a torque value of 1422 Nm (1050 lb/
ft).

Fig 1 Flexible Shaft Coupling with Intermediate Shaft

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Marine Propulsion S'stems

4 Do the following steps to check the alignment of the flexible shaft coupling.
Refer to the drawing "Arrangement of the Flexible Shaft Coupling" and the Rexnord document
"Instruction No. 92900 1 E" in the Appendix

4.1 Use the vernier caliper to measure the gap between the faces of the hubs. Make sure
you measure the correct gap and the tolerance for the type of coupling.

4.2 Use the vernier caliper to measure the distances at X' and 'Y' between the faces of the
hubs. Subtract the value you measure at Y' from the value you measure at 'X' to get the
angular offset. Make sure the tolerance for the angular offset is correct for the type of
coupling.

4.3 Use the dial gauge to measure the parallel offset between the faces of the hubs. Make
sure the tolerance for the parallel offset is correct for the type of coupling.

Requirements After Job Completion

Make sure that there are no tools or equipment in the work area and that the work area is
clean.

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Marine Propulsion Systems

Pitch Control System - Description

References
Table 1 References

Data Module/Technical Publication Title

None

Description
This subject is not applicable for the Transverse Thruster System.

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Marine Propulsion Systems

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 BTF-AILI PS-05
John Crane-Lips
Marine Propulsion Systems

Chapter 5- Structure
Table of Contents Page

Title Data Module No.

Structure - Description BTF-A-05-OO-OO-OOA-01 1 A-A
Outer Rope Guard Assembly - Removal BTF-A-05-1 O-OO-OOA-520A-B
Outer Rope Guard Assembly - Installation BTF-A-05-1 O-OO-OOA-720A-B
Tunnel Assembly - Removal BTF-A-05-20-OO-OOA-520A-B
Tunnel Assembly - Installation BTF-A-05-20-OO-OOA-720A-B
Sacrificial Anodes - Change BTF-A-05-21 -OO-OOA-921 A-B

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Marine Propulsion Systems

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 BTF-A/LIPS-05
John Crane-Lips
Marine Propulsion Systems

Structure - Description

References
Table 1 References

Data Module/ Technical Publication Title

None

Description
1 General
The structure for the transverse thruster provides:
- the mounting for the components of the transverse thruster;
- the protection against corrosion of the tunnel;
- the protection against debris fouling the propeller shaft;
- the alignment of the tunnel assembly.

2 Physical Description
The structure consists of these components:
- the tunnel assembly;
- the outer rope guard assembly.

2.1 Tunnel Assembly

The tunnel assembly comprises:
- the tunnel (1);
- the alignment frame (2) (Optional);
- the sacrificial anodes (3).
- the thruster blocks (4);

2.1.1 Tunnel
The factory constructs the tunnel (1) from mild steel to form a rigid structure. The tunnel (1) has a
flange around the top, which secures to the alignment frame (2) or the structure of the ship.
Bolts fasten the tunnel assembly to the alignment frame (2).

2.1.2 Alignment Frame

The alignment frame (2) allows the yard to align the tunnel (1) in the structure of the ship.
The alignment frame (2) is an optional requirement.

2.1.3 Sacrificial Anodes

The sacrificial anodes (3) comprise blocks of zinc, which the yard welds to the tunnel (1).

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Marine Propulsion Systems

2.1.4 Thruster Blocks

The factory makes the thruster blocks (4) from stainless steel. The thruster blocks (4) give support
to the bottom sides of the tunnel when the thruster is in use.

2.2 Outer Rope Guard Assembly

The outer rope guard assembly (5) comprises the upper and lower flange covers. Weld joints
secure the upper and lower flange covers. The outer rope guard assembly (5) forms the profile of
the pod to surround the propeller shaft.
Bolts fasten the outer rope guard assembly (2) to the hub of the propeller.

Fig 1 Structure - Component Location

Fig2 OlTunnel
O2Alignment Frame
O3Sacrificial Anodes
04 Thruster Blocks
O5Outer Rope Guard Assembly

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AU

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Marine Propulsion Systems

3 Functional Description
3.1 Tunnel Assembly
The tunnel assembly provides the structure for mounting the transverse thruster and the prime
mover. You can remove the transverse thruster complete with the tunnel assembly for
maintenance purposes.
The alignment frame fits between the tunnel assembly and the support structure in the ship. The
yard does the following steps:
- Installs the alignment frame temporarily with the tunnel assembly:
- Aligns the tunnel assembly with the structure of the ship;
- Measures the faces of the tunnel to obtain the correct alignment;
- Removes and trims the alignment frame;
- Installs and welds the alignment frame to the support structure.
The sacrificial anodes provide the protection against corrosion that the water causes.
The thruster blocks keep the lower part of the tunnel assembly steady when the transverse
thruster develops power. The thruster blocks consist of two parts, which the yard welds the
structure of the ship and the tunnel assembly.

3.2 Outer Rope Guard Assembly

The outer rope guard assembly provides protection against debris fouling the propeller shaft.

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Marine Propulsion Systems

Effectivity:
All
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Marine Propulsion Systems

S
Outer Rope Guard Assembly - Removal

References
Table 1 References

Data Module/Technical Publication Title

None

Preliminary Requirements

Required Conditions
Table 2 Required Conditions

Condition Data Module

None

Required Persons
Table 3 Required Persons

Number of Persons Category

2 Mech

Required Persons
Table 3 Required Persons

Number of Persons Category

1 Welder

Support Equipment
Table 4 Support Equipment

Nomenclature Identification No. Qty

Torch Cutter or Grinding Wheel 1

Consumables, Materials and Expendables

Table 5 Supplies

Nomenclature Identification No. Qty

None

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 BTF-NLI PS-05
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Marine Propulsion Systems

Safety Conditions
WARNINGS
MAKE SURE THAT WHEN YOU CONNECT WELDING EQUIPMENT YOU ALWAYS USE AN
EARTH CONNECTION. CONNECT THE EARTH CONNECTION AS CLOSE AS POSSIBLE TO
THE WELD POINT TO PREVENT INJURY OR DAMAGE TO EQUIPMENT.

'ALWAYS WEAR PROTECTIVE CLOTHING AND GLASSES WHEN YOU WORK ON

EQUIPMENT.
CAUTIONS
ALWAYS PROTECT THE SURROUNDING AREA FROM WELDING SPLATTER WHEN
WELDING.

Procedure
Safety Conditions
WARNINGS
MAKE SURE THAT WHEN YOU CONNECT WELDING EQUIPMENT YOU ALWAYS
USE AN EARTH CONNECTION. CONNECT THE EARTH CONNECTION AS CLOSE
AS POSSIBLE TO THE WELD POINT TO PREVENT INJURY OR DAMAGE TO
EQUIPMENT.

ALWAYS WEAR PROTECTIVE CLOTHING AND GLASSES WHEN YOU WORK ON

EQUIPMENT.

CAUTION
ALWAYS PROTECT THE SURROUNDING AREA FROM WELDING SPLATTER WHEN
WELDING.

1 Remove the weld points that fasten the upper flange cover (1) to the lower flange cover (4)
of the outer rope guard assembly. Use the torch cutter or the grinding wheel.

2 Remove the attaching screws (2) that fasten the upper flange cover (1) to the propeller (3).

3 Remove the upper flange cover (1) from the propeller (3).

4 Remove the attaching screws (5) that fasten the lower flange cover (4) to the propeller (3).

5 Remove the lower flange cover (4) from the propeller (3).

Eftectivity:
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 BTF-A/LI PS-05
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Marine Propulsion Systems

Fig 1 Rope Guard Assembly-Removal

Requirements After Job Completion

1 Make sure that there are no tools or equipment in the work area and that the work area is
clean.

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Marine Propulsion Systems

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John Crane-Lips
Marine Propulsion Systems

Outer Rope Guard Assembly - Installation

References
Table 1 References

Data Module! Technical Publication Title

None

Preliminary Requirements

Required Conditions
Table 2 Required Conditions

Condition Data Module

None

Required Persons
Table 3 Required Persons

Number of Persons Category

2 Mech

Required Persons
Table 3 Required Persons

Number of Persons Category

1 Welder

Support Equipment
Table 4 Support Equipment

Nomenclature Identification No. Qty

Electric Welding Tool 1

Consumables, Materials and Expendables

Table 5 Supplies

Nomenclature Identification No. Qty

None

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Marine Propulsion Systems

Safety Conditions
WARNINGS
'MAKE SURE THAT WHEN YOU CONNECT WELDING EQUIPMENT YOU ALWAYS USE AN
EARTH CONNECTION. CONNECT THE EARTH CONNECTION AS CLOSE AS POSSIBLE TO
THE WELD POINT TO PREVENT INJURY OR DAMAGE TO EQUIPMENT.

ALWAYS WEAR PROTECTIVE CLOTHING AND GLASSES WHEN YOU WORK ON

EQUIPMENT.
CAUTIONS
ALWAYS PROTECT THE SURROUNDING AREA FROM WELDING SPLATTER WHEN
WELDING.

Procedure
1 Install the lower flange cover (4) of the outer rope guard assembly on the propeller (3).

1.1 Put the lower flange cover (4) against the hub at the rear of the propeller (3). Make sure
the holes in the lower flange cover (4) align with the holes for the screws in the hub.

1 .2 Install the attaching screws (5) and tighten until finger tight.

2 Install the upper flange cover (1) of the outer rope guard assembly on the propeller (3).

2.1 Put the upper flange cover (1) against the hub at the rear of the propeller (3). Make sure
the holes in the upper flange cover (1) align with the holes for the screws in the hub.

2.2 Install the attaching screws (2) and tighten until finger tight. Make sure the sides of the
upper flange cover (1) touch the sides of the lower flange cover (4).

3 Tighten the attaching screws (2) to a torque value of 265 Nm (195 lb/if).

WARNINGS
MAKE SURE THAT WHEN YOU CONNECT WELDING EQUIPMENT YOU ALWAYS
USE AN EARTH CONNECTION. CONNECT THE EARTH CONNECTION AS CLOSE
AS POSSIBLE TO THE WELD POINT TO PREVENT INJURY OR DAMAGE TO
EQUIPMENT.

ALWAYS WEAR PROTECTIVE CLOTHING AND GLASSES WHEN YOU WORK ON

EQUIPMENT.

CAUTION
ALWAYS PROTECT THE SURROUNDING AREA FROM WELDING SPLATTER WHEN
WELDING.

4 Use the electric welding tool to weld the upper flange cover (1) to the lower flange cover (4)
of the outer rope guard assembly.

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Marine Propulsion Systems

S Fig 1 Rope Guard Assembly-Installation

Requirements After Job Completion

1 Make sure that there are no tools or equipment in the work area and that the work area is
clean.

S Effectivity:
All
BTF-A-05-1 O-OO-OOA-720A-B

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/I Marine Propulsion Systems

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 BTF-AILI PS-05
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Marine Propulsion Systems

S
Tunnel Assembly - Removal

References
Table 1 References

Data Module! Technical Publication Title

None

Preliminary Requirements

Required Conditions
Table 2 Required Conditions

Condition Data Module

Required Persons
Table 3 Required Persons

Number of Persons Category

4 Mech

Support Equipment
Table 4 Support Equipment

Nomenclature Identification No. Qty

Chains NR
Chain hoist 1

Consumables, Materials and Expendables

Table 5 Supplies

Nomenclature Identification No. Qty

None

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Marine Propulsion Systems

Safety Conditions
WARNINGS
ALWAYS USE APPROVED LIFTING POINTS AND CERTIFIED LIFTING EQUIPMENT. MAKE
SURE EQUIPMENT CANNOT TILT OR MOVE DURING LIFTING.
'MAKE SURE THAT WHEN YOU USE LIFTING EQUIPMENT THE FOLLOWING APPLIES:
- SUFFICIENT SPACE EXISTS FOR THE EQUIPMENT TO MOVE IN;
- PERSONNEL ARE IN SAFE POSITIONS.
'ALWAYS WEAR PROTECTIVE CLOTHING AND GLASSES WHEN YOU WORK ON
EQUIPMENT.
CAUTIONS
'ALWAYS PROTECT THE SURROUNDING AREA FROM WELDING SPLATTER WHEN
WELDING.
DO NOT ATTACH LIFTING EQUIPMENT TO MACHINED SURFACES, SHAFT ENDS, PIPING
WORK OR OTHER EXTERNALLY MOUNTED EQUIPMENT.

Procedure
1 Trim the level of the ship until the top of the alignment frame (7) becomes higher than the level
of the water.

2 Remove the electrical connections from the electric motor, if applicable.

3 Remove the pipe connections from the water-cooling system, if applicable.

4 Remove the pipe connections from the lubrication system.

WARNINGS
ALWAYS USE APPROVED LIFTING POINTS AND CERTIFIED LIFTING
EQUIPMENT. MAKE SURE EQUIPMENT CANNOT TILT OR MOVE DURING
LIFTING.

' MAKE SURE THAT WHEN YOU USE LIFTING EQUIPMENT THE FOLLOWING
APPLIES:

- SUFFICIENT SPACE EXISTS FOR THE EQUIPMENT TO MOVE IN;

- PERSONNEL ARE IN SAFE POSITIONS.

CAUTION
DO NOT ATTACH LIFTING EQUIPMENT TO MACHINED SURFACES, SHAFT ENDS,
PIPING WORK OR OTHER EXTERNALLY MOUNTED EQUIPMENT.

5 Use the chain hoist to support the load of the tunnel assembly (1):
- the load of the tunnel assembly (1) with the propeller drive motor (42,000 kg).
- the load of the tunnel assembly (1) without the propeller drive motor (30,000 kg).

6 Remove the bolts (2), the washers (3), the spring washers (4) and the nuts (5) that secure the
tunnel assembly (1) to the alignment frame (7).

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Marine Propulsion Systems

WARNINGS
ALWAYS USE APPROVED LIFTING POINTS AND CERTIFIED LIFTING
EQUIPMENT. MAKE SURE EQUIPMENT CANNOT TILT OR MOVE DURING
LIFTING.

MAKE SURE THAT WHEN YOU USE LIFTING EQUIPMENT THE FOLLOWING
APPLIES:

- SUFFICIENT SPACE EXISTS FOR THE EQUIPMENT TO MOVE IN;

- PERSONNEL ARE IN SAFE POSITIONS.

CAUTION
DO NOT ATTACH LIFTING EQUIPMENT TO MACHINED SURFACES, SHAFT ENDS,
PIPING WORK OR OTHER EXTERNALLY MOUNTED EQUIPMENT.

7 Use the chain hoist to lift the tunnel assembly (1) off the alignment frame (7).

8 Remove the tunnel assembly (1) from the access shaft.

9 Lower the tunnel assembly (1) into a safe position on the deck of the ship.

Fig 1 Tunnel Assembly - Removal

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Fig 2 Tunnel Assembly - Removal

Requirements After Job Completion

1 Make sure that there are no tools or equipment in the work area and that the work area is
clean.

Effectivity:
AH
BTF-A-05-20-OO-OOA-520A-B S
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 BTF-A/Ll PS-05
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Marine Propulsion Systems

Tunnel Assembly - Installation

References
Table 1 References

Data Module! Technical Publication Title

Welding Procedures - LIPS Transverse thruster, all types

Preliminary Requirements

Required Conditions
Table 2 Required Conditions

Condition Data Module

Hot work permit

Required Persons
Table 3 Required Persons

Number of Persons Category

4 Mech

Required Persons
Table 3 Required Persons

Number of Persons Category

1 Welder

Support Equipment
Table 4 Support Equipment

Nomenclature Identification No. Qty

Chains AIR
Chain Hoist
Eye Bolts 4

Consumables, Materials and Expendables

Table 5 Supplies

Nomenclature Identification No. Qty

None

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Marine Propulsion Systems

Safety Conditions
WARNINGS
ALWAYS USE APPROVED LIFTING POINTS AND CERTIFIED LIFTING EQUIPMENT. MAKE
SURE EQUIPMENT CANNOT TILT OR MOVE DURING LIFTING.

'MAKE SURE THAT WHEN YOU USE LIFTING EQUIPMENT THE FOLLOWING APPLIES:
- SUFFICIENT SPACE EXISTS FOR THE EQUIPMENT TO MOVE IN;
- PERSONNEL ARE IN SAFE POSITIONS.

CAUTIONS
'DO NOT ATTACH LIFTING EQUIPMENT TO MACHINED SURFACES, SHAFT ENDS, PIPING
WORK OR OTHER EXTERNALLY MOUNTED EQUIPMENT.

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Marine Propulsion Systems

Procedure
1 Do these steps to install the tunnel assembly:
Refer to Fig 1 and Fig 2

1.1 Install the rubber gasket (6) on the alignment frame (7).

1 .2 Use the chain hoist to lower the tunnel assembly (1) until the flange comes to rest on the
alignment frame (7). Make sure the holes in the flange align with the holes in the
alignment frame (7).

1 .3 Install the bolts (2), the washers (3), the spring washers (4) and the nuts (5) in the flange
and the alignment frame (7). Tighten the nuts (5) to a torque value of 380 Nm (280 lb/ft).

1.4 Remove the chains from the tunnel assembly (1) and the chain hoist from the access
shaft.

Fig 1 Tunnel Assembly - Lowering onto Alignment Frame

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Fig 2 Tunnel Assembly - Installation

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Requirements After Job Completion

1 Make sure that there are no tools or equipment in the work area and that the work area is
clean.

Effectivity: BTF-A-05-20-OO-OOA-720A-B
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/I14i Marine Propulsion Systems

Eftectivity:
All
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Marine Propulsion Systems

Sacrificial Anodes - Change

References
Table 1 References

Data Module/Technical Publication Title

None

Preliminary Requirements

Required Conditions
Table 2 Required Conditions

Condition Data Module

None

Required Persons
Table 3 Required Persons

Number of Persons Category

1 Mech

Support Equipment
Table 4 Support Equipment

Nomenclature Identification No. Qty

Electric Welding Tool 1

Grinding Wheel 1

Torch Cutter 1

Consumables, Materials and Expendables

Table 5 Supplies

Nomenclature Identification No. Qty

None

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Marine Propulsion Systems

Safety Conditions
WARNINGS
'MAKE SURE THAT WHEN YOU CONNECT WELDING EQUIPMENT YOU ALWAYS USE AN
EARTH CONNECTION. CONNECT THE EARTH CONNECTION AS CLOSE AS POSSIBLE TO
THE WELD POINT TO PREVENT INJURY OR DAMAGE TO EQUIPMENT.

ALWAYS WEAR PROTECTIVE CLOTHING AND GLASSES WHEN YOU WORK ON

EQUIPMENT.
CAUTIONS
ALWAYS PROTECT THE SURROUNDING AREA FROM WELDING SPLATTER WHEN
WELDING.

Procedure
Do these steps to remove the sacrificial anode(s):

WARNING
ALWAYS WEAR PROTECTIVE CLOTHING AND GLASSES WHEN YOU WORK ON
EQUIPMENT.

1 .1 Use the grinding wheel or the torch cutter to remove the welding joints at the sacrificial
anode mountings.

1.2 Remove the sacrificial anode from the tunnel assembly.

1.3 Repeat step 1.1 and step 1.2 to remove all the sacrificial anodes from the tunnel
assembly, if applicable.
2 Do these steps to install the sacrificial anode(s):

2.1 Put the sacrificial anode in position on the tunnel assembly.

WARNING
MAKE SURE THAT WHEN YOU CONNECT WELDING EQUIPMENT YOU ALWAYS USE
AN EARTH CONNECTION. CONNECT THE EARTH CONNECTION AS CLOSE AS
POSSIBLE TO THE WELD POINT TO PREVENT INJURY OR DAMAGE TO EQUIPMENT.

CAUTION
ALWAYS PROTECT THE SURROUNDING AREA FROM WELDING SPLATTER WHEN
WELDING.

2.2 Use the electric welding tool to weld the sacrificial anode to the mountings on the tunnel
assembly.

2.3 Repeat step 2.1 and step 2.2 to install all the sacrificial anodes on the tunnel assembly,
if applicable.

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Marine Propulsion Systems

WARNING
ALWAYS WEAR PROTECTIVE CLOTHING AND GLASSES WHEN YOU WORK ON
EQUIPMENT.

2.4 Paint the area around the mountings on the tunnel assembly, as necessary. For more
information on the paint you require, refer to the Hempel Coating Specification for Tunnel
Thrusters in the Appendix. Do not paint the sacrificial anode.

Requirements After Job Completion

1 Make sure that there are no tools or equipment in the work area and that the work area is
clean.

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Marine Propulsion Systems

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 CHAPTER 6

STEERING SYSTEM
 BTF-NLIPS-06
John Crane-Lips
Marine Propulsion Systems

Steering System - Description

References
Table 1 References

Data Module! Technical Publication Title

None

Description
This subject is not applicable for the Transverse Thruster System.

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John Crane-Lips
Marine Propulsion Systems

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S

CHAPTER 7

HYDRAULIC SYSTEM

S
 BTF-NLI PS-07
John Crane-Lips
Marine Propulsion Systems

Hydraulic Power - Description

References
Table 1 References

Data Module! Technical Publication Title

None

Description
This subject is not applicable for the Transverse Thruster System.

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Marine Propulsion Systems

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 CHAPTER 8

LUBRICATION SYSTEM
 BTF-A/Ll PS-08
John Crane-Lips
Marine Propulsion Systems

S
Chapter 8- Lubrication System
Table of Contents Page

Title Data Module No.

Lubrication System - Description BTF-A-08-OO-OO-OOA-01 1 A-A

Lubrication System - Filling BTF-A-08-OO-OO-OOA-21 2A-B
Lubrication System - Draining BTF-A-08-OO-OO-OOA-222A-B
Lubrication System - Flushing BTF-A-08-OO-OO-OOA-230A-B
Oil-Pressure Filter-Cartridge - Change BTF-A-08-21 -OO-OOA-921 A-A

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 BTF-A/LIPS-08
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Marine Propulsion Systems

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 BTF-A/LI PS-08
John Crane-Lips
Marine Propulsion Systems

Lubrication System - Description

References
Table 1 References

Data Module/ Technical Publication Title

None

Description

1 General
The lubrication system provides a constant supply of lubrication oil to the lower gearbox.

2 Physical Description
The lubrication system consists of these components:
- the headertank;
- the lubrication pump set;
- the shut-off valve SOV9 (Yard supply).
The yard installs the shut-off valve SOV9 near the header tank as an optional requirement. The
shut-off valve SOV9, in the 'closed' position, isolates the header tank from the lubrication pump
set and the lower gearbox. You can do these operations without affecting the contents in the
header tank:
- drain the lubrication oil from the lower gearbox;
- remove a component from the lubrication pump set.

2.1 Header Tank

The header tank comprises:
- the filler cap with a breather filter;
- the dip stick;
- the low-level switch.
The header tank contains the oil for the lubrication system. The height of the header tank above
the lower gearbox ensures the gravity maintains these conditions:
- fully floods the lower gearbox with the lubrication oil;
- puts pressure on the lubrication oil inside the lower gearbox.
The pressure of the lubrication oil assists the dynamic seals against ingress of the sea water.
During normal operation, the lubrication oil from the header tank completely fills the lower
gearbox. This prevents the possibility of these conditions:
- corrosion inside the lower gearbox;
- water ingress if damage occurs to the seals around the propeller shaft.

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Marine Propulsion Systems

The filler cap prevents particles from entering the header tank. The breather filter allows air into
the header tank, which prevents the forming of a vacuum or the build-up of pressure. It consists
of an air filter with a filler strainer, which prevents large particles from entering the tank during
filling.
The dip stick allows you to check the level of oil in the tank.
The header tank has the drain valve at the lowest point. It allows you to drain the contents of the
header tank.
The low-level switch provides an alarm signal when the oil in the header tank falls below the alarm
level.

2.2 Lubrication Pump Set

The lubrication pump set comprises:
- the electric motor (EM3);
- the lubrication-oil circulation-pump (P3);
- the lubrication-oil pressure-gauge (PG4);
- the lubrication-oil pressure-gauge valve (SOV14);
- the temperature gauge (W3);
- the pressure filter (PF3);
- the control shut-off valves (SOV1 5 thru SOV1 8);
- the pressure-safety valves (PSV3, PSV5).
The electric motor (EM3) provides the drive for the oil-circulation pump.
The lubrication-oil circulation-pump (P3) makes the oil circulate through the oil filter.
The lubrication-oil pressure-gauge (PG4) indicates the pressure of the oil in the lubrication
system.
The lubrication-oil pressure-gauge valve (SOV14) shuts automatically when you remove the
pressure gauge (PG4). This lets you change the pressure gauge (PG4) without the need to drain
the oil.
The temperature gauge (W3) indicates the temperature of the oil within the lubrication system.
The pressure filter (PF3) consists of a pressure filter assembly with a filter head and a screw-in
filter bowl.
The control shut-off valves (SOV1 5 thru SOV1 8) control the operation of the lubrication pump set.
Refer to Table 2 for the positions of the control valves.

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 BTF-AILI PS-08
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Marine Propulsion Systems

Table 2 Settings of theControl Shut-off Valves

Valve Settings SOV15 SOV16 SOV17 SOV18

Normal Operation 1 OPEN
2 3 2 3 2 3

Filling the Lower Gearbox 1 1 1 CLOSED

2 3 2 3 2

Draining the Lower Gearbox CLOSED

2 3 2 3 2 3

Draining the Lower Gearbox! OPEN or

Header Tank CLOSED
2 3 2 3 2

Filling the Header Tank CLOSED

S 2 3 2 3 2 3

Note 1
The symbols show the settings of the control valves when you view the lubrication pump set
from above.
Note 2
IT IS IMPORTANT TO MAKE SURE THE POSITION OF THE CONTROL SHUT-OFF
VALVES ARE CORRECT FOR "NORMAL OPERATION". AN INCORRECT POSITION OF
A CONTROL VALVE WILL CAUSE DAMAGE TO THE LUBRICATION SYSTEM.

3 Functional Description
Refer to Fig 1 and Fig 2
The lubrication oil lubricates the parts that move in the lower gearbox. At the same time the
lubrication oil extracts the heat from the moving parts.
S The electric motor (EM3) drives the lubrication-oil circulation-pump (P3). During normal operation,
the pump circulates the oil around the lubrication system. The pump sucks the oil from the lowest
point in the lower gearbox. The lubrication oil passes through these component parts back to the
lower gearbox:
- the suction pipe (LT);
- the fill-control valve (SO Vi 6) in the '1 - 2' position;
- the lubrication-oil circulation-pump (P3);
- the pressure filter (PF3);
- the suction-control valve (SOV15) in the '1 -2' position;
- the drain-control valve (SO Vi 7) in the '1 - 3' position;
- the flow-control valve (SO Vi 8) in the 'OPEN' position;
- the head-pressure pipe (ST).

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 BTF-AILIPS-08
John Crane-Lips
Marine Propulsion Systems

Fig 1 Lubrication Pump Set - Normal Operation

The pressure-safety valve (PSV3) protects the electric motor (EM3). The pressure-safety valve
(PSV3) operates at a pressure of 3 bar.
The pressure-safety valve (PSV5) protects the oil seals in the lower gearbox. The pressure-safety
valve (PSV5) operates at a pressure of 0.5 bar.
The pressure filter (PF3) filters the lubrication oil from the lower gearbox. The pressure gauge on
the housing of the filter shows the oil pressure at the filter. If the filter blocks the flow the pressure
gauge shows a higher pressure than for normal operation.
You switch off the power supply to the electrical motor EM3 before you change the filter. The
circulation-pump (P3) stops circulating the lubrication oil but does not affect the operation of the
transverse thruster. You can operate the transverse thruster for short periods without running the
circulation-pump (P3).

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 BTF-A/LI PS-08
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Marine Propulsion Systems

Fig 2 Lubrication System - Schematic

HEADER TANK
r
AB2

DS2

U LLS2
L
A

---o
DVT ST

Sovo

LUBRICATION PUMP SET

T ST4 32 SOV7

(D

SOV15
ISOVi8 Ii -®W3
SOVI4
- -(H E' -Ø PG4

PF3

0.5 bar PSV5 PSV3

3 bar

P3 EM3

SOV16
LT

- 3

TUNNEL r STLT

vii VT2
LOWER
GEARBOX

BTF25000000AO11AA

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 BTF-NLIPS-08
John Crane-Lips
Marine Propulsion Systems

Fig 3 D Drain Connection

F Fill Connection
LT Lubrication Suction Line
ST Head Pressure Line (LGB)
VT VentLine(LGB)

3.1 Filling the Lubrication System

You fiH these parts of the lubrication system:
- the lower gearbox;
- the headertank.
You must obey these precautions:
only use one of the lubrication oils that LIPS recommends (Ref. BTF-A-08-1O-OO-OOA-212A-
B).
set all the control shut-off valves to the "Normal Operation" after the filling
operation.

3.1.1 Filling the Lower Gearbox

Refer to Fig 4
Before you begin filling, make sure you isolate the lower gearbox from the header tank. Set the
flow-control valve (SOV1 8) to the 'CLOSED' position
You use one of these methods to fill the lower gearbox:
- use the oil directly from the header tank;
- set the control valves of the lubrication pump set and then 'Fill' from an external tank.

Fig 4 Lubrication Pump Set - Filling the Lower Gearbox

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 BTF-NLIPS-08
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During the filling operation, the lubrication-oil circulation-pump (P3) sucks the oil from the external
tank. The lubrication oil passes through these component parts to the lower gearbox:
- the 'Fill' connection (F);
- the fill-control valve (SOV16) in the '1 - 3' position;
- the lubrication-oil circulation-pump (P3);
- the pressure filter (PF3);
- the suction-control valve (SOV1 5) in the '1 - 3' position;
- the head-pressure pipe (ST).
The pressure-safety valve (PSV3) limits the pressure when you fill the lower gearbox with the
lubrication oil. The valve operates at a pressure of 3 bar.

3.1 .2 Filling the Header Tank

Refer to Fig 5
Before you begin filling, make sure you isolate the lower gearbox from the header tank. Set the
flow-control valve (SOV1 8) to the 'CLOSED' position
You use one of these methods to fill the header tank:
- remove the filler cap and then pour the lubrication oil into the breather filter;
- set the control valves of the lubrication pump set and then 'Fill' from an external tank.

Fig 5 Lubrication Pump Set - Filling the Header Tank

During the filling operation, the lubrication-oil circulation-pump (P3) sucks the oil from the external
tank. The lubrication oil passes through these component parts to the lower gearbox:
- the 'Fill' connection (F);
- the fill-control valve (SOV16) in the '1 - 3' position;
- the lubrication-oil circulation-pump (P3);
- the pressure filter (PF3);
- the suction-control valve (SOV15) in the '1 - 2' position;
- the head-pressure pipe (ST).

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Marine Propulsion Systems

3.2 Draining the Lubrication System

You drain these parts of the lubrication system:
- the lower gearbox;
- the headertank.
You must set all the control shut-off valves to the "Normal Operation" after the draining operation.

3.2.1 Draining the Lower Gearbox

Referto Fig6
Before you begin draining, make sure you isolate the lower gearbox from the header tank. Set the
flow-control valve (SOV1 8) to the 'CLOSED' position
You use one of these methods to drain the lower gearbox:
- remove the screw plug from the inspection cover under the lower gearbox;
- set the control valves of the lubrication pump set and then open the 'Drain' connection.

Fig 6 Lubrication Pump Set - Draining the Lower Gearbox

During the draining operation, the lubrication-oil circulation-pump (P3) sucks the oil from the lower
gearbox. The lubrication oil passes through these component parts to the catch tank:
- the lubrication suction pipe (LT);
- the fill-control valve (SOV16) in the '1 - 2' position;
- the lubrication-oil circulation-pump (P3);
- the pressure filter (PF3);
- the suction-control valve (SO Vi 5) in the '1 - 2' position;
- the drain-control valve (SOV17) in the '1 - 2' position;
- the 'Drain' connection (D).

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Marine Propulsion Systems

3.2.2 Draining the Header Tank

Refer to Fig 7
You use one of these methods to drain the header tank:
- remove the drain plug from the base of the header tank;
- set the control valves to the positions shown in Table 2 and then open the 'Drain' connection.

Fig 7 Lubrication Pump Set - Draining the Header Tank

During the draining operation, the lubrication-oil circulation-pump (P3) sucks the oil from the lower
gearbox. The lubrication oil passes through these component parts to the catch tank:
- the head-pressure pipe (ST);
- the flow-control valve (SOV1 8) in the 'OPEN' position;
- the lower gearbox;
- the lubrication suction pipe (LT);
- the fill-control valve (SOV1 6) in the '1 - 2' position;
- the lubrication-oil circulation-pump (P3);
- the pressure filter (PF3);
- the suction-control valve (SOV15) in the '1 - 2' position;
- the drain-control valve (SOV1 7) in the '1 - 2' position;
- the 'Drain' connection (D).

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 BTF-NLIPS-08
John Crane-Lips
Marine Propulsion Systems

3.3 Flushing the Lubrication System

You flush the lubrication system when one of these occurs:
- you suspect that particles contaminate the lubrication oil;
- you clean the piping before operating for the first time.
You do these steps to flush the lubrication system:
- install temporary pipes to bypass major components;
- create loops in the piping;
use a flushing unit to flush the loops of the piping;
- use a flushing fluid with a lower viscocity than the oil LIPS recommends for normal operation;
- use an oil that LIPS recommends for normal operation if the flushing fluid is not available;
- heat thick oil to 60 deg.0 (140 deg.F);
- flush each loop for a minumum of 2.5 hours;
- make sure that the velocity of the flushing fluid is at least 7 meters per second, for example
120 litres/mm in pipe dia. 22 x 1,5 mm;
stop the process of flushing after one hour for a 5 minute rest period;
- reverse the direction of the flow of the flushing fluid at regular intervals;
- check the filter(s) of the flushing unit regularly and replace as necessary;
- continue the process of flushing until the filter(s) and the flushing fluid remain clean;
- drain the loops of the piping;
- use dry air to blow the flushing fluid out of the loops of the piping;
- remove the temporary pipes;
- install the connections of the piping to the major components;
- fill the lubrication system with lubrication oil.

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 BTF-AILI PS-08
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Marine Propulsion Systems

Lubrication System - Filling

References
Table 1 References

Data Module! Technical Publication Title

None

Preliminary Requirements

l Required Conditions

Condition

None
Table 2 Required Conditions

Data Module

Required Persons
Table 3 Required Persons

Number of Persons Category

2 Mech

Support Equipment
Table 4 Support Equipment

Nomenclature Identification No. Qty

Oil Can/Container 1

Catch tank(s) NR

Consumables, Materials and Expendables

Table 5 Supplies

Nomenclature Identification No. Qty

Lubrication Oil See Table 6 See Table 7

Clean Cloth NR

Safety Conditions
WARNING
CAUTIONS
'MAKE SURE YOU USE A LUBRICATION OIL THAT LIPS RECOMMENDS.
'MAKE SURE YOU USE CATCH TANK(S) OF ADEQUATE SIZE WHEN YOU DRAIN OIL OR
FLUID FROM EQUIPMENT. ALWAYS COLLECT AND REMOVE THE OIL OR FLUID YOU
SPILL DURING REMOVAL OR INSTALLATION OF THE EQUIPMENT.

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 BTF-NLIPS-08
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Procedure
Do the following steps to fill the lower gearbox:

1.1 Gain access to the lubrication pump set.

WARNING
CAUTION
MAKE SURE YOU USE CATCH TANK(S) OF ADEQUATE SIZE WHEN YOU DRAIN OIL OR
FLUID FROM EQUIPMENT. ALWAYS COLLECT AND REMOVE THE OIL OR FLUID YOU
SPILL DURING REMOVAL OR INSTALLATION OF THE EQUIPMENT.

1 .2 Put the catch tanks in position to collect the oil you may spill during this procedure.

WARNING
CAUTION
MAKE SURE YOU USE A LUBRICATION OIL THAT LIPS RECOMMENDS.

1.3 Remove the blanking plug from the 'Fill' connection.

1.4 Connect a pipe between the 'Fill' connection and the oil container.

1.5 Make sure the suction-control valve SOV1 5 is set to the '1 - 3' position.

1.6 Make sure the drain-control valve SOV1 7 is set to the '1 - 3' position.

1.7 Set the flow-control valve SOV1 8 to the 'CLOSED' position.

1.8 Set the fill-control valve SOV1 6 to the '1 3' position.

1.9 Set the electric motor EM3 to 'On'.

1.1 0 Remove the VT connection pipe from the header tank.

1.11 Monitor the LT connection pipe until the lubrication oil starts coming out.

1.1 2Set the electric motor EM3 to 'Off".

1.1 3Set the fill-control valve SOV1 6 to the '1 - 2' position.

1.1 4Set the flow-control valve SOV1 8 to the 'OPEN' position.

1.l5Connect the VT connection pipe to the header tank.

1.l6Remove the pipe from between the 'Fill' connection and the oil container.

1.l7Connect the blanking plug to the 'Fill' connection.

2 Do the following steps to fill the header tank:
2.1 Gain access to the lubrication pump set.

WARNING

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CAUTION
MAKE SURE YOU USE CATCH TANK(S) OF ADEQUATE SIZE WHEN YOU DRAIN OIL OR
FLUID FROM EQUIPMENT. ALWAYS COLLECT AND REMOVE THE OIL OR FLUID YOU
SPILL DURING REMOVAL OR INSTALLATION OF THE EQUIPMENT.

2.2 Put the catch tanks in position to collect the oil you may spill during this procedure.

WARNING
CAUTION
MAKE SURE YOU USE A LUBRICATION OIL THAT LIPS RECOMMENDS.

2.3 Remove the blanking plug from the 'Fill' connection.

2.4 Connect a pipe between the 'Fill' connection and the oil container.

2.5 Make sure the suction-control valve SOV15 is set to the '1 -2' position.
2.6 Make sure the drain-control valve SOV17 is set to the '1 - 3' position.

2.7 Set the flow-control valve SOV1 8 to the 'CLOSED' position.

2.8 Set the fill-control valve SOV16 to the '1 - 3' position.

2.9 Set the electric motor EM3 to 'On'.

2.lOMonitorthe level of the lubrication oil in the headertank. Checkthe level of the lubrication
oil shown on the dip stick. Make sure it shows between the 'LOW' and the 'HIGH' level
marks.

2.11 Set the electric motor EM3 to 'Off".

2.l2Set the fill-control valve SOV16 to the '1 -2' position.

2.l3Set the flow-control valve SOV18 to the 'OPEN' position.

2.l4Remove the pipe from between the 'Fill' connection and the oil container.

2.l5Connect the blanking plug to the 'Fill' connection.

3 Do the following steps to top up the lubrication oil in the header tank:
3.1 Gain access to the header tank.

3.2 Check the level of the lubrication oil in the header tank.

3.3 Fill the oil can with the lubrication oil LIPS recommends, refer to Table 6.
3.4 Remove the filler cap that covers the 'Fill'access hole in the top of the header tank.

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WARNING
MAKE SURE YOU DO NOT OVERFILL THE HEADER TANK WITH LUBRICATION OIL.
THE PRESSURE IN THE LUBRICATION SYSTEM CAN CAUSE DAMAGE TO THE
SEALS IN THE LOWER GEARBOX.

3.5 Carefully pour the lubrication oil from the oil can into the 'Fill'access hole of the header
tank.

3.6 Check the level of the lubrication oil shown on the dip stick. Make sure it shows between
the 'LOW' and the 'HIGH' level marks.

3.7 Install the filler cap on the 'Fill'access hole of the header tank.

Table 6 Lubrication Oil Types for Fixed Pitch Thrusters

Manufacturer Type Pour Point Viscosity in cSt Visc.Index

deg.0 40 deg.0 60 deg.0
ARAL DEGOL BG 150 -21 150 55 95
BP ENERGOL GR-XP 150 -24 150 53 96
CASTROL ALPHA SP 150 -21 150 55 95
CHEVRON GEAR COMPOUND EP15O -21 150 56 98
ELF EPONAZ 150 -21 148 55 98
REDUCTELF SP 100 -21 142 54 98
ESSO/EXXON SPARTAN EP 150 -24 144 54 96
KU WA IT 08 GOYA 150 -27 150 55 96
MOBIL MOBILGEAR 629 -24 144 53 90
SHELL OMALA 150 -21 150 56 100
TEXACO MEROPA 150 -24 150 56 93
TRIBOIL 1100/150 -28 150 56 96

Table 7 Lubrication Oil Contents for Fixed Pitch Thrusters

Thruster Type FT125 FT15O FT175 FT200 FT225 FT250 FT275 FT300
Header Tank (Itrs) 35 35 35 35 80 80 80 300
Lower Gearbox (ltrs) 230 300 370 450 530 700 1000 1000
Total Contents (ltrs) 265 335 405 485 610 780 1080 1300

Requirements After Job Completion

Do the following to the lubrication oil you spilt during the procedure:

1.1 Remove the catch tanks;

1.2 Clean the area.

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Lubrication System - Draining

References
Table 1 References

Data Module! Technical Publication Title

None

Preliminary Requirements

Required Conditions
Table 2 Required Conditions

Condition Data Module

None

Required Persons
Table 3 Required Persons

Number of Persons Category

2 Mech

Support Equipment
Table 4 Support Equipment

Nomenclature Identification No. Qty

Catch tank(s) AIR

Consumables, Materials and Expendables

Table 5 Supplies

Nomenclature Identification No. Qty

Clean cloth AIR

Safety Conditions
WARNING
CAUTIONS
MAKE SURE YOU USE CATCH TANK(S) OF ADEQUATE SIZE WHEN YOU DRAIN OIL OR
FLUID FROM EQUIPMENT. ALWAYS COLLECT AND REMOVE THE OIL OR FLUID YOU
SPILL DURING REMOVAL OR INSTALLATION OF THE EQUIPMENT.

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BTF-NLI PS-08

Procedure
Do the following to drain the lower gearbox only:

1.1 Gain access to the lubrication pump set.

WARNING
CAUTION
MAKE SURE YOU USE CATCH TANK(S) OF ADEQUATE SIZE WHEN YOU DRAIN OIL OR
FLUID FROM EQUIPMENT. ALWAYS COLLECT AND REMOVE THE OIL OR FLUID YOU
SPILL DURING REMOVAL OR INSTALLATION OF THE EQUIPMENT.

1.2 Put the catch tanks in position to collect the oil you may spill during this procedure.

1.3 Remove the drain plug from the 'Drain' connection.

1.4 Connect a pipe between the 'Drain' connection and the catch tank.

1.5 Set the flow-control valve SOV1 8 to the 'CLOSED' position.

1.6 Set the drain-control valve SOV1 7 to the '1 - 2' position.

1.7 Make sure the suction-control valve SOV1 5 is set to the '1 - 2' position.

1.8 Make sure the fill-control valve SOV1 6 is set to the '1 - 2' position.

1.9 Set the electric motor EM3 to 'On'.

1.1 OMonitor the following:

- the flow of the lubrication oil that comes out of the 'Drain' connection;
- the pressure of the lubrication oil that indicates on the pressure gauge PG4.

1.11 Set the electric motor EM3 to 'Off" when the following occurs:
- the flow of the lubrication oil stops coming out of the 'Drain' connection;
- the pressure gauge PG4 indicates zero pressure.

1.1 2Set the drain-control valve SOV1 7 to the '1 - 3' position.

1.l3Remove the pipe from between the 'Drain' connection and the catch tank.
I
1.l4InstaIl the drain plug in the 'Drain' connection.

2 Do the following to drain the header tank and the lower gearbox:

2.1 Make sure the isolation shut-off valve 50V9 is set to the 'OPEN' position, if applicable.

2.2 Gain access to the lubrication pump set.

2.3 Put the catch tanks in position to collect the oil you may spill during this procedure.

MAKE SURE YOU USE CATCH TANK(S) OF ADEQUATE SIZE WHEN YOU DRAIN OIL OR
FLUID FROM EQUIPMENT. ALWAYS COLLECT AND REMOVE THE OIL OR FLUID
YOU SPILL DURING REMOVAL OR INSTALLATION OF THE EQUIPMENT.

2.4 Remove the drain plug from the 'Drain' connection.

Effectivity:
All
BTF-A-08-00-00-OOA-222A-B I
2002-02-01 Page 2
 BTF-AILI PS-08
John Crane-Lips
Marine Propulsion Systems

S 2.5 Connect a pipe between the 'Drain' connection and the catch tank.

2.6 Set the flow-control valve 50V18 to the 'OPEN' position.

2.7 Set the drain-control valve SOV17 to the '1 -2' position.

2.8 Make sure the suction-control valve SOV15 is set to the '1 -2' position.
2.9 Make sure the fill-control valve SOV1 6 is set to the '1 - 2' position.

2.lOSet the electric motor EM3 to 'On'.

2.11 Monitor the following:
- the flow of the lubrication oil that comes out of the 'Drain' connection;
- the pressure of the lubrication oil that indicates on the pressure gauge PG4;
- the level of the lubrication oil in the header tank.

2.l2For the header tank, set the electric motor EM3 to 'Off" when the level of the lubrication
oil indicates empty.
For the lower gearbox, set the electric motor EM3 to 'Off" when the following occurs:
- the flow of the lubrication oil stops coming out of the 'Drain' connection;
- the pressure gauge PG4 indicates zero pressure.

2.l3Set the drain-control valve SOV17 to the '1 - 3' position.

2.l4Remove the pipe from between the 'Drain' connection and the catch tank.
2.l5lnstall the drain plug in the 'Drain' connection.

Requirements After Job Completion

Do the following to the lubrication oil you spilt during the procedure:

1.1 Remove the catch tanks;

1.2 Clean the area.

Effectivity: BTF-A-08-OO-OO-OOA-222A-B
All

2002-02-01 Page 3
 BTF-NLI PS-08
John Crane-Lips
Marine Propulsion Systems

Effectivity: BTF-A-08-OO-OO-OOA-222A-B
All

2002-02-01 Page 4
 BTF-AILI PS-08
John Crane-Lips
Marine Propulsion Systems

Lubrication System - Flushing

References
Table 1 References

Data Module! Technical Publication Title

BTF-A-08-OO-OO-OOA-21 2A-A Lubrication oil filling

BTF-A-08-OO-OO-OOA-222A-B Lubrication oil draining
BTF-A-08-OO-OO-OOA-921 A-A Oil-pressure filter-cartridge
change

Preliminary Requirements

Required Conditions
Table 2 Required Conditions

Condition Data Module

Drain lubrication oil BTF-A-08-OO-OO-OOA-222A-B

Required Persons
Table 3 Required Persons

Number of Persons Category

2 Mech

Support Equipment
Table 4 Support Equipment

Nomenclature Identification No. Qty

Flushing Unit
Temporary Piping A/R

Consumables, Materials and Expendables

Table 5 Supplies

Nomenclature Identification No. Qty

Filter Cartridge AIR

Flushing Fluid AIR
Clean cloth A/R

Effectivity: BTF-A-08-OO-OO-OOA-230A-B
All

2002-02-01 Page 1
 BTF-A/LI PS-08
John Crane-Lips
Marine PropulsIon 'stems

Safety Conditions
WARNING
ALWAYS WEAR PROTECTIVE CLOTHING AND GLASSES WHEN YOU WORK ON
EQUIPMENT.
CAUTIONS
MAKE SURE YOU USE CATCH TANK(S) OF ADEQUATE SIZE WHEN YOU DRAIN OIL OR
FLUID FROM EQUIPMENT. ALWAYS COLLECT AND REMOVE THE OIL OR FLUID YOU
SPILL DURING REMOVAL OR INSTALLATION OF THE EQUIPMENT.
'MAKE SURE THAT YOU DRAIN SYSTEM OIL OR FLUID BEFORE EQUIPMENT
DISASSEMBLY.
'MAKE SURE THAT YOU USE CLEAN TEMPORARY PIPES AND COUPLINGS. DIRT OR
FOREIGN MATERIALS CAN CONTAMINATE THE OIL OR FLUID IN THE LUBRICATION OR
CIRCULATION SYSTEMS. THIS CAN CAUSE DAMAGE TO EQUIPMENT.

Procedure
Note 1
The flushing fluid has a low viscosity. If the flushing fluid is not available use one of the
lubrication oils LIPS recommends (Ref. BTF-A-08-00-00-OOA-212A-A). Make sure it is clean
and at a temperature of 60 deg C (140 deg F).

Note 2
Make sure the flushing unit produces a velocity of 7 metres per second (mis) or greater. The
velocity corresponds to a flow of 430 litres/mm for low pressure piping. The velocity
corresponds to a flow of 85 litres/mm for high pressure piping.

Note 3
The pipe(s) that LIPS provide for new installations do not require flushing.

1 Set the shut-off valve SOV9 to the 'closed' position, if applicable.

WARNING
CAUTION
MAKE SURE YOU USE CATCH TANK(S) OF ADEQUATE SIZE WHEN YOU DRAIN OIL OR
FLUID FROM EQUIPMENT. ALWAYS COLLECT AND REMOVE THE OIL OR FLUID YOU
SPILL DURING REMOVAL OR INSTALLATION OF THE EQUIPMENT.

2 Drain the oil from the pipes of the lubrication system only (Ref. BTF-A-08-00-00-OOA-222A-
B).

WARNING
CAUTION
MAKE SURE YOU USE CATCH TANK(S) OF ADEQUATE SIZE WHEN YOU DRAIN OIL OR
FLUID FROM EQUIPMENT. ALWAYS COLLECT AND REMOVE THE OIL OR FLUID YOU
SPILL DURING REMOVAL OR INSTALLATION OF THE EQUIPMENT.

3 Make the pipes of the lubrication system into a loop using the temporary piping and the
flushing unit.

Effectivity: BTF.A-08-00-00-OOA-230A-B
All

2002-02-01 Page 2
 BTF-NLIPS-08
John Crane-Lips
Marine Propulsion Systems

WARNING
CAUTION
MAKE SURE THAT YOU USE CLEAN TEMPORARY PIPES AND COUPLINGS. DIRT OR
FOREIGN MATERIALS CAN CONTAMINATE THE OIL OR FLUID IN THE LUBRICATION
OR CIRCULATION SYSTEMS. THIS CAN CAUSE DAMAGE TO EQUIPMENT.

4 Fill the flushing unit with the flushing fluid.

5 Set the flushing pump to 'on'. Continue flushing for a period of one hour. Set the flushing
pump to reverse the direction of the flow on a number of occasions. Check the condition of
the filter(s) in the flushing unit regularly. Replace the filter cartridge(s) as necessary (Ref.
BTF-A-08-00-00-OOA-921 A-A).

6 Set the flushing pump to 'off' for a period of five minutes.

7 Set the flushing pump to 'on'. Continue flushing for a period of one hour. Set the flushing
pump to reverse the direction of the flow on a number of occasions. Check the condition of
the filter(s) in the flushing unit regularly. Replace the filter cartridge(s) as necessary (Ref.
BTF-A-08-00-00-OOA-921 A-A).

8 Set the flushing pump to 'off' for a period of five minutes.

9 Set the flushing pump to 'on'. Continue flushing for a period of 30 minutes. Set the flushing
pump to reverse the direction of the flow on a number of occasions. Check the condition of
the filter(s) in the flushing unit regularly. Replace the filter cartridge(s) as necessary (Ref.
BTF-A-08-00-00-OOA-921 A-A).

10 Set the flushing pump to 'off'. Check the condition of the filter(s) in the flushing unit. Continue
flushing until:
- the filter(s) remain clean;
- the solid contamination reaches the level of acceptance (Code 16/12 ISO DIS 4406).

WARNING
ALWAYS WEAR PROTECTIVE CLOTHING AND GLASSES WHEN YOU WORK ON
EQUIPMENT.

CAUTION
MAKE SURE YOU USE CATCH TANK(S) OF ADEQUATE SIZE WHEN YOU DRAIN OIL OR
FLUID FROM EQUIPMENT. ALWAYS COLLECT AND REMOVE THE OIL OR FLUID YOU
SPILL DURING REMOVAL OR INSTALLATION OF THE EQUIPMENT.

11 Drain the flushing fluid from the pipes of the lubrication system. Use dry air to force out the
flushing fluid that remains in the pipes.

12 Remove the temporary piping and the flushing unit.

13 Connect the pipes of the lubrication system.
14 Fill the lubrication system with the lubrication oil LIPS recommends (Ref. BTF-A-08-00-00-
OOA-21 2A-A).

Effectivity: BTF-A-08-OO-OO-OOA-230A-B
All

2002-02-01 Page 3
 BTF-NLI PS-08
John Crane-Lips
Marine Propulsion Systems

Requirements After Job Completion

Do the following to the lubrication oil you spilt during the procedure:

1.1 Remove the catch tanks.

1.2 Clean the area.

Effectivity:
All
BTF-A-08-OO-OO-OOA-230A-B S
2002-02-01 Page 4
 BTF-NLI PS-08
John Crane-Lips
Marine Propulsion Systems

Oil-Pressure Filter-Cartridge - Change

References
Table 1 References

Data Modulel Technical Publication Title

BTF-A-08-OO-OO-OOA-21 2A-A Lubrication oil filling

Preliminary Requirements

Required Conditions
Table 2 Required Conditions

Condition Data Module

Fill lubrication oil BTF-A-08-OO-OO-OOA-21 2A-A

Required Persons
Table 3 Required Persons

Number of Persons Category

1 Mech

Support Equipment
Table 4 Support Equipment

Nomenclature Identification No. Qty

Catch Tank(s) AIR

Consumables, Materials and Expendables

Table 5 Supplies

Nomenclature Identification No. Qty

Filter Cartridge AIR

Clean Cloth AIR

Effectivity: BTF-A-08-21 -OO-OOA-921 A-A

All

2002-02-01 Page 1
 BTF-NLI PS-08
John Crane-Lips
Marine Propulsion Systems

Safety Conditions
WARNING
CAUTIONS
'MAKE SURE YOU USE CATCH TANK(S) OF ADEQUATE SIZE WHEN YOU DRAIN OIL OR
FLUID FROM EQUIPMENT. ALWAYS COLLECT AND REMOVE THE OIL OR FLUID YOU
SPILL DURING REMOVAL OR INSTALLATION OF THE EQUIPMENT.

Note
When you change the filter cartridge of the lubrication pump set the transverse thruster system
can remain in service.

Procedure
1 Gain access to the lubrication pump set.

2 Set the electric motor EM3 to Off", if applicable.

WARNING
CAUTION
MAKE SURE YOU USE CATCH TANK(S) OF ADEQUATE SIZE WHEN YOU DRAIN OIL OR
FLUID FROM EQUIPMENT. ALWAYS COLLECT AND REMOVE THE OIL OR FLUID YOU
SPILL DURING REMOVAL OR INSTALLATION OF THE EQUIPMENT.

3 Put a catch tank in position under the drain (D) and the fill (F) connections.

4 Set the suction-control valve SOV1 5 to the '1 - 2' position.

5 Set the fill-control valve SOV1 6 to the '1 - 3' position.

6 Set the drain-control valve SOV17 to the 1 -2' position.

7 Put a catch tank in position under the drain plug of the filter cartridge.

8 Remove the drain plug. Let the lubrication oil drain into the catch tank.

9 Remove the cover from the oil-pressure filter.

10 Remove and discard the filter-cartridge.

11 Clean the cover. Make sure you remove all the dirt and foreign matter.

12 Install the new oil-pressure filter-cartridge.

13 Install the cover.

14 Install the drain plug.

15 Set the suction-control valve SOV1 5 to the '1 - 3' position.

16 Set the fill-control valve SOV16 to the '1 - 2' position.

17 Set the drain-control valve SOV17 to the '1 - 3' position.

18 Replenish the lubrication system with the lubrication oil LIPS recommends, if necessary (Ref.
BTF-A-08-00-00-OOA-21 2A-A).

Effectivity: BTF-A-08-21 -OO-OOA-921 A-A

All

2002-02-01 Page 2
 BTF-NLIPS-08
John Crane-Lips
Marine Propulsion Systems

Requirements After Job Completion

1 Clean the area.

Effectivity: BTF-A-08-21 -OO-OOA-921 A-A

All

2002-02-01 Page 3
 BTF-NLIPS-08
John Crane-Lips
Marine Propulsion Systems

Effectivity:
All
BTF-A-08-21 -00-OOA-921 A-A S
2002-02-01 Page 4
 BTF-AILI PS-09
John Crane-Lips
/I141 Marine Propulsion Systems

Auxiliary Systems - Description

References
Table 1 References

Data Module! Technical Publication Title

BTF-A-09-1 O-OO-OOA-042A-A Auxiliary Systems, Shaft Brake

Description
1 General
The Auxiliary Systems of the transverse thruster provide extra functions to the standard version.
In this version, the transverse thruster only has the shaft brake system.

2 Shaft Brake System

The shaft brake system prevents the propeller from turning when the transverse thruster is not in
operation (Ref. BTF-A-09-1 O-OO-OOA-042A-A).

Effectivity: BTF-A-09-OO-OO-OOA-01 1 A-A

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2002-02-01 Page 1
 BTF-NLI PS-09
John Crane-Lips
Marine Propulsion Systems

Effectivity:
All
BTF-A-09-0O-00-OOA-000A-A S
2002-02-01 TOC Page 2
 BTF-AILI PS-09
John Crane-Lips
Marine Propulsion Systems

Auxiliary Systems, Shaft Brake - Description

References
Table 1 References

Data Module/Technical Publication Title

None

Description
1 General
The shaft brake system prevents the propeller from turning when the thruster is not in operation.

2 Physical Description
The shaft brake system consists of these components:
- the brake control panel;
- the disk-brake caliper.
The yard installs the brake control panel near to the installation of the transverse thruster.

2.1 Brake Control Panel

The brake control panel has these components:
- the pressure-control valve (3WVEL);
- the throttle/non-return valve (TNRV);
- the pressure switch (PRS).
The pressure-control valve (3WVEL) controls the air flow to the brake.cylinder (PC).
The throttle/non-return valve (TNRV) controls the operation of the brake cylinder (PC).
The pressure switch (PRS) operates over a pre-set range. The knob on the top of the housing sets
the range to 0.2 - 0.6 bar.

2.2 Disc-Brake Caliper

The disc-brake caliper has these components:
- the pneumatic actuator (1);
- the upper shoe-arm assembly (2);
- the lower shoe-arm assembly (8);
- the pivot base (3);
- the pad assembly (4);
- the pad springs (5);
- the equalising link (6);
- the torsion spring (7);
- the tension springs (9).

Effectivity: BTF-A-09-1 O-OO-OOA-01 1 A-A

All

2002-02-01 Page 1
 BTF-NLIPS-09
John Crane-Lips
Marine Propulsion Systems

The pneumatic actuator (1) has a piston-rod assembly. The piston rod applies pressure on the
lower shoe-arm assembly (8) when the brake system operates.
The pivot base (3) forms a pivot point for the shoe-arm assemblies (2, 8).
The tension springs (9) keep the tension on the upper part of the shoe-arm assemblies (2, 8)
during the operation of the brake system.
The torsion spring (7) forces the shoe-arm assemblies (2, 8) apart when the pressure on the brake
system releases.
The pad springs (5) retain the brake pad assemblies (4) on the shoe-arm assemblies (2, 8).
A bracket in the tunnel supports the weight of the disc-brake caliper in the horizontal plane. The
equalising link (6) compensates for the weight of the brake pads on the disc.

Fig 1 Disc-Brake Caliper - Component Location

BTFAO9I00000AO11AA1

Effectivity: BTF-A-09-1 O-OO-OOA-01 1 A-A

All

2002-02-01 Page 2
 BTF-A/LIPS-09
John Crane-Lips
Marine Propulsion Systems

3 Functional Description
Referto Fig 2
The shaft brake system prevents the propeller from turning when the transverse thruster is not in
operation. If you apply the brake above 50 revolutions per minute damage could occur.
The control system of the propeller drive motor controls the operation of the pressure-control valve
(3WVEL). Under no circumstances should you attempt to start the propeller drive motor with the
brake on.
The shaft brake system becomes active when:
- the pressure-control valve (3WVEL) energizes;
- the air pressure is above 6 bar.
When you apply the brake, the pressure control valve (3WVEL) receives an 'apply brake' signal
from the brake control in the ship. This causes the following to occur:
- the pressure control valve (3WVEL) opens;
- the air flows through the pressure control valve (3WVEL) to the throttle/non-return valve
(TNRV).
The throttle/non-return valve (TNRV) ensures that the brake cylinder (PC) pressurizes gradually.
When you release the brake, the brake control in the ship removes the 'apply brake' signal from
the pressure control valve (3WVEL). This causes these actions to occur:
- the pressure control valve (3WVEL) closes;
- the air stops flowing through the pressure control valve (3WVEL) to the throttle/non-return
valve (TNRV).
The throttle/non-return valve (TNRV) ensures that the brake cylinder (PC) de-pressurizes
immediately.
The pressure switch (PRS) sends a 'brake engaged' signal to the control panel in the ship. The
yard makes sure that this signal inhibits the start circuit of the propeller drive motor whilst the brake
is on.

Fig 2 Shaft Brake System - Schematic

BRAKE CONTROL PANEL DISC-BRAKE CALIPER

-I -

PR51
0,2-0,6 BAR
TNRV

AIR SUPPLY

I
PC
LW
fly
A,'
MAX. 7 BAR
MIN. 6BAR

I-
B1FO9100000AOI1AA2

Effectivity: BTF-A-09-1 O-OO-OOA-01 1 A-A

All

2002-02-01 Page 3
 BTF-AILIPS-09
John Crane-Lips
Marine Propulsion Systems

Effectivity: BTF-A-09-1 0-00-OOA-01 1 A-A

All

2002-02-01 Page 4
 BTF-A/LI PS-09
John Crane-Lips
Marine Propulsion Systems

S
Auxiliary Systems, Shaft Brake, Pads - Change

References
Table 1 References

Data Module! Technical Publication Title

None

Preliminary Requirements

Required Conditions
Table 2 Required Conditions

Condition Data Module

Required Persons
Table 3 Required Persons

Number of Persons Category

1 Mech

None
Consumables, Materials and Expendables
Table 5 Supplies

Nomenclature Identification No. Qty

None

Safety Conditions
WARNINGS
MAKE SURE THAT YOU DISENGAGE THE DRIVE MOTOR BEFORE YOU PROCEED. THIS
PREVENTS IT FROM BEING STARTED ACCIDENTALLY.

Effectivity: BTF-A-09-1 1 -OO-OOA-921 A-B

All

2002-02-01 Page 1
 BTF-AILI PS-09
John Crane-Lips
Marine Propulsion Systems

Procedure
WARNING
MAKE SURE THAT YOU DISENGAGE THE DRIVE MOTOR BEFORE YOU PROCEED.
THIS PREVENTS IT FROM BEING STARTED ACCIDENTALLY.

1 Gain access to the disc-brake caliper (1) in the tunnel assembly.

2 Remove and discard the pad spring (2) from the upper shoe-arm assembly (3).

3 Remove and discard the pad assembly (4).

4 Remove and discard the pad spring (5) from the lower shoe-arm assembly (6).

5 Remove and discard the pad assembly (7).

6 Clean both sides of the disc (8).

7 Install the new pad assembly (4) on the upper shoe-arm assembly (3).

8 Install the new pad spring (2) over the pad assembly (4).

9 Install the new pad assembly (7) on the lower shoe-arm assembly (6).

10 Install the new pad spring (5) over the pad assembly (7).

Fig 1 Disc-Brake Caliper, Pad Assemblies - Change

To be issued later

Effectivity: BTF-A-09-1 1 -OO-OOA-921 A-B

All

2002-02-01 Page 2
 BTF-A/LIPS-09
John Crane-Lips
Marine Propulsion Systems

Requirements After Job Completion

1 Make sure that there are no tools or equipment in the work area and that the work area is
clean.

Effectivity: BTF-A-09-1 1 -OO-OOA-921 A-B

All

2002-02-01 Page 3
 BTF-NLI PS-09
John Crane-Lips
Marine Propulsion Systems

Effectivity: BTF-A-09-1 1 -OO-OOA-921 A-B

All

2002-02-01 Page 4
 John Crane-Lips
Marine Propulsion Systems

APPENDIX
TRANSVERSE THRUSTER WITH
FIXED PITCH PROPELLER

LIPS ORDER No's: B02363

 John Crane-Lips
Marine Propulsion Systems

1 List of drawings

Drawinq number Desiqnation Fiçi. no.

W084832444 AU Arrangement of transverse thruster 1

W084832874 Al Arrangement flex, coupling la

925-640-010 Flex, coupling BSD-Modulflex lb
(2 sheets)

W084832516 Al Lubrication oil connections Ic

W084832656A1 Propeller 3

W084818636 Al Mounting of propeller 3a

W084832630 AU Assembly of the pod 4

R00845A3 Thruster seal 4a

W084830616 A2 Lubrication oil diagram 25

W084816646 A2 Lubrication pumpset 27

E000003202 A3 Starter lub. oil pump 27a

W084815094 A3 Brake control panel 28

W084833359 Al Arrangement shaft brake 29

W084833076 Al Cover 30

3005523 A4 Standard coating specifications 52

W084833619 A4 Order specific coating specifications 52a

The drawings contained in this manual as well as the drawings provided for
information and assembling purposes, remain the property of LIPS B.V.
They may not be copied or reproduced in any way, used by or shown to third
parties without the written consent of LIPS B.V.
 John Crane-Lips
Marine Propulsion Systems

List of instruction- and information sheets

Instruction- and information sheets of following parts are supplied in

this manual.

Name of component Paqe (part no.)

Information on Loctite products 2005099

to be used on thrusters

Torque manual 2050443E

Flexible coupling (type 925-640-010) W084819055

Torque limiting safety coupling W084833335

with electronic release indicator

Hydraulic pump W006010286

Pressure filter W0061 10206

Pneumatic pressure switch T002016868

Pneumatic pressure valve T003003034

S
Title: Arrangement transverse tunnel thruster Page: 1 of 1
Type: FT300 Drawing: W084832444
List: B023631519 Orderno: B02363
fig.nr.:

Itemno. Name Art. no. Quantity

001 Heavy type cyl. spring dowel M71 8500584 2,0
002 Hexagon screw M71 3000584 2,0
003 Flexible.coupling W084833342 1,0
004 Torque limiter W084833335 1,0
005 Hexagon bolt M71 3005589 122,0
006 Hexagon nut M71 4040039 122,0
007 Single coil spring washer M716100039 122,0
008 Plain washer MJoo0 122,0
009 Packing W084833266 1,0
010 Support W084833344 1,0
011 Zinc.anode W00899701 5 10,0
012 Indicator W084833706 1,0

Notes: - Item numbers not listed have not been used in this install.
- The quantities an partnumbers shown on the parts list
are believed to be correct, the quantities shown on the
drawing are for illustration only.

END OFLIST

7-1 1-01
W)04832444

A ---
290? SOMES5 STEEL THRUST 0)00(5 (LOOSE EEL) VERY)
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2, CATHCOIC PROTEC7IOI6 REOLIOFO 10 r 00-AL

31 FOR LOSCIL 446006(6 SEE IRA kING W08483060 A2

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6. MASS )EXCL (03155 E-MUTLR) APP??. 30000 kg

(lOSS f-MOTOR 12000 kg

fld46 ', L'

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i1i nen
LIPS
NetherIemds
APR. OF TRANS VERSE THRUSTER
OPSTELLING OWARSSCHROEF

see/zie 04(g) C
2001)50 FT300

26??

W084832444
 312

a E-motor shaft
without key

Mounting flange E-Moto,

0 180 há
Mounting flange 8-Motor

55

0 710

brake disc
H
- (/50 2(68-I I
to 'a te 'at
an an an an

pol
43 4, 42 45 'C, 42 ,2
43 45 45

L S.
.5 LIPS ARR. FLEX. COUPLING
shaft Drunen.The NetherIand
t V 0S7 74
-E ' A.JAI/ 2001(2628

20011'628

ç poo
W084832874 B Al
ate, maan,, macon, (01000W3
 Copyright protection acc. to DIN 34
The information contained in these
documents is entrusted to the Attent 10fl:
addressee for the described purpose Performance characteristics
only and must not be handed over to (Coupling selection for the
a third party without our explicit
consent. specific app! icat ion)
1288
acc. to DIN 740, part 2,
sections 2 2 and 3
240 835-2 213 Coupl ingparameLers acc. to
24,5 DIN 740, part 2, sect ion 2.
POD-SIDE 12, 7 E-MOTOR-S IDE -Nominal torque TKN :64000 Nm
-Maximum torque TKmax:125000Nm
(6,3)
-Axial Misal ignment Ka:±8, 2 mm
-Angular Misal ignment Kw:O, 75 grd
-Radial Misalignment i,Kr:g mm

101,5
-Torsional Spring Rate CTHSO:l2, 37x106Nm/rad
-Maximum speed n555:750 mln1
-Weight m :460 kg
178 -Moment of inertia J :12,3 km2
60 urn 1200 vers. *permanent strength at, 0,4 degree

---
0
40
20
3 x20 0 2x45°
2,5x45° 0 20 40 50 )

0 K at
51
7
-t The given misal iqnmnnts at-c maximum
o val ucs for onl y one direr uit ol
mi sal iqnmont If operut irrg rond it ions
require severa! miseliqnments
Prepared for Saveset ST-B 180 nimultarteauslyIhe values wil! he rr--
duced according to the nhown graph
and formul a
rS
(i3
.
755

rwzsz' For proper function of our

products as well as for the
118,5 equipment where they are
being installed, our products
- Ma1 422Nm
require performance characte-
ristics coverage acc. to DIN
-t 740, part 2 When in doubt
z. B. Gedore-Einsatz IN 21 22
Spacer Ring please contact us
4v Arretierbrücke (wird mitgelietert) Pre-Machined 30 mm ( del ivered)
z. B. Iedore-Orernometer £ Nur für Transport und Montage, bei -Noor 20 me-Min 15 mm
inbetriebnahrne kompiett entfernen. Screw-I ength compensat ion
4x Retaining device (to be supplied). not necessary
For transport arid assembly only, to be
removed completely at starting operation. Konserviert mit Tectyl 846 Instruction for installation,
Corrosion protection Tectyt 846 operation and maintenance 98 900 1
3x15°

AUFTRAGSBEZOGENE OS-VORGABEN BEACHTEN!

U-)

Observe quality specifications rel. to order!

Çustorner Dr,-No. : 11084833342
lOe oeLeO1l ai I ge:rI,I lIe 2?58I
eOOIob. .2 ,.400k
Ober S,,
dlrksl,lI,Holh,,119.
flObk,t-Nr

H:
Model I a Oe,er,k-N,
2001 0015 Oo0000Crg
,
Bob,:,eI 0 Her 8S0 - tors stiff coupl inc
Goo1I
Oor,, Type IIODULFLEX®
Einzelheit 'X' (2x) DO es) Reo,eo,-d 4r,te,ebsiechnik
Einzelheit 925-640-010.
Einzelheit"Y" (3x) Oortmünd. . L
M 3: 1
,- -oneoeh-Nr-.15025/.61
Cro fûr,lq,e 2)0001 jEr dol-ch
 /
1 2 3 4 3 5 6

um 120 0vers

Pl
0
C
3x20° 2x45°
Cu

0
Cu

I"
_16

X z Prepared For Saveset ST-B 180

I2,5x450 5

118,5

Na=1422Nri
t
za Gedore-Elnsatz IN 21 22
LB. Gedore-Dremorieter £

pos, Designotion fr'awing-no.

1 Aussennoioe/hub 921-640-00621
2 Brernsscheibe/bro,ke 927-640-01808
3 BSD-MIIDULFLEX-Kupptung/MUDULFLEX-coupling 920-640-021
4 Zwischenrohr/Spocer 925-640-01312
5 Ausgleichsscheibe/Length conpensotion ring R 2669
Customer Draw.-No.iV084833342
6 Aussenncxbe/hub 921-640-00622 1'2 It1& 400 kO

16x Zylinderschr./hex. sock.head cup screw M30x90 DIN 912 2001 t'..
IItdO

H@r. BSD - tors. stÇÇ coupling

G.r1ft
8 32x Zy1inderschr/hex sockheud cup screw M30x70 DIN 912 Ylt1d.
Fast Type MODULFLEX
Istt
925-640-010 2,
9 16x Zytincler'schr./hex. sock.head cxp screw M30x80 DIN 912 ,t ii - ._ Vs.dt-I45925461 L
Title: Lub. oil connections Page: 1 of 1

Type: FT300 Drawing: W084832516

List: B023631 521 Orderno: B02363
fig.nr.: IC

Itemno. Na m e Art.no. Quantity

001 Elbow fitting with progressive ring W00641 0067 1,0
002 Elbow fitting with progressive ring M71 0761134 1,0
003 Seamless precision tube M301035356 6000,0
004 Elbow fitting with progressive ring W00641 0048 2,0
005 Straight fitting w.progressive ring M71 0722234 1,0
006 Bulkhead.fitting.w.progressive ring W006350241 1,0
007 Straight male stud coupling W006350221 1,0
007A Reducing socket nipple M710190305 1,0
008 Elbow fitting with progressive ring M71 0761134 1,0
009 T-fitting with progressive ring M71 0801134 1,0
010 Red.standpipe w.progressive ring W006370035 1,0
011 Red.standpipe w.progressive ring W006370040 1,0
012 Plug W006574814 1,0
013 Bulkhead .fitting.w.progressive ring W00635024 1 1,0
014 Banjo fitting with progressive ring W006540028 1,0
015 Elbow fitting with progressive ring W00641 0009 1,0
016 Straight fitting w.progressive ring M71 0722234 1,0
017 Straight fitting w.progressive ring M71 0722234 1,0
018 Plug W006574817 1,0
019 Red.standpipe w.progressive ring W006370026 1,0
020 Seamless precision tube M301035272 500,0
023 Bulkhead.fitting.w.progressive ring W006350241 1,0
024 Seamless precision tube M301035272 100,0
025 Elbow fitting with progressive ring W00641 0044 1,0
026 Red.standpipe w.progressive ring W006370035 1,0
027 Straight fitting w.progressive ring M71 0722234 1,0
028 Straight male stud coupling W006356700 1,0
029 Pipe clamp T002006886 6,0

Notes: - Item numbers not listed have not been used in this instalL
- The quantities an partnumbers shown on the parts list
are believed to be correct, the quantities shown on the
drawing are for illustration only.

END OFLIST

7-11-01
31'

0
VT
000
0
I_I 0
0 0
II SECTION B-B
'UI
VT2

DETAIL 0

lul Zss, (O 2368-f I

lul .2' .4'

.45
.42 4,
"5
.45
.25
.48
.8
8W
88W
8W

.5

S0
LIPS Lub.oll connections
Drunen.The Netherlands Smo aensluitngen
NONE

AlA 365E 200105fl F1115-3000P

2oovse

W084832516 Al
 MAX. EXPANDED OUTLINE
RADIUS RAKE THICKNESS CLEARANCE CURVE PITCH DrSTRIBuTI0N PROJECTED OUTLINE BLADE SECTIONS

S RADIUS AT L.E. AND TE.

AT TIP = 114
13 5 558.6 558.6
1425.0 13.5 19.3 2220
1389.4 13.1 19.7 2220 . .

1363.8 12.6 20.1 2220 561.6 , , 661.5 '''''==. 0.96

1282.5 11.7 21.1 2220 564.3 564.3

1211.3 0.8 22.5 ____________________________________ 2220 666.7 566.7

1140.0 9.9 24.4

I
2220 567.5 667.5 I ,_U .809

T 709

997.6 8.! 30.4 2220 568.6 568.6 1

I,_II\
609

855.0 9.3 40.3

2.5

570.0
4.5

2.7
53.8

70.6 I I____ . I
.9

306

iii
427.5 0.9 99.6 2220 0.30

386,3 0.0 99.6 1 .. . 0.250

PROPELLER DATA
DIAMETER 2850 MM
PITCH, 2220 MM
NUMBER OF BLADES 4
293.6
DIRECTION OF MOTATION RIGHT-HANDED
YR M
EXPANDED BLADE AREA RATIO 0.696
INNEM DIAM NOZZLE 28871
SKEI4ANGLE 0.0 DEGR
PROPELLER RADIUS 142S?
'MASS- .
2179 KG
19.3
FOR Hue DETAILS SEE IJHC. 4064832633 MASS MOM. OF INERTIA PROP. IN AIR 819 K0M
9=7.7 ' .R=ll.6 MASS MOM. OF INERTIA OF ENTR. HATER 280 KGM
BLADE FINISHING TOLERANCES IN -ACCORDANCE WITH ISO CLASS I

,.-MRTFRIRL1SPECIFIQTIONANDMECHflNICPL PDPERTIES
ISO V-NOTCH- -.
TEY6SILE STRÊNOTH -VIELO STRESS ELOYSTR.T ION
1999Cr ENEROY. --7661- TERFER9TI54E
MIN. 6E0 W194 -pijN. 245N/PflI lijN. lB 0 CENT 10960E

TIE [615109 541095 0934)6 09814)90

15 TIE .POSOLLITE PROPERTY OF
--F.P.FROELLER
-LIPSPOELLER WORKS-
IT.RRT NOT BE COPIE5 OR R.RR0DUCE0
IT PRY NO BE EXECUTES BY USED FOR
DETHIL BLADE ROOT FI..LETS 'DETA L BLADE TIP OR' SHOWN TO THIRD FORTIES WITII3JT
INÛT-TO SCALE) -(SCALE 11.0) THE'WRITTEpl CONSENT OF'.TI 091Ev
-I.
HYOBDYIRMIC DESIGN'
pPARmENT
RRR J T LIg'teUjrY .1

- . ir1#,vis.' ' sit

 MAE/-I/NE DIMENSION "X' OF RETAINER PLATE
AFTER MOUNTING OF PROPELLER.
SEE DRWG. OF RETAINER PLATE FOR TOL ERA N/ITS G/BSP 1/4' (2X)

11
WHEN REMOUNTING THE PROPELLER, MACHINING OF
DIMENSION "Z" OF RETAINER PLATE MIGHT BE NECESSARY.
MEASURE BEP TH OF CHAMBER AFTER APPLYING THE'
PRE-LOAD AND CALCULATE DIMENSION "Z'
TAKING IN ACCOUNT THE REQUIRED PULL-UP.
Ztu
G/BSP 1/4'

ted.
MOUNTING PLATE W084818651

PLAIN WASHER M30 M716000046 18x)

- PULL 11/7 DIAGRAM - MATERIAL: CUMAL

FOR TEST FITTING PROCEDURE OF PROPELLER G/BSP 1/4 (2x)

7,8 -
Sp.e instruction no. 2006192: KEYLESS PROPELLER MOUNTING
DRUKKEN VOOR HYVR. HOER
PRESSURES FOR HYL1R. NUT 01W
7,6 - VOORDRUK
54 bar
START-POINT LOAD
MAX. INJEC11EDRUK 735 bar
MAX. INJEC7ION PRESSURE
MAX. DRUK HYOR. MOER
545 bar
MAX. PRESSURE HYOR. NUT

DRUKKEN VOOR HYOR. HOER

PRESSURES FOR HYOR. NUT OTHEÇ'S
VOORDRUK
73 bar
START-POINT LOAD
7,0 - MAX INJECTIELIRUK
900 bar
MAX INJECTION PRESSURE
MAX. DRUK FIYDR. MOER
660 bar
6,8 MAX. PRESSURE HYOR. NUT

6,6 - THE PROPELLER SHOULD HAVE THE FOLLOW/NE

Il/FORMATION HARD STAMPED ON THE OUTS/DE
OF TIlE 80551
6,4 - 0.WV. START POINT LOAD 101,9 hIll
AXIAL PULL IF AT 0°C 6,19 mm
AX/AL PULL UP AT 35°C 533 mm
6,2
START P0/NT LOAD /37,6 kN
OTHERS: AXIAL PULL UP AT 0°C 7,39 mm
AXIAL PULL IF AT 35°C 6.53 mm
'2-
6,0

5,8 -
a 00/
((P 0AS01SC(
ms 4, '4,
'(P
.52
00 so 5V 050
'5
300
.6

5.6 "5
-r ; LIPS PROPELLERMON JA GE

5.4
Orunen.The Netherlands
;; ,V' '=' MOUNTING OF PROPELLER

P.
113
Vg,w.e 98 0615
FT/F300

NUT: SKF HMV 52 / FAG RKP26O

W084818650
® QHYDRAULIC
MAX. STROKE 11 mm W007250045
5,2
-/5° -10° 5° 0° 5° 10° 15° 200 25° 30° 350
8x M3OX100 M712045540 TEHPERATURE bY DEER. CELCIUS
W084818636 A Al
-na, Sm,,
Title: Assembly of the pod Page: 1 of 3

Type: FT300 Drawing: W084832630

List: B023631 712 Orderno: B02363
Jig.nr.: 4

Itemno. Na m e Art.no. Quantity

001 M Gear set for pod W084821 962 1,0
002 0-ring W007000594 1,0
004 Locking.wire W007550008 2,7
005 Hexagon bolt M713005692 29,0
007 Suction linè W084816144 1,0
008 Straight male stud coupling W006350240 1,0
011 Copper sealing ring M731 000340 1,0
013 Hex. socket head cap screw M712045391 16,0
016 Locking nut T003003000 1,0
017 Compression spring T003000678 6,0
019 Adjusting.ring W084822448 1,0
020 V-ring M730030039 1,0
022 Heavy type cyl. spring dowel M718500379 1,0
023 Housing for sealing W084815343 1,0
025 Hex. socket head cap screw M712040380 4,0
026 Dubo retaining ring M716601036 4,0
052 Seamless 0-ring seal M730000459 2,0
053 Plug.air release W084815101 1,0
054 Sealing. ring.metal and rubber. bonded s M735000024 1,0
055 Oil seal W007065208 1,0
056 Supporting ring W004700330 1,0
058 Liner W084815342 1,0
059 0-ring W007000730 1,0
064 Hex. socket head cap screw M712045387 4,0
065 Adjusting.ring W08481 5347 1,0
067 Hexagon screw M71 3000732 2,0
068 Dubo retaining ring M716600050 2,0
100 Pod W084832882 1,0
130 Retaining ring for shaft W08481 1960 1,0
131 Spherical.roller.bearing.double.row W08481 7452 1,0
132 Hex. socket head cap screw M712040278 2,0
133 Hardened cyl. pin T003005581 1,0
137 Hardened cyl. pin W08481 7453 3,0
139 Hexagon socket pipe plug W08481 1041 3,0
143 Hexagon screw M713001528 1,0
144 Block W084814079 1,0
145 Dubo retaining ring M716600036 1,0
146 Cap W084815587 1,0

7-11-01
Title: Assembly of the pod Page: 2 of 3
Type: FT300 Drawing: W084832630
List: B023631712 Orderno: B02363
fig.nr.: 4

Itemno. N a m e Art.no. Quantity

150 Retaining ring for shaft M71 8700481 1,0
181 Seamless 0-ring seal W007001 326 1,0
182 Locking.wire W007550008 2,1
184 Hexagon bolt W0071 10149 24,0
185 Bearing flange W08481 5429 1,0
187 Hexagon bolt W0071 10230 12,0
230 Seamless 0-ring seal W007031 006 1,0
232 Spherical.roller.bearing.double.row W006200053 1,0
238 Hex. socket head cap screw W08481 6124 20,0
239 Plain washer W007375034 20,0
242 Hexagon screw W007100410 8,0
244 Inspection cover W004340844 1,0
245 Hardened cyl. pin T003001 745 1,0
246 Hex. socket head cap screw M71 2045284 2,0
247 Hexagon head screw plug W0065641 10 1,0
248 Sealing. ring.metal and rubber. bonded s M735000530 1,0
249 Spherical .roller.bearing.double.row W08481 7458 1,0
250 Block W08481 4082 1,0
251 Retaining ring for shaft W08481 7459 1,0
253 Seamless 0-ring seal W007024200 1,0
254 Hexagon head screw plug M71 0380248 4,0
256 Pipe clamp W005102812 2,0
257 Suction line W08481 6145 1,0
259 Support W00690574 1 2,0
260 Bearing housing W08481 7128 1,0
262 Seamless 0-ring seal W007030600 1,0
263 Flange cover W084832634 1,0
265 Hexagon bolt W0071 10144 12,0
266 Seamless 0-ring seal W007000373 1,0
268 Hexagon bolt W007110169 12,0
273 Hexagon screw W0071 00388 14,0
275 Propeller.shaft.sealing W084819113 1,0
277 Seamless 0-ring seal M73000045 1 1,0
278 Adjusting.ring W08481 5337 1,0
280 Distance.ring W08481 5349 1,0
281 Compression spring W084822698 4,0
284 Locking nut T003003220 1,0
287 Spherical roller thrust bearing M701661060 1,0

7-1 1-01
Title: Assembly of the pod Page: 3 of 3
Type: FT300 Drawing: W084832630
List: B023631712 Orderno: B02363
Jlg.nr.: 4

Itemno. Nam e Art.no. Quantity

289 Hex.socket set screw w.cup point M71 2085326 1,0
292 Hex. socket head cap screw W08481 8631 8,0
293 Sealing. ring.metal and rubber. bonded s M735000530 8,0
295 Plate.adjusting W08481 5925 1,0
298 Seamless 0-ring seal W08481 1703 1,0
301 Hexagon .socket.screw.plug W006564050 2,0
302 Copper sealing ring M731 000230 2,0
350 Propeller shaft W084817389 1,0
356 Hexagon screw M713001 580 4,0
357 Dubo retaining ring M716600039 4,0
359 Hexagon screw M713001580 4,0
361 Dubo retaining ring M716600039 4,0
364 Ring W084832694 1,0
365 Hexagon screw W007100387 8,0
367 Cord ring with vulcanized joint W084819882 1,0
368 Adjusting.ring W08481 7482 1,0
370 Bush.reducing W08481 7472 1,0
371 Tapered roller bearing W08481 7483 1,0
374 Equal bend W084830947 1,0
376 Hardened cyl. pin T003003221 1,0
377 Spherical roller thrust bearing W006260018 1,0
379 Hexagon head screw plug M710380243 6,0
380 Compression spring T003000678 6,0
382 Spherical roller thrust bearing M701 661052 1,0
383 Distance bush W084817484 1,0
385 Bearing housing W084815344 1,0

Notes: - Item numbers not listed have not been used in this install.
- The quantities an partnumbers shown on the parts list
are believed to be correct, the quantities shown on the
drawing are for illustration only.

END OFLIST

7-11-01
W084032R30
LA&'RPAILILET VLRI/IBIIIIEN lIT HLZE440EEII
SMEREN PIT ERI'ASLLP (10030601681 MEI80 TYPE MIV 31 OP 300 Ba' AYOEHTINÇ) VLZIRZ(N / PITOYKOTE RI (1002014693)
LMOASE WITH ECINASLI" (10630001681 MOE-S TRESS 003066855 WITH HSORAUIC 911E
TYPE (11V 34 Al 300 ba'
8//TE LCHT98SSP/W
LASSEN MET AVESIB EN AALAILAL 99168/NI P8/ER 9800 - 71800 MM VENTLMS PILE
WOW WI1H AVESE4 PE REQL4REO 1(340400 98)1 9800 - 7/800 MM
AA.9IH4ALPOINT 8ELNGSCIJOE8Y 35 91,,
R(OLSROV 1060)00 0CC/LOIS S/REk) 35 MM
00@0 58Q 64
0 65

VT?

LIOL8RNLEN INSLAAN lIST SLAGLETTERS

MARK (15185 98TH (15981 P9REH
HE(HTLASSEN as 910v0400
VUIL)' DWT8REKEMI PEP KOPPELJR9OEN EN/SE
OLOTWELO Al ASSEM9LV
PEtJE/EN ZE TEKENVOS '/9951 OWARSSCM?EEr
00 9853083 PINE (RIPE'. S .1/" /5
SEE 0041,981 'ARIIOT. TRANSVERSE IM/USIEIP'

370 AYSIELLEN EN /,ECH/OASSEN 81) P8017/SE

133) ADA/ST AM) 740/ WELD Al ASSEMBLY

368

367

(X) RIlITE OP VIELEN

((MOVER 19
T SOCL9E}IN1T
.L8EEE.NT

F
/
///// //////
11/
/ / / /
//
/

FOR INFO AND REQUIREMENTS

SEE CORRESPONDING "TOl' SHEET
LASSEN MET AVESL4 PS
28'. 263) 262 260 259 (257) 256 54 ) 23.5) 253) 44 1/1 18/) SGDEUSMM 300574 PS
1015)' AANH4ALMDMENTEN ZIE 2050443
29. (Ij) FOR REQUIRED TORQUES SEE 2050443
250
VOOR BORCAIIL18SELEN ZE 2065099

FOR AOI6SIVES SEE 3005099

AYS TELLEN EN PE(HTLAS.SEN 813 994W/ODE
AOAJST AlS 740) WELD Al ASSEMBLY
SPEREN NET (UPASLIP r0o3000168
00(351 101H COPASLL 1005000966
90' VERDRAAID (EYE//ENS
90' 9ASDRAWN LIPS SAMENSTELLING GOP/GEL
LASSEN BIJ NONT4GE O,',AfleflThe Nethe,-len06 ASSEMSLY OF IKE POD
LAOERP4KKET VOORORLARCEN 9817 HYDRA UI (SEMi Ni 5 0
'5, TYPE (99V 60 OP 250 WE 8'
P -S RE VAR/NO TH ((A (6)
/8' VERLRIAAIO GETEKEND 5' N 'a, a,, Eo.,. 7/816800 #7300
TYPE MMV 60 Ar 250 Ga,
8' IRSORAWN 2414168fl
AAWHAALMOPINT MOER 22006 - 26000 51, PASIN4ITEW EN LASSEN 8/) PICWO4GE
REQL0REÛ TONGUE 9E/T 22000 - 26000 MM 911 8900 GRID AT ASSINSLY
AAMMAALPOIJ9IENT BORUSCHROEF 35 MM W084832630
D'S ORE/EL 1E MM
 REQUIRED TORQUE
S 28 I 6
Nm REQUIRED TORQUE 23 Nm

21.:
VIEW A
= 20,

0.03 a
CN)v

AIR VENT OIL INLET

//
(12x) 022 L
/ EQUIDISP4CED

SEE 14 TAIL B
32/
/
.5.

\
CERAMIC CDA TING AL2 O3 T102 \UIL DRAIN
1 0x4 5

1191

NOTE FOR PRODUCTION

CA SING FL ANGE MA TERIAL GGG-4 0 -
DETAIL B FL ANGE BOL TS ARE CUSTOMER SUPPL Y I
YARD
ORDERNR wo...
0RINGS FOR LINER AND FLANGE ARE CUSTOMER SUFPL Y!
N.B. -
BOL T HOLES FOR MOUNTING THE CLAMPS NEED TO BE DRILLED CLASS
THROUGH THE CASING FL ANGE ! THESE HOL ES CAN BE USED -
TO PRESS THE FLANGE FROM THE STERNTUBE!
MASS APPROX: 64 KG
DIMENSIONS IN MILLIMETERS

MACHINING ALLOVANCE UNLESS

OTHCR'.I5E SECIIE0
fi17 John Crane MarineLips 11
ISO 2768)
flr'unn - ThE NpthQrIans
DIMENSION
TOLERANCE TITEL
z ABOVE up TO 6110
$4 SO I THRUS TER SEAL
6 JO sOD
TYPE F300 / W084R19113
120 315 505 SCALE DRAWN DATE T IRE
NOTE FOR SHIP YARD 315 200 SOS P.BLBM 16.11.98
10011 2000 21 2 AMERICAN PROJECTION
CASING PARTS TREA T AGAINST CORROSION 20011 AQUA
CHECRE S DATE
300
CLAMPS ® TO BE TAKEN AWAY AFTER 'Ii
4000 8000 L3,0
APPROVED DRIE
MK2M
INS' TALLA TION 11415 DPAIIING REMAINS THE PROPERTy
5 OF JOHN CRANE MARINE-LIPS IN
DRIJNE1I AND MAY WITHOUT WRITTEN OP DE T NL) lIRE P DRAW INONUM BEP
PERMISSION OF THE OWNER NOT BE MOD IF I-
MULTIPLIED OR ICED FOR THIRD CAl loll

=A
PARTIES OP RE GIVEN TO THIRD
PARTIES rap PERUSAL R00845 A A3
 S YNBOL S

AB2 AB2 FILLER / BREATHER

052 DIP STICK
052
LLS2 LOW LEVEL SWITCH
SOV9 SHUT OFF VALVE normally open
142
ST HEAD PRESSURE LINE POD

LLS2 142 HEADER TANK

ri LOW
VT VENTING LINE POD
LOW AL4ThY

PUMP SET
VT S EM3 E-MOTOR 0.4 kW 1500 mfri' 400 V 50 Hz
LOADED WATEILWE
LT LUBRICATION SUCTION LINE

P3 GEAR PUMP 8 dm3/min

DRAIN VT ST PF3 PRESSURE FILTER
PIPE 00. x /0. = 42 x 36 (2f)
PG3 PRESSURE GAUGE 0-6 bar
SOV9
PSV3 PRESSURE SAFETY VALVE set to 3 bar
PSV5 PRESSURE SAFETY VALVE set to 0.5 bar
50V14 PRESSURE GAUGE VALVE

50V15 THREE WAY VALVE

SOV16 THREE WAY VALVE

ST DRAINING CONNECTION SO Vi? THREE WAY VALVE

50V18 SHUT OFF VALVE normally open

W3 THERMOMETER
SOV1?

SO VIS I.

SO VIS

W3

SOV14

LIPS' SUPPLY

P5V3

PSV5 REMARKS:
TI-fE CALCULATED HEIGHT OF THE HEADER 14NK
SHOULD NOT EXCEED 15 MTR.
THE LUB. OIL UMT SHOULD SE PLACED AS CLOSE AS
POSSIBLE TO THE THRUSTER.
THE HEAD PRESSURE LINES (ST) AND THE VENTING LINE (VT)
MUST SE SLOPED UPWARDS TO THE 14NK.
FILLING CONNEC17ON
MAXLENGTH 20 Mli?, WITH MAX. 10 BENDS OF 90 DEGREES.
7AM(5, LUS.OIL UNIT AND P/PING MUST SE SITUATEO IN
SOVI6
FROST FREE COMPARTIMENTS.

Sr F ANY OF THESE CRITERIA CANNOT BE FULLFILLEU PLEASE

ASK LIPS ENGINEERING DEPARTEMENT FOR ADVISE.
PIPING AND. VALVES SOV9 NOT LIPS SUPPLY
VT ST LT
PIPES WITH LARGER INSIDE IJIAMETER AND SUFFICIENT
WALL THICKNESS MAY BE USED
WELD MPPLES FOR OTHER PIPEDIAMETERS NOT LIPS SUPPLY

VT1 VT2

; LIPS. LUBRICATION OIL DIAGRAM

Drunen The Netherlands
GEAR POD
11E 41.1E N1E IIE RTY LPS SV W 0741.14
N0?W 1.1Eff 1EnIU 11E.
01.1V? MIT E WRE 0?
F I PARI
A.JANSE
GV 17? 11151 PARISS S4I.

W084830676. A...A2:
Title: Assembly of pump unit Page: 1 of 1

Type: standaard Drawing:

List: W084833285 Orderno: B02363
fig.nr.: 27

Itemno. Na m e Art.no. Quantity

405A 3 phase E-motor with squirrelcage W08481 1181 1,0
410 Lantern piece W00501 0075 1,0
415 Flexible.coupling W002000983 1,0
425 Gear pump W006010286 1,0
435 Flange W006466146 2,0
440 Pressure filter W0061 10206 1,0
445 Pressure filter cartridge W0061 15133 1,0
450N Non return valve W084814609 1,0
455 Frame W084815203 1,0
460 Pressure gauge W006800190 1,0
465 Pressure gauge coupling W006400018 1,0
470N Measuring coupling W084821758 1,0
475 Thermometer W006840228 1,0
485 Ball.tap W08481 5748 1,0
486 BaIl.tap W08481 5748 1,0
487 Ball.tap W084821759 1,0
488 T-fitting with progressive ring W084824167 2,0
490N Non return valve W084815473 1,0
495 Ball.tap W084815748 1,0

Notes: - Item numbers not listed have not been used in this install.
- The quantities an partnumbers shown on the parts list
are believed to be correct, the quantities shown on the
drawing are for illustration only.

END OFLIST

7-! 1-0!
 FUNCTIONAL CONNECTIONS
042x3
018x2

VALVE SET11NGS
(Looking on top of SOV 15 SOy 16 50V 17 SOy 18
the valve handle).

NORMAL 2-3 2 OPEN

FILLING POD 23 23 23 CLOSED

)RAINING HEADERTANK
23 2-3 23 OPEN

23 23
DRAINING POD CLOSED
FILLING
CLOSED
HEADERTANK

EM3

SOV17 PG3 SOV14

PLUGGED
1/2" BSP

B
ST
- IIIIIIflfl 1I
iWij
PF3

uiu.uu iii..p-
-

SOV18
- l -IIII'_i
II Ip II
- W3
tijull
l!.I
!!
_w _5.n;

ï.!
- -u''JB
:1
-. Iii._Jh_
'1
riI!I!mu
fI;
SOV15

PSV3
1ILölIi1f' 1
iiiiiuIF. REMARKS:
Boll valves drawn in

i*:
I..... normal working position.
H
.0 MASS: 40 kg.
LT
II
."jUU ,_.Q

H_____
V
IUi1I1I -
1/2 BSP
0
I')

1QR

:&:

LUBRICA11ON PUMPSET
CflT3LUB SG9,7-1 8-071
 10 11 12 13 14 15 16 17 18 19

SUPPLY:

101 300 1 50
Li
a
L2

L3

I
1 P1

2
2. 5
32 1F2 32
0. 5 0, 5 RUNNING

¶3
1 P1
1 Si
113
1 Qi
3 _5 1 Ki R° 1
1K1
114
2 4 6 1T1

1 3 5 95
1F4
96
63 VA
52
2.
ii I

250

Ui Vi Wi

1 11 1 F2 1 F3

3 4

M11111R ST AR TER M NONC

1114 u)
11
11
1 Ki
234

1 Qi
1 F4

-J
z
C.)

C'-)
WIRING WHERE NUT MENTIONED i,5rin2
C,) CL AN DPL A T E FOR WALL-MOUNTI NC z
C-)

ELMA Ref.: 4 HOLES 9m-n z

z
CD
ci

(N
CD
(N
CD
CD
CD
SCALE: DATE: NAME:
CD MOD.: DATE: DESCRIPTION: INITIALS:
S. TYPE:

LIPS
ORIGINATES
CD
UJ 0)S

DRAWN:
STARTER HYDRAULIC PUMP FROM DRAWING:

Drunen,The Netherlands NTR 16-12-98 TAES (Below 25 Amp.)

z THIS OIEÔ.IWNG REWiNS 114E PROPERTY OF UPS CHECKED:
DIMENSIONS DEPARTMENT: DRAWINGNUMBER: ORDERNUMBER: PAGE: MOD.: SIZE:
NID MAY WITh&IUT 111E W7?IflEN PERMISSION OF 111E
IN
Q OWNER NOT BE MULI1PUED, BE USED FOR THIRD COMPANY RESTRICTED:
MILLIMETERS N-TR E000003202 STANDARD 01/01 A3
PMTIES OR BE OREN 10 THIRD PARTIES FOR PERSW.L.
I Passivation : RAL 7032 Inrada std.

SET TO 0,2-0,6 BAR

Brake Cylinder

Pg 9

--4

Pg 11

1/4NNPT male

1 /4"NPT mole

100
YARD
WEIGHT 3.25 KG N.B.

'
E
0
11 TEL

Brake Control Panel

Schaal

Proj.
: 1

Dotum
LIPS
Drunen, The Netherlands
BRAKE CONTROL PANEL
LIP1 1x3/2D-24VdcOOl
LIP1 1 x3/2D-24VdcOOl Getek. : RBW 23/10/97 ORIGINATES FROM ORAWING
OWDISOMS IN AMERICAN PR0..ECIION
MLUME1ER IS0 128

dl
C 375 Gezien
.
I- ThIS ORA*ING REMAINS TIE PROPERTY OF UPS &G. DRA 0A1E
TeL 010-4154944
Fox. 010-4378333
Klont Lips B.V. AND MAY 1HOUT ThE WRITTEN PERMISSION OF 11 RBW 23/1O/9
U
PoMbs 190 0*EW NOT:BE U(JLTpJI) BE USED.FCR ThIRD PARBES,
OCck
INRADA 3100 ADSchiedam Project: CR BE G1WN TO ThIRD PARTIES: FOR PER9JAL...
DATE:

'p S$ema&.
Engineering..
Tek.nr.

313-1981
Wijz.

A
INRADA 97701091 3T3-1981
Title: Arrangement brake.shaft Page: 1 of 1

Type: Drawing: W084833359

List: B023630368 Orderno: B02363
fig.nr.: 5

Itemno. Na m e Art.no. Quantity

001 Brace caliper W008996941 1,0
004 Support W084833360 1,0
005 Hexagon bolt M713005484 3,0
006 Hexagon nut M714040033 3,0
007 Single coil spring washer M716100033 3,0
010 Hose T003000616 1,0
011 Straight male stud coupling W006350223 1,0
012 Bar.t-.equal.hot rolled M301 108020 500,0

Notes: - Item numbers not listed have not been used in this install.
- The quantities an partnumbers shown on the parts list
are believed to be correct, the quantities shown on the
drawing are for illustration only.

END OFLIST

7-11-01
 Flex, coup/lig and brake al'sc
A

see draw/np flex, coup/lig

L7

Lassen bij monfag

0
Weld af assembly

VIEW A

N
N
N
N

MAX. OPERATING AIR PRESSURE I bar

MIN. PRESSURE 6 bar
FOR BRAKE CONTROL PANEL SEE ORWG. W0848!5094
CONNECTION BRAKE CALIPER TO P/P/NO FROM THE
BRAKE CONTROL TO BE MADE WITH FLEXIBLE HOSE
H/N, LENGTH 400mm.
PIPING AdO COUPLING BETWEEN BRAKE AND
BRAKE CONTROL PANEL NOT LIPS SUPPLY

(ISV 2268-I /

h 6W stm1O6
.6.3 .3,3 .45 .48 .13 .3 .' .5 .6
.45 .3 .15 .45

fl LI P S
Orunen,The Netherlands
SU1
OPSTELLING ASREM
APR61. SHAFT BRAKE
WW

(ó) i' W%, 3WWW5( 200N816

t'D 21101085

W084 833359 Al
 585.5 840 840 25

25 25

-+

tT tt
60
55 85

I 0 t
-0-
-0- -0-
-0-

4-I
4-
4-
114

0
Le

II
I.'
-0-

4-
4- DETAIL A
4- 4-
25
4- 4-
926 1030

4- 4-
+ 286
390
+
+
tt -

t225
T
t
0
=225=
see detail A
tt
T
T

0 2
Alle niet aangegeven lassen
u/f voeren a/s volgt;
All weldings not marked
should be;

1-'
4-

0 '4- 4-
Thickness of plates 8 10

Tunnel production procedure see KZP12O9E

4
12 14 16

7
18 20 2
10
0

A14S vieS free

4- 4- t,4t,4eoiteet,4a 57.44-2 1470-rQtIed,unlreated(StepblAdirlg Steel 4444744

LbJt,4.fe 44vl
4- 4-

±++ +
K47EO41
IlaJTIûSmsS
On 1s44Ita &rttTr,4. La9Vt00 Owa/Trfl. LJÇsAWÇ flea-v/me.

+ 4- G',d, A 30 400490 235 22

Ctad4 B > 50 390 - 480 225 21

+ +

40 40

125,5 26X105= 2730

t1A55 3750 kg
2981

8 PLATE SEE SPEC. 1030x200x25

250 50 7 PLATE SEE SPEC. 926x225x25
2 6 PLATE SEE SPEC. 1300x225x25

/ I.)
G \ 3
6
6
5

3
2
PLATE
PLATE
PLATE
PLATE
SEE SPEC
SEE SPEC.
SEE SPEC.
SEE SPEC.
425x425x25
298 1e200x25
1025x200x25
750x200x25
PLATE 3625x2981x25

-w
SEE SPEC.

L
444
'44 44,4 444

220 RONDOM I M4 .41 4, '44 47

N
1

.44 'le .4,

1 UPS COVER
DEKSEL
Drunen.The Netherlands
£7 3 MM
1.10 FT300
4 JA NSf 20099788
20010718

W084833076 A Al
 id.nbr. 3005523
d.d. 1997.05.30
index 2
HEMPEL COATING SPECIFICATION FOR TUNNEL THRUSTERS

sequence description product colour dry film application spec sheet

thickness nümber
(micron)
1 shot blasting
SA 2.5 (Iso 8501-
2 shopprimer HEMPELS E 1528 red 5089 25 áirle:spray 300.5524

POD (inner oil) side)

sequence description product colour dry film application

thickness
(micron).
1 shot blasting
SA 2.5 (ISO 8501-i)
2 primer HEMPADUR 1530 red 5089 50 airless spray 3002986

POD (outer (water) side )

sequence description product colour dry film

thickness
(micron)
1 shot blasting
SA 2.5 (ISO 8501-i)
2 primer HEMPADTJR 1530 red 5089 50 airless epray 30029.86 -.

3 degreasing
4 second layer HEMPADUR 4515 alum. grey 1987 90 brush]röller.. 3Q03199
5 third layer HEMPADUR 4515 light grey 1217 90 brush/roller;.
6 fourth layer HEMPADTJR 4515 alum. grey 1987 90 brush/roller 3003199

Notes:
-Final tunnel coating to be applied by the shipyard (same as on hull). If applicable, tiecoat and antifouling system
to be applied by the shipyard on water side of tunnel and outer side of pod (same as on hull)
-In case of damages/deterioration, the concerning spot has to be pretreated (blasting/degreasing) again and repainted
-Damages (e.g. caused by welding or transport) that can be recovered immediately may be repaired
-Surface preparations, equipment and applications to be strictly in accordance with paint manufacturers specifications
(part of this specification; id.nbrs. 3002986, 3002989, 3003199 and 3005524)
 John Crane-Lips
Marine Propulsion Systems

Jo/in Crane-Lips Coating Specification

COATING FOR POD

Name Code Product Dft Colour

Hempadur 1530 Epoxy primer 50 p Red
Note: parts that are not accessible after assembly has to be coated with the
complete standard Hempel coating system (see id. 3005523)

TUNNELCOATING (including frame and cover)

Name Code Product Oft Colour

Sigma EP universal 7417 Epoxy primer 50 p Gr.yellow

REMARKS:

All surfaces to be shot blasted SA 2.5 (ISO 8501-1)

MANUFACTURER: Hempel/SIGMA Coatings

Lips Standard Coating System

Pod No Coating specification transverse thruster
Tunnel No

Signed: Date: Ordernumber Specification no. Mod:

N. Dekker 2001-09-06 B02363 W0848336l9 B
2001-10-04
17850
PARTNUMBER - PARTLIST CROSS-REFERENCE B02363

This list can be used to find the location of a certain partnumber and as such can be used during maintenance, repair and overhauL

Part number Item catchword Partlist number Drawing figure Partlist catchword Item Need UM Class
M301035272 Seamless precision tube B023631521 26 Lub. oil connections 020 500 MM

M301035272 Seamless precision tube B023631521 26 Lub. oil connections 024 100 MM

M301035356 Seamless precision tube B023631 521 26 Lub. oil connections 003 6000 MM

M301108020 Bar.t-.equal.hot rolled B023630368 5 Arrangement brake.shaft 012 500 MM

M701 661052 Spherical roller thrust bearing B023631 712 4 Assembly of the pod 382 1 ST

M701661 060 Spherical roller thrust bearing B023631712 4 Assembly of the pod 287 1 ST
M7101 90305 Reducing socket nipple B023631521 26 Lub. oil connections 007A 1 ST

M710380243 Hexagon head screw plug B023631712 4 Assembly of the pod 379 6 ST
M710380248 Hexagon head screw plug B023631712 4 Assembly of the pod 254 4 ST
M710722234 Straight fitting w.progressive ring 8023631521 26 Lub. oil connections 017 1 ST
M71 0722234 Straight fitting w.progressive ring B023631521 26 Lub. oil connections 016 1 ST

M710722234 Straight fitting w.progressive ring B023631521 26 Lub. oil connections 005 1 ST

M710722234 Straight fitting w.progressive ring B023631521 26 Lub. oil connections 027 1 ST

M710761134 Elbow fitting with progressive ring B023631521 26 Lub. oil connections 008 1 ST
M710761134 Elbow fitting with progressive ring B023631521 26 Lub. oil connections 002 1 ST
M710801134 T-fitting with progressive ring B023631521 26 Lub. oil connections 009 1 ST
M712040278 Hex. socket head cap screw B023631712 4 Assembly of the pod 132 2 ST
M712040380 Hex. socket head cap screw B023631712 4 Assembly of the pod 025 4 ST
M712045284 Hex. socket head cap screw B023631712 4 Assembly of the pod 246 2 ST

7-11-01 Page 1 of 8
S

Part number Item catchword Partlist number Drawing figure Partlist catchword Item Need UM Class
M712045387 Hex. socket head cap screw B023631712 4 Assembly of the pod 064 4 ST

M712045391 Hex. socket head cap screw B023631712 4 Assembly of the pod 013 16 ST

M712085326 Hex.socket set screw w.cup point B023631712 4 Assembly of the pod 289 1 ST

M713000584 Hexagon screw B023631519 1 Arrangement transverse tunnel thruster 002 2 ST

M713000732 Hexagon screw B023631712 4 Assembly of the pod 067 2 ST

M713001528 Hexagon screw B023631712 4 Assembly of the pod 143 1 ST

M713001580 Hexagon screw B023631712 4 Assembly of the pod 356 4 ST

M713001 580 Hexagon screw B023631712 4 Assembly of the pod 359 4 ST

M713005484 Hexagon bolt B023630368 5 Arrangement brake.shaft 005 3 ST

M713005589 Hexagon bolt B023631519 1 Arrangement transverse tunnel thruster 005 122 ST

M713005692 Hexagon bolt B023631712 4 Assembly of the pod 005 29 ST

M714040033 Hexagon nut B023630368 5 Arrangement brake.shaft 006 3 ST

M714040039 Hexagon nut B023631519 1 Arrangement transverse tunnel thruster 006 122 ST

M716100033 Single coil spring washer B023630368 5 Arrangement brake.shaft 007 3 ST

M716100039 Single coil spring washer B023631 519 1 Arrangement transverse tunnel thruster 007 122 ST

M716600036 Dubo retaining ng B023631712 4 Assembly of the pod 145 1 ST

M716600039 Dubo retaining nng B023631712 4 Assembly of the pod 361 4 ST

M716600039 Dubo retaining ring B023631712 4 Assembly of the pod 357 4 ST

M716600050 Dubo retaining ring B023631712 4 Assembly of the pod 068 2 ST

M716601 036 Dubo retaining ring B023631712 4 Assembly of the pod 026 4 ST

M718500379 Heavy type cyl. spring dowel B023631712 4 Assembly of the pod 022 1 ST

M71 8500584 Heavy type cyl. spring dowel B023631519 1 Arrangement transverse tunnel thruster 001 2 ST

M718700481 Retaining ring for shaft B023631712 4 Assembly of the pod 150 1 ST

7-11-01 Page2 of 8
S
Part number Item catchword Partlist number Drawing figure Partlist catchword Item Need UM Class
M730000451 Seamless c-ring seal B023631712 4 Assembly of the pod 277 1 ST

M730000459 Seamless 0-ring seal B023631712 4 Assembly of the pod 052 2 ST

M730030039 V-ring B023631712 4 Assembly of the pod 020 1 ST

M731 000230 Copper sealing ring B023631712 4 Assembly of the pod 302 2 ST
M731000340 Copper sealing ring B023631712 4 Assembly of the pod 011 1 ST

M735000024 Sealing. ring.metal and rubber. bonded B023631712 4 Assembly of the pod 054 1 ST

M735000530 Sealing. ring.metal and rubber, bonded B023631712 4 Assembly of the pod 293 8 ST

M735000530 Sealing. ring.metal and rubber. bonded B023631712 4 Assembly of the pod 248 1 ST

T002006886 Pipe clamp B023631521 26 Lub. oil connections 029 6 ST

T003000616 Hose B023630368 T003000616 5 Arrangement brake.shaft 010 1 ST

1003000678 Compression spring B023631712 4 Assembly of the pod 017 6 ST

T003000678 Compression spring B023631712 4 Assembly of the pod 380 6 ST
T003001745 Hardened cyl. pin B023631712 3000231 4 Assembly of the pod 245 1 ST

T003003000 Locking nut B023631712 4 Assembly of the pod 016 1 ST

1003003220 Locking nut B023631712 4 Assembly of the pod 284 1 ST

T003003221 Hardened cyl. pin B023631712 3000231 4 Assembly of the pod 376 1 ST

T003005581 Hardened cyl. pin B023631712 3000231 4 Assembly of the pod 133 1 ST

W002000983 Flexible.coupling W084833285 27 Assembly of pump unit 415 1 ST

W004340844 Inspection cover B023631712 W004340844 4 Assembly of the pod 244 1 ST

W004700330 Supporting ring B023631712 W004700331 4 Assembly of the pod 056 1 ST

W005010075 Lantern piece W084833285 27 Assembly of pump unit 410 1 ST
W005102812 Pipe clamp B023631712 4 Assembly of the pod 256 2 ST
W006010286 Gear pump W084833285 27 Assembly of pump unit 425 1 ST

7-11-01 Page3of8
S
Part number Item catchword Partlist number Drawing figure Partlist catchword Item Need UM Class
W0061 10206 Pressure filter W084833285 27 Assembly of pump unit 440 1 ST

W0061 15133 Pressure filter cartridge B023630553 27 Arrangement of pump unit 004 0 ST

W0061 15133 Pressure filter cartridge W084833285 27 Assembly of pump unit 445 1 ST

W006200053 Spherical.roller.bearing.double.row B023631712 4 Assembly of the pod 232 1 ST

W006260018 Spherical roller thrust bearing B023631712 4 Assembly of the pod 377 1 ST

W006350221 Straight male stud coupling B023631521 26 Lub. oil connections 007 1 ST

W006350223 Straight male stud coupling B023630368 5 Arrangement brake.shaft 011 1 ST

W006350240 Straight male stud coupling B023631 712 W006350240 4 Assembly of the pod 008 1 ST

W006350241 Bulkhead.fitting.w.progressive ring B023631521 26 Lub. oil connections 023 1 ST

W006350241 Bulkhead.fitting.w.progressive ring B023631521 26 Lub. oil connections 006 1 ST

W006350241 Bulkhead.fitting.w.progressive ring B023631521 26 Lub. oil connections 013 1 ST

W006356700 Straight male stud coupling B023631521 26 Lub. oil connections 028 1 ST

W006370026 Red.standpipe w.progressive ring B023631521 26 Lub. oil connections 019 1 ST

W006370035 Red.standpipe w.progressive ring B023631521 26 Lub. oil connections 010 1 ST

W006370035 Red.standpipe w.progressive ring B023631521 26 Lub. oil connections 026 1 ST

W006370040 Red.standpipe w.progressive ring B023631521 26 Lub. oil connections 011 1 ST

W006400018 Pressure gauge coupling W084833285 27 Assembly of pump unit 465 1 ST

W006410009 Elbow fitting with progressive ring B023631521 26 Lub. oil connections 015 1 ST

W00641 0044 Elbow fitting with progressive ring B023631521 26 Lub. oil connections 025 1 ST

W006410048 Elbow fitting with progressive ring B023631521 26 Lub. oil connections 004 2 ST

W006410067 Elbow fitting with progressive ring B023631521 26 Lub. oil connections 001 1 ST

W006466146 Flange W084833285 27 Assembly of pump unit 435 2 ST

W006540028 Banjo fitting with progressive ring B023631521 26 Lub. oil connections 014 1 ST

7-11-0 1 Page4of8
S
Part number Item catchword Partiist number Drawing figure Partlist catchword Item Need UM Class
W006564050 Hexagon.socket.screw.plug B023631712 4 Assembly of the pod 301 2 ST

W0065641 10 Hexagon head screw plug B023631712 4 Assembly of the pod 247 1 ST

W006574814 Plug B023631521 26 Lub. oil connections 012 1 ST

W006574817 Plug B023631521 26 Lub. oil connections 018 1 ST

W006800190 Pressure gauge W084833285 27 Assembly of pump unit 460 1 ST

W006840228 Thermometer W084833285 27 Assembly of pump unit 475 1 ST

W006905741 Support B023631712 W006905741 4 Assembly of the pod 259 2 ST

W007000373 Seamless 0-ring seal B023631712 4 Assembly of the pod 266 1 ST

W007000594 0-ring B023631712 4 Assembly of the pod 002 1 ST

W007000730 0-ring B023631712 4 Assembly of the pod 059 1 ST

W007001 326 Seamless 0-ring seal B023631712 4 Assembly of the pod 181 1 ST

W007024200 Seamless 0-ring seal B023631712 4 Assembly of the pod 253 1 ST

W007030600 Seamless 0-ring seal B023631712 4 Assembly of the pod 262 1 ST

W007031006 Seamless 0-ring seal B023631712 4 Assembly of the pod 230 1 ST

W007065208 Oil seal B023631712 4 Assembly of the pod 055 1 ST

W007100387 Hexagon screw B023631712 4 Assembly of the pod 365 8 ST

W007100388 Hexagon screw B023631712 4 Assembly of the pod 273 14 ST

W007100410 Hexagon screw B023631712 4 Assembly of the pod 242 8 ST

W007110144 Hexagon bolt B023631712 4 Assemblyof the pod 265 12 ST

W007110149 Hexagon bolt B023631712 4 Assemblyof the pod 184 24 ST

W007110169 Hexagon bolt B023631712 4 Assemblyof the pod 268 12 ST

W0071 10230 Hexagon bolt B023631 712 4 Assembly of the pod 187 12 ST

W007375029 Plain washer B023631 519 1 Arrangement transverse tunnel thruster 008 122 ST

7-11-01 Page 5of8

 S
Part number Item catchword Part/is! number Drawing figure Part/is! catchword Item Need UM Class
W007375034 Plain washer B023631712 4 Assembly of the pod 239 20 ST

W007550008 Locking.wire B023631712 4 Assembly of the pod 004 3 MT

W007550008 Locking.wire B023631712 4 Assembly of the pod 182 2 MT

W008996941 Brace caliper B023630368 5 Arrangement brake.shaft 001 1 ST

W008997015 Zinc.anode B023631519 1 Arrangement transverse tunnel thruster 011 10 ST

W08481 1041 Hexagon socket pipe plug B023631712 4 Assembly of the pod 139 3 ST

W08481 1181 3 phase E-motor with squirrelcage W084833285 27 Assembly of pump unit 405A 1 ST

W08481 1703 Seamless 0-ring seal B023631712 4 Assembly of the pod 298 1 ST

W08481 1960 Retaining ring for shaft B023631 712 4 Assembly of the pod 130 1 ST

W084814079 Block B023631712 W084814079 4 Assembly of the pod 144 1 ST

W084814082 Block B023631712 W084814082 4 Assembly of the pod 250 1 ST

W084814609 Non return valve W084833285 27 Assembly of pump unit 450N 1 ST

W084815101 Plug.air release B023631712 W084815101 4 Assembly of the pod 053 1 ST

W08481 5203 Frame W084833285 27 Assembly of pump unit 455 1 ST

W084815337 Adjusting.ring B023631712 3001993 4 Assembly of the pod 278 1 ST

W084815342 Liner B023631712 W084815342 4 Assembly of the pod 058 1 ST

W08481 5343 Housing for sealing B023631712 W084815343 4 Assembly of the pod 023 1 ST

W084815344 Bearing housing B023631712 W084815344 4 Assembly of the pod 385 1 ST

W084815347 Adjusting.ring B023631712 3001990 4 Assembly of the pod 065 1 ST

W084815349 Distance.ring B023631712 W084815349 4 Assembly of the pod 280 1 ST

W084815429 Bearing flange B023631712 W084815431 4 Assembly of the pod 185 1 ST

W08481 5473 Non return valve W084833285 27 Assembly of pump unit 490N 1 ST

W084815587 Cap B023631712 W084815587 4 Assemblyof the pod 146 1 ST

7-11-01 Page 6of8

 S
Part number Item catchword Partlist number Drawing figure Partlist catchword Item Need UM Class
W084815748 BaIl.tap W084833285 27 Assembly of pump unit 485 1 ST
W084815748 BaIl.tap W084833285 27 Assembly of pump unit 486 1 ST

W08481 5748 Ball.tap W084833285 27 Assembly of pump unit 495 1 ST

W084815925 Plate.adjusting B023631712 W084815925 4 Assembly of the pod 295 1 ST

W08481 6124 Hex. socket head cap screw B023631712 4 Assembly of the pod 238 20 ST
W084816144 Suction line B023631712 W084816144 4 Assemblyof the pod 007 1 ST
W08481 6145 Suction line B023631712 W084816145 4 Assembly of the pod 257 1 ST
W084817128 Bearing housing B023631712 W084817128 4 Assembly of the pod 260 1 ST
W084817389 *
Propeller shaft B023631712 W084817389 4 Assembly of the pod 350 1 ST

W084817452 Spherical.roller.bearing.double.row B023631712 4 Assembly of the pod 131 1 ST

W084817453 Hardened cyl. pin B023631712 4 Assembly of the pod 137 3 ST
W084817458 Spherical.roller.bearing.double.row B023631712 4 Assembly of the pod 249 1 ST
W084817459 Retaining ring for shaft B023631712 4 Assembly of the pod 251 1 ST
W084817472 Bush.reducing B023631712 W084817472 4 Assembly of the pod 370 1 ST
W084817482 Adjusting.ring B023631712 3001990 4 Assembly of the pod 368 1 ST
W084817483 Tapered roller bearing B023631712 4 Assembly of the pod 371 1 ST
W08481 7484 Distance bush B023631712 W084817484 4 Assembly of the pod 383 1 ST
W08481 8631 Hex. socket head cap screw B023631 712 4 Assembly of the pod 292 8 ST
W084818651 Plate.adjusting B023630110 W084818651 Tool 005 1 ST
W0848191 13 Propeller.shaft.sealing B023631712 W084819059 4 Assembly of the pod 275 1 ST
W08481 9882 Cord ring with vulcanized joint B023631712 4 Assembly of the pod 367 1 ST
W084821758 Measuring coupling W084833285 27 Assembly of pump unit 470N 1 ST
W084821759 Ball.tap W084833285 27 Assembly of pump unit 487 1 ST

7-11-01 Page 7of8

S I
Part number Item catchword Partlist number Drawing figure Partlist catchword hem Need UM Class
*
W084821962 Gearsetfor pod B023631712 W084821895 4 Assemblyof the pod OO1M 1 ST
W084822448 Adjusting.ring B023631712 3001990 4 Assembly of the pod 019 1 ST
W084822698 Compression spring B023631712 4 Assembly of the pod 281 4 ST
W084824167 T-fitting with progressive ring W084833285 27 Assembly of pump unit 488 2 ST
W084826156 Manual.instruction B023630104 Manual.instruction 001E 5 ST
W084830947 Equal bend B023631712 W084830930 4 Assembly of the pod 374 1 ST

W084832634 Flange cover B023631712 W084832634 4 Assembly of the pod 263 1 ST

W084832656 Propeller.ship.fixed B023630109 W084832656 Propeller.ship.fixed 001 1 ST *

W084832694 Ring B023631712 W084832694 4 Assembly of the pod 364 1 ST

W084832836 Assembly of pump unit B023630553 W084816646 27 Arrangement of pump unit 001 1 ST
W084832882 Pod B023631712 4 Assembly of the pod 100 1 ST
W084832897 Tunnel with motor support B023631518 W084832897 Tunnel 001 1 ST *

W084833040 Frame B023631518 W084833040 Tunnel 002 1 ST *

W084833076 Cover B023631518 W084833076 1 ST *

Tunnel 003

W084833266 Packing B023631519 W084833266 1 Arrangement transverse tunnel thruster 009 1 ST

W084833335 Torque limiter B023631519 W084833335 1 Arrangement transverse tunnel thruster 004 1 ST
W084833342 Flexible.coupling B023631 519 W084833342 1 Arrangement transverse tunnel thruster *
003 1 ST
W084833344 Support B023631519 W084833344 1 Arrangement transverse tunnel thruster 010 1 ST
W084833360 Support B023630368 W084833360 5 Arrangement brake.shaft 004 1 ST
W084833365 Brake control panel B023630364 W08481 5094 Brake control panel 001 1 ST
W084833706 Indicator B023631519 1 Arrangement transverse tunnel thruster 012 1 ST
W084834190 Plate.liftng B023631518 W084834190 Tunnel 004 4 ST

7-11-01 Page8of8
 LIPS THRUSTERS DRUNENB.V. Sheet.no.2005099

index 4 (991210)

INFORMATION ON LOCTITE PRODUCTS TO BE USED ON THRUSTERS

L1OCTITE type Productnr 'Colour I Application

Drawing symbol Part no.

Nutlock 243 Blue Locking Fasteners

symbol: All Steel Bolts, Nuts
circle/black T00l048l97 and Studs

Studlock 270 Green Locking Fasteners

T002005540 All Stainless steel M20
symbol:
circle/half 275 Green All Stainless steel > M20
black W005903954 Bolts, nuts and studs

Penetrating 290 Green Sealing of existing

Adhesive connections (e.g. pipe
T002005541 fittings etc.)

Pipe sealant 577 l.brown Sealing of pipe joints

and fittings
T002007114

Superbonder 401 transpa Bonding 0-Rings, and

rant synthetic materials
TO 02 0 0 5543

Master Gasket 574 Orange Gasket fluid.

Sealing of machined
symbol: surfaces.
circle/quart. T002014948
black

High strength 307 transpa Superbonder of materials

adhesive rant as steel, bronze etc.
T002005545
Super Clean 706 transpa Cleaner for fasteners
rant and surfaces. Must be

t0Loctite products.
T00300506 used before applying any
 rn LIPS
S S
= jJ THRUSTEPS

TORQUE MANUAL SYMBOLS AND VALUES FOR TIGHThNING TORQUES AND LOCKING COMPONENTS SHEET NO.2050443E page 1 of 2 update 961230
On page 2 values are given in (lbft)
Important notes:
0.14 below heads and «t thread (i.e. surfaces which are clean and not or lightly lubricated with oil or locking compound).
1.Valid for fasteners with metric thread (DIN 13) and friction coefficients
2.Stainless steel fasteners < M16 property class 70 (yield 450 N/mn); > = M16 property class 80 (yield 600 N/mn)
3.If fasteners are mounted with Copaslip or equivalent anti-seize compound on thread and head, the friction coefficients become 0.10 and torque values out of theapropriate shaded column have to be used.
4.PREPARATION:
Surfaces of fasteners and fastened components must be undamaged and free of dirt and nist.Pay special attention to surface below head (nut).
If a locking compound is prescribed, thread surfaces have to be degreased prior to application. Pay special attention to tapped holes.
5.Apply torque corresponding to symbol specified on drawing
Only, check if property class marking on fastener is sufficient for the torque value specified on drawing.
EXAMPLES: G = 81 Nm (60 lbft) , Kl = 350 Nm (260 lbft) ((or 265 Nm (195 lbft) if anti seize compound is used on thread and head (nut) ]J and N3 = 2200 Nm.

LETTER THREAD Group 0 (mat. 8.8) Group 1 (Stainless steel) Group 2 (mat. 10.9) Group 3 (mat. 12.9)
SYMBOL SIZE
(dry) (+ank seIze) (city) (+sntlatize) (dry) . (+antistlze) (dry) +anti seize)
Nm Nm Nm ;; Nm Nm Nm Nm Nm

M3 1.25 0.87 1.75 2.1 135

B M4 2.85 2.2 2 4 3 4.8 mriuui

MS 5.6 4.2 3.9 2.95 7.8 9.4 Th

D M6 9.7 7.3 6.8 5.2 13.5 16.5 iuii

M8 23.5 17 16.5 125 33 24 39

MIO 47 35 33 25 66 49 79

G M12 81 60 57 115 86 135

M14 130 95 90 68 180 135 215 16G

I M16 195 145 185 .135..; 275 200 330

J MIS 270 200 255 :190... 380 .....280............... 460

M20 380 280 350 265 530 390 640 480

L M24 650 490 610 920 690 1100 800

M27 950 700 890 1350 1000 1600

M30 1300 950 1200 910 1800 1350 2200 1400

0 M36 2250 1650 2100 1550 3200 2400 3800 2800

P M39 2900 Z150 2700 2000 4100 3000 4900 2600

M42 3600 2700 3400 2500 5100 3800 6100 45181

M48 5400 4000 5100 7600 9100 6800

LOCKING COMPOUNDS: C) = LOCT1TE 270sM20 LOCITE 275 >M20 (see 2005099)

 S
TORQUE MANUAL SYMBOLS AND VALUES FOR TIGHTENING TORQUES AND LOCKING COMPONENTS SHEET NO.2050443E page 2 of 2 update 961230
On page 1 values are given in (Nm)
Impoitant notes:
1.Valid for fasteners with metric thread (DIN 13) and friction coefficients =0.14 below heads and on thread (i.e. surfaces which are clean and not or lightly lubricated with oil or locking compound).
2.Stainless steel fasteners < MÏ6 property class 70 (yield 450 NImn); > = M16 property class 80 yield 600 Nlmzei)
31f fasteners are mounted with Copaslip or equivalent anti-seize compound on thread and head, the friction coefficients become 0.10 and torque values out of the apropriate shaded column have to be used.
4.PREPARATION:
Surfaces of fasteners and fastened components must be undamaged and free of dirt and rust.Pay special attention to surface below head (nut).
If a locking compound is prescribed, thread surfaces have to be degreased prior to application. Pay special attention to tapped holes.
5.Apply torque corresponding to symbol specified on drawing
Only check if property class marking on fastener is sufficient for the torque value specified on drawing.
EXAMPLES: 0 = 81 Nm (60 lbft) , KI = 350 Nm (260 1W» [[or 265 Nm (195 Ibft) if anti seize compound is used on thread and head (nut))) and N3 = 2200 Nm.

LETTER THREAD Group 0 (ma.8.8) GOUD I (Stainless steel) Group 2 (mat. 10.9) Group 3 (mat. 12.9)
SYMBOL SIZE
(thy) (+anti5eize) (thy) (+anti seize) (thy) (+anti seize) (thy) +ánti seize)
lbft lbft lbft lbft Ibis lbft : lbft

M3 0.9 0.64 0.49 1.3 I 1.55

M4 2.1 1.45 1.11 2.9 2,2 3.5

M5 4.1 3.1 2.9 5.8 6.9

M6 7.1 53' 5 10 12

M8 17 13 12 9.2 24 13 29

MIO 35 26 24 18 49 37 58

Ml2 60 45 42 32 85 100

M14 95 7G 66 135 100 160

M16 145 1:10 135 100: 200 ISO 240

M18 200 150 185 140..:. 280 340

M20 280 210 260 195.: 390 :90::.:.:: 470

480 300 450 340. 670 500 800

700 525 660 90. 1000 750 1200

M30 950 '710 900 670 1350 ICOG 1600

M36 1650 1240 1550 fl50 2300 1700 2800 211X1

M39 2150 1600 2000 1450 3000 3600

R M42 2600 19S0 2500 1850 3700 4500

M48 4000 o00 3700 2800 5600 6700

LOCKING COMPOUNDS: = LOCTITE 243 LOCTITE 270M20 øcrrr 275>8(20 (see 2005099)
0
Instruction No. 929001 E
voiuS l/Lf
t-

Instructions for Installation, Service and Maintenance

Product: Torsionally Stiff, Flexible Shaft Couplings BSD THOMAS PLUS® and BSD THOMAS

Rexnord Drawing No
(to be completed Only If AppendIx 9 Is to be prepared)

ROTATING POWER TRANSMISSION PRODUCTS ARE POTENTIALLY DANGEROUS. It is the responsibility of the cus-
tomer/user to provide proper protection in compliance with applicable safety standards, relative to the type of equipment,
and to operate power transmission elements exclusively within their predetermined applications and their specified appli-
cation limits.
Contents:
General Operation
Transport Maintenance
Assembly and Operating Principle Stock of Spare Parts and Customer Service
Installation Appendix for Special Order Specifications
Initial Start-Up

General
According to their specified capacity flexible shaft couplings compensate for unavoidable alignment faults and misalign-
ments which occur during operation. The lesser alignment faults during installation, the higher compensation capacity, life-
time, and smooth running in service. Installation by skilled personnel only. Our instructions for installation, service and
maintenance have to be carefully studied and to be understood. The assembly drawing has to be in hand of the customer!
user at installation site.

Transport
After inspection on receipt, flexible shaft couplings are to be carried to their place of installation as delivered and in their ori-
ginal packing, if possible. Any transport protection and fixation of the shaft couplings provided by the manufacturer are only
to be removed at site. General: Keep shaft couplings in horizontal axial position to avoid external forces which could affect
the shaft coupling.

3. Assembly and Operating Principle 6 11 7

1 31
I Flange
/
2 Disc Pack
3 Hardened Bushing
4 Bolt
5 Locknut
6 Hub
7 Spacer

Figure 1 Figure 2 Figure 3

There are two different basic designs for torsionally stiff, flexible shaft couplings:
Figure 2: A complete shaft coupling consists of two disc pack assemblies (Figure 1), attached to one spacer and two
hubs. Disc pack assemblies are supplied ready to be installed. In general, they are already fixed to the spa-
cer on shipment, so that hubs only are to be fastened to the disc pack assemblies.
Disc pack assemblies compensate for axial and angular misalignment. Completed as couplings, they are
able to also compensate for radial misalignment resulting from admissible angular misalignment of two disc
pack assemblies. Please note that the indicated maximum values for axial and angular misalignment must
not be used as maximum simultaneously. For their interdependence please see graph in the assembly dra-
wing.
Figure 3: Disc packs are directly fastened to hubs or spacer, resp. In general, disc packs are already fixed to spacer on
shipment so that supplied bolts and washers only are to be attached to the disc packs by the customer/user,
in order to fasten the hubs onto the disc packs.
The operating principle of this design is the same as for figure 2.
Axial and angular misalignment may achieve their maximum simultaneously.

Seit/Since 1933:
Rexnord Antriebstechnik
Rexnotd Uberwasserstraûe 64
Postfach 103252
Tele fon 0231/8294-0
Telefax 0231/82 72 74
11111111111 0-4600 Dortmund 1 Telex 08227880
.1
 Features of operating principle and misalignment capacity for torsionally stiff, flexible BSD shaft couplings:

a -,

angular radial axial

4. Installation
4.1 See assembly drawing - Observe installation dimensions and positions.
4.2 Shaft ends and bores to be connected have to be free from dirt/corrosion particles and burrs. Install keys, if
required. Check fitting dimensions of shaft (and keys) and tolerances.
4.3 If finish bore or other fitting dimensions of the hubs are machined by customer/user, tolerances - both concentric
and rectangular - have to comply with our specifications or our standard sheet NR 860, resp. In case of doubt
please consult the manufacturer. Otherwise proceed as described in 4.2.
4.4 Only install products of our supply and use them under designated service conditions.
4.5 Do not change quantity and positioning of disc packs. Arrangements of bolts/locknuts and spacer sleeves or
washers only according to our assembly drawing.
4.6 Do not disassemble elements type 900 or type 920 (see figure 1).
4.7 Mount and secure hubs according to the designated hub/shaft connection. For special connection (flange, taper
bore, oil interference fit) length dimensions being specified in the assembly drawing have to be strictly observed.
4.8 After assembly of hubs or other connecting elements align driving and driven unit to each other in order to install
the spacer. Observe installation dimensions, position and admissible misalignments of our assembly drawing.
4.9 Attach spacer to element type 900/920 or the disc packs. For fitting dimensions and further instructions see our
assembly drawing.
4.10 Tighten bolts or locknuts according to the specified torque (see assembly drawing).
4.11 After installation, the coupling has to be aligned. The lesser misalignment faults, the higher compensation capaci-
ty, lifetime and smooth running during operation.
Check and align axial misalignment first. For admissible dimensions see our assembly drawing.
If service and/or ambient temperatures differ from a room temperature of 20° C, axial misalignment might become
undesirably high. In this case it might be necessary to preset axial misalignment at installation to achieve an opti-
mum axial misalignment at service temperature. Lifetime, misalignment capacity and smooth running are then
improved. If required, this will be clarified before ordering and specified in Appendix 9.
After axial alignment is done, angular and parallel offset are to be aligned. Besides optical methods it can be
done manually as follows, observing the max. admissible offsets according to our assembly drawing.
Figures 4 to 6 show alignment methods which may be used. Any readings being specified in this instruction are
reference values for alignment.

Figure 4 Figure 5 Figure 6

Description to Figures 4-6: Page 3

2
 oÇ5

Figure 4: Mount dial indicator and gauge. The measuring point should be close to the outer diameter of the coupling.
Rotate coupling 3600. The indicator reading should not exceed 0.015 mm per 10 mm outer diameter.
Example: Outer diameter 200 mm = 20 x 0.015 mm 0.3 max. indicator reading. Adjust driven and driving
unit until this value is achieved or is lower.
Figure 5: Use caliper with dial indicator. Description as figure 4. Instead of outer diameter scan diameter applies.
Figure 6: Use dial indicator with adapter. Description as figure 4. Max. indicator reading is 0.015mm per 10mm length ,,x".
Example:,,x" = 400 mm = 40 x 0.015 mm = 0.6 mm max. indicator reading.
After having aligned the coupling, driven and driving units are to be fixed and secured so that the position of the coupling
remains unchanged. We recommend to recheck the coupling according to point 4. to 6. after having secured drive and
driven units.
General: After the alignment procedure disc packs should look flat and parallel with the mating surfaces if no axial align-
ment was preset (see 4.11).

5. Initial Start-Up
5.1 After having assembled the shaft coupling and considering valid and applicable safety standards for the equip-
ment the coupling is subject to a trial run.
5.2 Recheck specified tightening torques of bolts and Iocknuts after a trial running time of 1 to 2 hours. If necessary,
readjust bolt connection with proper torque.
5.3 Observe coupling while operating. Any improperties occurring especially as to smooth running, might be caused
by insufficient or improper alignment or by subsequent deviations, e. g. setting of driving or driven unit. Cut off
equipment immediately and recheck alignment of installation dimensions and position according to point 4
(Installation). If necessary, correct dimensions.

Operation
6.1 Inspect shaft coupling after appr. 500 operating hours:
- Are tightening torques of bolts and locknuts still correct?
- Is the coupling still well aligned? Note: For certain designs misalignment values must not be used as maximum
simultaneously.
- Are the disc packs still flat and parallel with the mating surfaces?
Correct if necessary. Alignment and axial adjustment according to point 4. (Installation).
6.2 After inspection and correction, if so necessary, the shaft coupling is subject to usual inspection intervals of the
equipment. These inspections are to be carried out according to point 6.1. We assume that inspection and main-
tenance of the equipment is carried out once a year for one shift operation, twice a year for two shift operation and
three times a year for three shift operation.

Maintenance
7.1 The disc pack assembly (figure 1) or the disc pack (figure 3) are the most important performance components of
the shaft coupling.
7.2 Any deformation, cracks or corrosion of the disc pack including bolts, locknuts and washers which are noticed
during coupling inspection, may be caused by torque overload or excessive shaft misalignments.
Replace disc pack assemblies including bolts or the disc pack including bolts, locknuts and washers according
to point 4. (Installation). Important: Remove reason of coupling overload first.
7.3 All other components have to be carefully checked in case of such failures. In case of doubt please consult the
manufacturer.

Stock of Spare and Customer Service

8.1 In order to promptly replace any failed parts, it is recommended to keep a stock of disc pack assemblies (figure 1)
or disc packs (figure 3) with bolts, locknuts and washers at operation site.
8.2 If required, the manufacturer's customer service is available to you.

3
 3 05% L/Li

9. Appendix for Special Order Specifications

If certain operating instructions are required for the application, which differ from these general instructions or are
added to them, any deviations or additions are specified in this appendix. Such appendix refer to individual applica-
tions. Customer's name, our order number and type designation are always specified.
 VOITH TURBO
POWER TRANSMISSION

TORQUE LIMITING SAFETY COUPLING

Installation and
maintenance instruction

Coupling type : ST-B 180

Coupling no. :11590
Drawing no. : 22791
Voith ref. no. : 50882

Voith SAFESET AB Voith Turbo GmbH & Co.KG

Rönningevägen 8 Alexanderstr. 2 . D1
-
S-824 34 HUDIKSVALL D- 89522 Heidenheim U U.

Tel. +46-650-540150 Tel. 49-(0)7321 -37-4337

Fax. +46-650-540165 Fax.49-(0)7321 -37-7106
E-mail: [email protected] SS-EN Iso 9001
/

Voith Safeset AB

CONTENTS

Important information Page 2

Safety regulations Page 3

Assembly instruction Page 4

Lubricating instruction Page 5

Pressure setting instruction Page 6

Important before use Page 7

Maintenance Page 8

Warranty Page 8

Calibration diagram Page 9

Assembly drawing Page 10

Pump instruction Page 11

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Voith Safeset AB Page 2

IMPORTANT INFORMATION

The Safeset torque-limiting coupling has a hydraulic torque setting

system. By adjusting the hydraulic pressure the release torque can be
set to the required level.

When the pre-set torque is exceeded, the Safeset coupling slips and the
top of the shear tube is sheared off by the shear ring, releasing the oil
pressure in the coupling. This happens within a few milliseconds. After
release the coupling will run freely on the shaft.

How to handle the coupling after release is described in the following

pages.

The Safeset coupling is intended for transmission and limiting of torque.

Due to its design it has a limited ability to take up other types of loads, as
bending torque and radial loads. This must be take into account when installing
the Safeset coupling.

At installation it must also be observed that the Safeset coupling has no possibility
to take up alignment faults. In case such faults exist the Safeset coupling
must be installed in combination with another coupling, which can take up these
faults.

The combination must not lead to reaction forces such as loads or bending torque
on the Safeset coupling.

If the drive line where the SAFESET coupling is installed is not continuously
supervised a monitoring system discovering the release of the SAFESET coupling
must be installed.
This system will prevent that the SAFESET coupling rotates freely during a
longer period of time.

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 Voith Safeset AB Page 3

SAFETY REGULATIONS

I
Protection glasses must be worn during pressure
setting and handling of a SAFE SET coupling which is under
pressure.

Do not pressurise the SAFE SET coupling before installation.

S
At pressure setting and pressure release the shear tube or the valve
must be tightened before removing the pump.

When the SAFESET coupling releases, parts from the shear tube and
oil is thrown out of the coupling at very high pressure.
Smaller couplings are delivered with a protection band. If the
coupling lacks protection band, a plate cover must be installed
around the coupling. Min, plate thickness 1.5 mm.

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 Voith Safeset AB Page 4

ASSEMBLY INSTRUCTION SAFESET ST-B

Clean the SAFESET coupling inside, outside and the hub inside, with grease
dissolvent.

Press the SAFESET coupling into the appropriate hub (hub tolerance K7). Press the
ball bearing and the shaft seal into the hub.

Oil the SAFESET coupling inside (the sliding contact bearing) between the shaft seals.
Note that it is very important for the function of the SAFESET coupling that the
recommended oil is used. (Also the ball bearings should be lubricated with the
recommended oil).

S Push the shear ring, the distance ring with the 0-ring and the SAFESET coupling with
the hub onto the shaft. The shear ring is secured to the shaft by the pinch screw. The
tightening torque can be read below.

SAFESET dimension Pinch screw Tightening torque, Nm

ST-B 60 M8 26
ST-B 70- ST-B 220 MiO 52

When an end plate for the shaft end is supplied, make sure that there is a clearance
between the ball bearing and the endplate of 0.5 - 1.0 mm.

Fill SAFESET oil for the friction surface.

Loosen the plug M6 close to the shear tube and the M6 plug 90° away. Turn one of the
holes vertically; pump in oil with the small lubrication injector until it pours out though
the other hole. Re-install the plugs.
See also separate instruction, page 5.

Setting the torque;

A calibration diagram is enclosed with every coupling. The coupling has a number
close to the filling connection and the diagram is marked with the same number. In this
diagram the necessary torque can be read.
See separate instruction to set the torque, page 6.

Oil for oiling of sliding contact bearing and pressure setting cavity.
The SAFESET oil, which is delivered with the coupling, shall always be used both for
the slide bearing and the pressure setting pump.

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 A.

Voith Safeset AB Page 5

CHECK AND LUBRICANT FILLING PROCEDURE

(Lubrication oil type is specified on the drawing, page 10)

NOTE! Coupling must be depressurised during the following operation!

Remove the plastic plug from the filling connection, using the M8 screw provided.

Connect the pump to the filling connection. Check if there is enough room in the pump to
evacuate the oil.

Open the unloading valve on the pump (see page 11).

Loosen the sheartube Y2 turn to release pressure.

Tighten the sheartube when the pressure has dropped to 0 MPa.

S Disconnect the pump.

If the coupling is equipped with two sets of lubrication ports (i.e. 4 pcs of lubrication screws),
the following procedure must be applied on both lubrication ports!!

Turn one lubrication port to an upper vertical position.

Unscrew the lubrication plugs.

Fill SAFESET oil with the lubrication injector until a clear flow of oil emerges from the horizontal
port.

Reinstall the lubrication plugs.

To pressunse the coupling; See separate instruction, page 6.

Lubrication in ector

Level port

Lubrication oil

Filling connectio

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 Voith Safeset AB Page 6

PRESSURE SETTING OF SAFESET COUPLING

(For couplings equipped with more than one sheartube)

. Remove the damaged shear tubes

Insert the new shear tubes until they reach the bottom. The top of the sheartube is then formed to
fit the valve seat at the bottom of the hole. Tighten the shear tubes carefully (tightening torque
30-3 5 Nm). Unscrew the sheartube beside the filling connection Y2 turn upwards.

S Pull out the protection plug from the filling connection on the coupling using M8 screw. Press
the injection fitting on the pump into the filling connection on the coupling.

Pump oil into the coupling until the pressure gauge shows the correct pressure MPa.
(See calibration diagram, page 9).

Tighten the sheartube at the filling connection carefully (30-35 Nm). This makes the coupling
absolutely leakproof.

Lower the pressure before removing the pump!

Open the unloading valve on the pump (see page 11).

Reset the protection plug in the filling connection hole.

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 Voith Safeset AB Page 7

IMPORTANT BEFORE USE

Check that the shear ring is secured.

Check that lubrication oil is filled.

S Check that the coupling easily can be turned around without pressure.

Check if the coupling is equipped with a protection band, if not, a

protection device must be installed. (See also safety regulations)

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Voith Safeset AB Page 8

MAINTENANCE

After every 15:th release or once a year, new oil for the slide bearing
shall be refilled through the oil port on the SAFESET coupling.

WARRANTY

Warranty conditions are according to the conditions of sale valid for this
order.

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 Voith Safeset AB Page 11

INSTRUCTION FOR SAFESET PUMP P100B

The pump must be vented before use;

Tighten the unloading valve, item 33. Turn the injection fitting in vertical
position. Pump with the pump handle, until a firm, air free beam shows. The
pump is now ready to use.

When the pump is empty;

Pull the chain with the ring until the filling plug (plastic plug) comes out of the
handle. Unscrew the plug and fill with SAFESET oil. Vent the pump before
use.

S The pressure control valve, item 22, is positioned on the pump housing,
item 1.

The pressure control valve shall be set about 5 MPa higher than the required
pressure for the individual SAFESET coupling. (This is to prevent that the
pressure in the SAFESET coupling is exceeded.)

To test the pump and to set the pressure control valve, the protection cap, item
35, can be used as a plug. Push the protection cap onto the injection fitting,
item 29 and start pumping.

Setting the pressure control valve

Below the screw for the pressure control valve there are eleven plates totalling
5 mm thickness; (3 off t=l mm, 3 off t=0.5 mm and 5 off t=0.l mm.) By
reducing the number of plates under the pressure control valve screw the
pressure which can be pumped into the coupling is increased.

Plate thickness 5 mm corresponds P 30 MPa

Plate thickness 3 mm corresponds P 65 MPa
Plate thickness 1 mm corresponds P 100 MPa

Unloading valve (33)

Manometer (25) Filling plug (13)
Injection fitting (29)

J:;IiitiiuiilI.II
I.
'''"lI:I. ..:IlI
IIiii

Protection cap (35)

Pump body (1)
r ressure control valve (22)

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 &

Voith Safeset AB Blad 12

SAFESET®
Kalibreringsdiagram/Calibration diagram
)
Kopplings typ/Coupling type Order nr./Order No. KoppHngs nr./Coupling Nb
ST-B 180 3986-0416 11301
Safeset ritn. nr./Dwg. No. Voith Safeset Ref. nr Datum, Sign.
22791 50882 2001-11-16 HW

B02363 nominal torque 33.7 kNm

Set point of slipping torque 1.6 x nominal torque 54 kNm
S 54 kNm corresponds to a pressure of 72 MPa

Kalibrieringsdiagram/Calibration diagram
140 1H 1:
1 H
130
120
110
H
H.. ...:.. -
- I

0 HA
90 t

-------------- 1 -
w80
.1...._.L_H - .

U, 70
Ii a
II
0
U, I

I
.

t
.4
-:i
t
. :.. -
. 50-
-..........
H
I

30 -
20 -
:1:1 ±jEHTlHi4
10

0-
0 20 40 51t60 80 100 120

VridmomentlTorque ( kNm)

Framtagen av: REDatum: 9906

orginals.doc Utgava: A Fastställt av: PWP Datum: 9906
P I
300 Tr 0
.-1
Tr70 Nm
213±0.2
U
0 0 0
Safeset oil for
0000 00 0 friction surface
Tr52 Nm

,'
1.6
!2 'p;ej ç)
' /N
08
I
00 i1I 0
-;

'0 Level 'lui

(-4 C-
0 0
-c
0' 0 U, U\
'0 Cr (--4 21 2-0071 4 Screw MC6S 6x16
(--4 (-4
20 2-0089 4 Screw MC6S 10x25
19 1-0374 1 0-ring 03 Lr496
T40 Nm
Shaft lenght28l±0.2 18 5535 1 Plate
17 1-0120 1 S ha f t se al 190x225x16
16 1 Hub Supplied by rust
15 9037 1 Safeset ST-B 180
14 8020508 2 Shear tube
13 1-0303 2 Ballbearinq 61836 180x225x22
12 1-0128 1 Shaftseal 215x240x12
11 13469 4 Kutu
10 2-0092 1 Screw MC6S 10x40
9 22798 1 Shearring
0
m 8 2-0185 1 Pin FRP 05x20
7 2702 1 Distance
6 1-0374 1 0-ring 03 Lr575
5 8774 1 Protection plug
4 8612 1 Filling connection
3 2-0288 2 Screw MC6LS 6x12
2 1-0424 2 Seal washer. 6 .7 xlix 1

1:1
01-10-09 ITH 01-10-11PWP Safeset ST-B 180
Assembly
Torque range 4.9 - 9.8 kNie VOITH TURBO
POWER TRANSMISSION 22791
L /\
 Accessories
.

Electronic release indicator

122
ESC 130

The input and output speeds of a Safe-

r 106

set are monitored by 2 proximity sen-

sors. For this purpose the Safeset is
quipped with 2 lights. When the Safe- 0 ESC13O
et has released the speeds are no
S longer synchronous. The device
recognises this and a relay on the out-
put side will switch on an alarm.
24V DC
In cases where the speed difference Relais
can not be measured the Safeset can fl1
be quipped with a mechanical release n2 Assembly distance 3
indicator. Disconnecting distance 5
5m 60

-- dI:::
I::.I ..i
u' lj
St
M12x1 SW24 Safeset
M 18x1
dl:U S-.-
- I:: . ..iui
S.
 VOITH TURBO
POWER TRANSMISSION

INSTALLATION AND OPERATING INSTRUCTIONS

for speed controllers ESC 130
monitoring speed differences

part no.: 20761

IMPORTANT

Before installation and starting up operation of the product these installation and operation
instructions have to be carefully studied. Special attention must be paid to specific notes and
remarks refering to sources of danger.

These installation and operation instructions must be applied on the understanding that a
correct choice of product for your application has been made. Selection and design of the
product are not object of these installation and operation instructions.
If these installation and operation instructions are ignored or misconceived, any product liability
and guarantee on the part of expires; the same applies if our product is disassembled or
modified.

The installation and operation instructions have to be safely kept and in case our product is
passed on - either detached or as part of a machine - they must accompany the product in order
to be accessible to the user.

Safety information

Installation and starting up operation of our product must be carried out by skilled personnel.

Repair works must only be done by the manufacturer or by authorized representatives.

If malfunction is suspected, the product or machine resp. it is built in must immediately be

put out of operation and VOITH must be informed.

Before any works at terminals or electrical components switch of the power supply.

Voith Turbo GmbH & Co. KG page 1 D - 89509 Heidenheim

SI. Functional Description
The ESC 130 unit monitors differences of two speeds (slip). The maximum relative difference between both speeds
can be limited from to 0.5% to 14.3%. When one of these speeds changes and the difference exceeds the limit
(e.g. a belt pulley slips or a coupling has switched off) the built-in relay switches. When both speeds changes
uniformly no speed difference appears and the relay stays in normal position.

For speed detection proximity switches with NPN,PNP or NAMUR output can be used to detect rotating impulse
sources like screw heads or holes. These impulses will enter input 1 and input 2 of the ESC 130 as a periodical
rectangle signal. A proximity switch can be used to detect multiple impulse sources if they are uniform in distance
and dimension over the circumference. The quantity of impulse sources as well as the speeds can be different for
both inputs of the ESC 130 until no relative difference will occur. This constant relation between both inputs can be
adjusted by a DIP switch. This feature allows to detect speeds at any part of a shaft and to use existant mounting
screws.

When the plant is standing still no speed signals and no speed difference will occur so that the ESC will stay in
normal operation mode. When the plant stopped after operation this mode will start 15 seconds later. When the
plant starts again the ESC monitors immmediatly both inputs again. Without power supply and 0.5 seconds after
switching on the supply the relay is off (fail safe).

Four LEDs presents the actual mode of operation.

2. Terminals

Term. Function
PE Protective earth (only ESC 130 C)
1 Power supply +
2 Power suppy-
3 Relay, nc (normally closed)
4 Relay, common
5 Relay, no (normally open)
6 Input 1 +, speed signal PNP
7 Input I -, speed signal NPN
8 Proximity supply 0 V DC
9 Proximity supply +10 V DC
10 Input 2 +, speed signal , PNP
11 Input 2 -, speed signal, NPN
12 Proximity supply 0 V DC
13 Proximitysupply +1OVDC

Element j Status Function

LD1-green off Relay off, no contact K3-K4, contact K4-K5; speed limit exceed, if LD4 flashes
on Relay on , contact K3-K4, no contact K4-K5; speed inside the limit
LD2-yellow on Input 2 activated, input signal > 2,2 V (0,9 mA)
LD3-yellow on Input 1 activated, input signal > 2,2 V (0,9 mA)
LD4-red off Normal operation, if powered on
on Speed limit exceed or reset mode or speed below minimum 4 rpm
DIP1 Adapting NPN,PNP or NAMUR-Proximity switches (see chapter 3)
DIP2 sets the constant speed relation (see chapter 5)
DIP3/1-3 sets the limit of speed differences (see chapter 4)
DIP3/4-5,F1,F2 off sets the sensitivit of the ESC monitorinq function (see chapter 6)
DIP3/6,F3 off Automatic Reset with 25% Hysteresis, Auto-Reset
on Reset by power off - power on only
DIP3/7,F4 off Speed monitor active, normal operation
on Testprogramm for installation
Bi off K9 and K13 = 8 ,0 Volt for NAMUR-supply
on K9 and K13 = 10.15 Volt for NPN ore PNP- supply

Voith Turbo GmbH & Co. KG page 2 D - 89509 Heidenheim

3. Starting up operation
Use screw heads, edges of castings, bores or drilled holes as impulse sources which are suitable to the
proximity switch. A good detection is secured when the width of the impulse sources is as large in diameter as
the proximity switch and the depth or height is greater than the nominal switching distance s. In case multiple
impulse sources are employed on the circumference, it is important that they are mounted symmetrically on a
pitch circle and are of the same dimensions. Example: A proximity switch with M8x1 thread has 1,5 mm
nominal switching distance and will reliably detect impulse sources of 8mm width and 1,5 mm heigth (depth).
Apply the proximity switch in a distance of s - 50% in front of the impulse sources. If the impulse source to be
used is smaller in diameter than the diameter of the proximity switch then decrease the mounting distance. If the
impulse sources are flat and protrude less than s increase the mounting distance. Turn the plant slowly and
check that the proximity switch detects all the impulse sources.
Connect your power supply to Ki and K2 without switching on the power. If the material of the casing is
aluminium (type C) a connection between protective earth an terminal PE is necessary.
Switch on F4 = DIP 3/7 and switch off DIP 1/i ...4 and turn on the power supply. Neither input 1 nor input 2 must
been connected. This starts a selt test program which presents the four LEDs as follows:
Now switch on DIP i/i .4 and check that LD2 and LD3 are glowing.
Connect the no" contact or the ,,nc" contact of the relay and the ,,common" contact to your control devices.

LDI LD2 LD3 LD4 Results

flashes off off off ESC o.k. , the test was sufficient
flashes X X flashes ESC runs, but an input signal is wrong
X X X on ESC defect
The ,,nc" contact is closed, when the speed is o.k.. The ,,no" contact will be closed when the speed difference
exceeds the limit or no power is supplied
Connect the proximity switches to input I (K6..K9) and input 2 (Ki0...K13), set DIPI as shown and activate the
bridge Bi for PNP and NPN proximities or deactivate Bi for NAMUR switches. When different speeds are
present the proximity switch which detects the speed with the higher frequency is to connect to input 1.

If active external signals should be used instead of one ore both proximity switches connect only K6, K7 resp.

black
black ,
@7 [SC 130 @7 brow
I blue @8 hI je E 50130
blue
ESC 130 [SC 130
2 Ibrown z 8 @8
@9 brown - z @9
black @10
BI black ll0 81
@12 Bi
brow
Th blue @11 01Fl @11 @11
@12 on blue l2 DIPI bI
@12 DIR
2
z
brown 13 oF IP5
I 34
0
7 brown 13
on
off 2 34
@13
on
lII
of f 2 34 on
off
DIPI

234

Kb, Kil and set DIP 1 off completely.

Select Fl, F2 and F3 (DIP 3 l4..6) now.
Now set the limit of speed differences by DIP 3 /1 ..3, see chapter 4.
Set the actual relationship between both speed frequencies with DIP 2, see chapter 5.
Set the monitoring sensitivity with DIP 3/4..5, see chapter 6.

Attention: Modifications of settings at DIP2 or DIP3 are only valid after powering up the
speed monitor again

Voith Turbo GmbH & Co. KG page 3 D - 89509 Heidenheim

4. Setting the limit
The ESC 130 monitors the relation between speed

1 - - F.
DIP3/1 DIP3/2 DIP3/3 Difference %
signal n1 at input 1 and speed signal n2 at input 2. off off off 14,3
off off on 10,0
Input I is used as reference.
off on off 6,25
DIP3/1...DIP 3/3 are used to set a speed difference off on on 4,0
in percent. The relay is switched off (the contact switches from on off off 2,5
K3-K4 to K4-K5) when the speed difference in percent
,
on off on 1,5
exceeds this limit. on on off 1,0
The low differences 0,5% up to 1,5% should only be selected on on on 0,5
when both proximity switches detects only one impulse source on the circumference.

5. Adapting a constant speed relation

When the proximity switches are sensing screws or bores the input frequencies n1 fl2 are the products of
speed [rpm] x number of impulses per rotation. If the number of impulses per rotation are different resp. the
speeds in normal operation are different between input I and input 2 ( e.g. using a gear box) the ESC 130 unit is
able to handle this. It's necessary to adapt this constant relation between both input frequencies with DIP2. The
following formula gives as result a factor P, which is used to set DIP2 with the table below.
DIP2 DIP3
n1 speed 1 x number 1

123 b? n2 speed 2 x number 2

P DIP 2/ T P DIP 2/ P DIP 2/ P DIP 2/

1234567 1234567 1234567 1234567
1,000 0000000 1,333 0000011 2,000 0000001 4,000 0000010
1,008 1111111 1,347 11l11t1 2,032 1111110 4,129 1111100
1,016 0111111 1,362 0111101 2,065 0111110 4,267 0111100
1,024 1011111 1,376 1011101 2,098 1011110 4,414 1011100
1,032 0011111 1,391 0011101 2,133 0011110 4,571 0011100
1,041 1101111 1,407 1101101 2,169 1101101 4,741 1101100
1,049 0101111 : 1,422 0101101 2,207 0101110 4,923 0101100
1,058 1001111 1,438 1001101 2,246 1001110 5,120 1001100
1,067 0001111 1,455 0001101 2,286 0011110 5,333 0001100
1,076 1110111 1,471 1110101 2,327 1110110 5,565 1110100
1,085 0110111 1,488 0110101 2,370 0110110 5,818 0110100
1,094 1010111 1,506 1010101 2,415 1010110 6,095 1010100
1,103 0010111 1,524 0010101 2,462 0010110 6,400 0010100
1,103 1100111 1,542 1100101 2,510 1100110 6,737 1100100
1,123 0100111 1,561 0100101 2,560 0100110 7,111 0100100
1,133 1000111 1,580 1000101 2,612 1000110 7,529 1000100
1,143 0000111 1,600 0000101 2,667 0000110 8,000 0000100
1,153 1111011 1,620 1111001 2,723 1111010 8,533 1111000
1,164 0111011 1,541 0111001 2,783 0111010 9,143 0111000
1,174 1011011 1,662 1011001 2,844 1011010 9,846 1011000
1,185 0011011 1,684 0011001 2,909 0011010 10,67 0011000
1,196 1101011 1,707 1101001 2,977 1101010 11,64 1101000
1,208 0101011 1,730 0101001 3,048 0101010 12,80 0101000
1,219 1001011 1,753 1001001 3,122 1001010 14,22 1001000
1,231 0001011 1,778 0001001 3,200 0001010 16,00 0001000
1,243 1110011 1,803 1110001 3,282 1110010 18,29 1110000
1,255 0110011 1,829 0110001 3,368 0110010 21,33 0110000
1,267 1010011 1,855 1010001 3,459 1010010 25,60 1010000
1,280 0010011 1,882 0010001 3,556 0110010 32,00 0010000
1,293 1100011 1,910 1100001 3,657 1100010 42,67 1100000
1,306 0100011 1,939 0100001 3,765 0100010 64,00 0100000
1,320 1000011 1,969 1000001 3,879 1000010 128,0 1000000

Example: Proximity 1 shall be mounted in front of an gearbox with 10,3:1 (speed 1:speed 2) and proximity 2
behind. The impulse source for input I shall be the key of the motor shaft and the impulse sources for
input 2 shall be six mounting screws of a coupling. Now we can resume

Voith Turbo GmbH & Co. KG page 4 D - 89509 Heidenheim

 P = til 1n2 = (10,3 x 1)1(1 x 6) = 1,7167. Fora best adaption of this constant relation set Dip 2 to
1101001 = 1,707. The difference of 0.56% must be in mind when selecting the difference limit.

If fl1 = n2 then DIP 2 should be set off completely.

6. Monitoring Sensitivity
DIP2
Ojii
DIP3

12 3
DIP3/4 DIP3/5 sensitivity periods
off off low 7
The sensitivity of the ESC can be selected with DIP 3/4,5.
off on normal 5
The table shows how much periods are measured until the
ESC reacts on a limit override or a missing proximity signal. on off high 3
on on very high 2

7. Technical data
General
speed range 4.. .60000 impulses per minute
power supply 24VDC +/-20% r
operating current max. 80 mA
working temperature range 0.. .+ 60° Celsius
storage temperature range -20. ..+ 80° Celsius
EMV-Limits EN 50081-1, EN 50082-2

Relay
relay output 250 V AC, 5 amp.
30 V DC, 5 amp.
relay function changing contact

PNP or NPN
effective trigger voltages of inputs +2,2 V DC +1- 15% differential input
input current (10 V proximity supply) 7 mA
proximity supply, BI = on 10..15V

NAMUR
effective trigger current of inputs +0,9 mA +1- 15%
proximity supply, BI = off 8,0 V +1- 10%

dimensions without housing 104 x 89 x 30 mm

weight without housing 190 gramms

housings: Aluminium, 120 x 122 x 90 mm

protection grade for all housings I P65
bores 4x6,4mm 82/106mm

Voith Turbo GmbH & Co. KG page 5 D - 89509 Heidenheim

0

componeiit.nr. W006010286 Môd :

Date: 1992-04-21

Description
High performance gear pump
(fixed displacement pump)

Flow
Pump capacity 8,0 dm3/min at a pump
rotational frequency of 1450 min.

System pressure range

input P1 min = 0,7 bar absolute
P1 max = 1,5 bar absolute

output maximum pressure 250 bar

Direction of rotation
Pump only to be driven clockwise, looking at
the pump shaft.

Mass
2,25 kg

Repair
Repair set W006010287

Dimensions (mm]
inlet outlet
A B C DEc de
45 93,5 13,5 30 M6 13,5 30 M6
9o

11.5

lMp.I
SKews
S

,
Screiti nfl
Sn Cpu nul
I/pew KM
 a a..a u uuu.
LIF...S. Component nr. W006110206 Mod :
Date: 1994-05-li

Discription
Low pressure filter
With bypass valve and electrical indicator

Filter fineness
10 Mic Nominal

Max. operating pressure

60 Bar

Bypass opening pressure

p 3.5 Bar ±10%

Electrical data of contamination indicator

Maximum voltage: 220 V7=
Maximum current on contact: 2.SA
Link capacity: 6OVA/40W
Inrush current: 7OVA

Cable connection
IP 65
PG 11 ø 6-10

Mass
1 kg

Repair
Seal set W006110199
:

Filter element : W006115133

Electrical indicator W006110194
:

Dimensions [mm]
B C D E G 0fl
19 G3/4 248 308 19 66

en
 0
LIPS Component nr. T002016868 Mod
Date: 1996-03-29

Description
Pressure switch
with adjustable switching differential

Switching pressure range

0.2 - 6 bar

Switching differential
0.25 - 1.2 bar

S Medium temperature
max. +150 °C

Surrounding temperature
-40 to +70 °C

Enclosure
IP 66

Adjustment of switch point

The switch point is set with the knob (5) on
top of the housing while reading the set
point on the main scale.
The switching differential can only be set
when the front cover is removed. The scale of
the differential (1 - 10) is equally divided
over the stated range (0.25 - 1.2 bar).
 0
LIPS Component nr. T003003034 Mod
Date: 1996-03-29

Description
Pneumatic 3/2 way valve
Nenn width 6

System pressure
min. 1 bar
max. 10 bar

Surrounding temperature
-10 to +40 °C

Connect ion
R ¼"

Electrical
Voltage : 110/115 V
Frequency : 50/60 Hz
Power 22 VA

Mass
0.4 kg

21.5

7 21.8
21.4
21.14 21.9

21.2 31

21.36 21.1

-21.15

38