Cmhi19602 634 VCD Uds 017 Main Propulsion and Gears

Installation Manual Please discard this when the final instruction manual is available.
Brunvoll Volda Propulsion System

Inst. No.: 2312-13
Propeller Type: CP 85
Gear Type: AG600/SOF250
Yard: China Merchants Heavy Industry Co., Ltd DMHI

New building no.: CMHI-196-2
IMO Number: -
2019
BVo Installation Manual No.: 2312-13. IMO No.: -. Date: 2019-11-18
1
Introduction
2
Technical data
3
Technical description
4
2312-13 Propeller Type: CP 85
Preparation and
Gear Type: AG600/SOF250
Installation
5
Operating instruction and
Emergency instruction
Only Instruction Manual
6
Maintenance
Only Instruction Manual
7
Spare parts and Tools
8
Drawings and Manuals
9
Remote Control,
Manual and drawings
10
Notes
and/(if) HPU Manuals
Page 1 of 4
Table of Contents
Sheet No. Content Page
Chapter 1 General
SVI01-00-00-010 General - about this manual 1
Revisions 1
Safety alert notices 1
SVI01-00-00-011 Foreword 3
SVI01-00-00-014 Marking of the main components 4
SVI01-00-00-017 End of Life Disposal 5
05030501 Storage and Preservation Procedure 6
05030101 Lifting instruction for propeller shaft 15
05030102 Lifting instruction for gear box 16
Gear box - side views 17
Chapter 2 Technical data 1

SVI02-00-00-002 Technical data - Brunvoll Volda Installation no.: 2312-13 3
CP85 Propeller 3
Stern tube 3
Stern tube glands 3
Stern tube bearings 3
Intermediate shaft bearings 3
Electric oil pumps 3
Oil content 3
Main Gear AG600 4
Engine 4
SVI02-00-00-006 Lubrication recommendation for Brunvoll Volda equipment - Biodegradable oils 5
Gearbox 5
HPU. 5
Stern tube and Propeller 5
Roller Bearings -Grease. 6
Coupling Geartype -Grease. 6
Biodegradable Oils 6
Change of oil in service *. 6
Change of oil types (from biodegradeable oil to mineral oil or vice versa.) 6
Propeller intremediate shafts Bearings - Ced.-Wär. 6
SVI02-00-00-017 Biodegradable Oil list for Stern tube and Propeller hub 7
SVI02-00-00-020 Torque of bolts. M10 to M36 8
Chapter 3 Technical description 1

SVI03-01-00-003 Description of controllable pitch propeller - type CP68-CP105 3
SVI03-02-00-001 Main propeller shaft 4
SVI03-03-00-004 SOF servo pitch control system, General description 5
SVI03-05-00-005 Reduction gear description without clutch 6
Chapter 4 Preparation and Installation 1

05100100 Installation and commissioning of gear-propeller systems 3
SVI04-02-01-002 Mounting of separately delivered Propeller Blades (E)CP68 and up 5
SVI04-02-02-001 Rope Guard mounting 9
SVI04-02-03-001 Installation of propeller shaft 10
SVI04-02-04-010 Installation of intermediate propeller shaft 11
SVI04-04-00-001 Alignment Gear/Propeller Shaft - GAP & SAG. 12
SVI04-04-00-104 Jack-test Gear/Propeller shaft 2312 & 2313 14
GAP and SAG Open Condition for inst.: 2312 16
Table for GAP & SAG for inst.: 2312 17
Table for Jack-test for inst.: 2312 18
Brunvoll Volda AS, T: +47 700 59 000, Emergency: +47 47 8 24 365 (after office hrs), E: [email protected]
BVo Installation Manual No.: 2312-13. IMO No.: -. Date: 2019-11-18 Page 1
Page 2 of 4

SVI04-05-00-001 Stern tube important 22
SVI04-06-00-004 Connection of Push pull-rod and Oil pips, SOF Coupling 23
SVI04-06-00-021 Connection of single hydraulic Oil-Pipes, Gearbox 25
SVI04-07-00-030 SOF250 Shaft coupling, Mounting Description. VS306987 26
SVI04-08-00-001 Pipeline instruction for separate mounted el.driven pump 32
SVI04-09-00-020 Oil filling Propeller hub, Stern tube and Propeller shaft (See piping diagram) 33
SVI04-09-00-500 Oil filling of Gear box 34
SVI04-10-00-002 Alignment of Gear/Propeller and Gear/Engine V40021 36
SVI04-10-00-101 Temperature compensating instruction Brunvoll Volda. Gear without servo 37
Using the temperature compensating diagram, examples at 31 °C and 7 °C 38
BVo2312 & 2313 Temperature compensating - ambient temperature. 39
VI309155 Chocking Plan ACG 600 40
SVI04-12-00-001 Pressure switch setup for PS3 “Extra low lube oil” 41
SVI04-30-00-100 Test procedure for instrument alarms 42
05040212 Launching, start-up and sea trial procedures 44
05100101 Data sheet - Launching, start-up and sea trial procedures 49
05.06.05.04e Brunvoll Volda Hand over Document 53
Chapter 5 Operating instruction and emergency 1

SVI05-01-00-113 Starting and operating procedure El-motor driven gearbox 3
SVI05-03-00-010 PVG 120 Emergency pitch control 5
Chapter 6 Maintenance 1
SVI06-01-00-002 Routine maintenance - Propulsion system 3
Gear box 3
Cooler 4
Propeller system and Stern Tube 4
Coupling Intermediate shafts - Gear type 5
Pumps 5
ODS and HPU 5
Turning gear 5
Remote control and monitoring 6
SVI06-02-00-001 How to take Oil sample for chemical analysis and particle count, Stern Tube. 7
SVI06-02-00-002 How to take Oil sample for chemical analysis and particle count, Gear 8
SVI06-03-00-001 Troubleshooting and correction 9
SVI06-05-00-001 Repairing of propeller blades 12
SVI06-08-00-001 Instruction for draining and filling of Propeller hub, Propeller shaft and Stern tube 14
SVI06-10-00-001 Oil filling and oil draining of Gear box 15
PVG 120 Proportional Valves - Service Parts Manual 17
SVI06-99-00-001 Logbook 69
Chapter 7 Spare parts and tools (per ship set) 1
Chapter 8 Brunvoll Volda Drawings and Manuals from Sub-suppliers 1

VA106419 Shafting 3
VA106338 Piping diagram 4
VI307229A Pipline instruction for separate mounted el.driven pump 5
SVI08-01-01-200 Indicator Alarm interface connections 6
VS307066 CP Propeller hub w Shaft for SOF coupling 7
Page 3 of 4
604477BV Part list CW - V307066 8

604478BV Part list CCW - V307066 9
VS204296 CP85/4 Right Hand Assembly (CW) 10
604393BV Part list Propeller hub VA204296 12
VS204297 CP85/4 Left Hand Assembly (CCW) 13
511201 IHC Netcutter Double execution 16
VK206431 CP85/4 Rope guard 17
VA106535 Stern tube Arrangement 18
513183 Stern tube Gland -Outer 21
513184 Stern tube Gland -Inner 22
VA305850 Pressurized Stern tube Lubr. for Simplex/IHC Supreme Gland 23
508411 Oil Tank 80 L 24
UG-323 Connection box General drawing 25
MN-4119 Temp sensor type MN4119 for bearing 26
MN-3725 Temp sensor - Installation manual for MN---- in stern tube 27
VS306987 SOF 250 Shaft Coupling Assembly 28
603541BV Part list SOF V306987 29
VA206980 Shaft locking device Arr. G600 CW Rotation 30
VS306312 Bracket Shaft Lock CW Turning, Assembly 31
VA206981 Shaft locking device Arr. G600 CCW Rotation 32
VS306313 Bracket Shaft Lock CCW Turning, Assembly 33
VA207144 Intermediate shaft arr. Shaft NO.1 and NO.2. (BVO 2286) 34
VA207148 Intermediate shaft arr. Shaft no.3 (BVO 2287 ) 35
513221 Intermediate Shaft Bearing arrangement 36
513221 Intermediate Shaft Bearing. Aeration system - Clarification 37
513221 Part List Intermediate Shaft Bearing 38
509271 Cathodic Slipring Arrangement With mV-meter 39
VS207026 Bulkhead seal Bulkhead # 24 45
207026 Part list V207026 - Bulkhead seals 46
513575-513639 Fire Resistant Bulkhead seal Bulkhead # 33 47
VL106525 Longitudinal section and piping arrangement. CW and CCW Gearboxes 48
604473BV BVo2232 Part list Gear VL106525 52
VS305258 Pressure Switch panel - 8 valves 58
604398 Part list V308736v - Pressure Switch panel 60
VS403525 Pressure Gauge Panel 61
604399 Part list V403525 Pressure Gauge panel 62
VS202867 St-Ru-Si Valve Assembly 63
VS402432 Suction strainer with flange outlet 64
VS301485 Suction strainer ex. flange outlet 65
506740 Pick-Up - for Brunvoll Mar-El 66
506505 Danfoss PVG 120 Drawing 67
513216 Flexible shaft coupling Gear-Engine 68
513256 Oil Cooler Data Sheet 69
513256 Oil Cooler Drawing 70
513256 Bloksma Compact Cooler, Manual 71
503717 Sika 174B - 1/2” L0 40 mm- Thermometer for oil cooler pipelines 93
513369 Electrical by Pump 94
502628 High Pressure Duplex Filters - Models 22PD, 32PD 95
502628 SVO Sparepart numbers, Parker High Pressure Duplex Filters 99
Page 4 of 4
Chapter 9 Remote control. Manual and drawings 1
Chapter 10 Manual from Sub Suppliers and Notes 1

513183-84 Lagersmit - Supreme STA-STF Stern tube Manual 3
513221 SRP LSB2 Installation & Maintenance Manual 39
513221 LSB2 Värtsilä Intermediate bearings Customer Manual 80
513575 & 513639 Fire Resistant A60 Bulkhead Seal 157
513216 CX-50-78 GSS1-300 Mounting instruction 165
Page 1 of 2
SVI01-00-00-010 R.00
General - about this manual
IMO. No.: -
Brunvoll Volda Inst. No.: 2312-13
Shipyard: China Merchants Heavy Industry Co., Ltd CMHI
New building No.: CMHI-196-2
Type of propeller: CP 85
Type of gearbox: AG600/SOF250
Classification society BV 1A
Manual created: Volda 2019-11-18
Revisions
Revision Date Remarks Document/Drawing Ch
Safety alert notices

TEXT SET OFF IN THIS MANNER PROVIDES WARNING NOTICE THAT FAILURE TO
FOLLOW THESE DIRECTIONS IN THIS WARNING CAN RESULT IN BODILY HARM OR
LOSS OF LIFE AND/OR EXTENSIVE DAMAGE TO EQUIPMENT.
Text set off in this manner provides warning notice that failure to follow these directions in this
CAUTION can result in damage to equipment.
Text set off in this manner present clarifying information or specific instructions pertinent to
the immediate instruction.
Brunvoll Volda AS Tel.: +47 700 59 000

Hamnegata 24
E No: 917 225 702 VAT
P.O.Box 205 Emergency: +47 47 8 24 365 (after office hrs)
N-6101 Volda E-mail: [email protected]
Norway Homepage: http://www.brunvoll.com
BVo Installation Manual No.: 2312-13. IMO No.: -. Date: 2019-11-18 Chapter 1 - Page 1
Page 2 of 2
SVI01-00-00-010 R.00
Page 1 of 1
SVI01-00-00-011 R.02
Foreword
It will be important and may save your time if you read this Foreword carefully.
This instruction manual, issued with Brunvoll Volda No dismantling or adjusting work should be started,
Propulsion systems, is prepared for yard/operating unless the relevant instructions and procedures
personnel. have been carefully studied. This will secure that
The personnel should be familiar with working the work sequence is clear and necessary tools and
principles of the equipment and with the instructions equipment are at hand.
and precautions contained in this book.
It is of outmost importance that extreme cleanliness
Keep this book handy for Installation and operating is observed during all work on the equipment. Sand,
personnel at all times, to ensure that proper and dust or other impurities are detrimental to hydraulic
correct instructions can be observed and followed. equipment, and are most likely to impair the function
seriously. Keep hands and tools clean, use a
When using the book, note that all part numbers cleaning cloth of linen - never cotton waste - when
mentioned, unless otherwise stated, refer to the cleaning parts.
drawing number appearing in the description area of
the page and in the down right hand corner of each Multi-language manuals.
drawing. When internal conflict between multilingual
documents in this manual, English documents shall
prevail.
Direct all correspondence to our address:
Brunvoll Volda AS
Hamneg. 24, P.O.box 205,
N-6101 Volda, Norway
TELEPHONE: +47 70 05 90 00
24hrs EMERGENCY
SERVICE TELEPHONE:+47 478 24 365
TELEFAX: +47 70 05 90 01
E-MAIL: [email protected]
INTERNET: http://www.brunvoll.no
Brunvoll Volda AS, Tel.: +47 700 59 000, Emergency: +47 47 8 24 365 (after office hrs), E-mail: [email protected]
Page 1 of 1
SVI01-00-00-014 R01
Marking
Marking of
of the
the main
main components
components
Propeller blade
Examples
Marking
Propeller hub
Propeller shaft
OF-coupling
Gearbox
Classification stamp
Page 1 of 1
SVI01-00-00-017 R.00
End of Life Disposal
Companies specializing in reclaiming material can reclaim most of the iron, steel and copper from the
equipment. For more details, please contact Customer Service.
Recyclable material
Separate mechanically from each other the base materials, iron, copper and steel, removing paint, oil,
polyester resin, and insulation tape and/or plastics residues from all components.
Dispose of this “Waste material”
The iron, steel and copper can now be recycled.
Items requiring specialist treatment

Remove electrical cables, electronic accessories and plastic materials from the equipment.
These components need special treatment to remove the waste from the reclaimable material.
Forward the reclaimed materials for recycling.
Waste material
Dispose of waste material from both of the above processes via a spsialist disposal company.
Local laws
Follow the laws to the country - at the time - when the equipment are recycled.
Page 1 of 8
Page 1 of
05030501 R.01
05030501 R.0
Storage
Storage and
and Preservation
Preservation
Storage Procedure
Prosedure
and Preservation Prosedure
P a ge 1 of 7
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8
05030501 R.01
01
Storage and preservation instruction for propulsion systems
P a ge 2 of 7
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05030501 R.01
P a ge 3 of 7
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Page 4 of 8
05030501 R.01
ON
is
CI
P a ge 4 of 7
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Page 5 of 8
05030501 R.01
After curing of the VpCI
P a ge 5 of 7
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05030501 R.01
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Page 8 of 8
05030501 R.01
INTERVAL
Page 1 of 1
05030101 R.00
Lifting instruction for propeller shaft
All work must be performed by qualified personnel Place the fiber slings parallel in equal distance to the
using approved equipment. “Center of gravity”.
Lifting yoke must be approved for the weight to Check that the fiber slings will not destroy
be lifted. preservation barrier.
(See “Storage and Preservation Presedure
Length of the lifting yoke shal be approximately 05030501” in Ch.1 in the Scana Manual)
50% of the shaft.
Use fiber slings, never metal lifting devices in

contact with the shaft.
What you need:

-Lifting yoke.
-Fiber slings.
See “Packing list” or the drawing “Shafting” in Ch.8. in the Scana Manual
- Weight of Propeller Hub,
- Weight of Propeller Shaft
Center of mass
Page 1 of 2
05030102 R.00
Lifting
Lifting instruction
instruction for
for gear
gear box
box
All work must be performed by qualified personnel Fasten the shackles to the “Lifting bolts” - mounted
using approved equipment. on gear box. Brunvoll Volda supply.
Lifting yoke must be approved for the weight to

be lifted.
What you need:

- Lifting yoke.
See “Packing list” or the drawing “Shafting” in Ch.8 in the Brunvoll Volda AS Manual
- Weight of gear box.
Lifting bolts (Red painted).

Brunvoll Volda AS supply.
Lifting bolts
Brunvoll Volda AS supply.
Mounted on gear box
Page 2 of 2
05030102 R.00
Gear box - side views
Check that the chains are not in

contact with the epuipment on the
gear box
Page 1 of 2
Chapter 2 Technical data

SVI02-00-00-002 Technical data - Brunvoll Volda Installation no.: 2312-13 3
CP85 Propeller 3
Stern tube 3
Stern tube glands 3
Stern tube bearings 3
Intermediate shaft bearings 3
Electric oil pumps 3
Oil content 3
Main Gear AG600 4
Engine 4
SVI02-00-00-006 Lubrication recommendation for Brunvoll Volda equipment - Biodegradable oils 5
Gearbox 5
HPU. 5
Stern tube and Propeller 5
Roller Bearings -Grease. 6
Coupling Geartype -Grease. 6
Biodegradable Oils 6
Change of oil in service *. 6
Change of oil types (from biodegradeable oil to mineral oil or vice versa.) 6
Propeller intremediate shafts Bearings - Ced.-Wär. 6
SVI02-00-00-017 Biodegradable Oil list for Stern tube and Propeller hub 7
SVI02-00-00-020 Torque of bolts. M10 to M36 8
Page 2 of 2
SVI02-00-00-002
Technical data - Brunvoll Volda Installation no.: 2312-13
CP85 Propeller
Propeller Hub 850 mm
Propeller Diameter 3100 mm
Propeller Speed 201,5 rpm
Number of blades 4 pcs
2312 Propeller direction of rotation / Installation i vessel - see shafting Ch.8 CW Seen from aft
2313 Propeller direction of rotation / Installation i vessel - see shafting Ch.8 CCW Seen form aft
Stern tube
Stern tube glands
Maker: IHC Supreme
SVO itm no.: 513183-513184
Stern tube bearings
Bearing Clearance Min Max
Aft stern tube bearing (new) 0,65 0,839

Forward stern tube bearing (new) 0,35 0,539
Intermediate shaft bearings

BVo No.: 513221
Electric oil pumps

Maker: Parker
BVO itm no.: 513369 x 2 per gearbox.
Oil Pump Type -
El.Motor Type Hoyer
Voltage/Hz 690/50Hz
El.Motor Power 15kW
Speed RPM 970
Bar 55
Capacity litre/min 137
Oil content
Oil types - See Oil recommendations in chapter 2
Approximately Oil contents Propeller hub (Hub only,
85 litre
does not include Stern tube and header tank)
Approximately Oil contents Stern Tube and header tank. Piping between not included 750 litre
Approximately Oil contents Gear box 400 litre
SVI02-00-00-002
Main Gear AG600

Painting: RAL 7035
Reduction gear ratio: 4,964:1
System Oil pressure/Servo oil pressure 55 bar
Maximum oil pressure, safety valve 55 bar
Lubrication oil pressure 4-5 bar
Normal Gearbox oil temperature 52 °C
Clearance min max
Gear wheel backlash 341 507
Bearing clearance, output shaft aft (new) 0,100 0,200
Bearing clearance, output shaft fwd (new) 0,100 0,200
Thrust bearing, output shaft, axial clearance (new) 0,300 0,630
Bearing clearance, pinion shaft (new) 0,180 0,275
Pinion shaft, axial clearance (new)
Engine
Make kW RPM
El motor Ulstien 2200 1000
Set points on Pressure switches and temp. sensor See: Chapter 8 - Piping diagram
Page 1 of 2
SVI02-00-00-006 R.02
Lubrication recommendation for Brunvoll Volda equipment - Biodegradable oils
Gearbox
For Brunvoll Volda gearboxes single grade heavy- requirements as specified below. Oil specification
duty type gear oil must be used. Alternatively for alternative oil types must be sent to Brunvoll
hydraulic oil can be used if these oils fulfil the main Volda for approval for each separate case.
Multigrade oil of any kind can not be used. Do not mix motor oil or hydraulic oil with gear oils, even if
they fulfil the requirements of these specifications. Very small amounts of such oil types mixed in the
gear oil can lower the quality considerably.
For
Forthis
this installation
gearbox useuse
1XX150
cSt cSt at 40°C.
at 40°C.
andand fulfil
fulfil following
following requirements:
requirements:
1. Load carrying property
1. Load carrying property (FZG (FZG gear
gear test)
test) Load
Load step
step 1212
or or higher.
higher.
2. Antifoaming additives
2. Antifoaming additives applied. applied.
Min.
3. 3.Min. flash
flash point
point 150°C
150°C
* In addition - Gears with Ortlinghaus, HPC and LK clutches - the oil

must compile with the oil list from Ortlinghaus. See SVI02-00-00-014.
HPU.
HPU
* if present.
Oil types for HPU can be the same as The HPU may have special requirements for the oil.
specified for the gearbox. In that case, follow the oil specifications given by
the HPU supplier in the enclosed manual.
Stern
Stern tube
tube and
and Propeller
Propeller
(common oil lubrication arrangement for Propeller and Stern tube, see drawing ch.8)
Oil lubricated
Biodegradable oils can be used, see next page.
Oil types for propeller and stern tube can be the The various types of stern tube seals may have
same as specified for the gearbox. Alternatively it special requirements for the stern tube oil.
may be used motor oils with viscosity SAE30 or In that case, follow the oil specifications given by
SAE40. the stern tube seal supplier in the enclosed stern
tube seals manual.
Page 2 of 2
SVI02-00-00-006 R.02
Bulkhead Seal -Oil Tank lubricated / Gas-tight Bulkhead Seal -None

-none Oil Tank / Waterproof
* if present * if present
Any oil vith viscosity: If equipped with grease nipple:
ISO VG 220 (CST 220) – or equal. universal grease.
If no grease nipple - no lubrication needed.
Roller
Roller Bearings
Bearings -Grease.
-Grease. Propeller
Propeller intremediate
intermediate shafts
shafts Bearings
Bearings -- Ced.-Wär.
Ced.-Wär.
* if present. * if present.
SKF LGMT2 or NLGI Grade: No. 2. The oil must compile with the oil list from
See Ch.6 Maintenance Cedervall-Wärtsilä
See SVI02-00-00-015.
Coupling
CouplingGeartype
Geartype-Grease.
-Grease.
* if present.
See Ch.6 Maintenance and Ch.8 Coupling Manual -Geartype
Biodegradable
Biodegradable Oils
Oils
Propeller and Stern tube
(common oil lubrication arrangement for Stern tube and Propeller, see drawing ch.8)
Biodegradable oil can be used in Propeller and Stern tube. All biodegradeable oils must be approved by
Brunvoll Volda AS before use. See SVI02-00-00-017 (in Ch.2).
See also “Piping diagram” (ch.8) and manuals from sub suppliers.
Change
Change of
of oil
oil types
types (from
(from biodegradeable oiltotomineral
biodegradable oil mineraloiloilororvice
viceversa.)
versa.)
The ship must be dry docked.
All old oil must be removed from the propeller hub and stern tube.
The system must be properly cleaned before new oil can be filled in the propeller hub and stern tube.
Replace all oil seals in the propeller hub and the stern tube (Please contact Brunvoll
Volda according brand).
Change of oil in service

service*.*.
1. Discoloured oil from water content in the oil 3. The viscosity is lower than 15% below the
(grey oil) or from oxides (black oil). specified new viscosity.
2. Too high amounts of insoluble particles in the 4. Other serious irregularities specified from
oil. the oil company or the laboratory.
* See Ch.6 Maintenance.
Page 1 of 1
SVI02-00-00-017 R00
Biodegradable Oil list for Stern tube and Propeller hub

Product information
Klüberbio RM 2-100, 2-150
Klüberbio is the brand Brunvoll Volda AS has approved.

This list applies from September 2017 until a new list has been prepared and approved
Product information

Environmentally compatible, synthetic stern tube oils
Environmentally compatible, synthetic stern tube oils
Product data Klüberbio RM 2-100 Klüberbio RM 2-150

Article number
Product data Klüberbio RM 2-100 009031RM 2-150
Klüberbio 009025
Article number 009031 009025
EU Ecolabel registration number
EU Ecolabel registration number DE/027/110
DE/027/110
DE/027/111
DE/027/111
Lower service
Lower temperature
service temperature -10 °C / 14 °F -10
-10 °C /°C / 14
14 °F °F -10 °C / 14 °F
Upper service temperature 100 °C / 212 °F 100 °C / 212 °F
Upper service temperature 100 °C / 212 °F 100 °C / 212 °F
Density, DIN 51757, 20 °C approx. 0.94 g/cm³ approx. 0.92 g/cm³
Density, DIN DIN
Flash point, 51757,
EN ISO20 °CCleveland, open-cup apparatus
2592, >= 230 °C >=approx.
250 °C 0.94 g/cm³ approx. 0.92 g/cm³
Biodegradability according to OECD 301 F, (within 28 days) >= 60 % >= 60 %
Flash point, DIN EN ISO 2592, Cleveland, open-cup apparatus >= 230 °C >= 250 °C
Kinematic viscosity, DIN 51562 pt. 01/ASTM D-445/ASTM D 7042, 40 °C approx. 100 mm²/s approx. 150 mm²/s
Biodegradability according
Kinematic viscosity, to01/ASTM
DIN 51562 pt. OECDD-445/ASTM
301 F, (within
D 7042, 28
100 days)
°C approx. 14 mm²/s >= 60
approx. 18 %
mm²/s >= 60 %
Kinematic viscosity,
ISO viscosity DIN
grade, DIN ISO 51562
3448 pt. 01/ASTM D-445/ASTM D
1007042, 40 °C approx.
150 100 mm²/s approx. 150 mm²/s
Viscosity index, DIN ISO 2909 approx. 137 approx. 135
Kinematic viscosity, DIN 51562 pt. 01/ASTM D-445/ASTM D 7042, 100 °C approx. 14 mm²/s
Anticorrosive properties on steel, DIN ISO 7120, method A, steel, 24 h/60 °C no rust corrosion degree no rust corrosion degree
approx. 18 mm²/s
ISO Copper
viscosity grade,
corrosion, DIN
DIN EN ISOISO
2160,3448
24 h/100°C 1 - 100 corrosion 1 100
- 100 corrosion 150
degree degree
Viscosity index,
Pour point, DIN
DIN ISO ISO 2909
3016 <= -30 °C <=approx.
-30 °C 137 approx. 135
Anticorrosive properties
Minimum shelf on ofsteel,
life from the date DIN ISO
manufacture 7120,
- in a dry, method
frost-free place A,36
steel,
months24 h/60 °C 36no rust corrosion degree no rust corrosion degree
months
and in the unopened original container, approx.
Copper corrosion, DIN EN ISO 2160, 24 h/100°C 1 - 100 corrosion 1 - 100 corrosion
degree degree
Pour point, DIN ISO 3016 <= -30 °C <= -30 °C
Minimum shelf life from the date of manufacture - in a dry, frost-free place 36 months 36 months
and in the unopened original container, approx.
Klüber Lubrication München SE & Co. KG /

Geisenhausenerstraße 7 / 81379 München / Germany /
Klüber Lubrication – your global specialist phone +49 89 7876-0 / fax +49 89 7876-333.
Innovative tribological solutions are our passion. Through The data in this document is based on our general experience and knowledge at
the time of publication and is intended to give information of possible applications
personal contact and consultation, we help our customers to be to a reader with technical experience. It constitutes neither an assurance of
successful worldwide, in all industries and markets. With our product properties nor does it release the user from the obligation of performing
ambitious technical concepts and experienced, competent staff preliminary field tests with the product selected for a specific application. All data
are guide values which depend on the lubricant's composition, the intended use
we have been fulfilling increasingly demanding requirements by and the application method. The technical values of lubricants change depending
manufacturing efficient high-performance lubricants for more on the mechanical, dynamical, chemical and thermal loads, time and pressure.
than 80 years. These changes may affect the function of a component. We recommend
contacting us to discuss your specific application. If possible we will be pleased to
provide a sample for testing on request. Klüber products are continually improved.
Therefore, Klüber Lubrication reserves the right to change all the technical data in
this document at any time without notice.
Publisher and Copyright: Klüber Lubrication München SE & Co. KG. Reprints,
total or in part, are permitted only prior consultation with Klüber Lubrication
München SE & Co. KG and if source is indicated and voucher copy is forwarded.
Klüber Lubrication München SE & Co. KG /

Geisenhausenerstraße 7 / 81379 München / Germany /
Klüber Lubrication – your global specialist phone +49 89 7876-0 / fax +49 89 7876-333.
Innovative tribological solutions are our passion. Through The data in this document is based on our general experience and knowledge at
the time of publication and is intended to give information of possible applications
personal contact and consultation, we help our customers to be to a reader with technical experience. It constitutes neither an assurance of
successful worldwide, in all industries and markets. With our product properties nor does it release the user from the obligation of performing
ambitious technical concepts and experienced, competent staff preliminary field tests with the product selected for a specific application. All data
are guide values which depend on the lubricant's composition, the intended use
we have been fulfilling increasingly demanding requirements by and the application method. The technical values of lubricants change depending
manufacturing efficient high-performance lubricants for more on the mechanical, dynamical, chemical and thermal loads, time and pressure.
than 80 years. These changes may affect the function of a component. We recommend
contacting us to discuss your specific application. If possible we will be pleased to
provide a sample for testing on request. Klüber products are continually improved.
Brunvoll Volda AS, Tel.: +47 700 59 000, Emergency: +47 47 8Therefore,
24 365 (after office
Klüber hrs), E-mail:
Lubrication [email protected]
reserves the right to change all the technical data in
this document at any time without notice.
BVo Installation Manual No.: 2312-13. Publisher
IMO No.: -. Copyright:
and Date: 2019-11-18
Klüber Lubrication München SE & Co. KG. Reprints,
total or in part, are permitted only prior consultation with Klüber Lubrication
München SE & Co. KG and if source is indicated and voucher copy is forwarded.
Page 1 of 1
SVI02-00-00-020 R.02
Torque oftorque
Standard bolts. M10 to M36
of bolts. M10 to M36
Blade bolts: See propeller assembly drawing

Flange bolts: See propeller assembly drawing
Gearwheel bolts: See gear box longitudinal drawing
Shaft coupling bolts: See shaft coupling drawing
Push-pull rod connection flanges bolts: See connection flanges drawing
if not anything specified in relevant documentation use standard torque according to

following tables (lubricated with oil):
12.9 Bolt. Valid for Socket screws and hex head bolts
Quality of surface
Size SJG250/GG25 S355 SJK400 C45 NiAIBr
M10 55 Nm 60 Nm 60 Nm 60 Nm 60 Nm
M12 90 Nm 105 Nm 105 Nm 105 Nm 105 Nm
M16 215 Nm 250 Nm 250 Nm 250 Nm 250 Nm
M18 305 Nm 355 Nm 355 Nm 355 Nm 355 Nm
M20 440 Nm 460 Nm 460 Nm 460 Nm 460 Nm
M24 720 Nm 780 Nm 780 Nm 780 Nm 780 Nm
M30 1400 Nm 1600 Nm 1600 Nm 1600 Nm 1600 Nm
M36 2300 Nm 2600 Nm 2600 Nm 2600 Nm 2600 Nm
Quality of surface
M10 50 Nm 50 Nm 50 Nm 50 Nm 50 Nm
M12 85 Nm 85 Nm 85 Nm 85 Nm 85 Nm
M16 210 Nm 210 Nm 210 Nm 210 Nm 210 Nm
M18 255 Nm 255 Nm 255 Nm 255 Nm 255 Nm
M20 365 Nm 365 Nm 365 Nm 365 Nm 365 Nm
M24 600 Nm 600 Nm 600 Nm 600 Nm 600 Nm
M30 1160 Nm 1160 Nm 1160 Nm 1160 Nm 1160 Nm
M36 1410 Nm 1410 Nm 1410 Nm 1410 Nm 1410 Nm
Quality of surface
M10 36 Nm 36 Nm 36 Nm 36 Nm 36 Nm
M12 61 Nm 61 Nm 61 Nm 61 Nm 61 Nm
M16 150 Nm 150 Nm 150 Nm 150 Nm 150 Nm
M18 210 Nm 210 Nm 210 Nm 210 Nm 210 Nm
M20 290 Nm 290 Nm 290 Nm 290 Nm 290 Nm
M24 500 Nm 500 Nm 500 Nm 500 Nm 500 Nm
M30 1000 Nm 1000 Nm 1000 Nm 1000 Nm 1000 Nm
M36 1700 Nm 1700 Nm 1700 Nm 1700 Nm 1700 Nm
A4-80 Bolt. Valid for Socket screws and hex head bolts
Quality of surface
M10 33 Nm 33 Nm 33 Nm 33 Nm 33 Nm
M12 57 Nm 57 Nm 57 Nm 57 Nm 57 Nm
M16 135 Nm 135 Nm 135 Nm 135 Nm 135 Nm
M18 190 Nm 190 Nm 190 Nm 190 Nm 190 Nm
M20 270 Nm 270 Nm 270 Nm 270 Nm 270 Nm
M24 470 Nm 470 Nm 470 Nm 470 Nm 470 Nm
M30 920 Nm 920 Nm 920 Nm 920 Nm 920 Nm
M36 1600 Nm 1600 Nm 1600 Nm 1600 Nm 1600 Nm
Page 1 of 2
Chapter 3 Technical description

SVI03-01-00-003 Description of controllable pitch propeller - type CP68-CP105 3
SVI03-02-00-001 Main propeller shaft 4
SVI03-03-00-004 SOF servo pitch control system, General description 5
SVI03-05-00-005 Reduction gear description without clutch 6
Page 2 of 2
Page 1 of 1
SVI03-01-00-003
Description of controllable pitch propeller - type CP68-CP105
D
B
G
E
D
Main parts of a Propeller hub:

A. Propeller hub
B. Push pull rod
C. Guide
D. Sliding block
E. Crank disc.
F. Propeller blade flange
G. Propeller shaft flange
Page 1 of 1
SVI03-02-00-001
Main propeller shaft
C
B
The shafts are made of steel. They are hollow (A).

The centre bore contains the propeller pitch control
transmitting system
The aft end of the propeller shaft is flanged and Parts, which are in contact with sea water, are
bolted to the propeller hub (B). protected by corrosion resistant material.
The shaft flange is equipped with dowels (C) trans-
mitting the torque between the shaft and propeller
hub.
The shafts are connected with couplings of either The performance specifications and the
1. - SKF-OK type dimensions of the shaft and type of
2. - flange type coupling are given with the drawing
3. - split muff coupling. “Shafting arrangement”.
Page 1 of 1
SVI03-03-00-004
SOF
SOF servo
servo pitch
pitch control
control system,
system, General
General description
description
The propeller pitch is adjusted by the remote con- The push pull rod and the oil pipes are fixed to the
trol through the analogue control of the proportional SOF piston and the revolving guide ring in the reduc-
valve. tion gear, transferring the propeller pitch position to
the remote control by mechanical feedback.
The hydraulic proportional valve applies oil pres-
sure to either side of the SOF coupling servo piston
through oil pipes in the centre of the intermediate
shaft. The push pull rod connects the servo to the
propeller hub guide thus controlling the propeller
pitch.
Page 1 of 1
SVI03-05-00-005
Reduction gear description without clutch and servo
The reduction gear is a single-stage gear with heli- The gearbox shall have an oil temperature as stated
cal toothed, case hardened, and flank ground gear in “Data Sheet”, by adjusting the water flow through
wheels (A), built into a gearbox (B) of cast iron. the oil cooler.
The shafts (C) are bedded in pressure oil lubricated Lubrication pressure on bearings is to be as stated in
bearings(D) lined with white metal. The output shaft “Data Sheet”.
is fitted with a thrust bearing (E) Michell - bearing,
to absorb the propeller thrust.
A C
Page 1 of 2
Chapter 4 Preparation and Installation

05100100 Installation and commissioning of gear-propeller systems 3
SVI04-02-01-002 Mounting of separately delivered Propeller Blades (E)CP68 and up 5
SVI04-02-02-001 Rope Guard mounting 9
SVI04-02-03-001 Installation of propeller shaft 10
SVI04-02-04-010 Installation of intermediate propeller shaft 11
SVI04-04-00-001 Alignment Gear/Propeller Shaft - GAP & SAG. 12
SVI04-04-00-104 Jack-test Gear/Propeller shaft 2312 & 2313 14
SVI04-05-00-001 Stern tube important 22
SVI04-06-00-004 Connection of Push pull-rod and Oil pips, SOF Coupling 23
SVI04-06-00-021 Connection of single hydraulic Oil-Pipes, Gearbox 25
SVI04-07-00-030 SOF250 Shaft coupling, Mounting Description. VS306987 26
SVI04-08-00-001 Pipeline instruction for separate mounted el.driven pump 32
SVI04-09-00-020 Oil filling Propeller hub, Stern tube and Propeller shaft (See piping diagram) 33
SVI04-09-00-500 Oil filling of Gear box 34
SVI04-10-00-002 Alignment of Gear/Propeller and Gear/Engine V40021 36
SVI04-10-00-101 Temperature compensating instruction Brunvoll Volda. Gear without servo 37
Using the temperature compensating diagram, examples at 31 °C and 7 °C 38
BVo2312 & 2313 Temperature compensating - ambient temperature. 39
VI309155 Chocking Plan ACG 600 40
SVI04-12-00-001 Pressure switch setup for PS3 “Extra low lube oil” 41
SVI04-30-00-100 Test procedure for instrument alarms 42
05040212 Launching, start-up and sea trial procedures 44
05100101 Data sheet - Launching, start-up and sea trial procedures 49
05.06.05.04e Brunvoll Volda Hand over Document 53
Page 2 of 2
Page 1 of 2
05100100.docx Rev.06
Installation andcommissioning
Installation and commissioningofofgear-propeller
gear-propeller systems
systems
1 Objectives
The objective is to maintain an installation and com- 4.4 Electrical functions
missioning routine that gives the client the reliabil- Inspect electrical functions connected to the gear.
ity required. Ref. electrical drawings.
2 Scope All alarms for gearbox and propeller shaft

Guidance for installation and commissioning for must be active in all running modes (normal - and PTI-
gear- and propeller systems. It is a general pro- mode).
cedure for all our gears, and points obviously not
relevant to actual installation are to be ignored. 4.5 Propeller shaft earthing device
The procedure is relevant for all our service person- Check the function of the propeller shaft earthing
nel. device and if necessary install it before launching.
3 Responsibility and authority 4.6 Flushing

The service engineer from Volda has the responsi- Oil type: See Ch.2 “SVI02.- -Oil recommendaton”
bility to carry out each point in this section. Flushing is done with the Gear oil. Only filters will be
To accomplish his job, he has to require full co- changed.
operation with the yard. The objective of the flushing procedure is to
remove impurities from the gear box and piping
4 Description system that may reduce the lifetime and service of
the gear box. If a special flushing aggregate or other
4.1 Alignment equipment is available at yard, this may be used if
Check that alignment values are inside given toler- approved by Brunvoll Volda.
ances.
To do this, investigate signed alignment records Disconnect the return oil pipe from oil cooler at the
from yard or class institution. Alignment record lube oil distribution system. Plug the open connec-
is supposed to contain method of alignment. In tion on the lube oil distribution system.
case of doubt, it may after discussions with techni-
cal personnel at Brunvoll Volda be necessary to Connect a hose to the pipe from oil cooler and
execute a physical alignment inspection. drain the oil through an oil filter (Yard supply
- 20μ filter) directly to the gear box sump.
4.2 Piping
Check if the piping is according to piping diagram. Max pressure drop of 4-5 bar is allowed over the
It is very important to make sure that external flushing filter.
mounted pipe work is free of debris and contami-
nations that may be exported to the oil system of This is in order to flush the installation in by pass,
the gear. without passing through the oil distributor.
Fill the gear with oil and check the oil level. Start the stand by pump aggregate and run suffi-
Prior to starting the engine/gear, the oil level should ciently to flush the installation, at least 4 hours.
be a bit above the max level.
During the flushing operation with stand by pump
Filling of gear oil must not take place until the operating:
responsible commissioning service engineer has - run the servo motor at least ten times from full
inspected and approved the gear and the pipework ahead to full astern positions.
belonging to. - The clutch and servo functions can be tested and
adjusted.
4.3 Indicating and regulating equipment - Examine the pipe work for leakages.
Test pressure states and thermostats according to - Check the filter condition at intervals.
function and set points. - Check the oil level.
See Piping diagram.
Perform required adjustments. Ref. technical data
sheet and drawings.
Page 2 of 2
05100100.docx Rev.06
4.8 Technical sea trial

After the flushing operation is finished, examine Start engine and gear as described under point 4.7.
the oil cooler for internal contamination.
Reconnect the pipe work which was disconnected Record temperatures and pressures (also local
before start of flushing operation. surface temperatures) during the sea trial at certain
intervals.
4.7 Starting up It is of importance that these values are stable at full
Start the stand by pump and inspect all pressures. load trial.
Make sure that the functions, like the servo and
Check that clutch is disengaged. clutches function normally.
The main engine is now ready for starting. Test the remote control system and make sure that
the pitch speed is lower than the gear servo speed.
After the engine is started, stop stand by pump This may vary with the type of gear and pump ca-
and switch it over to “aut. start” position. Run the pacity.
gear for a while (0,5 to 1 hour) before engaging the
clutch. 4.9 After sea trial
Run the gear at quay unloaded for about 1 hour, Immediately after engine stop: check alignment
and after that with moderate load (30 - 50% load for over flex couplings on Gearbox PTO/PTI and
3 - 5 hours is sufficient). Gearbox – Engine.
Investigate pressures and temperatures until stable Open the suction filter and cleaned and exchange
running temperatures are achieved. pressure filter element.
Regarding pressure and temperature values, refer to
technical datasheet. Check that clogged filter alarm functions.
Record max. servo oil pressure at manoeuvring
around the 0-pitch area and check against the set Open inspection covers for inspection of gear con-
point of the gear safety valve. tact.
If necessary, adjust the set point to a higher level. Inspect contact by contact lacquer.
Prior to sea trial, the functions of the remote control Such lacquer is to be applied on 3-4 teeth prior to
shall be properly examined, and required adjust- sea trial.
ments possible to do ahead of sea trial carried out.
Normally, the lacquer is applied on teeth before
Check the output and input shaft sealings. shipping from Volda.
Leakages are easiest discovered by connecting and
disconnecting the clutch. 5 Documentation
Input shaft sealing shall also be investigated at stop Form 05100101 “Data sheet for sea trial Volda
and start of main engine. propulsion gear” and other records from installa-
tion and sea trial are to be filed in the data book for
actual installation.
6 Reason for new issue

Rev.06: Filter and pressure drop at section 4.6
added. Previous issues: 30.06.2017
Page 1 of 4
SVI04-02-01-002
Mounting of separately delivered Propeller Blades (E)CP68 and up
In case of packing problems or short delivery time, the propeller blades may be sent
separately packed (un-mounted).
If blades are sent separately, the shipyard will normally do the mounting, unless otherwise
is agreed upon.
Mounting procedure:
1. 3.
Make sure that the blade seal is properly fitted Attach a suitable lifting tackle to
and in good condition. Wipe the bearing the blade in a sequence as illustrated. (see fig.
surfaces in the hub and the crank disc clean, above)
and lubricate the propeller blade seal with Lift and inspect the propeller blade root to be in
water resistant grease, and the bearing with good condition. Clean and lubricate the surface
clean oil. and then lower it gently into position.
2.
Check that the fitted pins, the sealing and The arrow stamped on the blade root
bearing surfaces on the blade are clean and in marked “F” shall point forwards.
good condition. (see fig. next page)
Page 2 of 4
SVI04-02-01-002
8 bolts CP 115 - 135 shown,

6 bolts 68 - 105
Page 3 of 4
SVI04-02-01-002
8 bolts CP 115 - 135 shown,

6 bolts 68 - 105
4.
Ensure bolts to be clean and without damage, especially on
threads and sealing surface.
a. Fit 2 O-rings, lubricated with water resistant grease, to each

blade flange bolt.
Coat the bolt threads with Omega 99 / Interflon HT1200 or
similar as referred on assembly drawing to prevent seizing of
the bolt threads. This is important due to poor sliding proper-
ties of stainless steel bolts.
b. Put O-rings loose on bolt while entering threads fully. Take

care not to damage O-rings.
c. Slide O-rings into gap between bolt shaft and hole in blade
flange making sure O-rings is not squeezed between bolt
head and blade flange or damaged by the threads.
5.
a. Insert the bolts and screw in by hand to avoid seizing.
Finally tighten the bolts in a star pattern sequence according
to the torque values found in the propeller assembly drawing
in Ch.8.
b. Loosen bolts and repeat torque sequence.
6.
Test for leakage with air pressure. Use 0,5 - 1 bar pressure.
Don`t exceed 1 bar.
Page 4 of 4
SVI04-02-01-002
Welding of locking bars.
The welding ground cable must be connected to the first bolt to be welded.
Make sure the welding current does not pass through and damage the equipment.
7. 9.
When work on the propeller is completed, Seal the gap between blade root and hub, and
secure the blade bolts by locking bars spot between blade bolts and blade root, with water
welded to the bolt heads using stainless resistant grease, to prevent crevice corrosion
steel electrodes. during out-fitting period and prolonged
harbour lay in stagnant water.
8. 10.
Mount the plugs in the lifting holes. Fill the propeller hub with specified oil.
Page 1 of 1
SVI04-02-02-001
Rope Guard mounting
1. 3.
The rope guard is delivered in two halves as shown Connect the two halves by welding together the
in the rope guard drawing in chapter 8. plates on the surface of the rope guard.
2. 4.
Weld each half on to the ships` stern tube pipe by a
continious weld as shown on the drawing.
Make sure that there is a clearance between the hub
and the rope guard. The rope guard must be coated before launching.
Page 1 of 1
SVI04-02-03-001
Installation of propeller shaft
When installing the propeller shaft and stern tube glands, the following points must be observed:
1. When lifting the shaft, do not use any slings on 7. Clamp the propeller shaft preliminarily in its
the liner of the outer gland. proper position and mark this position inside
the ship. Mark also Gear Box position for further
Use fiber slings, and no metal lifting devices in references.
contact with the shaft.
8. Turn the propeller blades to the “ahead” position
(the push‑pull rod is moved astern). If necessary,
make a lever out of two planks clamped to one of
Use of metal slings will damage the surface of the the blades.
shaft.
9. Install the stern tube lubrication system and the
2. Shaft, stern tube and glands must be cleaned circulation tank for the forward stern tube seal
thoroughly. Make sure that the shaft has no due to the stern tube lubrication arr. (Ch.8).
bruises or scratches.
(See stern tube important Ch. 4) 10.
3. Check that both stern tube liners are provided

with axial oil grooves in their total length for oil
circulation. Before launching, fill propeller and stern tube with
oil as described in sheet “Lubrication of stern-
4. tube and propeller - procedures” .
11. Check the propeller and both stern tube glands

Prepare mounting of Stern tube sealing A. for leakages.
Insert the shaft carefully into the stern tube, and

put it forward to its proper position. Fasten the
gland carefully.
Ref.: Instructions for stern tube sealings. (Ch.8)
5. Slide the inner stern tube gland in assembled

condition and with the liner fitted on to the forward
end of the propeller shaft and fasten it to the stern
tube
Ref.: Instructions for stern tube sealings. (Ch.8)
6. Turn the propeller until one of the vent plugs be‑

tween the blades is on the top of the propeller.
Page 1 of 1
SVI04-02-04-010
Installation of intermediate propeller shaft
Make sure that the bearing foundation is stable.
When installing the intermediate propeller shafts, the following points have to be observed:
1. The intermediate propeller shaft arrangement 5. Connect the hydraulic pipes as shown on the
contains of the parts described in the intermedi- intermediate shaft assembly drawings. Make sure
ate propeller shaft arrangement (Ch.8) that O-rings are present and without damages
before mounting the tubes together.
2.
6. Ream the fitted bolt holes in the intermediate
flanges together. Turn the supplied rough ma-
When lifting the shafts, use fiber slings and no chined fitted bolts specifically to each hole in
metal lifting devices in contact with the shaft. order to achieve an interference fit of +0.01 mm.
3. Before installation of the intermediate propeller 7. Connect the intermediate shafts together as
shaft, the intermediate shaft bearings have to be shown on the intermediate propeller shaft ar-
prepared for installation according to the instal- rangement (Ch. 8). Make sure that the O-ring
lation manual (see Ch.8 Manual - intermediate between the shaft is present and without damage
shaft bearings). Make sure that the shafts have before mounting the shafts together. Remember
no bruises or scratches. The shafts are normaly to tighten the nuts for the fitted bolts according to
delivered in assembled condition with hydraulic specified torques.
pipes and pipe connections.
Final assembly
4. Hang the shafts in chain blocks and position them Connect foremost shaft to the gear box output
into the intermediate shaft bearings. Align the shaft. Finally connect the aftermost intermediate
shafts by means of the alignment screws on the shaft to the forward propeller shaft by means of
bearing foundations due to the alignment proce- the OF-coupling. Ref. OF shaft coupling assem-
dures in Ch. 4. Support the bearing housing by bly instructions (Ch. 4).
means of chock liners.
8. Connect the intermediate shaft bearings to the
cooling water system as specified in the installa-
tion manual for the intermediate shaft bearings.
Install the temperature sensors and connect them
to the ship alarm system.
Page 1 of 2
SVI04-04-00-001
Alignment Gear/Propeller
Gear/Intermediate
Shaft
Shaft
- GAP
- Propeller
& SAG. Shaft, GAP & SAG.
Basic data: Our calculation is based on a theoretical straight centreline. Deflections and other movements of
the hull structure is not considered.
The deflection-curve for the free-hanging shaft is

Always when doing the final alignment and jack-test, calculated and the best corresponding position of the
the vessel must be afloat, and as close to the normal gearbox output flange is given as GAP/SAG-values.
operating condition as possible. All welding-work at
the hull must be finished. To verify the accuracy of the practical alignment, the
calculations give 1 or 2 (normally used 2) jack-forces
This procedure describes the way of doing the align- at specific given jacking points given as a distance
ment based on theoretical alignment-calculations. from the aft end of the propeller.
The method is calculating the deflection curve for
a free-hanging shaft and giving the bearing forces
for stern tube - and - gear-bearings. The program
calculates also the coupled system and gives the The calculation print out also gives bearing loads
corresponding bearing forces for cold condition (no for the nearest bearing. This procedure describes
loaded system) and warm condition (loaded system). hereafter only the alignment method. In addition to
this, the three additional procedures must be avail-
For the alignment situation a no-coupled free hang- able and followed.
ing system in cold condition is utilized.
This three additional procedures must be available and followed.

1. Alignment of Gear/Propeller and Gear/Engine
2. OF-Shaft coupling, Mounting Description
3. ”Connecting of pitch control system in the propeller shaft”
1. Mount the shaft and/or the intermediate shaft, in 3. Move the gearbox to a position, which corre-
its final position. Place the OF-Coupling 10 mm sponds roughly with its final position. The position
(or alternatively 15 mm) behind its final position. of the gearbox output-flange must be in its lon-
(see procedure for OF-Shaft coupling, Mounting gitudinal correct position. Now there is theoreti-
Description) cally 10 mm (or alternatively 15 mm) between the
flange faces when the shaft is in the same line.
2. Measure the circular run-out by rotating the shaft This distance is only to get a practical outfit of the
and note the deviations read on a dial gauge GAP/SAG measurements, so all other alterna-
placed on the shaft end/flange. The circular tively distances close to the given may be used.
run-out equals the measured deviations divided
by 2 (see Figure 1.).
When aligning the shaft system, circular run-out

must be taken into consideration. Rotate the shaft
until the circular run-out is directed upwards. The
actual sag value used is the theoretical sag value,
given for the installation, minus the half of the
total circular run-out.
Figure 1.
Page 2 of 2
SVI04-04-00-001
4. Now look at the calculation Figure “GAP and SAG

open condition” in the procedure “Jack-test Gear/
Propeller shaft”, which gives the exact GAP/SAG- There must be no (or only small) deviation on
values for this specific installation. the gap on each side of the flanges.
By using the adjustment screws on the gearbox See Figure 2.
bed, you must move the gearbox to a position
which gives you the exact measurements be-
tween the two flanges corresponding to the GAP/
SAG values adjusted for the circular run-out of
the shaft. The shaft flanges must be complete
free of each other. The axial gap on the top of the
flanges must be added to the GAP-value for the
lower part of the flanges.
Figure 2. Top view, g2 = g4.
5. Check the GAP/SAG-readings and

fix the gearbox to the foundation bed
completely with steel chocks or by
chocking resin. Follow the guidelines on
the chocking plan for the specific instal-
lation. Be careful not to alter the position
of the gearbox during the chocking pro-
cedure or when tightening the founda-
tion bolts.
6. Now you can make a final reading of

the GAP /SAG-values before lifting the
propeller shaft to the same line as for
the gearbox-shaft.
See procedures:
“OF-Shaft coupling,
Mounting Descrption”
and
“Connecting of the pitch control system
in the propeller shaft”.
Figure 3. Instruction for measuring

Gap and Sag values.
Page 1 of 7
Scana sheet number: SVI04-04-00-104_R01
Jack-test Gear/Propeller shaft 2312 & 2313
The purpose of the jack test is to find the actual bearing load. Since the jacking point is located a distance
away from the bearing, the shaft will, when jacking, bend slightly before it is lifted clear of the bearing. There-
fore a certain jack height is required to lift the shaft off the bearing.
For this installation a 5 ton (5000kg) jack is recommended.

For this installation a ___ ton (x000kg) jack is recommended.
If a larger jack is used, the jacking force must not exceed
If a larger jack is used, the jacking force must not exceed
Fmax= =____
Fmax 5 ton.
ton.
IfIfjack
jackforce
forceisismeasured
measured in
in pressure
pressure bar – Please
Please report
reportthe
thepiston
pistondiameter.
diameter.
-see
-see sheet
sheet “Table for Jack-test..”
Jack-test..”
1. Place the jack on the correct position for JACK 1, 3. Repeat procedure (2) to verify the readings.
and place a dial gauge on the bearing foundation
or another fixed position so that it can measure 4. Repeat jacking procedure 1. 2. and 3. until all
the vertical shaft deflection directly above the jacking positions are finished.
jack.
5. Send the results to Brunvoll Volda for approval.
2. Now lift the shaft by adding pressure to the jack
and record the lifting height and the correspond- Use the sheets
ingjack pressure. To verify the bearing load a “Table for Jack-test for inst. ........... .”
curve similar to the drawings on the next page “Table for GAP & SAG Open Condition for inst.
has to be plotted. Values of lifting height versus ............. .”
jack pressure must also be recorded when lower- back in this procedure.
ing the shaft.
See table for lifting heights next pages.
Page 2 of 7
Page 3 of 5
VoPB-3700-40-02R01_eng
GAP and SAG Open Condition for inst.:

GAP and SAG Open Condition for inst.: 2312
Jack 5
Jack 4
2 Temporary-
Support
1000 mm from
front of flange
Jack 3
Before Jack-test make sure all flanges are connected
1
Jack 2
Jack 1
Brunvoll Volda AS, Hamnegata 24, P.O. Box 205, N-6100 Volda, Norway
T: +47 700 59 000, T: Emergency: +47 47 8 24 365 (after office hrs), E: [email protected], W: brunvoll.no, E No: 917 225 702 VAT
Page 5 of 7
Table for
Table for GAP
GAP &
& SAG
SAG for
for inst.:
inst.: 2312
Fill in the actual data and send it to Brunvoll Volda by fax or e-mail.
(see: Procedure for GAP & SAG. Allignment Gear/Propeller shaft
SVO Inst. No.: _________________
2286 Calculated Measured/actual
Sag
1 Calculated mm
Measured/actual
Sag 0,88 mm
Gap mm
Gap 0,31 mm
2286
Sag 0,44 mm
Gap 0,05 mm
2286
Sag 2,25 mm
Gap 0,62 mm
Place: _____________________Date:____________________
Sign: ________________________________________________
Page 6 of 7
Table for Jack-test for inst.: 2312

If jack force is measured in Piston Diameter: Place:

pressure bar. Please report Date:
the piston diameter!
Sign:
* Please contact Brunvoll Volda if the jack must be moved !

Jack 1 Jack 2 Jack 3 Jack 4 Jack 5
From aft Jack- From aft Jack- From aft Jack- From aft Jack- From aft Jack-
Position - mm Test Position - mm Test Position - mm Test Position - mm Test Position - mm Test
11805 N 14695 N 19895 N 24695 N 27546 N

Lifting Fill in Lifting Fill in Lifting Fill in Lifting Fill in Lifting Fill in
Height: mm ↓ Height: mm ↓ Height: mm ↓ Height: mm ↓ Height: mm ↓
↑ 0,01 ↑ 0,01 ↑ 0,01 ↑ 0,01 ↑ 0,01
↑ 0,02 ↑ 0,02 ↑ 0,02 ↑ 0,02 ↑ 0,02
↑ 0,03 ↑ 0,03 ↑ 0,03 ↑ 0,03 ↑ 0,03
↑ 0,05 ↑ 0,05 ↑ 0,05 ↑ 0,05 ↑ 0,05
↑ 0,08 ↑ 0,08 ↑ 0,08 ↑ 0,08 ↑ 0,08
↑ 0,10 ↑ 0,10 ↑ 0,10 ↑ 0,10 ↑ 0,10
↑ 0,15 ↑ 0,15 ↑ 0,15 ↑ 0,15 ↑ 0,15
↑ 0,20 ↑ 0,20 ↑ 0,20 ↑ 0,20 ↑ 0,20
↑ 0,25 ↑ 0,25 ↑ 0,25 ↑ 0,25 ↑ 0,25
↑ 0,30 ↑ 0,30 ↑ 0,30 ↑ 0,30 ↑ 0,30
↑ 0,35 ↑ 0,35 ↑ 0,35 ↑ 0,35 ↑ 0,35
↑ 0,40 ↑ 0,40 ↑ 0,40 ↑ 0,40 ↑ 0,40
↑ 0,45 ↑ 0,45 ↑ 0,45 ↑ 0,45 ↑ 0,45
↑ 0,50 ↑ 0,50 ↑ 0,50 ↑ 0,50 ↑ 0,50
—↓ —↓ —↓ —↓ —↓
↓ 0,45 ↓ 0,45 ↓ 0,45 ↓ 0,45 ↓ 0,45
↓ 0,40 ↓ 0,40 ↓ 0,40 ↓ 0,40 ↓ 0,40
↓ 0,35 ↓ 0,35 ↓ 0,35 ↓ 0,35 ↓ 0,35
↓ 0,30 ↓ 0,30 ↓ 0,30 ↓ 0,30 ↓ 0,30
↓ 0,25 ↓ 0,25 ↓ 0,25 ↓ 0,25 ↓ 0,25
↓ 0,20 ↓ 0,20 ↓ 0,20 ↓ 0,20 ↓ 0,20
↓ 0,15 ↓ 0,15 ↓ 0,15 ↓ 0,15 ↓ 0,15
↓ 0,10 ↓ 0,10 ↓ 0,10 ↓ 0,10 ↓ 0,10
↓ 0,08 ↓ 0,08 ↓ 0,08 ↓ 0,08 ↓ 0,08
↓ 0,05 ↓ 0,05 ↓ 0,05 ↓ 0,05 ↓ 0,05
↓ 0,03 ↓ 0,03 ↓ 0,03 ↓ 0,03 ↓ 0,03
↓ 0,02 ↓ 0,02 ↓ 0,02 ↓ 0,02 ↓ 0,02
↓ 0,01 ↓ 0,01 ↓ 0,01 ↓ 0,01 ↓ 0,01
Page 4 of 7
GAP
GAP and
and SAG
SAG Open Condition
with Shaft for inst.: 2313
Support
Jack 4
Jack 3
1
Jack 2
Support
Jack 1
Before Jack test make sure all flanges are connected
Page 5 of 7
Table for
Table for GAP
GAP &
& SAG
SAG for
for inst.:
inst.: 2313
(see: Procedure for GAP & SAG. Allignment Gear/Propeller shaft
SVO Inst. No.: _________________
1 Sag Calculated mm
Measured/actual
Sag 0,18 mm
Gap mm
Gap 0,61mm
2287
Sag 1,97 mm
Gap 0,58 mm
Place: _____________________Date:____________________
Sign: ________________________________________________
Page 7 of 7
Table for Jack-test for inst.: 2313

Piston Diameter: If jack force is measured in Place:

pressure bar. Please report Date:
the piston diameter!
Sign:
* Please contact Brunvoll Volda if the jack must be moved !

6
Jack 1 JackJack
7 2 Jack 8 Jack 3 Jack 9 Jack 4 Jack 10
From aft Jack- aft aft Jack-
FromFrom From aft From Jack-
aft From aft Jack-
From aft From aft Jack-
Position - mm Test Position
Jack-Test - mm - mmTest Jack-Test
Position Position - mm - mm Position
PositionTest - mm
Jack-Test Test - Position
Position mm - mm
Jack-Test Test
* 11805 N N * 14695 N *N 18295

N * N 20901*
N N N
Lifting FillFill
in in Lifting
Lifting Fill in Lifting
Fill in Lifting
Fill in Lifting
Fill in FillLifting
in LiftingFill in Fill in
Height: mm ↓↓ Height: mm mm ↓
Height: ↓
Height: mmHeight:↓mm ↓ mm
Height: ↓ mm
Height: Height: mm ↓ ↓
↑ 0,01 ↑ 0,01↑ 0,01 ↑ 0,01 ↑ 0,01 ↑ 0,01 ↑ 0,01 ↑ 0,01
↑ 0,02 ↑ 0,02↑ 0,02 ↑ 0,02 ↑ 0,02 ↑ 0,02 ↑ 0,02 ↑ 0,02
↑ 0,03 ↑ 0,03↑ 0,03 ↑ 0,03 ↑ 0,03 ↑ 0,03 ↑ 0,03 ↑ 0,03
↑ 0,05 ↑ 0,05↑ 0,05 ↑ 0,05 ↑ 0,05 ↑ 0,05 ↑ 0,05 ↑ 0,05
↑ 0,08 ↑ 0,08↑ 0,08 ↑ 0,08 ↑ 0,08 ↑ 0,08 ↑ 0,08 ↑ 0,08
↑ 0,10 ↑ 0,10↑ 0,10 ↑ 0,10 ↑ 0,10 ↑ 0,10 ↑ 0,10 ↑ 0,10
↑ 0,15 ↑ 0,15↑ 0,15 ↑ 0,15 ↑ 0,15 ↑ 0,15 ↑ 0,15 ↑ 0,15
↑ 0,20 ↑ 0,20↑ 0,20 ↑ 0,20 ↑ 0,20 ↑ 0,20 ↑ 0,20 ↑ 0,20
↑ 0,25 ↑ 0,25↑ 0,25 ↑ 0,25 ↑ 0,25 ↑ 0,25 ↑ 0,25 ↑ 0,25
↑ 0,30 ↑ 0,30↑ 0,30 ↑ 0,30 ↑ 0,30 ↑ 0,30 ↑ 0,30 ↑ 0,30
↑ 0,35 ↑ 0,35↑ 0,35 ↑ 0,35 ↑ 0,35 ↑ 0,35 ↑ 0,35 ↑ 0,35
↑ 0,40 ↑ 0,40↑ 0,40 ↑ 0,40 ↑ 0,40 ↑ 0,40 ↑ 0,40 ↑ 0,40
↑ 0,45 ↑ 0,45↑ 0,45 ↑ 0,45 ↑ 0,45 ↑ 0,45 ↑ 0,45 ↑ 0,45
↑ 0,50 ↑ 0,50↑ 0,50 ↑ 0,50 ↑ 0,50 ↑ 0,50 ↑ 0,50 ↑ 0,50
—↓ — ↓— ↓ —↓ —↓ —↓ —↓ —↓
↓ 0,45 ↓ 0,45↓ 0,45 ↓ 0,45 ↓ 0,45 ↓ 0,45 ↓ 0,45 ↓ 0,45
↓ 0,40 ↓ 0,40↓ 0,40 ↓ 0,40 ↓ 0,40 ↓ 0,40 ↓ 0,40 ↓ 0,40
↓ 0,35 ↓ 0,35↓ 0,35 ↓ 0,35 ↓ 0,35 ↓ 0,35 ↓ 0,35 ↓ 0,35
↓ 0,30 ↓ 0,30↓ 0,30 ↓ 0,30 ↓ 0,30 ↓ 0,30 ↓ 0,30 ↓ 0,30
↓ 0,25 ↓ 0,25↓ 0,25 ↓ 0,25 ↓ 0,25 ↓ 0,25 ↓ 0,25 ↓ 0,25
↓ 0,20 ↓ 0,20↓ 0,20 ↓ 0,20 ↓ 0,20 ↓ 0,20 ↓ 0,20 ↓ 0,20
↓ 0,15 ↓ 0,15
↓ 0,15 ↓ 0,15 ↓ 0,15 ↓ 0,15 ↓ 0,15 ↓ 0,15
↓ 0,10 ↓ 0,10↓ 0,10 ↓ 0,10 ↓ 0,10 ↓ 0,10 ↓ 0,10 ↓ 0,10
↓ 0,08 ↓ 0,08↓ 0,08 ↓ 0,08 ↓ 0,08 ↓ 0,08 ↓ 0,08 ↓ 0,08
↓ 0,05 ↓ 0,05↓ 0,05 ↓ 0,05 ↓ 0,05 ↓ 0,05 ↓ 0,05 ↓ 0,05
↓ 0,03 ↓ 0,03↓ 0,03 ↓ 0,03 ↓ 0,03 ↓ 0,03 ↓ 0,03 ↓ 0,03
↓ 0,02 ↓ 0,02↓ 0,02 ↓ 0,02 ↓ 0,02 ↓ 0,02 ↓ 0,02 ↓ 0,02
↓ 0,01 ↓ 0,01↓ 0,01 ↓ 0,01 ↓ 0,01 ↓ 0,01 ↓ 0,01 ↓ 0,01
Page 1 of 1
SVI04-05-00-001_R01
Stern tube important
It is of outmost importance that gravity tank and pip- The diametrical clearance of the tailshaft in the bush-
ing are cleaned properly before the propeller shaft is ings, is stated in the “Technical data” in ch. 2.
installed, and that only clean oil is used. manual.
Negligence to this matter will inevitably lead to ex-

cessive wear and leakage of stern tube glands.
The propeller must not run with propeller rpm below

30 rpm as this speed is too low for obtaining the load
carrying properties of the oil lubricated stern tube
It is outmost important that both propeller hub and bearings.
propeller shaft are completely filled with oil before
launch.
This will be obtained by opening drain plugs in hub

and on propeller shaft during filling of oil. Cooling of inner Stern tube Bearings.
The plugs are located on the hub and right in front of Space outside inner stern tube (including tank) to be
the inner stern tube seal. filled with lliquid to get cooling from sea to stern tube.
The stern tube has steel bushing lined with white

metal alloy, and four outer and two inner axial oil
grooves run through the bushing’s full length. The
bushings are to be fitted with the inner oil grooves
facing each other in a horizontal position.
Page 1 of 2
SVI04-06-00-004 R01
Oil pips,
Connection of Push pull-rod and oil pips, SOF
SOF Coupling
Coupling
13
27
12
25 29 C
9 28
8 22
24
A 15
Fig.1. SOF 250 (for CP85-CP75) Mount / Assembly. Parts inside the coupling
1. See also Instruction “SVI04-07-00-030”, Check that the Pressure disc (Pressure Plate Servo) is mounted
on the Push-pull rod -see ”A” Fig.1.
2. Check for damage and lub the O-rings/seals with lub oil before mounting.
3. Torque: See Fig.2 and/or drawing in Ch.8.
1. The push pull rod in the propeller shaft must be 6. Push the feed-back rod to its extreme forward
moved astern (into the shaft) to make room for position.
the mounting of the push-pull rod flange, by mov-
ing the propeller blades to forward pitch before 7. Apply light lube oil at the threads of the forward
launching. Make sure there is room for tools aft of push-pull rod end and screw the flange (item12)
flange. on to the rod end. If the push-pull rod is too far aft
to allow fitting of flange screws with the flange in
2. Fit the shaft coupling preliminary to the shaft as place, insert the screws in the flange before this
described under “Shaft-coupling Mounting” with is mounted on the rod. The flanges should not be
10 mm space to gear box flange. flush with the end of the rods.
3. The lining up of the gearbox can now be carried Insert the servo piston (item 8) into the push pull
out with 10 mm clearance between the flanges. rod and check that there is a certain gap between
Check that the distance between the fore end of the flange (item 12) and the servo piston (item 8).
propeller shaft and output gear flange is accord- -see “B” in Fig.2 and drawing i Ch.8.
ing to the shafting drawing.
See instructions for alignment ch.4. Connect the flange to the servo piston by means
of the bolts (item 9). Remember to use Locktite
4. Bolt the gearbox to the bed using clearance bolts 270 and tighten to the specified torque (see Fig.2
and four fitted bolts. The fitted bolts are to be item 9). Lock with locking screws (item 15)
mounted on each side at the forward and aft end
of the gearbox.
Check that the gap i uniform around the push -
5. Dismount the shaft coupling, and move it back to pull nut.
give access to the push-pull rod coupling.
Page 2 of 2
SVI04-06-00-004 R01
720Nm
9
130Nm
25 22 28 C
29
24
130Nm
Fig.2. SOF 250 (for CP85-CP75) Assembled
8. Mount the O-rings/seals -(item 13 and 27) 10.Connect the servo piston (item 8) to the forward
stopper -Oil pipe flange - (item 22) by means of
Check for damage and lub the O-rings/seals the bolts (item 24).
(item 13-27) with lub oil before mounting
Check for damage and lub the O-rings/seals (item

9. Mount the oil pipe flange (item 22) by means of 25) before mounting.
the bolts (item 28) to the oil pipe -see “C” in Fig.2. Use Locktite 270 and tighten to the specified
Thorque - see Fig.2. item 28. torque, see Fig.2. item 24.
Check for damage and lub the o-rings/seals 11. Mount the shaft coupling as described in section
(item 29) “Shaft coupling, Mounting” in ch.4.
Page 1 of 1
SVI04-06-00-021 R00
Connection of single hydraulic Oil-Pipes, Gearbox
1. The Gearbox is lined up -

“Procedures for GAP & SAG. Alignment Gear/Propeller Shaft”
and the OF-shaft coupling is mountet according to -
“OF-Shaft coupling, Mounting Descrtption - D. Dismounting procedure” -
in this chapter.
2. Pull the hydraulic pipe in the gear box afterwards by hand force. Connect the hydraulic pipes.
Check the O-rings before mounting.
3.
Take into consideration that the distance between the fore end of propeller shaft and output gear flange is
according to the “Shafting drawing” in chapter 8.
4. Mount the coupling.
Tighten the screws (see torque above) and lock with locktite/caulking.
5. Mount the shaft coupling as described in section “Shaft coupling, Mounting - E. Final mounting”.
Page 1 of 6
SVI04-07-00-030_R01
SOF250 Shaft coupling, Mounting Description. VS306987
SOF Coupling arrangement VS306987. Larger drawing in Ch. 8
A. Coupling Description
At its forward end the propeller shaft is connected to When, at the same time, oil is pumped into the N-6101 Volda, NO
Tel: +47 70059000
the gear output shaft by means of an SOF-type oil mounting cylinder (through hole, bore B), the cou- E-mail: volda@sca
pressure mounted coupling. The coupling is a heavy pling will be pushed onto the tapered sleeve against
muff coupling which is combined with a servo motor the output flange. By releasing the oil pressure
in the forward end for actuation of the propeller pitch on ejectors connected to bore A, the coupling will
movement. The neck of the coupling is flanged to the contract. This contraction will give friction between
output shaft of the reduction gearbox. the coupling parts and the shaft, strong enough to
transmit torque and thrust from propeller to gear. The
An inner sleeve (item 2) is fitted between the cou- oil holes are closed with threaded plugs.
pling and the shaft. The bore of the sleeve is cylindri-
cal and has a clearance fit on the forward end of the The propeller pitch mechanism in the forward end of
shaft. The outside of the sleeve is slightly tapered the coupling consists of a servo piston (item 8) which
and carefully fitted to a corresponding tapered sur- is installed in the cylinder section in the forward
face inside the coupling. At the thinner aft end of the part of the shaft coupling. The servo piston is con-
sleeve a threaded piston (item 3) with seals fits into nected in the aft end to the propeller shaft integrated
the aft end of the coupling, also referred to as the push-pull rod, and in the aft end it is connected to
mounting cylinder. The mounting cylinder is used to the feed-back rod in the gear box. This feed-back rod
push the coupling on the tapered sleeve. is also provided with pressure channel, B from the
hydraulic proportional valve, for actuation of after-
The coupling hub has radial oil holes. Through these wards pitch movement. The pressure channel, B for
holes (bore A) oil is injected to build up a film be- actuation of forward pitch movement is lead on the
tween the coupling and the tapered surface of the outside of the feed-back rod. Item 12 and 22 func-
sleeve. The pressure in this film will increase the tion as mechanical stoppers for the servo piston. The
diameter of the coupling hub. servo end plate (item 16) have three functions. In the
Page 2 of 6
SVI04-07-00-030_R01
first place it function as an end stopper plate, but it secure correct position of the liner (item 2). The liner
also function as a seal housing for the aft pressure is provided with a factory adjusted stopper (item 23).
seal (item 20) of the coupling. The third function is to
B. Required equipment
1. Mounting pump (hydraulic hand pump for pres- 6. Operating the SKF oil injectors, SKF 226400 and
sure up to 200-300 kp/cm² with an oil capacity of the SKF mounting pump, (or similar)
about 2,7 litres).
* Alternativelly air pressure driven pump.

Operating manual for the pumps lies in the box.
2. 2 pcs oil injectors SKF-type nr. 226400 or similar
for pressure up to 1000 kp/cm². To fill a SKF injector, unscrew the oil feeder, dip
(For larger shaft couplings (OF320 and up), 4 the nozzle into the oil and pull the piston handle.
injectors could be required.) Then turn the nozzle upwards and by pushing
in the valve ball and pressing the piston slightly,
3. For oil pressure mounting a clean particle-free permit any trapped air to escape. Now screw the
engine or hydraulic mineral oil is to be used in the feeder back on the injector and screw the injec-
injectors as well as in the mounting pump. The oil tors in the oil holes (bore A) on the coupling. Turn
shall have a viscosity of 100-150 cst. coupling so that the vent screws in the mount-
Fatty oils are not suitable as they cause a lasting ing cylinder face upwards to let any trapped air
reduction of the friction between the coupling and escape. Open the vent screws and pump a few
the sleeve. strokes until clean oil free of air seeps through at
the vent screws. Then shut the vent screws and
4. Special wrench for mounting piston. the injectors are ready for operation. Connect the
mounting pump to the oil inlet (bore B).
5. 2 Guide bolts. Not included in the delivery.
No leakage in the injector connections

is permitted.
Mounting pump SKF TMJL 50 Oil injector SKF 226400 Wrench
Page 3 of 6
SVI04-07-00-030_R01
C. Mounting for SAG/GAP Alignment Gear/Propeller shaft.
Required equipment: see “B. Required equipment”
Do not use gloves. Keep a clean working area.
1. Check the sleeve seating on the forward end 3. Coat the entire outer tapered surface of the
of the shaft. Remove and polish any burrs or sleeve (item 2) with oil and pull the coupling
scratches. (item1) forward upon the sleeve taper until it
The surface must be clean and free of oil. Clean stops, properly centred on the sleeve. Take care
the tapered bore of the coupling. to not damage the o-ring (item 20). Screw the
Remove burrs and polish any scratches. Coat mounting piston (item 3) on to the sleeve tak-
the threads of the mounting piston (item 3) with ing care that the threads enter properly. Use the
anti-seize compound, and with the seal (item 4) special wrench and screw this all the way in.
mounted, push it into the shaft.
4. Connect the pumps, see B 6
Pull the propeller shaft backwards in order to give
enough space in the forward end for installation
of the coupling hub (item 1) into the propeller No leakage in the injector connections
shaft. Lift the coupling hub (item 1) and insert is permitted.
it carefully into the forward end of the propeller
shaft such that there is good space for mounting 5. Screw out the plug (item 32) in order to bleed out
of the sleeve (item 2). Mount the forward stopper leaking oil from the injectors.
(item 22). Remember to mount the o-ring (item Now operate the SKF injectors to build up a pres-
29). Tighten the bolts (item 28) to the specified sure between the tapered surfaces to expand
torque, use Locktite 270 or similar. the coupling diametrically. After a short time the
operators of the injectors will observe that the in-
2. Clean the bore of the sleeve. There should be jector pressures do not increase any more. Then
no lubrication and the bore must therefore be start to operate the mounting pump simultaneous-
thoroughly wiped clean of any oil (To facilitate ly with a continued operation of the injectors.The
the mounting of the sleeve (item 2), the shaft end pressure in the mounting cylinder will now push
should be moist with clean solar oil). Take care to the coupling onto the tapered sleeve. Thispres-
avoid any damage or scratching of shaft or cou- sure should not exceed 100-150 bar. (The injector
pling. Insert the sleeve (item 2) carefully into the pressure may during this process reach approx.
shaft. Thereafter mount the pressure plate servo 2-3000 bar). The movement of the coupling rela-
(item 16). tive to the stationary sleeve shall proceed until
the aft end of the flange of the coupling (C) is 10
mm (or alternatively 15 mm) behind its correct po-
sition on the shaft. Remember to mount the plugs
Remember to mount the seals (item 30 and 31) (item 5, 6 and 32).
towards the propeller shaft and the seals (item 17
and 18) towards the push-pull rod. Also seal the ref: Procedures for GAP & SAG-Alignment Gear/
bolt heads and tighten the bolts (item 19) to the Propeller Shaft
specified torque.
Pull the liner forward until it stops towards the
servo end plate.
See also shaft coupling assembly drawing in
chapter 8.
Page 4 of 6
SVI04-07-00-030_R01
D. Dismounting procedure.
See also ¨”B required equipment”
Clean the coupling and surroundings thoroughly. Do not use gloves. Keep a clean working area.
1. Operating the pumps, see B 6
2. Connect the mounting pressure pump to the hole pressure in the mounting pump rises. This opera-
(bore B). Pump a quantity of oil with the mounting tion may take approximately 15 minutes.
pump until the pump pressure rises to about 25 Open the vent screw on the mounting pump to re-
bar and maintain this pressure. This quantity of lease the pressure and continue a steady opera-
oil in the cylinder has the purpose of braking and tion of the injectors until the coupling slides astern
dampening the coupling movement when it later on the tapered sleeve. Remember to mount the
slides off the tapered sleeve. plugs (item 5, 6 and 32).
Make sure the shaft is completely clean and free
of burrs and scratches and push the coupling aft
No leakage in the injector connections when it loosens from the shaft.
is permitted Handle coupling parts with great care to avoid
burrs or scratches on contact surfaces.
3. Screw out the plug (item 32) in order to bleed out Maintain a high level of cleanliness.
leaking oil from the injectors. Operate the injec-
tors simultaneously and slowly to permit the pres- Protect the coupling and the shaft to avoid impuri-
sure in the oil film between the coupling and the ties, corrosion and damage.
sleeve to build up and thus expand the coupling
diametrically.
After a few strokes the injectors should feel rather
compact and heavy to operate. The propeller push pull rod or oil tubing
Maintain these pressures by slowly operating the must be connected after reduction
injectors until the coupling loosens. This is usually gear is lined up and supported..
characterized by a sound, and simultaneously the
Page 5 of 6
SVI04-07-00-030_R01
E. Final Mounting
Make sure the propeller push-pull rod, the servo piston with end stoppers are connected to the feed-back
rod in the gear box as stated on the shaft coupling assembly drawing, Ch. 8.
Clean the coupling and shaft thoroughly. Do not use gloves, or rags that leaves particles.
Keep a clean and tidy working area.
1. If the coupling i dismounted - assemble the Cou-

pling as described under C1-3.
2. Operating the pumps, see B 6. e
3. It is important that the coupling do not move or E

turn during the final mounting. The tapered sleeve
(Item 2) shall rest against the servo end plate (Item
16). Put a reference mark (D) on the shaft 50 mm
from the rear end of the mounting piston to main-
tain control of the location of the sleeve during the
procedure.
Bolt holes (E) in the flanges must line up. Use one
or two guide bolts (e) during the mounting proce-
dure to keep the flanges from turning relative to Guide bolts (e). Not included in the delivery
each other.
4. Pump up the coupling as described under C5. Check that the measurement between the rear end
Take care to not damage the seals (item 13 and of the mounting piston and the reference mark (D) is
27) when inserting the servo piston (item 8) into still 50 mm when the shaft coupling is pumped for-
the cylinder. The movement of the coupling rela- ward to achieve the designated length “L”, or aligns
tive to the stationary sleeve shall proceed until with the machined step (F) on the mounting piston
the aft end of the coupling reaches the pull–up (3). Check the final position of the coupling hub (item
limit, marked “L” stamped on the outside on the 1) relative to the servo end plate (item 16) by means
rear of the coupling hub, or a machined step (F) of inserting a pin gage into the hole. It shall be pos-
on the outer diameter of the piston (item 3). sible to insert an Ø4 mm pin gauge in between the
The length “L” indicates the distance the piston forward end of the servo end plate (item 16). If this is
protrudes the coupling hub. not possible, make contact with Scana Volda.
See also Shaft coupling assembly drawing in

chapter 8 The shaft coupling may be damaged if the
coupling is pulled beyond the pull-up limit.
Page 6 of 6
SVI04-07-00-030_R01
5.
L
*Service
F - If there is no designated length of pull-up “L”
marked on the coupling see “F, Service and
maintenance”
- If the coupling has been taken apart during
L; dismounting see “F, Service and Maintenance”.
6. At this point open the vent screws in the injec-

tor pumps to release the pressure. The cou-
pling will then contract and provide an ample
friction force against the sleeve and the shaft,
to transmit the propeller torque and thrust. Re-
3 lease the mounting pump after approximately
L;
20 minutes. Detach the mounting equipment,

vent and drain oil from the coupling, and plug
D
the oil hole openings used for injectors and
pump.
7. Remove the guide bolts and insert the pro-

vided flange fitted bolts. Mount and tighten the
bolts on the flange according to torque values
specified in shaft coupling assembly drawing in
chapter 8.
The coupling should remain unloaded for at least 4 hours in order to obtain adequate connection.
F. Service and maintenance.

See also “B required equipment”
Clean the coupling and surroundings If the shaft or any vital parts of the coupling is
thoroughly. replaced, the machined step or earlier designated
Do not use gloves. Keep a clean working length “L” will only be used for guidance. Refer to
area. Brunvoll Volda Service for new correct lengths or
ways of measuring correct pull-up distance.
See: D. Dismounting procedure and
E. Final mounting procedure. The new length should be stamped on the coupling
hub for later use.
Page 1 of 1
SVI04-08-00-001
Pipeline instruction for separate mounted el.driven pump
Install the stand-by pump according to specifications on the piping diagram drawing in Chapter 8.
All connections to the gear box are shown on the piping diagram drawing.
1. Install the suction pipe. 3.

Make sure that the suction pipe is as short as
possible and without sharp bends.
The pipelines must be flushed before filling the
It is important that the pressure drop in the suc- system with oil.
tion pipe is reduced to a minimum and less than
0,2 atm continuous. - See Chapter 4 “ 05.10.01e Installation and
commissioning of gear-propeller systems”
See Note B: (Piping diagram drawing).
4. Connect the electrical motor to the starter of the
2. Install the pressure pipes. pump. Check direction of rotation during commis-
Make sure that the preassure pipe is as short as sioning.
possible and without sharp bends.
Scana
Scana
Scana
ScanaVolda
Voldaas
as
N-6101
N-6101Volda,
Volda,NORWAY
NORWAY
Tel:
Tel:+47
+4770059000
70059000 Fax:
Fax:+47+4770059001
70059001
www.scana.no
www.scana.no e-mail:
e-mail:[email protected]
[email protected]
Page 1 of 1
SVI04-09-00-020
Propeller
Oil filling of hub,
Propeller Stern
hub, tube
Stern and
tube Propeller
and shaft
Propeller shaft
(See piping diagram)
This installation has one gravity tank, one for both propeller hub lubrication and for stern tube lubrication.
See also piping diagram.
For suitable oils, see special page Ch.2 in this manual.
With the ship in dry-dock the propeller hub and stern tube can be filled as follows:
1. Turn the propeller hub to bring one of the air vent 5. Turn the 3-way valve to close the connection
plugs up and remove this. See Fig.1. between the gravity tank and the stern tube.
In this possition the 3-way valve will open for
2. Turn the 3-way valve to obtain connection be- drainage of the stern tube.
tween the inner stern tube gland and the oil tank. See Fig.1
3. Pump oil through the bottom plug hole of the pro-

peller hub or through a propeller blade bolt hole. To save time a hand pump or a small electric
oil pump can be connected to the valve.
4. When only clean oil is coming out of the propeller
top plug hole, refit this plug.
6. Finally check that all plugs and propeller blad

bolts are tightened and properly locked.
Fig.1. 3-way valve Yard supply
Page 1 of 2
SVI04-09-00-500 R02
Oil filling of Gear box
A1. Oil should preferably be added to the gear via

one of the oil strainers, see photo in fig. a1.
After filling, the element should be cleaned before
the cover is re-fitted. Ensure that the sealing in the cover, see
Please fill som oil in all suction strainers - above photo in fig. a1, (X) (o-ring and the akulon wash-
the flange before starting the pumps. er under the screw head), are fitted correctly and
that they seal the cover completely.
This can be controlled with the pump running by
putting some oil around the screw head and the
gap between the cover and the housing.
A2.Oil should be added until the level reaches the

maximum mark on the dip-stick. After the start-up
with empty oil system, the level must be re-
checked and extra oil added if necessary. The oil level must at all times be between the
See drawing: “VI307229 Seperate mounted minimum and maximum mark on the dip-stick.
El.driven stand by pump with suction pipeline”. - Too low oil level can cause the pump to
suck air.
When checking the oil level during service, - Too high oil level can cause increased
the clutch must be engaged to obtain the heating of the oil and of the gear itself.
correct reading of the oil level.
Suction strainer X
Oil filling via both stand by O-ring and an akulon washer
pump strainer and main under the screw head
pump strainer.
Photo of Suction strainers.
Fig. a1. Piping diagram and photo of suction strainers for Stand by oil pump(-Pipe line not mounted-) and Main oil pump.
Page 2 of 2
SVI04-09-00-500 R02
VI307229 Pipeline instruction for separate mounted El.driven pump
Scana
Scana Scana Volda as
Scana Volda as
N-6101 Volda, NORWAY
Tel: +47 70059000 Fax: +47 70059001
Tel: +47 70059000 Fax: +47 70059001
www.scana.no e-mail: [email protected]
Drawing VI307229. Pipeline instruction for separate mountetd el.driven pump. See also ch.8.
The pump must not run dry
Page 1 of 1
SVI04-10-00-002 R03
Alignment
BRUNVOLLofVOLDA
Gear/Propeller
AS and Gear/Engine V40021
Page 1 of 1
SVI04-10-00-101 R00
Temperature compensating instruction Brunvoll Volda.

Volda.Gear
Gearwithout
withoutservo.
servo
Temperature compensating calculation are based on:

Oil temperature: 52°C.
Gearhouse temperature: 47°C.
Ambient temerature: 15°C.
All mesasures in mm.
Exemple shown on this page has 5 (A-B-C-D-E) calculating dimensions.
The temperature compensation are calculated from the formula:
Δ L:
1,1
L x x 32 x 0,7 [mm]
100 000
L=
Length (A, B, ... E.)
1,1
=
100 000
mm
Expanding factor of steel mm °C
32 =
Temperature differance of Gearhousing - on a running Gear - and the ambient temperatrure
(workshop/machine room), 47°C - 15°C = 32°C.
0,7 =
Value based on experience (Brunvoll Volda estimated). [-]
BVo Installation Manual No.: 2312-13. IMO No.: -. Date: 2019-11-18 Chapter 4 - Page. 37
Page 2 of 3
SVI04-10-00-101 R00
Using the temperature compensating diagram, examples at 31 °C and

31°C and 77 °C
°C
Brunvoll Volda calculation -

(A) L = 1000 mm
Ambient temerature: (A) L = 1000 mm (A) L = 1000 mm
15°C Ambient temerature: 31°C. Ambient temerature: +7°C.
L ΔL Comp. ΔL ΔL Comp. ΔL
(mm) (mm) 15°C factor: (mm) 31°C (mm) 15°C factor: (mm) 7,0°C
A 1000 0,246 mm 0,246 x 0,5 0,123 mm 0,27 mm 0,246 x 1,25 0,308 mm
Page 3 of 3
SVI04-10-00-101 R00
BVo2312
BVO & Temperature
XXXX 2313 Temperature
compensating - ambient
compensating temperature
- ambient 15°C.
temperature.
Bruk reknearket som ligg i

Girinfo-mappa! (Konstruksjons-
guide - Teknisk.)
Ligg snarveg i 4-10 mappa!!
Ulike teikninar for ulike gear
Gearhouse temperature 47°C

Ambient temperature: 10°C 15°C 20°C 25°C
L ΔL ΔL ΔL ΔL
[mm] [mm] [mm] [mm] [mm]
A 818 0,233 0,202 0,170 0,139
B 753 0,215 0,186 0,157 0,128
C 800 0,228 0,197 0,166 0,136
VI309155 Chocking Plan ACG 600
Page 1 of 1
SVI04-12-00-001_R01
Pressure switch setup for PS3 “Extra low lube oil”
Brunvoll Volda requests the use of a system for overriding.
Standard arrangement for Brunvoll Volda Installations:
Pressure switch PS3 “Extra low lube oil pressure the alarm plant with request to shut down the main
request stop of main engine” is to be connected to engine.
Singel screw
If the system is to be arranged for automatic to prevent engine shut down if malfunction in
shut down of main engine, the system will be one PS3 switch.
arranged with two PS3 (PS3A and PS3B)
Page 1 of 2
SVI04-30-00-100 R00
Test
Test procedure
procedure for
for instrument
instrument alarms
alarms
The following procedures describe testing of pressure switches, pressure transmitters,

Temperature sensors and level switches for Brunvoll Volda as delivered equipment.
All predefined set point is given in the piping diagram, Ch.8.

Tools: OMICRON-Pump or similar, small screwdriver and an Allan key.
Temperature sensors
The following procedure describes testing of PT100 temperature sensors.
• Remove the sensor. • If necessary, calibrate the alarm system indication

• Boil the sensor in an oil test tube. Check that the to the local instrument.
temperature on the local instrument is the same • Check that an alarm is given at the predefined set
as in the alarm system. point.
Stern tube bearing PT100 temperature sensor:

We do not recommend removing the stern tube bear- The cable from the coupling box to the alarm system,
ing PT100 temperature sensors for testing. This is can be tested by jumper connection.
because the risk of damage.
Pressure switches and transmitters

The following procedures describe testing of pressure switches and pressure transmitters.
Pressure switches (Marked with ON/OFF): Pressure transmitters (Marked - P/I (transmitter) ):
• Remove the plastic cap covering the minimess • Remove the plastic cap covering the minimess
connection. connection.
• Connect the test pump. Pump the pressure to • Connect the test pump. Pump the pressure to
predefined set point. predefined set point.
• Check that correct indication is given in the alarm • Check that the pressure value is corresponding
system when predefined set point is reached. on the local instrument and the alarm system.
• Check that the alarm is given according to speci- • Check that an alarm is given in the alarm sys-
fied increasing / decreasing pressure. tem at the correct set point, and according to the
See Piping diagram in Ch.8 specified increasing / decreasing pressure.
See Piping diagram in Ch.8
Clogged oil filter (– switch PS:11)
• Stop engine and stand by pump • Operate the switch with a small screwdriver or an
• Release oil pressure. Allan key.
• Remove unit
Page 2 of 2
SVI04-30-00-100 R00
Level switch
The following procedure describes testing of level switches.
• Gearbox. Level switch is tested before and after • Gravity tank. Level switch can be tested by re-
oil filling. Check that the level switch indication moving the switch and test in an external oil tank.
change after filling. • The connection to the alarm system can be
• It is difficult to test the level switch when the gear- tested by a jumper connection.
box is filled with oil. The connection to the alarm • The oil level is visually checked by sight glass.
system can be tested by a jumper connection in
the gearbox terminal box.
Possible time delay of oil pressure and oil level alarms are about 10-15 seconds
Remote control alarms

The following procedures describe testing of Remote control system alarms
Power failure: Soft clutch failure:

• Disconnect one of the power supplies, and check
that a power failure alarm is given in the alarm
system. Test with stopped engine. (Stationary shaft)
• Disconnect the soft clutch valve (remove cap).
System failure: • Clutch in.
• Disconnect one wire on the pitch feedback pot • Check that an alarm is given within 30 sec.
meter, and check that a system failure alarm is • Reconnect soft clutch valve. The alarm is reset
given in the alarm system. after the first successful clutch-in sequence.
Page 1 of 4
05040212_R05
Launching, start-up and sea trial procedures
Important! All activities until § 1.3.8 are to be carried out by the yard.
A signed copy of this formula is to be sent to Brunvoll Volda before attendance of our service engineer.
All activities from § 2.1 and until § 2.3.8 are to be confirmed by date and signature by Brunvoll Volda service
engineer.
Yard / NB.no Brunvoll Volda inst.no.:
POS DESCRIPTION COMPLETION DATE / SIGN
1.1 BEFORE LAUNCHING:

1.1.1 Mounting of stern tube/stern tube bearings.
1.1.2 Arrangement/mounting of reduction gear
Mounting of blades and locking of blade bolts
(alternatively also mounting of propeller hub C
1.1.3
to propeller shaft if supplied separately). For
big propellers, blades may be mounted after O
installing of tail shaft. (due to crane capacity
etc.) N
1.1.4.
Cleaning of stern tube, installation of tail shaft
and mounting of stern tube glands. Cleanness
F
to be accepted by owners representative.
Preliminary mounting of shaft coupling with
I
1.1.5
reduced drive-up (for lining up of shafting). R
Installing of gravity tank and pipes for stern
tube. M
1.1.6 Pipes and tank to be inspected and cleaned
before oil filling (accepted by owner’s repre- E
sentative).
Oil filling of propeller hub, stern tube and stern D
1.1.7 tube glands. Air to be bled when filling oil in
hub. Make note of type and quantity filled.
During the outfitting period oil level must be
checked periodically, refill if necessary.
B
1.1.8
Y
Air pressurized oil tanks must be pressurized
before launching.
Installing of intermediate shaft(s), bulkhead
Y
1.1.9 gland(s) and bearing(s) (or possibly after
launching).
A
R
1.1.10
Add oil to the bearing housing before propeller
D
shaft can be rotated
Page 2 of 4
05040212_R05

1.2 AFTER LAUNCHING

Alignment of shafting.
1.2.1
Send recorded GAP/SAG data to Brunvoll Volda.
Final mounting of push-pull rod (or telescopic
1.2.2 pipe), shaft coupling(s), bulkhead glands(s)
and shaft bearing(s)
Mounting and alignment of PTO-driven equip- C
1.2.3 ment if any. Send recorded alignment data to
Brunvoll Volda. O
1.2.4
Arrangement and mounting of cooler, stand-by
pump, hydraulic panels etc.
N
1.2.5
Installation of hydraulic piping according to
diagram.
F
1.2.6
Installation of pneumatic piping (if any) for I
remote control.
1.2.7
Arranging of electrical components and instal- R
lation of electric cables according to diagram.
Preparation and connecting up hydraulic pipes M
installed by shipyard for flushing according to
1.2.8 Brunvoll Volda flushing procedure 05100100. E
Flushing to be carried out under supervision of
Brunvoll Volda service engineer. D
Blow air through pneumatic pipes (if any) for
1.2.9
cleaning.
1.2.10
Filling of oil and grease in shaft bearing(s),
bulkhead gland(s) and toothed coupling(s) etc.
B
Note type of oil/grease filled.
COMMISSIONING / CHECKING TO BE CAR-
Y
RIED OUT BY SHIPYARD BEFORE
1.3
BRUNVOLL VOLDA SERVICE-ENGINEER IS
REQUIRED FOR PERFORMING START-UP: Y
That all equipment is mounted and piping
1.3.1
completed. A
1.3.2 That flushing is prepared for.
1.3.3 That all external cabling are completed. R
1.3.4
That all connections are checked according
to cable lists and that all terminal blocks are D
properly tightened.
That electric power is available (and switched
1.3.5
off).
1.3.6 That system is ready for testing.
That there is undisturbed access to all equip-
1.3.7
ment.
1.3.8 That necessary oil is available.
Page 3 of 4
05040212_R05

ACTIVITIES PERFORMED UNDER SUPER-

2 VISION OF BRUNVOLL VOLDA SERVICE C
ENGINEER(S): O
2.1 BEFORE STARTING UP N
Check shaft installations made by the shipyard F
2.1.1 (as far as possible without demounting of cou- I
pling, gland etc.)
Check hydraulic (and pneumatic, if any)
R
installations made by the shipyard (position M
2.1.2
of components, piping according to diagram, E
cleanness of pipes (take samples). D
Check gear sump for dirt introduced after leav-
2.1.3 ing factory prior to oil filling. Remove anti-corro-
sion device (if any) from gearbox.
B
2.1.4 Oil filling. Type of oil and quantity to be noted. Y
Starting up electric stand-by pump. Flushing
system according to Brunvoll Volda flushing B
2.1.5
procedure 05100100. Check system for leak- R
ages. Filters to be checked and renewed after
flushing. If necessary also before and during
U
flushing. N
Checking of set point for relief-, sequence- and V
2.1.6
reduction-valves etc. O
Testing of pitch manoeuvre and clutch control L
2.1.7 locally from gearbox. Make adjustment of pitch L
actuator etc.
Checking of electric cabling for remote control
2.1.8
and surveillance system. S
2.1.9 Switch on power to system. E
Starting up the remote control system. Pre- R
2.1.10
adjustment of same (max. Pitch ahead and V
astern, feed-back transmitter, pith actuator, I
indication systems, RPM pick-up(s) etc.)
Checking of set points for pressure- and tem-
C
perature switches. E
2.1.11
If possible in co-operation with shipyard/clas-
sification society. E
Checking function of alarms, auto-start/stop N
2.1.12 servo pump, interlocks etc. If possible in co-
operation with shipyard/classification society.
G
2.1.13 Checking interface with other systems. I
2.2 DOCK TRIAL: N
Start main engine, check direction of rotation E
2.2.1 and that mechanical driven pump gives pres- R
sure, (first with disengaged clutch, if arranged).
Page 4 of 4
05040212_R05

Running installation. Adjustments of practi-

cal zero-pitch. Observations of temperatures,
C
2.2.2 pressures, filter condition, oil level and other
O
leakage’s. Readjusting of valves if necessary.
N
Observe possible running-in procedure.
F
I
Checking and recording of time for clutching R
2.2.3
“IN” and “OUT”. (Soft clutch) M
Preliminary adjustment of max. Pitch, RPM, E
2.2.4
automatic pitch reduction etc D
Function test of systems for shipyard/classifica-
2.2.5
tion society prior to sea trail (if required). B
Preparation for sea trial (filter condition, oil Y
2.2.6
levels etc.)
AT SEA TRIAL: B
2.3 R
Observation of temperatures, pressures, filters, U
2.3.1 oil level and eventual leakages when loading- N
up the system. V
Loading up the system with final adjustment O
of max.pitch ahead, astern, engine RPM L
2.3.2
and indicators. Observe eventual running-up L
procedure(s) for gearbox and main engine.
S
Final adjustment and test of automatic pitch
E
2.3.3 reduction system and other functions that have
R
to be completed at sea trial.
V
Adjustment of mechanical pitch limitation, mi- I
2.3.4
cro switches (if any), etc. C
2.3.5 Manoeuvre tests for classification society. E
2.3.6
Manoeuvre tests for completion of “Sea Trial E
Report” N
Checking of gear wheels after finishing sea G
2.3.7 trial. (If Brunvoll Volda service engineer still is I
present). N
E
2.3.8 Acceptance of installations. (Sea Trial Report) E
R
Page 1 of 2
05100101 R01
Data sheet - Launching, start-up and sea trial procedures
Vessel name: .....………………..……..…......................................….... Type: ..............................
Inst. serial no.: …….……… Type:…........…….…....... Gear ratio: .................….
Propeller make: ..………… Propeller speed/rotation, RPM: .......…/.......…. PTO speed,RPM: ..........
Engine make: ...……………… Engine speed, RPM: ..……...... BHP: ...............................

SEA TRIAL TEST OBSERVATIONS
1 Servo oil pressure bar
2 Clutch* pressure main clutch (clutch engaged) bar
3 Clutch* pressure PTO (clutch engaged) bar
4 Lubrication oil pressure bar
5 Safety valve pressure, (no. of springs: pcs. bar
6 Control oil pressure (when Volda rem. control) bar
7 Air* pressure (when pneum. remote control) bar
8
9 Cooling water temp., inlet °C
10 Cooling water temp., outlet °C
11 Oil temp. cooler, inlet °C
12 Oil temp. cooler, outlet °C
13 Pitch reversing speed 0-full ahead sek
14 Pitch reversing speed 0-full astern sek
15 Pitch reversing speed, full ahead-full astern sek
16 Clutch* engaging time sek
17 Clutch* disengaging time sek
18 Oil temps when readings °C
19 Time for readings (hour and minute):

H: M:
20
Full loaded engine for hours: max temp: o
C
* TS-gear
Tooth mesh main gear - pinion
21
(give sketch and photo) Aft: Aft
Tooth mesh main PTO* gear

22
(give sketch and photo) Aft
23 Remarks:
* if present
Are all points in starting up procedure fulfilled yes no
Date and place for sea trial:......................…………………......…………………………..
Tested by service eng.:...................................……………………………………………...
Page 2 of 2
05100101 R01
05100101 Data sheet - Launching, start-up and sea trial procedures
Vessel name: .....………………..……..…......................................….... Type: ..............................
Inst. serial no.: …….……… Type:…........…….…....... Gear ratio: .................….
Propeller make: ..………… Propeller speed/rotation, RPM: .......…/.......…. PTO sped,RPM: ............
Engine make: ...…………...... Engine speed, RPM: ..……...... BHP: ...............................

SEA TRIAL TEST OBSERVATIONS
1 Servo oil pressure bar
2 Clutch* pressure main clutch (clutch engaged) bar
3 Clutch* pressure PTO (clutch engaged) bar
4 Lubrication oil pressure bar
5 Safety valve pressure, (no. of springs: pcs. bar
6 Control oil pressure (when Volda rem. control) bar
7 Air* pressure (when pneum. remote control) bar
8
9 Cooling water temp., inlet °C
10 Cooling water temp., outlet °C
11 Oil temp. cooler, inlet °C
12 Oil temp. cooler, outlet °C
13 Pitch reversing speed 0-full ahead sek
14 Pitch reversing speed 0-full astern sek
15 Pitch reversing speed, full ahead-full astern sek
16 Clutch* engaging time sek
17 Clutch* disengaging time sek
18 Oil temps when readings °C
19 Time for readings (hour and minute):

H: M:
20
Full loaded engine for hours: max temp: o
C
* TS-gear
Tooth mesh main gear - pinion
21
(give sketch and photo) Aft: Aft
Tooth mesh main PTO* gear

22
(give sketch and photo) Aft
23 Remarks:
* if present
Are all points in starting up procedure fulfilled yes no
Date and place for sea trial:......................…………………......…………………………..
Tested by service eng.:...................................……………………………………………...
Page 1 of 8
05060504
Brunvoll Volda Hand over Document
This document confirms that the Brunvoll Volda equipment with installation number(s)
BVO Inst. No.: ........………...........…....... IMO No.: .........................................

has been inspected and started up by a Brunvoll Volda service engineer. The installation(s) have completed
sea trials for final adjustments and tuning and the set up of the Brunvoll Volda deliveries are to the customers
satisfaction.
By signing this document;

The Brunvoll Volda service engineer confirms he has registered all necessary recordings during
tests and trials.
○ All pressures as mentioned in piping/alarm diagram
○ All temperatures as mentioned in piping/alarm diagram
○ Were remote control is delivered or repaired;
• All modes are tested and found to be in function
• 0-pitch is set.
• Load curves adjusted according to owner or/and engine manufacturers advice.
• Pitch speed is set according to owners and/or systems requirement.
The customer acknowledge and approve the settings both mechanical and for the remote control
(if supplied by Brunvoll Volda)
The customer is made familiar with the facts that;

○ The Brunvoll Volda service engineer must, on a daily basis, keep time sheets with description
of the work he has carried out. Time sheets must be counter signed and accepted by the
customer’s representative together with Brunvoll Volda service engineer.
○ Customer’s non-fulfilment of payment obligations towards this contract will set the warranty
nil and void.
○ All correspondence in matter of warranty shall be in writing.
All contacts related to the equipment should be reported to Brunvoll Volda Service at the following address.
Brunvoll Volda AS
Hamneg. 24, P.O.box 205, N-6101 Volda, Norway
Tel: +47 70 05 90 00. Fax: +47 70 05 90 01

e-mail: [email protected]
Emergency Service (after office hrs.): +47 478 24 365
Date .............../.........................20.............
........................................................................... ...............................................................................
Brunvoll Volda service engineer Customer representative
............................................................................ ................................................................................
Shipyard representative Ship owner representative
Page 3 of 8
05060504
SVO Inst. No.: ........………...........…....... IMO No.: .........................................

satisfaction.

tests and trials.
• 0-pitch is set.

nil and void.
Brunvoll Volda AS
Tel: +47 70 05 90 00. Fax: +47 70 05 90 01

Date .............../.........................20.............
........................................................................... ...............................................................................
............................................................................ ................................................................................
Page 5 of 8
05060504
SVO Inst. No.: ........………...........…....... IMO No.: .........................................

satisfaction.

tests and trials.
• 0-pitch is set.

nil and void.
Brunvoll Volda AS
Tel: +47 70 05 90 00. Fax: +47 70 05 90 01

Date .............../.........................20.............
........................................................................... ...............................................................................
............................................................................ ................................................................................
Page 7 of 8
05060504
SVO Inst. No.: ........………...........…....... IMO No.: .........................................

satisfaction.

tests and trials.
• 0-pitch is set.

nil and void.
Brunvoll Volda AS
Tel: +47 70 05 90 00. Fax: +47 70 05 90 01

Date .............../.........................20.............
........................................................................... ...............................................................................
............................................................................ ................................................................................
Page 1 of 2
Chapter 5 Operating instruction and emergency

SVI05-01-00-113 Starting and operating procedure El-motor driven gearbox 3
SVI05-03-00-010 PVG 120 Emergency pitch control 5
Page 2 of 2
Page 1 of 2
SVI05-01-00-113
Starting
Startingand
andoperating
operatingprocedure
procedureEl-motor
El-motordriven
drivengearbox
gearbox
A. Precautions before starting main engine
1. Check that all equipment including coupling to- 5. Switch on the alarm circuit
wards main engine are completely
assembled. 6. Switch over to “Bridge control”
2. Check the oil level in the gearbox. Replenish if 7. Check that the propeller is in neutral pitch.
necessary. The main engine can now be started upon a signal
from the bridge.
3. Set the selector switch for oil pumps in position
“Remote” and start the pump from engine control 8. For some ships there may be special instructions
room. made by the shipbuilder for starting up of engine.
If so, follow these instructions.
4. Check that the oil pressures are according to “Data
Sheet”. The oil pressures may be somewhat higher
when the oil is cold.
B. General rules
1. Check all pressures and the oil temperature regu- 2. The sterntube glands, the oil distribution box and
larly. Any discrepancies should be investigated at the oil pumps should be checked regularly for
once. The servo pressure may vary considerably, overheating and unusual sounds.
especially during manoeuvres but also during con-
stant operation due to small self-adjusting move- 3. Regularly check the equipment for oil leaks that
ments of the propeller. The oil temperature should may develop. Keep the equipment clean and tidy.
be kept as indicated in “Data Sheet” by adjusting the
water flow through the oil cooler. 4. Check that the oil level in the gravity tank is always
at the top when running.
C. Propulsion Modes
Activation of the main propulsion modes is performed See Remote control manual Ch. 9.
by activating the corresponding push-button.
D. Windmilling
1. Stand-by pump for lubrication of gearbox must 4. Pitch to be in maximum forward position. Put con-
be running. trol lever full ahead on panel in command.
2. Alarm system must be in operation.

On panels with only combinatory mode the motor will
3. Oil levels, temperatures and pressures for stern run at max rpm if lever is put in full ahead position. (If
tube and gearbox lubrication should be at correct motor is running.) On engine control room panel you
level. Running the propeller in windmilling without can adjust pitch and motor rpm independently.
satisfactory lubrication might damage the equip-
ment.
Page 2 of 2
SVI05-01-00-113
5. Use windmilling only in transit condition to achieve 6. In low speed/Fi-Fi operation, the propeller should
sufficient propeller shaft speed. A minimum of 30 not be set in windmilling condition. The propeller to
rpm on propeller shaft is recommended for suffi- be in 0-pitch position to avoid rotation of propeller.
cient oil film in stern tube bearings. (Avoid windmill-
ing for longer periods at propeller rpm lower than
30.)
Twin screw ships, one propeller out of operation:

The propeller shaft not in operation should not be rotating as long as alarm- and lubrication system is
not in operation
Page 1 of 1
SVI05-03-00-010 R.00
PVG 120 Emergency pitch control
When operating the control arm

see feedback arrangement on
Gearbox!
Fig.1. PVG 120
Fig.2. Local operation pitch switch
Manual operation of the pitch control
The Emergency Pitch Control is available at any time.

When the Emergency Pitch operation switch (Fig.2) is turned to local (the switch will illuminate),
the remote pitch control is disabled.
The pitch can now be controlled manually by moving the arm (Fig. 1).
Using emergency operating mode will disable the remote pitch control. All other functions in the remote con-
trol system will operate as normal.
During local operation, the pitch must be manually controlled all the time.
During local operation, the overload system in the remote control is disabled.
Page 1 of 2
Chapter 6 Maintenance

SVI06-01-00-002 Routine maintenance - Propulsion system 3
Gear box 3
Cooler 4
Propeller system and Stern Tube 4
Coupling Intermediate shafts - Gear type 5
Pumps 5
ODS and HPU 5
Turning gear 5
Remote control and monitoring 6
SVI06-02-00-001 How to take Oil sample for chemical analysis and particle count, Stern Tube. 7
SVI06-02-00-002 How to take Oil sample for chemical analysis and particle count, Gear 8
SVI06-03-00-001 Troubleshooting and correction 9
SVI06-05-00-001 Repairing of propeller blades 12
SVI06-08-00-001 Instruction for draining and filling of Propeller hub, Propeller shaft and Stern tube 14
SVI06-10-00-001 Oil filling and oil draining of Gear box 15
PVG 120 Proportional Valves - Service Parts Manual 17
SVI06-99-00-001 Logbook 69
Page 2 of 2
Page 1 of 4
SVI06-01-00-002_Rev.02
Routine maintenance - Propulsion system
Hydraulic mechanisms are precision units, and their continuous smooth

operation depends on proper care. Therefore follow the instructions given below.
Maintenance interval in hour
■:
16 000
32 000
40 000
48 000
96 000
Others
Planned Overhaul
1 000
2 000
4 000
8 000
Remark
○: Daily
500
Based on observation
Gear
Gear box
box
Leakage inspection ○ Detailed inspection, minimum monthly
Minimum every 6 mths. The oil should at least meet
Analyse oil sample ■ the requirements of ISO 17/14.
Change oil if necessary
Pitch mechanichal transmission
○ Inspection
leakage
Gear wheels ○ Visual inspection
Carrier tappet servo piston ■ Change
Bronze bushings servo piston ■ Change
Piston ring servo piston ■ Change
Sealrings clutch oil inlet,telescopic pipe ■ Change
Main pump ■ Change
Change in connection with pto OH.
Seals/Gaskts ■ Change in connection with input roller bearings
(96’hrs)
Change in connection with pto OH.
Clutch oil inlet rings ■ Change in connection with input roller bearings
(96’hrs)
Filter
○ Change after completed commisioning.
■ Change filter elements
* Pressure filter is equipped with alarm
High pressure oil filter *
For duplex filter, change immediately over to the
○ other section at clogged filter alarm. Clogged oil
filter elements to be replaced by new with out delay
(see Chapter 8 “High pressure filters”)
Breather gear box - filter/stainer ■ Clean every 12 mths
Day after extensive maintance of gearbox.

Suction strainer * ■ ■ * The 380 gearbox is not delivered with
suction strainer for the stand by pump
Bearings (gear)
Thrust bearing clearance ■ Clearance recording, acc to classification
Roller bearings on input shaft ■ Change
Roller bearings on input shaft w/PTO ■ Change
White metal bearing on output shaft &
■ Inspection
pinion shaft
■ Every 12 mths Change Grease. SKF LGMT2 or
NLGI Grade: No. 2. Fill completely the Bearing with
Roller Bearings on PTO shaft(s) grease. Fill the Bearing Housing between 30 to
(Grease lubricated) 50% with grease.
■ Change Bearing
Roller Bearings on PTO shaft(s)
■ Change Bearing
(Oil lubricated)
■:
16 000
32 000
40 000
48 000
96 000
Others
Planned Overhaul
1 000
2 000
4 000
8 000
Remark
Daily
○:
500
Page 2 of 4
SVI06-01-00-002_Rev.02

■:
16 000
32 000
40 000
48 000
96 000
Others
Planned Overhaul
1 000
2 000
4 000
8 000
Remark
Daily
○:
500
Clutch ○ Inspection
Small amount of Grease every 12 months (2 nods)

Output shaft - Seal nipple ○
Use general purpose grease
Cooler
■ Check the waterside, clean if necessary
■ Change anodes
Propeller system
Propeller system and
and Stern
Stern Tube
Tube
Propeller hub outside visual inspection ■ Minimum every dry-docking
Propeller blade surface visual
■ Every dry-docking
inspection
Propeller blade seals change ■ Every dry-docking
Propeller blade seal surface inspection ■ Every dry-docking
To be changed if threads or seal surface
Propeller blade bolt to be changed ○ underneath head flange is damaged or if changing
old propeller blade for new.
Propeller crankpin ring/
■ * - or acc. to classification
hub wear recording *
Propeller shaft coating ■ Minimum every dry-docking
Propeller shaft bearings ■ Inspection every dry-docking, acc to classification
In case of water lubricated propeller shaft, see
propeller lubrication system for changing seals on
Propller oil inlet ring - U-gaskets ○ ■
oil inlet ring.
See Shafting and/or oil lub. System
Propeller lube oil system * ■ Leakage check. * See sub supplier`s manual
Gravity tank ○ Any variation in oil level, check for oil leaks
Minimum every 6 months.The cleanliness of the oil
Analyse oil sample ■ should at least meet the reqiurements of ISO 17/14.
Change oil if necessary
Change every 5 years
Stern tube seal ■ Inspection from engineroom side, acc. to
classification.
Oil inlet Box- Propeller shaft * ■ * For separated propeller hub lubrication
■:
16 000
32 000
40 000
48 000
96 000
Others
Planned Overhaul
1 000
2 000
4 000
8 000
Remark
Daily
○:
500
Page 3 of 4
SVI06-01-00-002_Rev.02

■:
16 000
32 000
40 000
48 000
96 000
Others
Planned Overhaul
1 000
2 000
4 000
8 000
Remark
Daily
○:
500
Intermediate shafts and Bulkhead seals

Bearing - white metal.
○
Intermediate shaft - Propeller
Roller Bearing,
○
Intermediate shaft - Propeller
○ ■ Change
Roller bearing
Intermediate shaft - Engine ■ ■ Relubricate every 300* hours (15g+15g), Refill
Grease lubricated * every 3 years. (fills approximately 40% of the free
space in the housing. Grease - SKF LGMT 2)
*Grease lubricated - Refill once a year.
Push Pull Rod * - In Intermediate shaft ○
*If nipple - Refill every 6 months.
Bulkhead seals * ○
Leakage check. *Oil Tank lubricated, use any oil
Bulkhead seals - Gas-tight seals * ■ ○
with viscosity ISO VG 220 (CST 220) – or equal
Coupling
Coupling Intermediate shafts - Gear type
(Typically used on Intermediate shaft between Gear and Engine)
■ Replenish grease,
* See manual ch.8
Coupling - gear type * ■ Maximum 2 years - Dismount outer sleeve, clean
the parts and replenish grease.
■ High temp -more than 60°C, maximum 1 year
Pumps
El-pumps ○ Functions test in port
Main pump elastic coupling (if fitted) ○ ■ Change
Main pump spline coupling (if fitted) ○ Check
Stand-by pump ○ Test the stand-by pump
ODS and HPU

ODS and HPU
Bearings * ○ * See manual
Turning gear
Gear
Oil * ■ * Once a year. Oil type: see Ch.2 “Lub. recomm..”
* Replenish grease once a year.
Grease coupling* ■ -see Ch.2 “Lub. recomm..”
■:
16 000
32 000
40 000
48 000
96 000
Others
Planned Overhaul
1 000
2 000
4 000
8 000
Remark
Daily
○:
500
Page 4 of 4
SVI06-01-00-002_Rev.02

■:
16 000
32 000
40 000
48 000
96 000
Others
Planned Overhaul
1 000
2 000
4 000
8 000
Remark
Daily
○:
500
Remote
Remote control and monitoring
Overload control ○ ■ Observe during hard manouvering
Test 24V on both power supplies ○ ■ Measure input voltage
Backup control wheel house ○ ■ Test functions and transfer betw emergency/normal
Backup control engine room ○ ■ Test functions and transfer betw emergency/normal
Set points on pressure switches ■ Calibrate/test
Set points on thermo element ■ Calibrate/test
Float switches ■ Function test
Actuator arrangement ■ Check Actuator arr w/linkage
Feecback pot.meter ■ Change every 5th year
PLC Battery ■ Change every 4th year
■:
16 000
32 000
40 000
48 000
96 000
Others
Planned Overhaul
1 000
2 000
4 000
8 000
Remark
Daily
○:
500
Page 1 of 1
SVI06-02-00-001
How to take Oil sample for chemical analysis and particle count, Stern Tube.
You need a bucket.
1.
Use the three way cock valve.*
2.
Drain out 1/2 to 1 liter of oil before you take the oil sample.
3.
Take the oil sample.
Double check that the cock is in normal posision after taking the oil sample! *
* Three-vay cock valve.

-Yard supply.
To be marked with:
“OIL SAMPLE OUTLET”
Page 1 of 1
SVI06-02-00-002 R01
How to
How to take
take Oil
Oil sample
sample for
for chemical
chemical analysis
analysis and
and particle
particle count,
count, Gear
Gear
1 2 3
You need a bucket and a test hose with mini-mess

coupling.
Brunvoll Volda No.: 502594 TESTHOSE SMA3-400.
1.
Use PS 4 .
“Alarm low system oil pressure”.
- * Alternative: “Alarm low servo oil pressure”.
2.
Remove the protection.
3.
Fasten the test hose gently.
Remember to have a bucket ready to drain out 1/2 to 1 liter
of oil before you take the oil sample.
Please observe the alarm may start!
4.
Take the oil sample.
Disconnect the test equipment and fasten the protection.
Double check that the valve remains open!
Page 1 of 3
SVI06-03-00-001
Troubleshooting and
Troubleshooting and correction
correction
These guidelines are standards, which are used for various combinations of gearboxes and propellers.
Therefore there may be some advice not valid for your specific installation.
Fault 1
It is impossible to change the propeller pitch or the movement is too slow.
Possible causes:
A.
If the servo oil pressure is low or non existing. 6. Excessive clearance in bearing where servo-oil
1. Insufficient oil in the system. is taken through. Possible oil leakage from the
2. Leakage on the suction side of the oil pump, al- bearing can be seen through gearbox inspection
lowing this to suck air. Oil is foaming. opening.
3. Pressure pipes leakages. 7. Oil is too thin or too hot.
4. Pump (aggregate) failure.
5. Leakage in safety valve. Valve stuck in open posi-
tion.
B
If the servo oil pressure is normal.
1. Main slide valve is stuck. Change to “Engine piston. If this is in order, the fault lies in the
room” control and try to operate the propeller remote control. (For G380 and 450 free move-
with the mechanical control handle on the gear- ment is approx. 11 mm). See Remote control
box. The spool valve should have a free manual for servicing the remote control
movement of approx. 19 mm relative to the
C.
If the servo oil pressure rises considerably and blows the safety valve when the slide valve is moved.
(With declutched propeller).
1. Seizure in propeller hub or shafting. 2. Seizure in the servomotor. Disconnect the push
pull rod connection to determine of which end
the seizure is. The faulty unit will have to be dis-
mantled for inspection.
D.
If the oil pressure is constantly too high.
1. The choke valve in valve block is stuck. 2. Restricted pressure line from oil pump to servo.
Fault 2.
Clutch will not engage or is engaged with too low clutch pressure.
Possible causes:
E.
If the oil pressure is too low.
1. Same causes as under A. 4. Clutch valve piston sticking.
2. Choke valve sticking. 5. Clutch valve faulty F.
3. Choke valve spring faulty
For AG installations (without clutch) disregard clutch faults.
Page 2 of 3
SVI06-03-00-001
Fault 2. cont.
Clutch will not engage or is engaged with too low clutch pressure.
Possible causes:
F
If the oil pressure is normal.
1. Electric supply cut off. Relays for solenoid valve 2. Leakage or blockage in the oil inlet to the clutch.
damaged. Faulty wiring. Check valve movement 3. Insufficient of faulty movement of solenoid valve.
manually with power to valve solenoids switched off.
Fault 3.
The clutch will not disengage.
Possible causes:
G.
If the propeller shaft rotates considerably slower than with the clutch engaged.
1. Excessive lubrication of clutch plates, or 3. Insufficient or faulty movement of the solenoid
too thick oil. valve.
2. Clutch piston not completely withdrawn.
H.
If the propeller shaft rotates with the same speed, regardless of the clutch control.
1. Refer to F1
2. Seizure or other faults inside clutch.
Fault 4.
Servo oil pressure at full engine speed lower than min. servo oil pressure specified in “Data Sheet”.
Possible causes:
I.
1. Choke valve in valve block is stuck. 3. Same causes as under A.
2. Spring in choke valve too weak.
Fault 5.
Propeller pitch difficult to adjust accurately.
Possible causes:
J
1. Excessive backlash in transmission between aux- 3. Faults in the remote control system, see in fault
iliary servo and reduction gear. Ev. transmission finding procedure for this system.
in control stand on bridge.
2. Faults in the auxiliary servo.
Page 3 of 3
SVI06-03-00-001
Fault 6.
Reduction gear running too hot. (Gearbox oil temperature above that specified in “Data Sheet”).
Possible causes:
K.
1. Insufficient cooling water. 4. Clutch slipping.
2. Oil cooler clogged. 5. Oil level too high
3. Bearings running hot.
Fault 7.
Rattling noise from gearbox.
Possible causes:
L
If rattling occurs at certain engine speed only.
1. Torsional vibration resonances.
Avoid running the engine at this speed.
M.
If gear rattles at all engine speeds.
1. Gearwheels or bearing damaged.
Fault 8.
Excessive oil consumption in propeller system. (The gravity tank for propeller lubrication needs
frequent topping up).
Possible causes:
N.
1. Sterntube gland leaking. 4. Leakage from oil seal in front end of propeller
2. Propeller hub leaking. shaft or from plug in shaft coupling (only for
3. Leakage from oil seals in propeller shaft. clamp coupling w/oil inlet).
Fault 9.
Excessive oil consumption in gearbox. (Gearbox needs frequent topping up).
Possible causes:
O.
1. Leakage in oil cooler.
2. Leakage from pipe connections etc.
3. Leakage from oil seal input or output shaft.
Fault 10.
Gearbox oil contaminated with water.
Possible causes:
P.
1. Leakage in oil cooler.
2. Bilge water entering gearbox.
3. Condensed air moisture.
Page 1 of 2
SVI06-05-00-001
Repairing of
Repairing of propeller
propeller blades
blades
GENERAL
1.1. Repairing of propeller blades using methods sary the Classification Societies may require
given below must only be carried out in co- subsequent heat treatment. Methods of heat
operation with representatives from the Clas- treatment, however, are not described in this
sification Societies. If permission to repair the instruction.
propeller blades is given and welding is neces-
1.2 Propeller blades being heavily damaged general be condemned. When straightening
more than blades edges, should be repaired or replacing larger parts of the blade correct
at Scana Volda works where the necessary blade shape is difficult to obtain, particularly
know-how tools and control equipment is at correct pitch and pitch distribution.
hand. Blades being bent further than 1/3 of
the length, measured from blade tip, should in
1.3 In order to perform a correct repair of a propel- If all blades are damaged and a spare blade
ler blade the possibility of comparing with an is not at hand the possibilities of repairing
undamaged blade should be present. outside Scana Volda works are small.
1.4 Scana Volda takes no responsibility for repairs Generally no guarantee is given on blades
carried out outside Scana Volda works using being repaired.
below methods.
1.5 Fitting of new blades together with repaired

weight.
1.6 When a propeller blade has been repaired it If all blades have been repaired they must be
must be controlled for similarity in shape and mutually similar.
weight with the undamaged blades.
1.7 When ordering spare blades and one or order to make possible adjustments on the
more of the remaining blades have been renew blades.
paired, Scana Volda must be informed in
Page 2 of 2
SVI06-05-00-001
PRACTICES
1. Filling welds.
Filling welds may be carried out in order to repair is not required. Welded area must be ground,
small damages and scratches on blade edges correctly shaped and polished. For the correct
and blade surfaces. For small repairs preheating shape compare with an undamaged blade.
2. Bent blades should be straightened as much as ened with the use of a sledge hammer and plane
possible before starting repair welding. During pieces. After straightening the blade must be
straightening bronze blades must be heated to controlled for correct shape by comparing with an
about 50 oC, and stainless steel blades to about undamaged blade.
100oC. Straightening should be done in a press. The blade must be polished after straightening.
Blade edges and small dents may be straight-
3. Replace parts of propeller blades.

This must be done if parts of blade have been
broken off, if deformation has resulted in cracks
or if correct straightening is impossible.
Replacing of parts is done as follows:

3.1 Cut out damaged part using carbon elec- 3.5 Observe distortion of blade during weld-
trodes and compressed air, chisel or grinder. ing. Correct welding sequence may assist
2.2.2 Replacement parts must have added straightening.
thickness on both sides and on blade edges
for grinding to correct shape against meas- 3.6 Course grinding. Compare with undamaged
uring jig. blade.
3.2 Weld preparations (double V) must be made 3.7 Grind blade contour using template made
on replacement parts and on blade. from undamaged blade.
3.3 Preheat to about 100oC prior to welding. 3.8 Control of blade shape. Small straightening
may be necessary.
3.4 Weld in replacement parts using correct
electrode material. Argon shield welding is 3.9 Finish grind and polish.
preferred.
Page 1 of 1
SVI06-08-00-001 R02
Instruction for draining and filling of Propeller hub, Propeller shaft and Stern tube
Common lubrication systems for Propeller hub/Propeller shaft and Stern tube. See Piping diagram!
A.
Draining the propeller hub and sterntube.
With the ship in dry-dock the propeller hub and stern tube can be drained as follows:
Propeller hub: Sterntube:

1. Shut the three-way cock between the stern tube 1. Turn the three-way cock and close the connec-
and the gravity tank. tion to the gravity tank through oil pipe and open
for drainage of stern tube. To save time, a hand
2. Remove the two drain plugs (between the propel- pump or a small electric oil pump can be con-
ler blades), one at the top and one at the bottom nected to the cock and the oil pumped into an oil
of the bottom of the hub, and let the oil flow out. drum or similar.
The hub can be drained more quickly through
one of the propeller blade bolt holes, and if the
propeller blades are to be removed, this method
is recommended.
B.
Filling the propeller hub/propeller shaft and sterntube.
For suitable oils, see special page.
1. Turn the propeller hub to bring one of the air vent 5. With continued pumping, the oil will fill up the
plugs up and remove this. bore in the propeller shaft and fill up the stern
tube and gravity tank. The oil level in the gravity
2. Turn the three-wvay cock to obtain connection tank may be checked through the sight glass. (To
between the inner sterntube gland and save time, oil can also be filled directly into the
the gravity tank. gravity tank).
3. Pump oil through the bottom plug hole of the pro- 6. Finally check that all plugs and propeller blade
peller hub or through a propeller blade bolt hole. bolts are tightened and properly locked.
4. When only clean oil is coming out of the propeller

top plug hole, refit this plug.
Drain
Bulk head Stern tube gland
Three way cook
Page 1 of 2
SVI06-10-00-001 R02
Oil filling and oil draining of Gear box
Oil filling
A1. Oil should preferably be added to the gear via

one of the oil strainers, see photo in fig a1).
After filling, the element should be cleaned
before the cover is re-fitted. Ensure that the sealing in the cover, see
Please fill some oil in all suction strainers - above photo in fig. a1, (X) (o-ring and the akulon
the flange before starting the pumps. washer under the screw head), are fitted
correctly and that they seal the cover completely.
This can be controlled with the pump running by
putting some oil around the screw head and the
gap between the cover and the housing.
A2. Oil should be added until the level reaches the

maximum mark on the dip-stick. After the start-up
with empty oil system, the level must be
re-checked and extra oil added if necessary. The oil level must at all times be between the
See drawing: “VI307229 Seperate mounted minimum and maximum mark on the dip-stick.
El.driven stand by pump with suction pipeline”.
- Too low oil level can cause the pump to suck air.
- Too high oil level can cause increased heating
of the oil and of the gear itself.
When checking the oil level during service,
the clutch must be engaged to obtain the
correct reading of the oil level.
Suction strainer X
Oil filling via both stand by O-ring and an akulon washer
pump strainer and main under the screw head
pump strainer.
Photo of Suction strainers.
Fig. a1. Piping diagram and Photo of Suction strainers for Stand by oil pump(-Pipe line not mounted-) and
Main oil pump.
Page 2 of 2
SVI06-10-00-001 R02
Scana
Scana Volda as
Tel: +47 70059000 Fax: +47 70059001
Drawing VI307229. Pipeline instruction for separate mountetd el.driven pump. See also ch.8.
Oil draining of gearbox

Brunvoll Volda recommend to use the stand by pump for draining of gear box.
B1. B2.
Dismount the pressure side of the pipline on the To completely empty the gear box open the
stand by pump, (see fig. b1). Mount a hose to the lower hatch on the gear box and manually
flange on the stand by pump. Connect the hose clean the gear sump.
to a tank for used oil.
Start the stand by pump and pump the oil to the
tank for used oil. ( The pump must not run dry)
Stand by oil pump -

Flange on pressure side.
(Pipeline yard supply)
-connection for oil draining-
The pump must not run dry
Fig. b1. Piping diagram, Flange Stand by oil pump - pressure side.
PVG 120 Proportional Valves - Service Parts Manual
MAKING MODERN LIVING POSSIBLE
Service Manual
Proportional Valve Group

PVG 120
powersolutions.danfoss.com
Service Manual PVG 120 Proportional Valve Group
Revision history Table of revisions
Date Changed Rev
May 2014 Converted to Danfoss layout – DITA CMS, major revision JA
Jan 2012 Pos. 3 change ID
Feb 2011 Table on page 35 changed, layout changes - all pages IC
Feb 2010 Handles on drawings IA
Jan 2010 Japan location HC
2 520L0247 • Rev JA • May 2014
Contents
PVG 120 service parts exploded view
PVG 120 sectional view
Safety in application
Control system example................................................................................................................................................................ 8
Examples of wiring block diagram..................................................................................................................................... 10
Identification
Identification ...................................................................................................................................................................................12
Installation
Installation and plug orientation..............................................................................................................................................13
Connection, PVP, Pump Side Module.....................................................................................................................................13
Oil flow direction............................................................................................................................................................................14
Tightening Torques.......................................................................................................................................................................14
PVM, Lever Positions.....................................................................................................................................................................16
Setting of max. flow...................................................................................................................................................................... 16
Pressure Setting..............................................................................................................................................................................17
PVP, LS Relief Valve Pressure Setting.................................................................................................................................17
PVB, LS Relief Valve Pressure Setting.................................................................................................................................17
Option, Oil Flow Direction and Setting of max Flow.........................................................................................................18
Installation of PVE.......................................................................................................................................................................... 18
Bleeding.............................................................................................................................................................................................20
PVPE/PVH relief valves................................................................................................................................................................. 20
PVPH and LS connections........................................................................................................................................................... 21
PVPE technical data.......................................................................................................................................................................21
Connection PVPE............................................................................................................................................................................22
PVP
PVP, Pump Side Module.............................................................................................................................................................. 23
PVPD, PVPH, PVPE, Accessories for PVP................................................................................................................................. 25
PVLP / PVLA
PVLP / PVLA, Shock and Suction Valve Port A/B................................................................................................................. 27
PVBP, PVBR, PVBC, PVBU
PVBP, PVBR, PVBC, PVBU Accessories for PVB......................................................................................................................29
PVM
PVM, Mechanical Activating Module...................................................................................................................................... 31
PVMD and PVH
PVMD, Cover for PVM and PVH, Hydraulic Activation...................................................................................................... 33
PVGI
PVGI, Interface for PVG 120 and PVG 32................................................................................................................................ 34
PVEH and PVEO
PVEH and PVEO, Electrical Activating Module, ON-OFF...................................................................................................35
PVT
PVT, Tank Side Module – Upper Part.......................................................................................................................................37
PVT, Tank Side Module – Lower Part.......................................................................................................................................39
PVAS and PVGI
PVGI, Assembly Kit......................................................................................................................................................................... 41
PVAS, Assembly Kit........................................................................................................................................................................41
Asssembly sequence............................................................................................................................................................... 41
Set of seals
Set of Seals .......................................................................................................................................................................................43
PVG 120 Modules Selection Chart
PVG 120 module selection chart.............................................................................................................................................. 44
Order specification
520L0247 • Rev JA • May 2014 3
Contents
Ordering of modules for oil flow exceeding 180 l/min [47.6 US gal/min].................................................................48
Order Form....................................................................................................................................................................................... 48
Reordering...................................................................................................................................................................................49
4 520L0247 • Rev JA • May 2014
13
14
10
3
11
9
3
12
8 4
7
5
3 6
4
5
1 6
2
5
14 6 V310144.A
520L0247 • Rev JA • May 2014 5
X-X
10 11 4
12
11
p
ma
T P T
X
X
P A 9 2 A 1 B
13
T P T
LS
A 7 5 1 B 8
P B
13
T P T
6 5
V310100.A
Legend:
1 – Main spool 7 – Shock and suction valve PVLP

2 – Pressure adjustment spool in PVP 8 – Suction valve PVLA
3 – Shuttle valve 9 – Orifice, closed center PVP; Plug, open center PVP
4 – Pressure relief valve in PVP 10 – LS connection
5 – Pressure compensator in PVB 11 – Orifice, open center PVP
6 – LS pressure relief valve in PVB 12 – Plug, closed center PVP
6 520L0247 • Rev JA • May 2014
All makes and all types of control valves (incl. proportional valves) can fail, thus the necessary protection
against the serious consequences of function failure should always be built into the system. For each
application an assessment should be made for the consequences of pressure failure and uncontrolled or
blocked movements.
To determine the degree of protection that is required to be built into the application, system tools such
an FMEA (Failure Mode and Effect Analysis) and Hazard and Risk Analysis can be used.
FMEA – IEC EN 61508

FMEA (Failure Mode and Effect Analysis) is a tool used for analyzing potential risks. This analytical
technique is utilized to define, identify, and prioritize the elimination or reduction of known and/or
potential failures from a given system before it is released for production. Please refer to IEC FMEA
Standard 61508.
Hazard and risk analysis ISO 12100-1 / 14121

This analysis is a tool used in new applications as it will indicate whether there are special safety
considerations to be met according to the machine directives EN 13849. Dependent on the determined
levels conformity this analysis will detirmine if any extra requirements for the product design,
development process, production process or maintenance, i.e. the complete product life cycle.
W Warning
All makes/brands and types of directional control valves – inclusive proportional valves – can fail and
cause serious damage. It is therefore important to analyze all aspects of the application.
Because the proportional valves are used in many different operation conditions and applications,
the manufacturer of the application is alone responsible for making the final selection of the products –
and assuring that all performance, safety and warning requirements of the application are met.
The process of choosing the control system – and safety levels – is governed by the machine directives
EN 13849 (Safety related requirements for control systems).
520L0247 • Rev JA • May 2014 7
Control system example
Example of a control system for manlift using PVE Fault monitoring input signals and signals from external
sensors to ensure the PLUS+1® main controllers correct function of the manlift.
Legend:
1 – Main power supply
2 – Emergency stop/man present switch
3 – HMI/Joystick control
4 – Movement detection sensors
5 – Main controller
6 – PVG control valve
7 – Hydraulic deactivation
8 520L0247 • Rev JA • May 2014
Electrical block diagram for the above illustration
W Warning
It is the responsibility of the equipment manufacturer that the control system incorporated in the
machine is declared as being in conformity with the relevant machine directives.
PVG 32 – mainly used in system with fixed displacement pumps:

• PVSK, commonly used in crane application - full flow dump
• PVPX, LS dump to tank
PVG 100 – alternative LS dump or pilot supply disconnect:
• PVPP, pilot oil supply shut off
• External cartridge valve connecting LS pressure or main pressure to tank
PVG 120 – pump disconnect / block for variable pumps:

• PVPE, full flow dump for the PVG 120
• External cartridge valve connecting LS pressure to tank
520L0247 • Rev JA • May 2014 9
Examples of wiring block diagram
Example of a typical wiring block diagram using PVEH with neutral power off switch and fault monitoring
output for hydraulic deactivation.
Emergency Man present
stop switch
A
PVE 1 Neutral detection / Supply control PVEH

1) with AMP
C signal connector
OFF
≠ Delay US
neutral UDC2
B Error
PVE 2 Neutral detection / Supply control PVEH

1) with AMP
C signal connector
OFF
≠ Delay US
neutral UDC2
B Error
E1 E2
2) Alarm
logic
Output
OR
3) Memory
high=on
AND
low=off
Hydraulic
Fault detection output D deactivation
P301 318
A– Emergency stop / man present switch

B– PVE Fault monitoring signals
C– Neutral signal detection.
D– Hydraulic deactivation
System Control Logic e.g. PLUS+1® for signal monitoring and triggering signal for deactivation of the
hydraulic system.
W Warning
10 520L0247 • Rev JA • May 2014
Example of fault monitoring for deactivation of the hydraulic system with extra fault inputs using the PVE’s
with DI (Direction Indication) function.
Emergency Man present
Stop switch
PVE 1 Neutral detection / Supply control PVEH-DI

1) AMP supply
signal connector
OFF
≠ Delay US
neutral UDC2
Error
PVEH-DI
AMP connector
2) Fault detection DI-A
DI-B 3) 4) DI-B
DI-A DI Output Delay Memory
US Logic Error
PVE 2 Neutral detection / Supply control PVEH-DI

1) AMP supply
signal connector
OFF US
≠ Delay
neutral UDC2
Error
PVEH-DI
AMP connector
Fault detection DI-A
2)
DI-B 3) 4)
DI-A DI Output Delay Memory
US Logic Error
OR
AND
high=on
low=off
Hydraulic
Fault detection output deactivation
P301 319
System Control Logic e.g. PLUS+1® for signal monitoring and triggering signal for deactivation of the
hydraulic system.
W Warning
520L0247 • Rev JA • May 2014 11
Identification
Identification
PVG 120 Identification
PVB
PVM
PVT
PVM
PVP
PVEH G
P
PVEO MA
S
F
C
D
PVH
PVMD V310156.A
C: PVG – number, week and year of installation

D: PVP – pressure setting
E: PVP – number, week, year and day manufacturing, issue and series No.
F: PVB – A-Port, number, week, year and day manufacturing, issue and series No.
G: PVT – week and year of manufacturing
12 520L0247 • Rev JA • May 2014
Installation
Installation and plug orientation

Installation Dimensions
190 [7.48]*
190 [7.48]*
60 Nm 60 Nm
[530 lbf•in] [530 lbf•in]
4xM12x18
[4x7/16-14UNCx0.7]
105 [4.13]
L
100 [3.94]*
100 [3.94]*
V310179.A
* Room for dismantling
Module of PVB 1 2 3 4 5 6 7 8
L mm 168 235 302 369 436 503 570 637
L in 6.61 9.25 11.88 14.53 17.17 19.80 22.44 25.08
Connection, PVP, Pump Side Module
520L0247 • Rev JA • May 2014 13
Installation
Oil flow direction
Mechanical / electrical actuation Mechanical / hydraulic actuation
A A
P B
P A
B
B
PB
PA P
V310169.A
V310163.A
A A
P B P A
B B
PB
PA P
V310162.A
V310170.A
Tightening Torques
Max. tightening torques – Connection Threads Type G (ISO 228/1)

Max. tightening torques
Ports PA, PB MA LS, LX, PP

Sealing thread G 1/4 G 1/4 G 3/8
With steel washer 35 N•m [310 lbf·in] 40 N•m [350 lbf·in] 60 N•m [530 lbf·in]
With cooper washer 30 N•m [270 lbf·in] 20 N•m [180 lbf·in] 35 N•m [310 lbf·in]
With aluminium washer 30 N•m [270 lbf.in] 30 N•m [270 lbf.in] 40 N•m [350 lbf·in]
With cutting edge 35 N•m [310 lbf.in] 40 N•m [350 lbf.in] 60 N•m [530 lbf·in]
14 520L0247 • Rev JA • May 2014
Installation
Max. tightening torques – Mounting Threads in SAE J 518c Flanges

Port Size Threads Tightening torque
P 1 in M12, 18 deep 68 N•m
7/16 - 14 UNC 0.7” deep [600 lbf·in]
A/B 3/4 in M10, 17 deep 45 N•m
3/8 - 16 UNC 0.7” deep [400 lbf·in]
T 1 in M10, 17 deep 45 N•m
3/8 - 16 UNC 0.7” deep [400 lbf·in]
Max. tightening torques – UN and UNF Connection Threads – O-ring Boss Port
Max. tightening torques
Ports P A/B T PA/PB MA LS, LX, PP

Sealing 1 5/16 in-12 UN 1 1/16 in-12 UN 1 5/16 in-12 UN ½ in-20 UNF ½ in-20 UNF ¾ in-20 UNF
/Thread
O-ring 160 N•m 120 N•m 160 N•m 30 N•m 30 N•m 60 N•m
[1410 in•lbs] [1060 in•lbs] [1410 in•lbs] [270 in•lbs] [270 in•lbs] [530 in•lbs]
Ports identification
520L0247 • Rev JA • May 2014 15
Installation
PVM, Lever Positions
Base with an angle of 37.5° Base with an angle of 22.5°
19.5
˚
19.5˚
19
19
.5˚
.5˚
37.5 67
˚ .5˚
97
.5˚
22.5˚
127
52
.5˚ 82
.5
.5
˚
˚
157.5˚
11
2.5
142.5
˚
187.5˚
˚
172.5˚
V310018.A
V310014.A
Setting of max. flow

Setting of Max. Flow
Q max.A
Q max.B Q max. Q max.
A B
LX
PP
3[0.12]
Q max.B -
8 Nm
+ [70 lbf in]
Q max.A -
+
10[0.39]
V310101.A
16 520L0247 • Rev JA • May 2014
Installation
Pressure Setting
PVP, LS Relief Valve Pressure Setting

PVP, LS Relief Valve Setting
6[0.24]
3[0.12]
P
MA
LS
3[0.12]
6[0.24]
3[0.12]
360° ~ 130 bar
[360° ~ 1900 psi] 3 Nm 35 Nm
[27 lbf•in] 8[0.31] [310 lbf•in]
V310102.A
PVB, LS Relief Valve Pressure Setting

PVB, LS Relief Valve Setting
6[.24]
3[0.12]
LX
PP
3[0.12]
6[.24]
3[0.12]
360° ~ 130 bar

[360° ~ 1900 psi] 3 Nm 8[0.31] 35 Nm
[27 lbf•in] [510 lbf•in]
V310094.A
520L0247 • Rev JA • May 2014 17
Installation
Option, Oil Flow Direction and Setting of max Flow
Oil flow direction
A P A
B A P B
PVEH MA
S
PVEO
V310158.A
Installation of PVE
For security reasons, any replacement of O-rings between valve block 1 and intermediate plate 2 may
only be effected at service shops authorized by Danfoss.
C Caution
Mixing up PVE series 2 for PVG 120 may lead to self-actuation.
18 520L0247 • Rev JA • May 2014
Installation
PVEH, PVEO
520L0247 • Rev JA • May 2014 19
Installation
Bleeding
PVG 120 installed vertically
*
190[7.48]
LX
T
PP
100[3.94] *
V310105.A
If the group is installed vertically, it is recommended to bleed it at the adjusting screws.
PVPE/PVH relief valves
Max. tightening torque for PVPE/PVH

Position Across flats Max. tightening torque
1 22 mm [0.87 in] 5 N•m [45 lbf•in]
2 36 mm [1.42 in] 85 N•m [750 lbf•in]
3 36 mm [1.42 in] 85 N•m [750 lbf•in]
Tightening PVPE/PVH
2.5[0.098]
2 Nm
[17.5 lbf•in)
PVPE
PVPH
2
LS
P
MA
LS
LS
PVP
V310157.A
20 520L0247 • Rev JA • May 2014
Installation
PVPH and LS connections
Max. tightening torque for PVPH and LS

Sealing Threads, DS/ISO 228/1 Max. tightening torque
Steel washer PVPH: G ¼ 40 Nm [350 lbf·in]
LS: G 3∕ 8 60 Nm [530 lbf·in]
Cupper washer PVPH: G ¼ 20 Nm [180 lbf·in]
LS: G 3∕8 35 N•m [310 lbf·in]
Aluminium washer PVPH: G ¼ 30 N•m [270 lbf·in]
LS: G 3∕ 8 40 Nm [350 lbf·in]
Cutting edge PVPH: G ¼ 40 Nm [350 lbf·in]
LS: G 3∕8 60 Nm [530 lbf·in]
PVPE technical data
PVPE technical data

Max. operation pressure 350 bar [5085 psi]
Max. pressure drop a an flow of 0.20 l/min. [0.053 US gal/min] 1.2 bar [17 psi]
Oil temperature Recommended temperature 30 to 60°C [86 to 140°F]

(inlet temperature)
Min. temperature –30°C [–22°F]
Max. temperature 90°C [194°F]
Max. coil surface temperature 155°C [311°F]
Ambient temperature –30 to 60°C [–22 to 140°F]
Oil viscosity Operating range 12 to 75 mm²/s [65 to 347 SUS]
Min. viscosity 4 mm²/s [39 SUS]
Max. viscosity 460 mm²/s [2128 SUS]
Response time for pressure relief to tank 600 ms
Enclosure to. IEC 529 IP 65
Rated voltage 12 V 24 V
Max. permissible deviation from rated supply voltage ± 10 % ± 10 %
Current consumption at at 22°C [72°F] coil temperature 1.55 A 0.78 A

rated voltage
at 85°C [230°F] coil temperature 1A 0.5 A
at 22°C [72°F] coil temperature 19 W 19 W
at 85°C [230°F] coil temperature 12 W 12 W
520L0247 • Rev JA • May 2014 21
Installation
Connection PVPE
Installing the wire
When installing the wire remember to connect the built-in diode to the plug pins.
22 520L0247 • Rev JA • May 2014
PVP
PVP, Pump Side Module
520L0247 • Rev JA • May 2014 23
PVP
With O-ring Boss port connection 1 5/16 in - 12 UN Code No.

PVP – closed center incl. PVPD 155G5022
PVP – open center excl. PVPD, PVPH, PVPE 155G5023
PVP – open center incl. uprating kit excl. PVPD, PVPH, PVPE 155G5028
PVP – closed center without relief valve 155G5031
7/16 - 14 UNC Code No.

× 18 deep Code No.

Item Description Code No.

631X2036 1 1 1 1
1 Plug
155L6405 1 1 1 1 1 1 1 1
2* Bonded seal 14.7 × 1.5 [0.58 × 0.06 in] 633B9017 1 1 1 1 1 1 1 1 1 1 1 1
3 Plug 155G6212 1 1 1
4* O-ring 30.3 × 2.4 [1.19 × 0.09 in] 633B1441 1 1 1
5 Insert incl. item 3, 4 155G5041 1 1 1
6 Plug 155G5325 1 1 1 1 1 1 1 1 1
7* O-ring 13.3 x 2.4 [0.52 × 0.09 in] 633B1462 1 1 1 1 1 1 1 1 1
8 Relief valve incl. pos. 9 155G8561 1 1 1 1 1 1 1 1 1
9* Washer 7.0 × 14.0 × 1.5 [0.28 × 0.55 × 0.06 in] 684X2367 1 1 1 1 1 1 1 1 1
10 Pump side housing – 1 1 1 1 1 1 1 1 1 1 1 1
631X2038 1 1 1 1
11 Plug
631X9716 1 1 1 1 1 1 1 1
12* Bonded seal 17.4 × 1.5 [0.69 × 0.06 in] 633B9018 1 1 1 1
O-ring 16.36 × 2.21 [0.64 × 0.09 in] 633B0046 1 1 1 1 1 1 1 1
13 Plug 681X3019 1 1 1
× ∅0.5 [0.2 × 0.02 in] 155G5318 1 1 1 1 1 1
14 × ∅0.5 [0.2 × 0.02 in] 155G5318 1 1 1 1 1 1
15 Plug 155G5314 1 1 1 1 1 1 1 1 1
16* O-ring 33.3 x 2.4 [1.31 × 0.09 in] 633B1029** 1 1 1 1 1 1 1 1 1
155G5330 1 1 1 1 1 1
17 Spring
155G5333** 1 1 1
155G5331 1 1 1 1 1 1
18 Spring
155G5334** 1 1 1
19 Washer 19.3 × 34.0 × 3.0 [0.76 × 1.34 × 0.12 in] 155G5317** 1 1 1 1 1 1 1 1 1
20 ∅0.5 [0.2 × 0.02 in] 155G5318 1 1 1
Screw M5 [0.2 in] 681X3019 1 1 1
155G5312 1 1 1 1 1 1
22 Spool
155G5321** 1 1 1
23 Plug 070-2741 1 1 1 1 1 1 1 1 1
24* Bonded seal 10.35 × 2.0 [0.41 × 0.08 in] 633B9016 1 1 1 1 1 1 1 1 1
25 Pin – 1 1 1 1 1 1 1 1 1
26 Name plate 155A5021 1 1 1 1 1 1 1 1 1 1 1 1
27 Drive srew 681Z8055 2 2 2 2 2 2 2 2 2 2 2 2
633X1028 1 1 1 1 1 1 1 1
28 Plastic plug
633X0064 1 1 1 1
* Set of seals 155G8501 1 1 1 1 1 1 1 1 1 1 1 1
** Uprating set for PVP ( PVB incl. 155G6035 see page 42) 155G5035
24 520L0247 • Rev JA • May 2014
PVP
PVPD, PVPH, PVPE, Accessories for PVP
520L0247 • Rev JA • May 2014 25
PVP
Additional Module for PVP Open Center
Type Code No.

12 V 155G5052
PVPE – extra electrical relief valve
24 V 155G5054
PVPD – Plug 155G5041
PVPH – extra hydraulic relief valve 155G5061

1 Electrical plug 155G5451 1 1
155G5013 1
2 Electrical relief valve incl. item 3, 4, 5
155G5025 1
3* O-ring 29.82 × 2.62 [1.18 × 0.10 in] 633B0069 1 1
4* Back-up ring 27.0 × 2.0 [1.06 × 0.08 in] 633B0068 1 1
5* O-ring 26.7 × 1.78 [1.05 × 0.07 in] 633B0070 1 1
6 Spring 155G5332 1 1
7 × ∅0.5 [0.2 × 0.02 in] 155G5318 2 2 2
8 Spool 155G5311 1 1 1
9 Plug 631X2040 1
10* O-ring 30 × 3 × 2.4 [1.18 × 0.09 in] 633B1441 1 1
11 Insert incl. item 9, 10 155G5041 1
12 Plastic plug 633X7018
13 Nut 155G5404 2
14 Bushing 155G5403 1
15* Back-up ring 155G2316 1
16* O-ring 25.3 × 2.4 [1.0 × 0.09 in] 633B1440 1
17 Spool 155G5405 1
18 Cone 155G5406 1
19 Seat 155B4478 1
20 Spring 155G3317 1
155G8527 1 1
* Set of seals
155G8526 1
26 520L0247 • Rev JA • May 2014
PVLP / PVLA
PVLP / PVLA, Shock and Suction Valve Port A/B
520L0247 • Rev JA • May 2014 27
PVLP / PVLA
Type Code No.

PVLP, pressure setting: 50, 75, 100, 125, 175, 200, 225, 250, 275, 300, 325, 350
,
375, 400 bar [725, 1087, 1450, 1813, 2538, 2900, 3263, 3625, 3988, 4351, 4713, 155G0...
5076, 5438, 5801 psi]
PVLA 155G1065

14 Plug 155G1386 1 1
15* Back-up ring 633B0014 1 1
16* Back-up ring 633B0016 1 1
17* O-ring 20.35 x 1.78 [0.80 × 0.07 in] 633B0015 1 1
PVLP 50 bar [725 psi] 155G0051 1
PVLP 75 bar [1087 psi] 155G0076 1
PVLP 100 bar [1450 psi] 155G0101 1
PVLP 125 bar [1813 psi] 155G0126 1
PVLP 150 bar [2175 psi] 155G0151 1
PVLP 175 bar [2538 psi] 155G0176 1
PVLP 200 bar [2900 psi] 155G0201 1
18 PVLP 225 bar [3263 psi] 155G0226 1
PVLP 250 bar [3625 psi] 155G0251 1
PVLP 275 bar [3988 psi] 155G0276 1
PVLP 300 bar [4351 psi] 155G0301 1
PVLP 325 bar [4713 psi] 155G0326 1
PVLP 350 bar [5076 psi] 155G0351 1
PVLP 375 bar [5438 psi] 155G0376 1
PVLP 400 bar [5801 psi] 155G0401 1
19 Plastic plug to protect cartridge 633X0053 1
20 Spring 155G1387 1 1
21 PVLA 155G1066 1
* Set of seals 155G8525 1 1
28 520L0247 • Rev JA • May 2014
PVBP, PVBR, PVBC, PVBU Accessories for PVB
520L0247 • Rev JA • May 2014 29
Type Code No.

PVBU - uprating kit for PVB 155G6035
PVBR - LSA/B relief valve 155G6080
PVBP - plug 155G6081
PVBC - connection for external LS-signal 155G6082

1 Plug 155G5325 1
2* O-ring 13.3 × 2.4 [0.52 × 0.09 in] 633B1462 1
3 Relief valve incl. item 4 155G8561 1
4* Washer 7.0 × 14.0 × 1.5 [0.28 × 0.55 × 0.06 in] 684X2367 1
5 Plug 155G2313 1
6* O-ring 30.3 × 2.4 [1.19 × 0.09 in] 633B1441 1 1 1 1
7* Back-up ring 155G2316 1 1 1 1
8* O-ring 25.3 × 2.4 [1.0 × 0.09 in] 633B1440 1 1 1 1
9** Adjustment disc. 155G2315 4 4 4 4
10 Spring 155G2317 1 1 1
11 Plug 155G2322 1
12 Plug 631X2036 1 1
13 Bonded seal 14.7 × 1,5 [0.58 × 0.06 in] 633B9017 1
14 Plug 155G2323 1
15 Spring 155G2324 1
16 Plug 155G2319 1
17 Washer 13.5 × 17.5 × 1.5 [0.53 × 0.69 × 0.06 in] 684X2120 1
* Set of seals 155G8502 1 1 1 1
30 520L0247 • Rev JA • May 2014
PVM
PVM, Mechanical Activating Module

9
8
8±1 Nm
[70±10 lbf•in]
5[0.20]
3
13 12
11 8±1 Nm
[71±9 lbf•in]
10
7
3[0.12]
4
PVM
6
5
3
10[0.39]
2.5±1 Nm
[22±9 lbf•in]
8±1Nm
4 mm [70±9 lbf•in]
[0.12 in] 5[0.20]
8± 0.5 Nm
2 [70±4.5 lbf•in]
8±1 Nm
[70±9 lbf•in]
1
8±1 Nm
13 mm [70±9 lbf•in]
[0.51 in]
6 mm
[0.24 in]
14
V310171.A
520L0247 • Rev JA • May 2014 31
PVM
Type Code No.

PVM with PVMD or PVE 22.5° / 37.5° 155G3040
PVM with PVH 22.5° / 37.5° 155G3050

1 Handle, black knob, including nut 1 1
2 Base, including set screw 22.5° / 37.5° 1 1
3 Screw M6 × 20 [0.24 × 0.78 in] 681X9266 8 8
4 PVM housing 155L3431 1 1
5 Seal nut M6 681X8270 2 2
6 Threaded pin M6 × 25 [0.80 × 0.07 in] 681X0323 2 2
7* 155L3430 1 1
8 Intermediate plate 155G3301 1 1
9* O-ring 42.0 × 2.0 [1.65 × 0.08 in] 633B1005 1 1
10 Spool control pin 155G3313 1 1
11 Stop 155G3314 1 1
155G3317 1
12 Spring
155G3318 1
13 Stop 155G3315 1 1
Spare Part, Kits Available

Item Description Code no.
14 Lever, with black knob handle and base 11046724
* Set of seals 155G8518
Lever, with red knob handle and base 11064640
1 Handle, black knob, including nut 11077262
2 Base, including set screw 11064641
32 520L0247 • Rev JA • May 2014
PVMD and PVH
PVMD, Cover for PVM and PVH, Hydraulic Activation
Type Code No.

PVM + PVH assy - UNF 155G4021
PVH assy - BSP.F - thread 155G4022
PVMD assy 155G4061

17 Screw M6 × 25 [0.80 × 0.07 in] 681X1198 4 4 4
633X7018 2
18 Plastic plug
633X0018 2
155G4301 1
19 Cover
155G4201 1
20* O-ring 6.0 × 2.0 [0.24 × 0.78 in] 633B1460 4 4 4
21* O-ring 27.0 × 2.0 [1.06 × 0.78 in] 633B0407 1 1 1
22 Cover 155G4402 1
* Set of seals 155G8505 1 1 1
520L0247 • Rev JA • May 2014 33
PVGI
PVGI, Interface for PVG 120 and PVG 32
Type Code No.

155G7033
PVGI sddy 1 5/16 in - 12 UN 155G7031
3/8 in - 16 UNC 155G7032

1 Combination module – 1 1 1
2 O-ring 24.0 × 2.0 [0.94 × 0.08 in] 633B1428 1 1 1
3 O-ring 10.0 × 2.0 [0.39 × 0.08 in] 633B1461 2 2 2
4 Bonded seal 14.7 × 1.5 [0.58 × 0.06 in] 633B9017 1 1 1
G 1/4 631X2036 1
5 Plug 1/2 - 20 UNF 155L6405 1 1
6 Plug 631X2040 3 3 3
7 O-ring 30.3 × 2.4 [1.19 × 0.08 in] 633B1441 3 3 3
633X1028 1 1
8 Plastic plug
633X0019 1
• Rev IE • Oct 2012
34 520L0247 • Rev JA • May 2014
PVEH and PVEO
PVEH and PVEO, Electrical Activating Module, ON-OFF
520L0247 • Rev JA • May 2014 35
PVEH and PVEO
Type Connector Code No.

Fault monitoring active, Hirschman 155G4092
11-32V AMP 155G4094
PVEH
Fault monitoring passive, Hirschman 155G4093
11-32V AMP 155G4095
12V 155G4272
Hirschman
24V 155G4274
PVEO
12V 155G4282
AMP
24V 155G4284
155G4284
155G4282
155G4274
155G4272
155G4095
155G4093
155G4094
155G4092
1 El. plug DIN 43650 Black PG 9 984L3156 1 1 1 1
2 Plastic plug 155U2779 1 1 1 1 1 1 1 1
3 PVEH assy – 1 1
PVEH assy. with passive fault monitoring – 1 1
PVEO assy – 1 1 1 1
4 Screw M6; l = 15 [0.24 in] 681X9266 4 4 4 4 4 4 4 4
5* O-ring 7 × 2 [0.28 × 0.78 in] 633B1148 1 1 1 1 1 1 1 1
6* O-ring 15 × 2 [0.59 × 0.78 in] 633B1030 1 1 1 1 1 1 1 1
7* O-ring 10 × 2 [0.39 × 0.78 in] 633B1267 2 2 2 2 2 2 2 2
8* O-ring 27 × 2 [1.06 × 0.78 in] 633B0407 1 1 1 1 1 1 1 1
* Set of seals 155G8519 1 1 1 1 1 1 1 1
36 520L0247 • Rev JA • May 2014
PVT
PVT, Tank Side Module – Upper Part
520L0247 • Rev JA • May 2014 37
PVT
With LX-connection Code No.

PVT, SAE UNF, mounting thread 3/8 in - 16 UNC 155G7025
PVT, Boss port connection 1 5/16 in - 12 UN 155G7024
× 23 deep 155G7023
Without LX-connection Code No.

PVT, SAE UNF, mounting thread 3/8 in - 16 UNC 155G7022
PVT, Boss port connection 1 5/16 in - 12 UN 155G7021
× 23 deep 155G7020

631X2038 2 2
1 Plug
631X9716 2 2 2 2
2* Bonded seal 17.4 x 1.5 [0.69 × 0.06 in] 633B9018 2 2
O-ring 16.36 x 2.21 [0.64 × 0.09 in] 633B0046 2 2 2 2
3** Screw M5; l = 6 [0.2 in] 681X1925 1 1 1
4** Bonded seal 5.7 x 1.0 [0.22 × 0.04 in] 633B9029 1 1 1
5** Plug (item 3 and 4) 155G8555
6* O-ring 10.0 x 2.0 [0.39 × 0.08 in] 633B1461 2 2 2 2 2 2
7* O-ring 24.0 x 2.0 [0.94 × 0.08 in] 633B1428 1 1 1 1 1 1
633X1028 1 1 1 1
8 Plastic plug
633X0064 1 1
9 Tank part assy - 1 1 1 1 1 1
* Set of seals 155G8507 1 1 1 1 1 1
** Used only when load signal is carried to LX-port 155G8555 1 1 1 1 1 1
38 520L0247 • Rev JA • May 2014
PVT
PVT, Tank Side Module – Lower Part
520L0247 • Rev JA • May 2014 39
PVT
UNC Code No.

PVT with pilot supply for PVE 155G7042
PVT without pilot supply for PVE 155G7062
BSP.F. thread Code No.

PVT with pilot supply for PVE 155G7040
PVT without pilot supply for PVE 155G7060

10 Screw M8 x 60 [0.31 × 2.36 in] 681X1146 3 3 3 3
11 Tank part assy - 1 1 1 1
12 Plug 155G7372 1 1
13* O-ring 17.5 x 2.4 [0.69 × 0.09 in] 633B1335 1 1
14* Filter 155B4056 1 1
15 Plug 155G7373 1 1
16* O-ring 19.3 x 1.5 [0.76 × 0.06 in] 633B1136 1 1
17 Stop 155G7376 1 1
18 Washer 10.0 x 16.0 x 0.5 [0.39 × 0.63 × 0.02 in] 684X2094 2 2
19 Spring 155G7375 1 1
20 Spool 155G7374 1 1
21 Plug 155L1373 1 1
22* O-ring 16.0 x 1.5 [0.63 × 0.06 in] 633B1813 1 1
23 Stop 155G7382 1 1
24 Washer 7.4 x 11.5 x 1.0 [0.29 × 0.45 × 0.04 in] 684X2547 2 2
25 Spring 155G7381 1 1
26 Ball 689X1040 1 1
* Set of seals 155G8524 1 1
Kit for hydraulic activation 155G7041 1 1
40 520L0247 • Rev JA • May 2014
PVAS and PVGI
PVGI, Assembly Kit
PVAS, Assembly Kit
Asssembly sequence
1. Mount nut on short thread and torque 10 N•m
2. Mount seal
3. Assemble PVG
4. Mount seal and nut on long thread and torque 10 N•m
5. When all three stay bolts are mounted, torque full to 80 N•m
W Warning
Do not reuse stay bolts or loosen torque. The stay bolts are not designed as motor bolts and do not keep
strength when remounted.
520L0247 • Rev JA • May 2014 41
PVAS and PVGI

PVGI, Assembly Kit (continued)
Type Code No.

PVGI for 0 basic module 155G8040
PVAS, Assembly Kit (continued)
Type Code No.

PVAS for 1 basic module 155G8031

1 Nut 155G8312 3 3 3 3 3 3 3 3 3 3 3 3 3
2* / 2** Bonded seal 17.4 x 1.5 [0.69 × 0.06 in] 633B9018 6 6 6 6 6 6 6 6 6 6 6 6 6
Stay bolt M12 [0.47]; l = 234 [9.21 in] 155G8201 3
Stay bolt M12 [0.47]; l = 302 [11.89 in] 155G8202 3
Stay bolt M12 [0.47]; l = 369 [14.53 in] 155G8203 3
Stay bolt M12 [0.47]; l = 436 [17.17 in] 155G8204 3
Stay bolt M12 [0.47]; l = 503 [19.80 in] 155G8205 3
3 Stay bolt M12 [0.47]; l = 571 [22.48 in] 155G8206 3
Stay bolt M12 [0.47]; l = 638 [25.12 in] 155G8207 3
Stay bolt M12 [0.47]; l = 705 [27.76 in] 155G8208 3
Stay bolt M12 [0.47]; l = 124.5 [4.90 in] 155G8330 3
Stay bolt M12 [0.47]; l = 192.5 [7.58 in] PVGI 155G8331 3
4* / 4** Pin 682L2006 18 16 14 12 10 8 6 4 10 8 6 4 2
5* / 5** O-ring 33.3 x 2.4 [1.31 × 0.09 in] 633B1029 18 16 14 12 10 8 6 4 10 8 6 4 2
6* / 6** O-ring 28.24 x 2.62 [1.118 × 0.10 in] 633B1956 9 8 7 6 5 4 3 2 5 4 3 2 1
7* / 7** O-ring 11.91 x 2.62 [0.47 × 0.10 in] 633B1955 18 16 14 12 10 8 6 4 10 8 6 4 2
8 O-ring 5.0 x 2.0 [0.20 × 0.08 in] 633B1809 2 2 2 2 2
9 O-ring 16.0 x 2.5 [0.63 × 0.10 in] 633B1817 4 4 4 4 4
11 O-ring 10.0 x 2.5 [0.39 × 0.10 in] 633B0120 1 1 1 1 1
* 155G8522 1 1 1 1 1 1 1 1 1 1 1 1
** Set of seals for additionel sections 155G8523 7 6 5 4 3 2 1 3 2 1
42 520L0247 • Rev JA • May 2014
Set of seals
Set of Seals
Type Code No.

PVP 155G8501
PVB / PVB additional module 155G8502
PVPH 155G8526
PVPE 155G8527
PVLP / PVLA 155G8525
PVM 155G8518
PVEH / PVEO 155G8519
PVH / PVMD 155G8505
PVT, Upper part 155G8507
PVT (with pilot supply), Lower part 155G8524
155G8522
PVAS for additional sections 155G8523

1 O-ring 8.3 x 2.4 [0.33 × 0.09 in] 633B0011 1
2 O-ring 20.35 x 1.78 [0.80 × 0.07 in] 633B0015 1
3 O-ring 16.36 x 2.21 [0.64 × 0.09 in] 633B0046 2 1
4 O-ring 29.82 x 2.62 [1.17 × 0.10 in] 633B0062 1
5 O-ring 26.7 x 1.78 [1.05 × 0.07 in] 633B0071 1
6 O-ring 27.0 x 2.0 [1.06 × 0.08 in] 633B0407 1 1
7 O-ring 6.3 x 2.4 [0.25 × 0.09 in] 633B1004 2
8 O-ring 42.0 x 2.0 [1.65 × 0.08 in] 633B1005 1
9 O-ring 33.3 x 2.4 [1.37 × 0.09 in] 633B1029 2 4 1
10 O-ring 15.0 x 2.0 [1.59 × 0.08 in] 633B1030 1
11 O-ring 8.0 x 2.0 [0.31 × 0.08 in] 633B1056 1
12 O-ring 19.3 x 2.4 [0.76 × 0.09 in] 633B1136 1
13 O-ring 8.0 x 2.0 [0.31 × 0.08 in] 633B1148 1
14 O-ring 10.0 x 2.0 [0.39 × 0.08 in] 633B1267 2
15 O-ring 17.5 x 2.4 [0.69 × 0.09 in] 633B1335 1
16 O-ring 24.0 x 2.0 [0.94 × 0.08 in] 633B1428 1
17 O-ring 25.3 x 2.4 [1.00 × 0.09 in] 633B1440 1 1
18 O-ring 30.3 x 2.4 [1.19 × 0.09 in] 633B1441 1 2 1
19 O-ring 6.0 x 2.0 [0.24 × 0.08 in] 633B1460 4 1
20 O-ring 10.0 x 2.0 [0.39 × 0.08 in] 633B1461 2
21 O-ring 13.3 x 2.4 [0.52 × 0.09 in] 633B1462 1 1
22 O-ring 20.3 x 2.4 [0.78 × 0.09 in] 633B1521 1
23 O-ring 16.0 x 1.5 [0.63 × 0.06 in] 633B1813 1
24 O-ring 10.52 x 1.83 [0.41 × 0.07 in] 633B1834 1
25 O-ring 11.91 x 2.62 [0.47 × 0.10 in] 633B1955 2 4
26 O-ring 28.24 x 2.62 [1.11 × 0.10 in] 633B1956 1 2
27 × 0.09 in] 155L3430 1
28 Washer 7.0 x 14.0 x 1.5 [0.28 × 0.55 × 0.06 in] 684X2367 1 1
29 Washer 16.2 x 19.9 x 1.5 [0.64 × 0.78 × 0.08 in] 684X2565 1 1
30 Bonded seal 10.35 x 2.0 [0.41 × 0.08 in] 633B9016 1
31 Bonded seal 14.7 x 1.5 [0.58 × 0.06 in] 633B9017 1
32 Bonded seal 17.4 x 1.5 [0.69 × 0.06 in] 633B9018 6 6 2 1
33 Bonded seal 5.7 x 1.0 [0.22 × 0.04 in] 633B9029 1
34 Back-up ring 633B0014 1
37 Back-up ring 155G2316 1 1
38 Filter 155G4710 1
39 Filter 155B4056 1
40 Seal nut 681X8270 2
41 Pin 682L2006 2 4
520L0247 • Rev JA • May 2014 43
PVG 120 module selection chart

PVG 120 modules exploded view
0
LS
P
d
1-8
f
e
a
10 9
11
c
V310173.A
PVB, high basic module

SAE O-ring Metric flange Weight
flange Boss kg [lb]
Facilities for shock valves AB 155G6007 155G6006 155G6005 10.2 [22.5]
PVB, low basic module

SAE O-ring Metric flange Weight
flange Boss kg [lb]
No facilities for shock valves AB 155G6016 155G6015 155G6014 8.9 [19.6]
44 520L0247 • Rev JA • May 2014
Accessory modules for PVB

Code number Weight, kg [lb]
Plug, PVBP 155G6081 0.4 [0.9]
LSA/B press. relief valve, PVBR 155G6080
External LS connection, PVBC 155G6082
Module for oil flow > 180 l/min [47.6 US gal/min], PVBU 155G6035
PVBS, mechanical actuation

Oil flow, l/min [US A B C D
gal] 65 [17.2] 95 [25.1] 130 [34.3] 180 [47.6]
155G6452 155G6454 155G6456 155G6458
155G6464 155G6466 155G6468
155G6476 155G6478
Weight, kg [lb] 0.35 [0.8]
PVM, mechanical actuation

PVM + PVMD or 155G3040 22.5°
PVM + PVE 155G3041 37.5°
PVM + PVH 155G3050 22.5°

155G3051 37.5°
Weight kg [lb] 0.5 [1.1]
PVMD, cover for PVM

Code number Weight, kg [lb]
155G4061 0.3 [0.7]
PVT, tank side module

Code number SAE O-ring Metric Weight
flange Boss flange kg [lb]
Upper part excl. LX connection 155G7022 155G7021 155G7020 4.6 [10.1]
Upper part incl. LX connection 155G7025 155G7024 155G7023
Lower part incl. pilot oil supply for PVE 155G7042 155G7040 4.4 [9.7]
Lower part excl. pilot oil supply for PVE 155G7062 155G7060
Lower part incl. pilot oil supply for PVH 155G7044 155G7043
520L0247 • Rev JA • May 2014 45
PVP, pump side module

Code number O-ring SAE Metric flange Weight
Boss flange kg [lb]
Open Excl. PVPD, PVPH, PVPE 155G5023 155G5037 155G5021 10.0 [22.1]
centre
For PVB-oil flow > 180 l/min [47.6 155G5028 155G5029 155G5027
US gal/min]
Excl. PVPD, PVPH, PVPE
Closed Incl. pressure relief valve and plug 155G5022 155G5038 155G5020 10.2 [22.5]
centre PVPD
Excl. pressure relief valve 155G5031 155G5032 155G5030 11.0 [24.3]
Accessory modules for open centre PVP

Description Code number Weight
kg [lb]
Plug, PVPD 155G5041 0.4 [0.9]
Hydraulic relief valve, PVH 155G5061 0.5 [1.1]
Electrical relief valve, PVPE 12 V 155G5052 0.7 [1.5]
24 V 155G5054
PVH, cover for PVRHH

Port Code number Weight, kg [lb]
1/2 in - 20 UNF 155G4021 0.4 [0.9]
G 1/4 155G4022
PVE, electrical actuation

Connector PVEH fault monitoring PVEO voltage
Active Passive 12 V 24 V
Hirschmann 155G4092 155G4093 155G4272 155G4274
AMP 155G4094 155G4095 155G4282 155G4284
Weight, kg [lb] 1.25 [2.76] 1 [2.2]
PVLA suction valve A/B

Code number Weight
kg [lb]
155G1065 0.2 [0.4]
PVLP, shock and suction valve A/B

Pressure setting
bar [psi] Code number
50 725 155G0050
75 1100 155G0075
100 1450 155G0100
125 1800 155G0125
150 2200 155G0150
46 520L0247 • Rev JA • May 2014
PVLP, shock and suction valve A/B (continued)

Pressure setting
175 2550 155G0175
200 2900 155G0200
225 3250 155G0225
250 3650 155G0250
275 4000 155G0275
300 4350 155G0300
325 4700 155G0325
350 5100 155G0350
375 5400 155G0375
400 5800 155G0400
Weight, kg [lb] 0.175 [0.386]
PVAS, assembly kit

PVB’s 1 2 3 4 5 6 7 8
Code number 155G8031 155G8032 155G8033 155G8034 155G8035 155G8036 155G8037 155G8038
Weight kg 0.8 1.0 1.1 1.2 1.4 1.7 1.9 2.1
[lb] [1.8] [2.2] [2.4] [2.6] [3.1] [3.7] [4.2] [4.6]
520L0247 • Rev JA • May 2014 47
Order specification
Ordering of modules for oil flow exceeding 180 l/min [47.6 US gal/min]
Modules for pump with fixed displacement
1. Ordering: Order accessory module 155G6035, main spool D, and pump side modules 155G5027 /
155G5028 / 155G5029.
2. Conversion: In open center systems a max. oil flow exceeding 180 l/min [47.6 US gal/min] can be
achieved by changing the following parts in the pump side and basic modules:
• Open center pump side module
– Pressure adjustment spool
– The springs behind the pressure adjustment spool
– The plug behind the pressure adjustment spool
Parts from kit 155G5035 may be used.
• Closed center pump side module (A closed center pump side module can be changed into an
upgraded open center pump side module by means of kit 155G5035.)
• Basic module
– Spring behind pressure compensator
– The plug behind the pressure compensator
Spring and plug with code number 155G6035 (PVBU, accessory module).
Modules for pump with variable displacement
1. Ordering: Order accessory module 155G6035 and main spool D.
2. Conversion:In closed center systems a max. oil flow exceeding 180 l/min [47.6 US gal/min] can be
achieved by changing the following basic module parts:
– The spring behind the pressure compensator.
– The plug behind the pressure compensator.
The code number of the spring and plug is 155G6035 (PVBU, accessory module).
Order Form
An order form for PVG 120 hydraulic valve is shown on next page. The form can be obtained from the
Danfoss Power Solutions Sales Organisation.
The module selection chart on the next page and the order form are divided into fields.
Each module has its own field:

0: PVP, pump side modules
d: PVPD, PVPH and PVPE, accessory modules
1-8: PVB, basic modules
e: PVBS, main spools
f: PVBP, PVBR, PVBU and PVBC, accessory modules
a: PVM, mechanical actuation
c: PVMD, cover for mechanical operation; PVH, cover for hydraulic operation; PVEO and PVEH, electrical
actuations
b: PVLP, shock and suction valve; PVLA, suction valve
9: PVT, tank side module
10: PVAS, assembly kit
48 520L0247 • Rev JA • May 2014
Order specification
Please state:
• Code numbers of all modules required
• Required setting (p) for pump side module
• Required setting of LSA/B pressure relief valves, if accessory module PVBR is ordered.
Reordering
The space at the top right-hand corner of the form is for Danfoss to fill in. The code number for the whole
of the specified valve group (PVG No.) is entered here. In the event of a repeat order all you have to do is
enter the number Danfoss has given on the initial confirmation of order.
If PVG 120 is to be used with phosphate-esters this must be stated on the order form (See Non-flammable
Fluids for more information).
520L0247 • Rev JA • May 2014 49
Order specification
50 520L0247 • Rev JA • May 2014
520L0247 • Rev JA • May 2014 51
Products we offer: Danfoss Power Solutions is a global manufacturer and supplier of high-quality hydraulic and
electronic components. We specialize in providing state-of-the-art technology and solutions that
• Bent Axis Motors excel in the harsh operating conditions of the mobile off-highway market. Building on our extensive
applications expertise, we work closely with our customers to ensure exceptional performance for a
• Closed Circuit Axial Piston broad range of off-highway vehicles.
Pumps and Motors
We help OEMs around the world speed up system development, reduce costs and bring vehicles to
• Displays market faster.
• Electrohydraulic Power Danfoss – Your Strongest Partner in Mobile Hydraulics.
Steering
Go to www.powersolutions.danfoss.com for further product information.
• Electrohydraulics
• Hydraulic Power Steering Wherever off-highway vehicles are at work, so is Danfoss.
• Integrated Systems We offer expert worldwide support for our customers, ensuring the best possible solutions for
outstanding performance. And with an extensive network of Global Service Partners, we also provide
• Joysticks and Control comprehensive global service for all of our components.
Handles
• Microcontrollers and Please contact the Danfoss Power Solution representative nearest you.
Software
• Open Circuit Axial Piston
Pumps
• Orbital Motors
• PLUS+1® GUIDE
• Proportional Valves
• Sensors
• Steering
• Transit Mixer Drives
Comatrol
www.comatrol.com
Schwarzmüller-Inverter
www.schwarzmueller- Local address:
inverter.com
Turolla
www.turollaocg.com
Valmova
www.valmova.com
Hydro-Gear
www.hydro-gear.com
Daikin-Sauer-Danfoss
www.daikin-sauer-danfoss.com
Danfoss
Power Solutions
Danfoss Danfoss Danfoss (Shanghai) Co., Ltd.
Power Solutions US Company Power Solutions GmbH & Co. OHG Power Solutions ApS Building #22, No. 1000 Jin Hai Rd
2800 East 13th Street Krokamp 35 Nordborgvej 81 Jin Qiao, Pudong New District
Ames, IA 50010, USA D-24539 Neumünster, Germany DK-6430 Nordborg, Denmark Shanghai, China 201206
Phone: +1 515 239 6000 Phone: +49 4321 871 0 Phone: +45 7488 2222 Phone: +86 21 3418 5200
Danfoss can accept no responsibility for possible errors in catalogues, brochures and other printed material. Danfoss reserves the right to alter its products without notice. This also applies to
products already on order provided that such alterations can be made without changes being necessary in specifications already agreed..
All trademarks in this material are property of the respective companies. Danfoss and the Danfoss logotype are trademarks of Danfoss A/S. All rights reserved.
520L0247 • Rev JA • May 2014 www.danfoss.com © Danfoss A/S, 2014
Page 1 of 2
SVI06-99-00-001 R.00
Logbook
Date Note Signature
Page 2 of 2
SVI06-99-00-001 R.00
Logbook
Date Note Signature
Chapter 7 Spare parts and tools (per ship set)
Sparepart list
Filter elements for Parker 32PD duplex filter.
502629 6 pcs
2 pcs Filter elements used during startup
Filter elements for Parker 513276 duplex filter.
511008 8 pcs
4 pcs Filter elements used during startup
Tools list
301979 Wrench for OF-Coupling Ø 250 1 pc
506151 Pipe for Propeller blade bolt NV55 1 pc
Page 1 of 2
Chapter 8 Brunvoll Volda Drawings and Manuals from Sub-suppliers

VA106419 Shafting 3
VA106338 Piping diagram 4
VI307229A Pipline instruction for separate mounted el.driven pump 5
SVI08-01-01-200 Indicator Alarm interface connections 6
VS307066 CP Propeller hub w Shaft for SOF coupling 7
604477BV Part list CW - V307066 8
604478BV Part list CCW - V307066 9
VS204297 CP85/4 Left Hand Assembly (CCW) 13
511201 IHC Netcutter Double execution 16
VK206431 CP85/4 Rope guard 17
VA106535 Stern tube Arrangement 18
513183 Stern tube Gland -Outer 21
513184 Stern tube Gland -Inner 22
VA305850 Pressurized Stern tube Lubr. for Simplex/IHC Supreme Gland 23
508411 Oil Tank 80 L 24
UG-323 Connection box General drawing 25
MN-4119 Temp sensor type MN4119 for bearing 26
MN-3725 Temp sensor - Installation manual for MN---- in stern tube 27
VS306987 SOF 250 Shaft Coupling Assembly 28
603541BV Part list SOF V306987 29
VA206980 Shaft locking device Arr. G600 CW Rotation 30
VS306312 Bracket Shaft Lock CW Turning, Assembly 31
VA206981 Shaft locking device Arr. G600 CCW Rotation 32
VS306313 Bracket Shaft Lock CCW Turning, Assembly 33
VA207144 Intermediate shaft arr. Shaft NO.1 and NO.2. (BVO 2286) 34
VA207148 Intermediate shaft arr. Shaft no.3 (BVO 2287 ) 35
513221 Intermediate Shaft Bearing arrangement 36
513221 Intermediate Shaft Bearing. Aeration system - Clarification 37
513221 Part List Intermediate Shaft Bearing 38
509271 Cathodic Slipring Arrangement With mV-meter 39
VS207026 Bulkhead seal Bulkhead # 24 45
207026 Part list V207026 - Bulkhead seals 46
513575-513639 Fire Resistant Bulkhead seal Bulkhead # 33 47
VL106525 Longitudinal section and piping arrangement. CW and CCW Gearboxes 48
VS305258 Pressure Switch panel - 8 valves 58
604398 Part list V308736v - Pressure Switch panel 60
VS403525 Pressure Gauge Panel 61
604399 Part list V403525 Pressure Gauge panel 62
VS202867 St-Ru-Si Valve Assembly 63
VS402432 Suction strainer with flange outlet 64
VS301485 Suction strainer ex. flange outlet 65
506740 Pick-Up - for Brunvoll Mar-El 66
506505 Danfoss PVG 120 Drawing 67
513216 Flexible shaft coupling Gear-Engine 68
513256 Oil Cooler Data Sheet 69
513256 Oil Cooler Drawing 70
Page 2 of 2

513256 Bloksma Compact Cooler, Manual 71
503717 Sika 174B - 1/2” L0 40 mm- Thermometer for oil cooler pipelines 93
513369 Electrical by Pump 94
502628 High Pressure Duplex Filters - Models 22PD, 32PD 95
502628 SVO Sparepart numbers, Parker High Pressure Duplex Filters 99
VA106419 Shafting
VA106338 Piping diagram
VI307229A Pipline instruction for separate mounted el.driven pump
Scana
Scana Volda as
Tel: +47 70059000 Fax: +47 70059001
SVI08-01-01-200
Indicator Alarm interface connections
China Merchants Heavy Industry Date:

Brunvoll Volda Inst. No.: 2312-13 12.11.2019
AG85/600
PRESSURE SWITCHES, TEMP FEELERS, TEMP SENSORS AND LEVEL SENSORS
Alarm Description Main_group Condition Range Signal Make Vendor Set Set Remarks Rev
Action Type Min Max
PS1A AUTO START PUMP 2 GEAR BOX LOW 5-40 BAR NC ON/OFF BRUNVOLL 17 NO ALARM SIGNAL TO
PRESSURE 504977 VOLDA BAR STAND BY PUMP STARTER
CABINET
PS1B AUTO START PUMP 1 GEAR BOX LOW 5-40 BAR NC ON/OFF BRUNVOLL 17 NO ALARM SIGNAL TO
PRESSURE 504977 VOLDA BAR STAND BY PUMP STARTER
CABINET
PS2 ALARM LOW LUB. OIL PRESSURE GEAR BOX LOW 0-16 BAR 4-20mA ANALOGUE BRUNVOLL 1,5 TO IAS, COMMON SENSOR rev 3
PRESSURE 504979 VOLDA BAR FOR LOW AND LOW LOW
PRESSURE ALARM
PS2 ALARM LOW LOW LUB OIL PRESSURE GEARBOX LOW 0-16 BAR 4-20mA ANALOGUE BRUNVOLL 1,0 TO IAS, COMMON SENSOR rev 3
PRESSURE 504979 VOLDA BAR FOR LOW AND LOW LOW
PRESSURE ALARM
PS3A EXTRA LOW LUB. OIL PRESSURE. AUTOMATICLY GEAR BOX LOW -1-10 BAR NO ON/OFF BRUNVOLL 1,0 SHUT DOWN SIGNAL TO
SHUT DOWN M.E. PRESSURE 504978 VOLDA BAR DRIVE. (PS3A and PS3B ONE
COMMON SIGNAL TO DRIVE)
PS3B EXTRA LOW LUB. OIL PRESSURE. AUTOMATICLY GEAR BOX LOW -1-10 BAR NO ON/OFF BRUNVOLL 1,0
SHUT DOWN M.E. PRESSURE 504978 VOLDA BAR
PS4 ALARM LOW SYSTEM OIL PRESSURE GEAR BOX LOW 0-100 BAR 4-20mA ANALOGUE BRUNVOLL 18 TO IAS
PRESSURE 504991 VOLDA BAR
PS11 ALARM CLOGGED OIL FILTER GEAR BOX HIGH NO ON/OFF BRUNVOLL 7 BAR TO IAS
DIFFERENTIAL 504583 VOLDA
PRESSURE
PS20 INTERLOCK REMOTE CONTROL AND START ME GEAR BOX LOW 0-40 BAR 4-20mA ANALOGUE BRUNVOLL 10 NO ALARM SIGNAL TO
PRESSURE 504996 VOLDA BAR REMOTE CONTROL UNIT
PS26 LOW LUB. OIL PRESSURE GEAR BOX LOW 0-16 BAR 4-20mA ANALOGUE BRUNVOLL 1,5 NO ALARM SIGNAL TO
PRESSURE 504979 VOLDA BAR REMOTE CONTROL UNIT
PS35 ALARM LOW AIR PRESSURE GRAVITY TANK LOCAL ON STERN LOW ON/OFF IHC BRUNVOLL 0,5 TO IAS
TUBE GRAVITY PRESSURE VOLDA BAR
TANK
TS1 ALARM HIGH LUB. OIL TEMPERATURE GEAR BOX HIGH TEMP. 0-100 ºC Pt100 ANALOGUE BRUNVOLL 50 ºC TO IAS
VOLDA
TS2 ALARM HIGH TEMPERATURE THRUST BEARING GEAR BOX HIGH TEMP. 0-100 ºC Pt100 ANALOGUE BRUNVOLL 67 ºC TO IAS
VOLDA
TS3 ALARM HIGH TEMPERATURE FWD STERN TUBE BULKHEAD HIGH TEMP. 0-100 ºC Pt100 ANALOGUE BRUNVOLL 60 ºC TO IAS
BEARING VOLDA
TS4 ALARM HIGH TEMPERATURE AFT STERN TUBE BULKHEAD HIGH TEMP. 0-100 ºC Pt100 ANALOGUE BRUNVOLL 60 ºC TO IAS
BEARING VOLDA
TS5 ALARM HIGH TEMPERATURE MID STERN TUBE BULKHEAD HIGH TEMP. 0-100 ºC Pt100 ANALOGUE BRUNVOLL 60 ºC TO IAS
BEARING VOLDA
TS6 ALARM HIGH TEMPERATURE INTERMEDIATE SHAFT CARRIER HIGH TEMP. 0-100 ºC Pt100 ANALOGUE BRUNVOLL 60 ºC TO IAS
BEARING 6 BEARING VOLDA
TS10 ALARM HIGH SERVO OIL TEMPERATURE GEAR BOX HIGH TEMP. 0-100 ºC Pt100 ANALOGUE BRUNVOLL 65 ºC TO IAS rev 5
VOLDA
TS11 HIGH HIGH TEMPERATURE THRUST BEARING, GEAR BOX HIGH TEMP. 0-100 ºC Pt100 ANALOGUE BRUNVOLL 75 ºC TO DRIVE rev 4
REQUEST SLOW DOWN VOLDA
TS13 HIGH HIGH LUB. OIL TEMPERATURE, REQUEST GEAR BOX HIGH TEMP. 0-100 ºC Pt100 ANALOGUE BRUNVOLL 60 ºC TO DRIVE rev 4
SLOW DOWN VOLDA
LS1 ALARM LOW OIL LEVEL GEAR GEAR BOX LOW OIL NO ON/OFF BRUNVOLL X TO IAS
LEVEL 501423 VOLDA
LS2 ALARM LOW OIL LEVEL STERN TUBE GRAVITY TANK LOCAL ON STERN LOW OIL NO ON/OFF BRUNVOLL X TO IAS
TUBE GRAVITY LEVEL 501423 VOLDA
TANK
MS1-NO INTERLOCK START DRIVE SHAFT LOCK ACTIVATED SHAFT LOCK NO ON/OFF BRUNVOLL NO ALARM SIGNAL TO rev 4
VOLDA REMOTE CONTROL UNIT
MS1-NC ALARM SHAFT LOCK ACTIVATED SHAFT LOCK NC ON/OFF BRUNVOLL TO IAS rev 4
VOLDA
X1 POWER FAILURE REMOTE CONTROL SYSTEM REMOTE VOLTAGE NO CLOSED BRUNVOLL TO IAS
CONTROL FAILURE CONTACT VOLDA
SYSTEM
X2 SYSTEM FAILURE REMOTE CONTROL SYSTEM REMOTE SYSTEM NO CLOSED BRUNVOLL TO IAS
CONTROL FAILURE CONTACT VOLDA
SYSTEM
VS307066 CP Propeller hub w Shaft for SOF coupling
Brunvoll Volda AS Page 1
29.05.2019
604477BV PROPHUB W/SHAFT CP85 12:45:25
604477BV Part list CW - V307066
Item number Item name Drawing no.
604477BV PROPHUB W/SHAFT CP85 V307066
Position Item number Item name Quantity Unit Drawing no.

001 403599 BLIND PLATE CP85/4 4,00 pcs V403599
002 604393BV PROP.HUB CP85 RH ASSY DEVA 1,00 pcs V204296
003 106329 PROPELLER SHAFT 1,00 pcs V106329
004 207167 PUSH PULL ROD CP85 1,00 pcs V207167
005 206970 FLANGE COVER CP85/4FOR IHC. 1,00 pcs V206970
006 500267 SOCKET SCREW 12,00 pcs DIN 912
007 501798 WASHER 12,00 pcs
008 405782 BUSHING INNER 1,00 pcs V405782
013 504496 PLUG 1,00 pcs DIN 908 MF
015 513255 O-RING 1,00 pcs
Brunvoll Volda AS Page
29.05.201
604478BV PROPHUB
604478BV W/SHAFT
Part list CCW CP85
- V307066 12:46:2

604478BV PROPHUB W/SHAFT CP85 V307066

001 403599 BLIND PLATE CP85/4 4,00 pcs V403599
002 604394BV PROP.HUB CP85 LH ASSY DEVA 1,00 pcs V204297
003 106329 PROPELLER SHAFT 1,00 pcs V106329
004 207167 PUSH PULL ROD CP85 1,00 pcs V207167
005 206970 FLANGE COVER CP85/4FOR IHC. 1,00 pcs V206970
007 501798 WASHER 12,00 pcs
008 405782 BUSHING INNER 1,00 pcs V405782
013 504496 PLUG 1,00 pcs DIN 908 MF
015 513255 O-RING 1,00 pcs
VS204296 CP85/4 Right Hand Assembly (CW)
A
250 350 370 170
18
Loctite 572
n764
H
F
H
Loctite 572 Preload 330Nm

Loctite 243
13 13 18 14
Loctite 572 A
Tack weld to bolts
28 6 20
n 84
40
A
°
57
Detail F
Blade Bolts Preload
Apply anti seize compound to threads
Each bolt to be mounted with a preload of 200Nm.
Then tighten 57° or a choord of 40mm at Ø84
GENERAL TOLERANCES: SCALE

TOLERANCE: ISO 2768m. THREADS: 6g/6H 1:5
DRAWN APPR. DATE
HB
Brunvoll Volda AS
AM 07.09.2000 N-6101 Volda, NORWAY
Tel: +47 70059000 Fax: +47 70059001
D 20942 14.03.2019 AM www.brunvoll.no e-mail: [email protected]
C 11442 23.06.2008 MP CP85 PROPELLER DWG.NO. REV.

Right hand assembly D
B 8422 20.01.2007 MP
A 7008 09.01.2006 ØF VS 204296
REV DESCR. DATE APP. REF. Copyright of Brunvoll Volda as, whose property this document remains. No part of the document may SHEET
REVISION TABLE be disclosed, copied, duplicated, or in any other way made use of, except with approval of Brunvoll Volda as. 1 /2
VS204296 CP85/4 Right Hand Assembly (CW)
Apply teflon grease,

Tack weld to bolts
(PTFE)
18 Mt 330Nm, Loctite 243
Preload 200Nm
+ choord 32mm at Ø84
26 5 14 2 7 31 29 10 6 28 16 1 25 20 24
6 15
B
Loctite 243 29 7
1
12 30 31
7
16

(PTFE)
C
L
100 100
D
Wrench size 85 Nut
Anti seize compund.
Tighten to an
elongation of the bolt
of :L = 1.10mm Open for oil flow D
at the grooves
Section A-A Use anti seize compound on threads

Scale 1:5 B Section B-B
Loctite 2701 Scale 1:5
27 19 17 27 19
1 9
Loctite 243
21 3 22 23 Loctite 2701 in crank disc

Preload 200Nm
+ choord 40mm at Ø84 13 13
6
8 Section D-D
Tack weld to disc 29 Section G-G Loctite 572
15 Scale 1:5
Tack weld to nut Scale 1:5
30
Open for oil flow
23 31 at the grooves at 90°
4 GENERAL TOLERANCES: SCALE

Section C-C TOLERANCE: ISO 2768m. THREADS: 6g/6H 1:5
Scale 1:5 DRAWN APPR. DATE
HB
Brunvoll Volda AS
Section H-H Tel: +47 70059000 Fax: +47 70059001
Scale 1:5 D 20942 14.03.2019 AM www.brunvoll.no e-mail: [email protected]
C 11442 23.06.2008 MP CP85 PROPELLER DWG.NO. REV.

Right hand assembly D
B 8422 20.01.2007 MP
A 7008 09.01.2006 ØF VS 204296
604393BV Part list Propeller hub VA204296
12.11.201
604393BV PROP.HUB CP85 RH ASSY DEVA 14:15:5

604393BV PROP.HUB CP85 RH ASSY DEVA V204296

001 103201BV PROPELLER HUB CP85/4 1,00 pcs V103201
002 102443 GUIDE CP85/4, RIGHT HAND 1,00 pcs V102443
003 303575 BOLT FOR PUSH PULL ROD C85/4 1,00 pcs V303575
004 303576 NUT FOR PUSH PULL ROD BOLT 1,00 pcs V303576
005 203055 AIR CHAMBER CP85/4 1,00 pcs V203055
006 303578 BOLT FOR BLADE CP85 24,00 pcs V303578
007 204333 CRANK DISC CP85 RH 4,00 pcs V204333
008 403570 GUIDE PIN IN BLADEFLANGE CP85 4,00 pcs V403570
009 403571 GUIDE PIN IN SHAFTFLANGE CP85 4,00 pcs V403571
010 303573 SLIDING BLOCK 4,00 pcs V303573
011 402234 GUIDING DISC 2,00 pcs V402234
013 508506 PLUG 3,00 pcs DIN 908 MF
015 512195 O-RING 48,00 pcs
016 512857 O-RING FOR PROPELLER BLADE 4,00 pcs
017 513254 O-RING 1,00 pcs
018 506070 SET.SCREW 3,00 pcs DIN 916
019 403834 BUSHING CP85/4 2,00 pcs V403834
020 502350 ACID PROOF STEEL 3 490,00 mm
021 504487 HEX.BOLT 2,00 pcs DIN 933
022 403572 PLATE CP85/4 1,00 pcs V403572
023 501918 ROD STEEL FLAT 85,00 mm
024 303789 BOLT 12,00 pcs V303789
025 403748 NUT FOR PROP.SHAFTFLANGE CP85 12,00 pcs V403748
026 308382 ANODE Aluminium 8KG 1,00 pcs V308382
027 500642 SNAP RING 2,00 pcs DIN 472
028 404135 PLUG FOR PROPELLER BLADE 8,00 pcs V404135
029 304948 CP85 RADIAL BUSHING 4,00 pcs V304948
030 404838 PIN 32,00 pcs V404838
031 304946 CP85 INNER AXIAL BUSHING 4,00 set V304946
VS204297 CP85/4 Left Hand Assembly (CCW)
A
250 350 370 170
18 B
Loctite 572
n764
H
Loctite 572 Preload 330Nm

Loctite 243
13 13 18 14
Loctite 572 A
Tack weld to bolts
28 6 20
n 84
40
°
57
Detail F A
Blade Bolts Preload
Apply anti seize compound to threads
Each bolt to be mounted with a preload of 200Nm.
Then tighten 57° or a choord of 40mm at Ø84

DRAWN APPR. DATE
HB
Brunvoll Volda AS
Tel: +47 70059000 Fax: +47 70059001
www.brunvoll.no e-mail: [email protected]
CP85 PROPELLER DWG.NO. REV.

Left hand assembly VS 204297 D
REF. Copyright of Brunvoll Volda as, whose property this document remains. No part of the document may SHEET
be disclosed, copied, duplicated, or in any other way made use of, except with approval of Brunvoll Volda as. 1 /2
Tack weld to bolts
(PTFE)
18 Mt 330Nm, Loctite 243 B Preload 200Nm
+ choord 32mm at Ø84
26 5 14 2 7 31 29 6 28 16 1 25 20 24
6
B
Loctite 243 29 7
1
12 30 31
7
16

(PTFE)
C
L
C
100 100
D
Wrench size 85 Nut
Anti seize compund.
Tighten to an
elongation of the bolt Open for oil flow
of :L = 1.10mm at the grooves
D
Use anti seize compound on threads

Section A-A
Scale 1:5 B C
Section B-B
Loctite 2701 Scale 1:5
27 19 17 10 27 19
1 9
Loctite 243 Open for oil flow

at the grooves at 90°
21 23 4 3 22 23 Loctite 2701 in crank disc
Preload 200Nm 13 13
6
Tack weld to disc + choord 40mm at Ø84
Section D-D
Tack weld to nut 8 Section G-G Scale 1:5 Loctite 572
15
Scale 1:5
30
29
Section C-C 31
Scale 1:5 GENERAL TOLERANCES: SCALE
DRAWN APPR. DATE
HB
Brunvoll Volda AS
Tel: +47 70059000 Fax: +47 70059001
D 20949 19.03.2019 AM www.brunvoll.no e-mail: [email protected]
Section H-H C 11443 23.06.2008 MP CP85 PROPELLER DWG.NO. REV.

Left hand assembly D
Scale 1:5 B 8423 20.01.2007 MP
A 7009 09.01.2006 ØF VS 204297
604394BV Part list Propeller hub VA204297

29.11.201
604394BV PROP.HUB CP85 LH ASSY DEVA 13:04:4

604394BV PROP.HUB CP85 LH ASSY DEVA V204297

001 103201BV PROPELLER HUB CP85/4 1,00 pcs V103201
002 102442 GUIDE CP85/4, LEFT HAND 1,00 pcs V102442
003 303575 BOLT FOR PUSH PULL ROD C85/4 1,00 pcs V303575
004 303576 NUT FOR PUSH PULL ROD BOLT 1,00 pcs V303576
005 203055 AIR CHAMBER CP85/4 1,00 pcs V203055
006 303578 BOLT FOR BLADE CP85 24,00 pcs V303578
007 204328 CRANK DISC CP85 LH 4,00 pcs V204328
008 403570 GUIDE PIN IN BLADEFLANGE CP85 4,00 pcs V403570
009 403571 GUIDE PIN IN SHAFTFLANGE CP85 4,00 pcs V403571
010 303573 SLIDING BLOCK 4,00 pcs V303573
011 402234 GUIDING DISC 2,00 pcs V402234
013 508506 PLUG 3,00 pcs DIN 908 MF
015 512195 O-RING 48,00 pcs
016 512857 O-RING FOR PROPELLER BLADE 4,00 pcs
017 513254 O-RING 1,00 pcs
018 506070 SET.SCREW 3,00 pcs DIN 916
019 403834 BUSHING CP85/4 2,00 pcs V403834
020 502350 ACID PROOF STEEL 3 490,00 mm
021 504487 HEX.BOLT 2,00 pcs DIN 933
022 403572 PLATE CP85/4 1,00 pcs V403572
024 303789 BOLT 12,00 pcs V303789
025 403748 NUT FOR PROP.SHAFTFLANGE CP85 12,00 pcs V403748
026 308382 ANODE Aluminium 8KG 1,00 pcs V308382
027 500642 SNAP RING 2,00 pcs DIN 472
028 404135 PLUG FOR PROPELLER BLADE 8,00 pcs V404135
029 304948 CP85 RADIAL BUSHING 4,00 pcs V304948
030 404838 PIN 32,00 pcs V404838
031 304946 CP85 INNER AXIAL BUSHING 4,00 set V304946
511201 IHC Netcutter Double execution
REV DESCRIPTION NAME DATE

A Original issue MVGEMEREN 29-Nov-2012
96
40
20
10
O 10 (2x)
10
10 20
40
This document remains the property of IHC Sealing Solutions. All rights reserved. This document or any part thereof may not be made public or disclosed, copied or otherwise reproduced or used in any
form or by any means, including but not limited to use hereof for the design and manufacturing of identical or similar parts or products, without prior permission in writing from IHC Sealing Solutions.
DRAWN MVGEMEREN General tolerances acc. ISO 2768-mK

Shape and position tolerances acc. ISO 1101
29-Nov-2012
DRAWN DATE
IHC Sealing Solutions Roughness Ra according ISO 1302
APPR. mvgemeren
ALBLASSERDAM HOLLAND REF.:
APPR. DATE 29-Nov-2012 13:47 -
MATERIAL: AISI316 TITLE: DRAWING NO.: REV.
WEIGHT: 0.2 kg NETCUTTER 46261991 A

STATUS: Double execution
A4
PROJ.: SCALE: UOM:
60 -:- mm
VK206431 CP85/4 Rope guard
215 Mounting
A Weld
210
5
15
15
5
Split Split
(Ø774)
n744
n670
50
100
^
Net cutter
30 50 50 50 (35)
Plug weld
Mounting of rope guard

8
Ropeguard
(two halves welded together)
to be fitted at mounting.
5
A
Section A-A 1 2
Scale 1 : 5
Split after rolling
1
The ropeguard must be sandblasted
2 and coated with primer
Only welded to one part

(when mounting also to the other)
4 STEEL PLATE T=15, 100X50 3 Steel NVA (St37) 1 kg
1 PLATE, T=15, Ø744/Ø670 2 Steel NVA (St37) 10 kg
1 PLATE, T=15, 2400X210 1 Steel NVA (St37) 59 kg
QTY DESCRIPTION POS ART.NO MATERIAL WEIGHT
DRAWN APPR. DATE
LAA 23.01.2014
Brunvoll Volda AS
Tel: +47 70059000 Fax: +47 70059001
CP 68/4
DWG.NO. REV.
B
A
20769
17611
12.18.2018 LAA
18.03.2014 LAA
ROPE GUARD VK 206431 B
VA106535 Stern tube Arrangement
4 1 2 3 11 L 12 10 E
50 780 5013 340 3647 330 A
5
F
G J
Ø355 (Nominal)
Ø450 (Nominal)
Ø449(Nominal)
A B
Ø360 (Nominal)
U r 0.04AB r 0.04AB j 0.04AB U
(Ø370)
(Ø300)
(Ø290)
G J 19
View F F
Scale 1 : 10 200 STERNTUBE, L E
4 NOT BRUNVOLL VOLDA SUPPLY 86
Section E-E 10 12 A
Scale 1 : 10
5843 4317 Sterntube seen from aft
End of sterntube
Scale: 1 : 10
10160
Yard supply
(boss & chockfast)
36
1. Brunvoll Volda is not responsible for

the scantling of the stern tube.
The stern tube is sketched on this drawing
only for making general impression.
2. Pipes and fittings not shown in partlist
are to be delivered by yard.
End of temp.sensor pipe in bearings
is to be plugged. Radius of bends in
temp. sensor pipe to be min. 50 mm.
3. Machining in bearings for temp. sensor pipes,
to be prepared by Brunvoll Volda.
1 160 4. Tempsensor tubes to be securely
20 Section U-U 21 22 clamped, min. 15 mm from rotating parts.
Scale 1 : 10
(330) 3
Seen from aft
TEMP.SENS. TEMP.SENS. NOTES:
Seen from aft Position of inner sterntube INNER S.T. BUSHING TEMP.SENS. 1. "ART.NO" = "YS" MEANS YARD SUPPLY
MIDDLE S.T. BUSHING
512 bearing temp. sensors 3 8 OUTER S.T. BUSHING
(END OF TUBE TO BE 170
Position of aft sterntube Position of middle sterntube 170 PLUGGED) 9 6
7 9 16 12 9 20
bearing temp. sensors Section M-M bearing temp. sensors Section R-R
(END OF TUBE TO BE Scale 1 : 10 (END OF TUBE TO BE Section P-P Scale 1 : 10
PLUGGED) PLUGGED) Scale 1 : 10 21
Equally
22
spaced
13 13 Equally 16
13 spaced
1 13 13 A 20977 29.03.2019 MK
Equally REV DESCR. DATE APP.
spaced 13 REVISION TABLE
R 3 FITTING S12-12 BRASS 36 503402 Brass

P 1 PREC.TUBES STERNT.12.0X1.0 22 YS Stainless Steel
2
M 13
1 PREC.TUBES STERNT.12.0X1.0 21 YS Stainless Steel
13 16 1 PREC.TUBES STERNT.12.0X1.0 20 YS Stainless Steel
13
R 12 SOCK.SCR. NS5735 M12X40 19 500187 Steel 12.9
13 P 3 FITTING FB12-1/2BSP BRASS 16 503403 Brass
12 SET.SCREW DIN916 M12X40 13 500078 Steel 45H
13 10 12 Section L-L
13 2 FITTING GE 28 PLR 12 500324 Steel
M Section G-G
Section J-J
Scale 1 : 10
1 PACKING, GASKOID 1.0 mm 11 502068 Mule
Scale 1 : 10 Seen from forw.
Scale 1 : 10 1 OIL INLET RING SUPRE.330 10 305005 Cast Iron 56 kg
GG25
3 TEMP.SENSOR COUPLING BOX 9 503481
A1
12xM20x2.5
15°
B C UG-323
45DEEP 30 15° 1 TEMP.FEEL.MN4119SU50 8 504804
° C ° 12xM12x1.75
A2 h 0.03C 1.6 30 1 TEMP.FEEL.MN4119SU75 7 507144
35 DEEP 1 TEMP.FEEL.MN4119DU150 6 508852
See also A3 1 STERNT.GL.INNER STF 330 - Ø290 5 513184 130 kg
20
30
Sheet 3 1.6 n4
°
1.6 1.6 12.5 A 1 STERNT.GL.OUTER STA 400-Ø370 4 513183 175 kg

)
0
+ 0.07
n 57 1.6 1 STERNTUBE BUSHING INNER 3 309193 Steel St52-3N 80 kg
Ø460 - 00.09
0
Ø520 H7 (
ø290x330
50 1 STERNTUBE BUSHING INNER 2 309192 Steel St52-3N 77 kg
n670
B3 ø300x340
1 X 45° B2 1 STERNTUBE BUSHING OUTER 1 309191 Steel St52-3N 300 kg
1 X 45° B1 GENERAL TOLERANCES: SCALE
3.2 View C TOLERANCE: ISO 2768m. THREADS: 6g/6H 1:10
10150
B Scale 1 : 10 DRAWN
MK
APPR.
AM
DATE
26.03.2019
Brunvoll Volda AS
Hole Table 10 N-6101 Volda, NORWAY
(10160) C
Tel: +47 70059000 Fax: +47 70059001
HOLE XDIM YDIM DESCRIPTION TOL.
3.2
View B
CP85/4 STERNTUBE
A1 -73.76 275.29 M20x2.5 - Hole Table

Scale 1 : 10 Section A-A HOLE XDIM YDIM DESCRIPTION TOL.
DWG.NO. REV.
A2 -201.53 201.53 M20x2.5 - ARRANGEMENT
3.2
A3 -275.29 73.76 M20x2.5 - Scale 1 : 10 B1 54.35 -202.84 M12x1.75 `0.1 VA 106535 A

Only sterntube shown B2 148.49-148.49 M12x1.75 `0.1 REF. Copyright of Brunvoll Volda as, whose property this document remains. No part of the document may SHEET
B3 202.84 -54.35 M12x1.75 `0.1 be disclosed, copied, duplicated, or in any other way made use of, except with approval of Brunvoll Volda as. 1 /3
Temp.sensor
middle sterntube bearing
Temp.sensor
7
outer sterntube bearing
Bend Radius MIN. 50 mm 6
21
20
Bend Radius MIN. 50 mm
1
Temp.sensor tube
outer sterntube bearing
Bend Radius MIN. 50 mm 10

20
Temp.sensor 22
inner sterntube bearing
8
20
9
9
6 Temp.sensor tube
12 outer sterntube bearing
20
2
21
16
Temp.sensor tube 21
16
16 7 Temp.sensor tube
21
22
16 21
9
21
21
20 16
3
Temp.sensor tube
inner sterntube bearing
22
16 22
Temp.sensor tube
20 inner sterntube bearing
20
20
Showing tubes.
Some part omitted

DRAWN APPR. DATE
MK 26.03.2019
Brunvoll Volda AS
AM N-6101 Volda, NORWAY
Tel: +47 70059000 Fax: +47 70059001
CP85/4 STERNTUBE
DWG.NO. REV.
ARRANGEMENT VA 106535 A
1
1
0.
4`
During final turning
R
45
at Shipyard
LD AT
n
VO ED
A
LL RN
1.6
VO T U
1.6 15
15°
UN H
BR U G
RO
0.5
10
Detail AP
Scale 2 : 1
45°
45°
Nominal diameter n450

197
.5
20°
4xM12x1.75 -50 DEEP

DRILL AFTER PRESSING INTO THE BOSS
390
10 AP
n12.5 -650 DEEP
DRILLED IN BRUNVOLL VOLDA
R
(780)
VIEW FROM THE BOW VIEW FROM AFT

Section R-R
AFT S.T. BUSHING Scale 1 : 2.5 AFT S.T. BUSHING
Scale: 1 : 2.5 Scale: 1 : 2.5
0.1
0.1
359 `
364 `
4xM12x1.75 -50 DEEP During final turning
An
LL V ED AT
An
LL V ED AT
DRILL AFTER PRESSING INTO THE BOSS at Shipyard
2
OL D
OLD
During final turning 3
N
at Shipyard
BRU H TUR
BRU H TUR
NVO
NVO
15 S
G
R OU
ROU
15
1.6 T 1.6
15°
15°

45°
45°
45°
45°
.5
162
25° 25°
n12.5 -210 DEEP

n12.5 -210 DEEP
T S
(340)
VIEW FROM AFT VIEW FROM THE BOW 4xM12x1.75 -50 DEEP VIEW FROM AFT
(330) INNER S.T. BUSHING MIDDLE S.T. BUSHING DRILL AFTER PRESSING INTO THE BOSS MIDDLE S.T. BUSHING
Scale: 1 : 2.5 Scale: 1 : 2.5 Section S-S Scale: 1 : 2.5
VIEW FROM THE BOW Scale 1 : 2.5
Section T-T
INNER S.T. BUSHING Scale 1 : 2.5 GENERAL TOLERANCES: SCALE
Scale: 1 : 2.5 1:5
The middle stern tube
TOLERANCE: ISO 2768m. THREADS: 6g/6H
The aft and fore stern tube

DRAWN APPR. DATE
MK 26.03.2019
Brunvoll Volda AS
bearings to have a pressure fit

Tel: +47 70059000 Fax: +47 70059001
bearings to have a pressure fit CP85/4 STERNTUBE

DWG.NO. REV.
with interference 0.03 mm with interference 0.05 mm ARRANGEMENT VA 106535 A

513183 Stern tube Gland -Outer
A Original issue NDHARTOG 18-okt-2017
SECTION A-A (1:1) SECTION B-B (1:2)

View "P" (1:4)
107 115 115 107 112 112 B
108 109 101 102 114 103 114 104 117 113 110 111 A
15°
200 ±4
30
° (1
104 2x
Place serial number )
19 125
.
x..
21
P 5 A
6
30°
106 118 118

27 B
116 119 PCD. 570
B
A
Liner O 380,5
PCD. 460
-0,59
-0,68
O 424 g6
O 500
O 520
O 610
125 1 Name Plate Bronze 46255006
124 1 Measuring plug G-1/4 Brass 46261501
225
123 1 Box Wood 46255142 Contains Pos. 122
122 1 Vernier calliper (IWS) Steel 46255141
Note for customer assembly floor / yard: A 121 6 HH Screw M12x20 D933 Steel 8.8 00141764
1 After installation fill chamber with biodegradable oil. Stern tube hole tolerance H7
Same as used in stern tube. 120 3 Bracket 380-670 Steel MC380-670
B 111 119 2 Lip seal spring 400 AISI 316 36261613
Hub hole tolerance H7
118 3 Lip Seal 400 FKM-EAL 36263063
112
117 1 Gasket 400 AFCF 46261363
116 1 Lip seal spring 400 Hastelloy C-4 36262613
115 4 Sealing Ring 14x18 D7603-A Copper 02150553
114 4 HHS Plug G-1/4 D910 A4 00625042
113 12 Collar Bolt M20x60 AISI 316Ti 46230050
122 112 36 Spring ring M10 D127-B A4 00353210
Bracket View(1:1) 111 24 HSH Screw M10x35 - D912 A4-70 00252721
Remove after installation 124 123 110 12 HSH Screw M10x20 - D912 A4-70 00252624
109 12 Collar Bolt M16x40 AISI 316Ti 46230026
120
108 1 Gasket 400 LB AFCF 46267263
107 1 Securing Wire AISI 316 46255151 L= 5 m
19
106 1 Liner STA-CP 400 Stainless steel LB010400-380
20
104 1 Flange Ring STA-400 Bronze HB010400
121
103 1 Int. Support Ring STA-400 Bronze HB030400
102 1 End Support Ring STA-400 Bronze HB040400
107
101 1 End Ring 2/2 SC STA-400 Bronze HB061400
POS QTY Description Material Art. / DRAWING No Remarks
This document remains the property of Lagersmit. All rights reserved. This document or any part thereof may not be made public or disclosed, copied or otherwise reproduced or used in any
form or by any means, including but not limited to use hereof for the design and manufacturing of identical or similar parts or products, without prior permission in writing from Lagersmit.
DRAWN NDHARTOG General tolerances acc. ISO 2768-mK
LAGERSMIT
DRAWN DATE 18-okt-2017
Roughness Ra according ISO 1302
APPR. rbenjamins
THE ORIGIN OF SEALING SOLUTIONS REF.:
APPR. DATE 24-Oct-2017 13:00 -
Securing wire TITLE: DRAWING NO.: REV.
MATERIAL:
Stern tube measuring point WEIGHT: 109,3 kg SUPREME STA-400 X01400JV380 A
STATUS: N2
60 - Final Shaft dia 363 - 380 PROJ.: SCALE: UOM:
A1
1:4 (1:1; 1:2) mm
513184 Stern tube Gland -Inner
SECTION B-B (1:2) A Original issue NDHARTOG 25-Feb-2016
View P (1:2)
SECTION A-A (1:1) B 210
A
217 15°
206 216 203 223 202 201 204 213 211 12

x3
0°
+3
160 0
69 Place serial number

5 17
.
..
3 0°
x.
30°
G3/8 (3x)
P
15 40
212
A
214 205
215
B
A
C
Liner O 290 F7
-0,51
-0,58
208
O 515
O 435
O 400 207 209

180
223 1 Scraper NBR 75 46261951

A Stern tube hole tolerance H7 222 2 HH Screw M10x16 D933 Steel 8.8 00141722
221 2 Bracket STF 220-355 S235JR (1.0037) MC220-355F
B Shaft diameter tolerance h6
C
220 2 Nut M12 D934 Steel 8 00185162
B
PCD. 480 - 12xM16 218 1 HHS Plug G-3/8 D910 A4 00625043
216 1 HHS Plug G-1/8 D910 A4 00625041
215 2 Lip seal spring 330 AISI316 36261610
214 2 Lip Seal 330 FKM85 36263060
213 1 Clamp Ring 330 EN-GJL-250 46251160-290
SECTION C-C (1:1) 212 1 Name Plate Bronze 46255006
211 8 HH Screw M12x40 D933 Steel 8.8 00141772
Bracket View (1:1) 210 12 HH Screw M8x25 D933 Steel 8.8 00141686
Remove after installation 209 12 Spring ring M8 D127-26 Steel 00353009

208 12 HSH Screw M8x35 - D912 Steel 8.8 ELVZ 00251235
222 221 220 207 12 HH Screw M16x40 D933 Steel 8.8 00141852
206 1 Gasket 330 AFCF 46261360
205 1 O-Ring 285,1x7 NBR70 10029093
204 1 Liner STF-330 Stainless steel LB070330-290
203 1 Flange Ring STF 330 EN-GJL-250 HB200330
202 1 Support Ring STF-330 EN-GJL-250 HB210330
201 1 Lock Up Ring STF 330 EN-GJL-250 HB220330
POS QTY Description Material Art. / DRAWING No REMARKS
218 This document remains the property of Lagersmit. All rights reserved. This document or any part thereof may not be made public or disclosed, copied or otherwise reproduced or used in any
form or by any means, including but not limited to use hereof for the design and manufacturing of identical or similar parts or products, without prior permission in writing from Lagersmit.
DRAWN NDHARTOG General tolerances acc. ISO 2768-mK
219 LAGERSMIT
DRAWN DATE 25-Feb-2016
Roughness Ra according ISO 1302
APPR. ndhartog
THE ORIGIN OF SEALING SOLUTIONS REF.:
APPR. DATE 07-Mar-2016 09:08 -
TITLE: DRAWING NO.: REV.
MATERIAL:
WEIGHT: 74.5 kg SUPREME STF-330 X20330AS290 A

STATUS: N2
60 - Final Shaft dia 295 PROJ.: SCALE: UOM:
A1
1:2 (1:1) mm
VA305850 Pressurized Stern tube Lubr. for Simplex/IHC Supreme Gland
508411 Oil Tank 80 L
UG-323 Connection box General drawing
MN-4119 Temp sensor type MN4119 for bearing
MN-3725 Temp sensor - Installation manual for MN---- in stern tube
VS306987 SOF 250 Shaft Coupling Assembly
GENERAL TOLERANCES:
TOLERANCE: ISO 2768m. THREADS: 6g/6H
Brunvoll Volda AS
Tel: +47 70059000 Fax: +47 70059001
603541BV Part list SOF V306987
Brunvoll Volda AS Pa
29.11.2
603541BV SHAFT COUPLING 15:2

603541BV SHAFT COUPLING V306987

001 103088BV SOF-COUPLING 1,00 pcs V103088
002 201100 OF250 SLEEVE FOR COUPLING 1,00 pcs V201100
003 300795 OF250 MONT.PIST.FOR COUPL 1,00 pcs V300795
004 500820 HYDR SEAL 1,00 pcs
005 500065 PLUG CONICAL 2,00 pcs
008 306279 SERVOMOTORPISTON ø450 1,00 pcs V306279
011 401274 FITTED BOLT 12,00 pcs V401274
012 301721 CONNECT.FLANGE Ø225/M80*3 1,00 pcs V301721
013 508481 O-RING 2,00 pcs BS 4518
014 500413 LOCK NUT 12,00 pcs DIN 985
015 500069 SET.SCREW 8,00 pcs DIN 916
016 205700 PRESSURE PLATE SERVO G680 1,00 pcs V205700
017 512558 O-RING 1,00 pcs
018 504705 U-PACKING 1,00 pcs
020 500803 O-RING 1,00 pcs BS 1806
022 306988 G680 SERVO CONNECTING DISC 1,00 pcs V306988
023 503164 SET.SCREW 1,00 pcs DIN 916
025 506393 O-RING 1,00 pcs BS 4518
026 501798 WASHER 4,00 pcs
027 508480 PROFILE-RING 2,00 pcs
029 500735 O-RING 1,00 pcs BS 1806
030 513261 O-RING 1,00 pcs BS 1806
031 507529 O-RING 1,00 pcs
032 500073 SET.SCREW 1,00 pcs DIN 916
VA206980 Shaft locking device Arr. G600 CW Rotation
(420)
1
3 SEEN FROM AFT
Scale 1 : 5
2
A A
016
833
n1
8x M24x110 SOCKETSCREW
AND 8 xM24 LOCK NUT,
548
YARD SUPPLY
20
FOUNDATION,
YARD SUPPLY
40 210 40 310
220
315 290 350 140
140 40
3 (605)
40
2 SECURING BOLT
(LOCKED POS.) 1
30
5
SECURING BOLT
210
290
(OPEN POS.)
5
10 SOCK.SCR. NS5735 M20X60 3 500228 Steel 12.9
Section A-A 1 BRAKE DISC 2 206978 132 kg
Scale 1 : 5
1 SHAFT LOCKING ASSY RIGHT 1 306312 101 kg
HAND
QT DESCRIPTION PO ART.N MATERIAL WEIGHT
LUBE WITH GENERAL TOLERANCES: SCALE
GREASE TOLERANCE: ISO 2768m. THREADS: 6g/6H 1:5
Notes / Operating intstruction: DRAWN APPR. DATE
MK 10/01/2018
Brunvoll Volda AS
1. Make sure all power is switched off from the shaft line, and that the ship is not moving. AM N-6101 Volda, NORWAY
Tel: +47 70059000 Fax: +47 70059001
2. Disconnect the securing bolt at the handle
SHAFT LOCKING DEVICE ARR.
3. Push the locking slide into corresponding hole in the disc (pos2) DWG.NO. REV.
4. Insert and tighten the securing bolt in the locking slide. G600, CW ROTATION VA 206980
5. Reverse operations to unlock the shaft line.
6. Make sure the securing bolt is tightened and safely locks the slide in the open position. REF. Copyright of Brunvoll Volda as, whose property this document remains. No part of the document may SHEET
1 5 2 12 5 2
LOCKED 5 2
POSITION 1
VS306312
11 12
7 11
9 7
Ø70
10 9
3
4 3 10
1
6 7 4
A A
648
B
548
120
220
1 BRACKET 12 307134 2 kg
4 HEX.BOLT NS5720 M12X25 11 501873 Steel 8.8 0 kg
290
1 MICROSWITCH 10 506420 0 kg
40
Section A-A 1 MICROSWITC ADJUSTING PLATE 9 404274 Steel S235JRG2 0 kg
Scale 1 : 5 2 SOCK.SCR. NS5735 M5X12 8 500138 Steel 12.9 0 kg
605 2 SOCK.SCR. NS5735 M6X12 7 500149 Steel 12.9 0 kg
1 LOCK NUT DIN 985 M10 6 500405 Steel 8 0 kg
Bracket Shaft Lock CW Turning, Assembly
120
1 HEX.NUT NS5730 M 16 4 501008 Steel 10 0 kg
40

1 SHAFT LOCKING BOLT 2 405526 Steel 12 kg
12
1 SHAFTLOCK BRACKET 1 205260 Steel 87 kg
QT DESCRIPTION POS ART.N MATERIAL WT
11
DATE DRAWN SCALE
02.02.2006 KjK 1:5 Scana
APPR. CONF. TRAC. Scana Volda as
10  N-6101 Volda, NORWAY
Tel: +47 70059000 Fax: +47 70059001
1 5 2 4 3 www.scana.no e-mail: [email protected]
BRACKET SHAFT LOCK DWG.NO.
B 15999 19.10.2012 HO 6 CW. TURNING, ASSEMBLY
A 12933 29.06.2009 KjK
VS 306312 
REV DESCR. DATE APP. REF.  

REVISION TABLE 1/1
Chapter 8 - Page 31
VA206981 Shaft locking device Arr. G600 CCW Rotation
1
(420)
3 2
16
10
n
SEEN FROM AFT

Scale 1 : 5
8x M24x110 SOCKETSCREW
AND 8 xM24 LOCK NUT,
YARD SUPPLY
A A
833
548
20
FOUNDATION,
YARD SUPPLY
3 2
40
350 1
IN LOCKED
POSITION 40 210 40
140
220 310 290 315
(605)
SECURING BOLT
(LOCKED POS.)
1
Notes / Operating intstruction:
SECURING BOLT
1. Make sure all power is switched off from the shaft line, and that the ship is not moving.
40
(OPEN POS.) 2. Disconnect the securing bolt at the handle

3. Push the locking slide into corresponding hole in the disc (pos2)
4. Insert and tighten the securing bolt in the locking slide.
5
5. Reverse operations to unlock the shaft line.

290
210
30
6. Make sure the securing bolt is tightened and safely locks the slide in the open position.
5
10 SOCK.SCR. NS5735 M20X60 3 500228 Steel 12.9

1 BRAKE DISC 2 206978 132 kg
LUBE WITH
GREASE 1 SHAFT LOCKING ASS'Y LEFT HAND 1 306313 101 kg
40 140
220 GENERAL TOLERANCES: SCALE
Section A-A DRAWN APPR. DATE
MK 10/01/2018
Brunvoll Volda AS
Scale 1 : 5 Tel: +47 70059000 Fax: +47 70059001
SHAFT LOCKING DEVICE ARR.

DWG.NO. REV.
G600, CCW ROTATION VA 206981
6 2
7 2 LOCKED 5 1 1
POSITION 2 5 5
4
VS306313
12
3
11
10
9
9
Ø70
7
10 3 4
7 11 12 6
A A
120
648
B
548
220
1 BRACKET 12 307134 2 kg
290 1 MICROSWITCH 10 506420 0 kg
Section A-A 1 MICROSWITC ADJUSTING PLATE 9 404274 Steel S235JRG2 0 kg
40
Scale 1 : 5 2 SOCK.SCR. NS5735 M5X12 8 500138 Steel 12.9 0 kg
2 SOCK.SCR. NS5735 M6X12 7 500149 Steel 12.9 0 kg
315 190 1 LOCK NUT DIN 985 M10 6 500405 Steel 8 0 kg
5
Bracket Shaft Lock CCW Turning, Assembly
1 HEX.BOLT NS5720 M10X120 500952 Steel 8.8 0 kg

1 HEX.NUT NS5730 M 16 4 501008 Steel 10 0 kg
40

1 SHAFT LOCKING BOLT 2 405526 Steel 12 kg
12
1 SHAFTLOCK BRACKET 1 205259 Steel 87 kg
11 DATE DRAWN SCALE
02.02.2006 KjK 1:5 Scana
10  N-6101 Volda, NORWAY
Tel: +47 70059000 Fax: +47 70059001
3 4 2 5 1
BRACKET SHAFT LOCK DWG.NO.
B 16003 21.10.2012 HO 6 CCW. TURNING, ASSEMBLY
A 12938 29.06.2009 KjK
VS 306313 

REVISION TABLE 1/1
Chapter 8 - Page 33
VA207144 Intermediate shaft arr. Shaft NO.1 and NO.2. (BVO 2286)
1000Nm (31) 11 1000Nm
6 7 (38) 10 2 7 3 5 4 7 1 3 4
2 6036 3 4 5
5351
Ø250 h6 (- 00.029) 250 h6 (- 00.029)

Detail C
Detail D
1620 310 1065 3735

310
7885 6645
14530
Connection to SOF250 Shaft coupling

Section A-A
Scale 1:15
Thread locking adhesive to be applied O-ring

see note 1
Thread locking adhesive to be applied

O-ring
see note 1
~1
A
~1
NOTES:
1. MAKE SURE THAT O-RING IS PRESENT, WITHOUT ANY DAMAGE
AND LUBED BEFORE MOUNTING THE SHAFTS TOGETHER.
2. SHAFT ENDS ARE MARKED BY SPECIFIED INSTALLATION FLAGS o.
3. ALL FITTED BOLTS HAVE TO BE LUBRICATED WITH
MOLYBDENUM DISULPHIDE BEFORE MOUNTING.
To be spot welded 4x25 mm, a=4 mm

Spread equally.
A To be done after mounting of oil pipes.
Detail C 1 WATER TIGHT AND FIRE 11 513689 130 kg
View SEEN FROM AFT
Scale 1:2.5 PROOF BULKHEAD SEAL ø250
Scale 1:10
Detail D 1 SPLIT BULKHEAD SEAL Ø250. 10 207026 165 kg
Scale 1:2.5 3 BEARING Ø250 7 513221 260 kg
To be spot welded 4x25 mm, a=4 mm 1 O-Ring 510x5 6 511278 Rubber
Spread equally.
1 O-RING 430.66x5.33 5 507763 NBR
To be done after mounting of oil pipes.
20 LOCK NUT DIN 985 M36 4 500413 Steel 8
20 FITTED BOLT Ø40h6x165 Gu 3 401274 Steel 2 kg
M36x4 34CrNiMo6
1 INTERMEDIATE SHAFT NO.2, 2 207147 3120 kg
ASSEMBLY
1 INTERMEDIATE SHAFT NO.1 1 207146 2597 kg
DRAWN APPR. DATE
MK 03/12/2018
Brunvoll Volda AS
Tel: +47 70059000 Fax: +47 70059001
INTERMEDIATE SHAFT ARR.

DWG.NO. REV.
SHAFT NO.1 AND 2. VA 207144
Inst.: 2286 be disclosed, copied, duplicated, or in any other way made use of, except with approval of Brunvoll Volda as. 1 /1
VA207148 Intermediate shaft arr. Shaft no.3 (BVO 2287 )
7885
B
Ø710
Ø600
Section A-A
Scale 1:10
1 2
10xn40 H6 (+00.016) 12xn40 H6 (+00.016)

A 10xM20x2.5 THRU 2xM20x2.5
5
40 n63
n5
A View B
Scale 1:10
1 TELESCOPIC PIPE ASSY. 2 207151 141 kg

INTERM. SHAFT NO.3
1 INTERMEDIATE SHAFT No.3 1 106335 Steel C45N 2978 kg
DRAWN APPR. DATE
MK 03/12/2018
Brunvoll Volda AS
Tel: +47 70059000 Fax: +47 70059001
INTERMEDIATE SHAFT NO.3

DWG.NO. REV.
ASSEMBLY VS 207148
2287 be disclosed, copied, duplicated, or in any other way made use of, except with approval of Brunvoll Volda as. 1 /1
513221 Intermediate Shaft Bearing arrangement
IN FLOODED CONDITIONS
INSTALLATION DETAILS
AERATION SYSTEM PT-100 INSTALLATION POSITION
104,79 SB PS SB PS
PIPE LENGTH 1 METER ABOVE THE WATER LEVEL
24 25 26 27 28
A 1 2 3 4 5 6 7 8 9 10 11 12
SB PS
29
30 AFT FWD
23
CLOCKWISE ROTATION COUNTERCLOCKWISE ROTATION
22
INSTALLATION POSITIONS
31 Z AFT FWD
21
20
X2
X1
19 250
,35
H7
562
32
33 200 Max. angle 4°

34 SLOPED SHAFT MAX SHAFT MISALIGNING
SELF-LUBRICATION WORKING PARAMETERS
280
35 Cooling water doorway MATTING SURFACES TO BE PROTECTED WITH RUST CORROSION PREVENTIVE COATING
(AS TECTYL OR SIMILAR)
Acc. to JIS B2220 (5K-20A)
OIL QUALITY............................................................................ ISO VG 150
OIL QUANTITY......................................................................... 2.5 liters
36
MAX COOLING WATER PRESSURE DROP...................... 0.1 bar
37 MAX COOLING WATER PRESSURE.................................. 3 bar
33
30
COOLING WATER FLOW....................................................... 7-14 l/min

38 17 17 49
MAX COOLING WATER INLET TEMPERATURE............. 38 C
RECOMMENDED SHAFT SPEED RANGE........................... 15-202 rpm (AT MAX. 45 C ENVIRONMENT TEMP.)
Cooling water doorway 42 41 40 39
A MAX PROJECTED PRESSURE............................................. 0.60 MPa (30kN)
Acc. to JIS B2220 (5K-20A) CENTER PLANE 16 15 14 13 PAINT......................................................................................... EPOXY PRIMER
EXTERNAL PAINT COLOUR................................................. GREY (RAL 7038)
Acc. to JIS B2220 (5K-25A) 210 259 SRP OPERATION CONDITIONS
MAX WATER PRESSURE IN FLOODED CONDITIONS... 1.2 bar
SECTION A-A MAX TIME DURING FLOODED CONDITIONS.................... 3 days
MAX OPERATING TIME AT 95 C...................................... 4 hours

Acc. to JIS B2220 (5K-15A)
AFT FOR OTHER PERFORMANCE PARAMETERS, PLEASE CONTACT WITH THE MANUFACTURER.
LEG SUPPORTING AREA 50 43 44 45 46

BEFORE BEARING INSTALLATION, PLEASE READ THE INSTALLATION MANUAL FOR SRP BEARINGS.
PLUNGE GRIND PITCH AND TWIST FREE THE FINAL OIL LEVEL HAS TO BE VERIFIED BY MARKS OF THE OIL LEVEL DIPSTICK.
Rz 4
2 x 10 SEALING NOTES
(PRE-MACHINED HOLE APPLY CURIL T STANDARD OR SIMILAR UNIVERSAL JOINTING COMPOUND IN THE FOLLOWING
FOR TAPERED PIN 12 COMPONENTS, DURING THE ASSEMBLY PROCESS:
47 0.02 0.02 0.02
DIN7978) - BETWEEN THE TWO BODIES OF THE BEARING HOUSING. CURIL T
Ra 0.8 - BETWEEN THE TWO BODIES OF THE SEAL HOUSING.
- BETWEEN THE BEARING HOUSING AND THE INSPECTION PLATE. 53

- BETWEEN THE BEARING HOUSING AND THE SEAL HOUSING, AND ON THE THREADS OF THE BOLTS
THAT JOIN THEM TOGETHER.
48
75
- ON THE THREAD OF THE DIPSTICK ADAPTER.

A
42
250 h7
250 h7
SB
220
PS
469
485
49
75
3 x EXT. LUB. BY GREASE

JOINT LUBRICATION HOLE
50
2 x M16 51
(LEVEL SCREW)
0.03 A 95 146
0.03 A
4 x 32 52 0.0.2 243 292 0.0.2
(FIXATION BOLT M30)
293 342
CENTER PLANE 17
FWD
635 18
SHAFT
Distance between suports

shall not exceed 370 mm.
530
572 D DETAIL Z
T FW SCALE 1 : 2
600 AF
GGENERAL REVISION 12.03.19 DVR POL. IND. AS GÁNDARAS - 206, B-3
All rights reserved www.wartsila.com

FGENERAL REVISION 25.10.17 DVR 36475 PORRIÑO - PONTEVEDRA - SPAIN
TELF:+34 986 344 048
EGENERAL REVISION 28.09.17 DVR FAX:+34 986 344 716
E-mail: [email protected]
DDRAWING NUMBER UPDATED 20.09.17 DVR
CGENERAL REVISION 15.09.17 BGQ INTERMEDIATE SHAFT BEARING
D T
FW
MODIFICATIONS DRAWN REVIEWED APPROVED
19 1 SENSOR PT-100 COMMERCIAL MN524S200U AF CUSTOMER MATERIAL QUALITY WEIGHT General arrangement - LSB2-270
2 1 BEARING SHELL EN-GJL-250/SnSb8Cu4 or WJ2 --- --- --- --- 276.6 kg DTWG 170978-03.ISB.00
1 1 BEARING HOUSING EN-GJL-250 --- PROJECT REFERENCE --- FORMAT SCALE VERSION OPSQ-SRP
REPLACED BY ---
ITEM QTY DESCRIPTION MATERIAL REFERENCE --- --- --- A2 1:5 ORIGINAL DRW ---
BVo Installation Manual No.: 2312-13. IMO No.: -. Date: 2019-11-18 Chapter 8 Page 36
513221 Intermediate Shaft Bearing. Aeration system - Clarification
AERATION SYSTEM
(Stainless steel pipe
with legth 1 meter above the water level
in flood condition. 20
This pipe is supplied by shipyard)
FWD
84
50
Male stud coupling
supplied by Wärtsilä
(for pipe Ø20mm)
E POL. IND. AS GÁNDARAS - 206, B-3

D 36475 PORRIÑO - PONTEVEDRA - SPAIN

TELF:+34 986 344 048
C FAX:+34 986 344 716
B
A DRAWING CREATION 15.11.17 LLG INTERMEDIATE SHAFT BEARING
CUSTOMER MATERIAL QUALITY WEIGHT Aeration system - Clarification
--- 266.3 kg DTWG 170978-03.ISB.I1
PROJECT REFERENCE --- FORMAT SCALE VERSION LSB2-270-SRP
REPLACED BY
--- A4 1:8 ORIGINAL DRW
513221 Part List Intermediate Shaft Bearing
50 1 SEALING COMPOUND --- --- --- CURIL T

49 1 INLET PLUG G1/2" --- PPA "GRIVORY" --- TCNB-12
48 8 WASHER M10 --- 8.8 --- DIN7980
47 8 HEXAGON SCREW M10x45 42Nm 8.8 --- DIN933
46 2 SCREW M10x55 42Nm 8.8 --- DIN912
45 2 DOWEL PIN 10x40 --- 100Cr6 --- DIN7979
44 2 DOWEL PIN 10x24 --- 100Cr6 --- DIN6325
43 1 BLIND FLANGE JOINT (JIS B2220 5K-15A) --- COMPRESSED FIBRED SHEET --- LSB2-07
42 1 BLIND FLANGE (JIS B2220 5K-15A) --- MILD STEEL --- LSB2-06
41 1 PLUG M16x1.5 --- STAINLESS STEEL --- DIN908
40 1 IDENTIFICATION PLATE --- ALUMINIUM --- LSB2-01
37 1 PLUG G1/2" --- STAINLESS STEEL --- DIN908
36 16 SCREW M10x30 42Nm 8.8 --- DIN912
35 16 WASHER M10 --- STEEL --- DIN125A
30 16 SCREW M10x30 42Nm 8.8 --- DIN912
28 1 V-SHAPED THERMOMETER G1/2" - 110x30 --- COMMERCIAL --- LSB2-05
27 3 BONDED SEAL G1/2" --- RUBBER-METAL --- ZT21008
26 8 SCREW M6x35 9Nm 8.8 --- DIN912
24 1 INSPECTION PLATE --- POLYCARBONATE 0.2 LSB2-Serie2-SRP-16
23 1 FRAME --- STAINLESS STEEL 0.6 LSB2-Serie2-SRP-16-01
22 2 EYE BOLT M16 --- C15 --- DIN580
21 1 ADAPTER M-F G1/2"- 14 --- MILD STEEL 0.05 LSB2-03
20 1 DIPSTICK --- STEEL 0.14 LSB2-04-SRP
19 1 SENSOR PT-100 --- COMMERCIAL --- MN524S200U
18 1 MALE STUD COUPLING G1/2" --- GALVANIZED --- DIN2353
17 1 DEFLECTION RING 10x10 --- NITRILE --- LSB2-09
16 2 SRP SEAL --- --- 26.1 170978-03.ISB.11
15 1 COOLER PLATE --- MILD STEEL 2.1 LSB2-270-15
13 18 HEXAGON SCREW M8x25 21Nm 8.8 --- DIN933
12 1 COOLER PLATE JOINT --- NBR 0.1 LSB2-270-15-01
11 2 SCREW M8x40 21Nm 8.8 --- DIN912
10 2 NUT M8 --- 8 --- DIN985
9 1 OIL RING --- AlSi7Mg 5.2 LSB2-270-SRP-250-09
8 1 OIL SCRAPER --- AlSi7Mg 0.2 LSB2-Serie25-07
7 1 SET OF LEVELING PLATES M8 --- STEEL --- LSB2-02
6 1 WASHER M8 --- STEEL --- NL8sp
5 1 SCREW M8x25 21Nm 8.8 --- DIN6921
4 1 ANTI-ROTATION D14 x L30 --- ST --- ISO8752
3 1 MALE STUD COUPLING G1/2- 20 --- GALVANIZED --- DIN2353
2 1 BEARING SHELL --- EN-GJL-250/SnSb8Cu4 or WJ2 61.29 LSB2-270-250-03
1 1 BEARING HOUSING --- EN-GJL-250 140.7 LSB2-270-01
TORQUE SUPPLY
ITEM QTY DESCRIPTION MATERIAL MASS DRAWING/STANDARD
MAX.
E POL. IND. AS GÁNDARAS - 206, B-3
D 36475 PORRIÑO - PONTEVEDRA - SPAIN

TELF:+34 986 344 048
C GENERAL REVISION 25.10.17 DVR FAX:+34 986 344 716
B PART LIST UPDATE 24.10.17 BGQ
A DRAWING CREATION 28.08.17 BGQ INTERMEDIATE SHAFT BEARING
CUSTOMER MATERIAL QUALITY WEIGHT Part list - OPSQ-F 270
--- --- --- 266.2 kg DTWG 170978-03.ISB.BOM
PROJECT REFERENCE --- FORMAT SCALE VERSION LSB2-270-SRP
REPLACED BY ---
--- --- --- A4 --- ORIGINAL DRW ---
509271
509271 Cathodic Slipring Arrangement With mV-meter
Impressed Current Cathodic Protection System

(ICCP)
INSTALLATION / INSTRUCTION
MANUAL
Slipring Arrangement
With mV-meter
Customer : Scana Volda AS
Yard/Y.No :
Impressed Current Cathodic Protection System Vessel/Project:
(ICCP)
15 Sept 2004
Cathodic AS, P.O. Box 110, NO-3995 Stathelle

Telephone: +47 35 96 77 40, Telefax: +47 35 96 77 01
MANUAL
With mV-meter
Yard/Y.No :
Vessel/Project:
15 Sept 2004

509271
Y.No./Yard/Vessel:
BONDING OF PROPELLER SHAFT
w/mV-meter Impressed Current Cathodic Protection System
(ICCP)
Complete kit for one shaft: INSTALLATION / INSTRUCTION

MANUAL
1 steel ring with silver liner, shaft dia. = ø mm
1 brush holder - double Slipring Arrangement
1 brush holder - single With mV-meter
3 brushes, silver graphite

1 bracket for brush holders Customer : Scana Volda AS
1 monitor with mV-meter Yard/Y.No :
1 flexible grounding lead (wire) from brush holder Vessel/Project:
to the hull (yard supply). Min. 35 mm2
Assemble instructions 15 Sept 2004

1. Find a suitable location for assembling the slipring arrangement. The slipring e-mail: [email protected]
should be located as far as possible away from the shaft bearings, and also away
from the shaft coupling. The shaft bolts can then be removed without interfering
with the slipring.
2. The area where the slipring is to be assembled should be clean. A line should be
drawn around the periphery of the shaft perpendicular to its axis, as accurate as
possible.
3. The ring halves are marked indicating how they should be positioned relative to
each other (both marks to be viewed from the same side of the ring). On one end
of each half the silver band sticks out from the steel base.
Assemble the slipring parallel with the scribed line and tighten the four bolts
lightly. Ensure that the gap between the two halves of the slipring is the same on
both sides. If the silver band of the two halves touch each other before the bolts
are fully tightened, the silver band protrusions must be reduced by using a fine cut
file. After adjusting the silver band the four bolts may be tightened further.
If possible, the slipring alignment should be checked prior to final bolt tightening.
This can be done by stationary measurements (e.g. from a flange or a coupling
device) or when the shaft is rotated.
Finally, there may be a small gap in the silver band between the two halves.
Be sure that the gap is adequately smooth so that the silver graphite brushes are
subject to minimum wear in use.
509271
4. Mount the bracket for brush holders.
5. Mount the double brush holder to the bracket. Connect the brush.
6. Mount the single brush holder to the bracket. Connect the brush. (ICCP)
7. Adjust the bracket for correct alignment. INSTALLATION / INSTRUCTION

MANUAL
8. Fit the slipring monitor on a suitable firm place.
Connect the positive + terminal to the single (insulated) brush holder. Slipring Arrangement
Use a 2 x 1,5 mm2 cable (yard supply). With mV-meter
Connect the negative – terminal to the hull by a 2 x 1,5 mm2 cable.

2
9. Use a flexible lead (wire) (min. 35 mm ) for connecting the brush holders to the :Yard/Y.No
hull. This will ensure an adequate connection. Vessel/Project:
15 Sept 2004
Maintenance Cathodic AS, P.O. Box 110, NO-3995 Stathelle

Oilfumes and humid air as well as oil from liner bearings will stick to the silver contact
way. This will reduce the conductivity and, after a while, partly insulate the shaft from
the hull. A mixture of oil, carbon and silver from the brushes will act as an abrasive and
wear down brushes and silver liner.
All components must be kept clean and free of dirt, grease and oil.
Both slipring and brushes should be cleaned regularly. Use dry rag or pressure air only
for cleaning the slipring arrangement. If solvent must be used we recommend Lectra
Clean. This solvent must not get in contact with the silver brushes. Finally clean with
pressure air. Do not use any abrasive on the silver contact way.
Measurement of shaft potential

All readings should be taken when propeller is rotating.
mV-meter readings once a day shall be recorded in the logbook.
Value should be less than 75 mV for adequate propeller shaft grounding.

250-350 mV values give indication of no efficiency of the slipring arrangement.
The value should always be zero when the shaft is not rotating.
Pcs. Item No. Material/comments
TO BE WELDED OR SCREWED A 1 SLIPRING 1 w/ SILVER LINER, BOLTS & NUTS

TO A FIRM FOUNDATION 1 BRACKET 2 w/ PINS & INSULATION SLEEVE
1 BRUSHHOLDER SINGLE 3 BRASS
1 BRUSHHOLDER DOUBLE 4 BRASS
1 EARTH BONDING CABLE 5 MIN. 35sqmm (YARD SUPPLY)
HOLE 25x12 3 BRUSH 6 SILVER ALLOY
50
CABLE FOR
MONITOR 2 5
EARTH BONDING CABLE

(YARD SUPPLY)
NOTES:
1. THE SLIPRING HALVES TO BE MOUNTED
INSULATED PIN
WITH PUNCH MARKS POSITIONED AS SHOWN.
4
h
4 2. SILVER LINER TO BE PRECISELY CUT AND
REFERENCE BRUSH FOR ADJUSTED TO OBTAIN A SMOOTH CONTACT
MONITOR SURFACE.
3 A 3. THE SLIPRING SHOULD NOT BE FITTED

CLOSE TO BEARING.
4 6
4. MOUNTING HEIGHT h OF BRACKET PIN
1 ABOVE SILVER LINER:
M.
DIA
SHAFT DIAM. 150 250 315 350 400 450 500 550 600
G
h (mm) 42,0 38,0 37,0 36,5 36,0 35,5 35,0 35,0 35,0
RIN
.
P
AM
SLI
DI
A FT
SH
PUNCH MARK
62
12 50

0 02-12-94 ISSUED FOR CONSTRUCTION TEO TIM
Rev.no. Date Description Drawn Design Check. Appr. Client appr.
Project: Scale: Replacement for:

Customer
Yard/Y.No
Replaced by:
Dwg. title:
Vessel/Project:
:
Detail DRW File name:

SLIPRING w/ MONITORING Cath SA 04105
Dwg. no.:
¯16
FOR PROPELLER SHAFT

15 Sept 2004
(ICCP)
With mV-meter
04 - 105
: Scana Volda AS
Cathodic AS
MANUAL
Code Sequence no. Sheet no. Rev. no.

Stathelle - Norway
VIEW A-A e-mail: [email protected]
509271

Chapter 8 - Page 42
Pcs. Item No. Material/comments
SEE NOTE 4 SEE NOTE 5 SEE NOTE 5
1 SLIPRING 1 w/ SILVER LINER, BOLTS & NUTS
1 BRACKET 2 w/ PINS & INSULATION SLEEVE
1 BRUSHHOLDER SINGLE 3 BRASS
1 BRUSHHOLDER DOUBLE 4 BRASS
1 EARTH BONDING CABLE 5 MIN. 35 (YARD SUPPLY)
3 BRUSH 6 SILVER GRAPHITE ALLOY
SHAFT MONITOR SHAFT MONITOR WITH
(STANDARD) SHAFT MONITOR COMPUTER
WITH ALARM SEE NOTE 3
TRANSMITTER CARD
- + X1 1 2 3 4 5 6 7 X1 1 2 3 4 5 6 7
SLIP RING
2x1,5 2x1,5
2x2,5 230V AC 230V AC
SEE NOTE 7 2x2,5
HULL SEE NOTE 6
2x2,5
2x1,5 OPTION HULL
SEE NOTE 2 HULL
SEE NOTE 2
2x1,5 SEE NOTE 2
2x1,5
TO BE WELDED OR SCREWED
TO A FIRM FOUNDATION
CABLE FOR
Slipring position on
OPTIONAL 2 5
SHAFT MONITOR propeller shaft typ.
INSULATION SLEEVE EARTH BONDING CABLE
(NOTE 2)
NOTES:
REFERENCE BRUSH
(INSULATED PIN)
1. ALTERNATIVE BRACKET POSITION.
4
2. SAME POINT GROUNDING FOR EARTH BONDING
1
CABLE FROM BRUSH HOLDER AND SLIPRING
MONITOR.
CABLE SUPPLIED BY YARD.
3 3. SLIPRING SHOULD BE POSITIONED ON THE
INTERMIDIATE SHAFT AND AWAY FROM BEARINGS.
6
4. MONITORING UNIT SEE DWG Cath SA 04110.
SEE NOTE 1
ER
ET
AM
T DI
AF
SH

0 15.09.04 ISSUED FOR CONSTRUCTION TEO TIM
Rev.no. Date Description Drawn Design Check. Appr. Client appr.
Project: Scale: Replacement for:

Customer
Yard/Y.No
Replaced by:
Dwg. title:
Vessel/Project:
:
Slipring
File name:
with mV-meter Monitor Cath SA 04100
Dwg. no.:
for Propeller Shaft
ARRANGEMENT DRAWING
15 Sept 2004
(ICCP)
04 - 100
With mV-meter
: Scana Volda AS
Cathodic AS Code Sequence no. Sheet no. Rev. no.

MANUAL
Stathelle - Norway
SLIP RING e-mail: [email protected]
509271

Chapter 8 - Page 43
509271

(ICCP)
MANUAL
With mV-meter
Yard/Y.No :
Vessel/Project:
15 Sept 2004

VS207026 Bulkhead seal Bulkhead # 24
A 1
6 A3 7
B
7
7
A2
1 6
2
2 2
A1
1 3 3
Ø790
2
12xn13 THRU
n7 3 3
55
Hole Table
HOLE XDIM YDIM DESCR. TOL. 4
A1 364.64 97.70 n13 THRU `0.1
A2 266.93 266.93 n13 THRU `0.1 5 6 5
A3 97.70 364.64 n13 THRU `0.1
6 38
B °
A 30
Section A-A Section B-B
15° Scale 1 : 5 Scale 1 : 5
7 6 7
Sealing
Bulkhead compound
Z (Yard supply)
r 0.2 A 1
b 0.2 A
A Opening to get shaft thru 2
(Ø790)
(Ø250)
4
Ø720
Shaft
Sealing TOLERANCE: ISO 2768m. THREADS: 6g/6H 1:5
compound DRAWN APPR. DATE
MK 11/3/2017
Brunvoll Volda AS
(Yard supply) BO N-6101 Volda, NORWAY
Tel: +47 70059000 Fax: +47 70059001
Z
SPLIT BULKHEAD SEAL
(38)
12x M12 Socked head bolt DWG.NO. REV.
(Yard supply) Ø250 VS 207026
Section Z-Z
Scale 1 : 10 be disclosed, copied, duplicated, or in any other way made use of, except with approval of Brunvoll Volda as. 1 /1
207026 Part list V207026 - Bulkhead seals
05.01.2018
207026 SPLIT BULKHEAD SEAL 13:19:28

207026 SPLIT BULKHEAD SEAL V207026

001 309206 PLATE SPLIT 1,00 pcs V309206
002 308363 SPLIT COVERBULKHEADSEAL 2,00 pcs V308363
003 511689 SHAFT SEAL 2,00 pcs
004 500958 HEX. BOLT 16,00 pcs DIN 931
006 502400 GREASE NIPPLE 2,00 pcs
007 501913 PLUG 2,00 pcs DIN 908 MF
513575-513639 Fire Resistant Bulkhead seal Bulkhead # 33
8 7 6 5 4 3 2 1
Zur Befestigung 8 Stück
Zylinderkopfschraube DIN 912 M12 A4-70 / Ansicht ohne Isolation und Abdeckung
Kundenzeichnung / Costumer Drawing
A-A For Installation 8 ea View without Isolation and Covers
F Cylinder Head Bolt DIN 912 M12 A4-70 F
24
1 Im Lieferumfang/ A
Delivered with Seal Montagebohrungen M12/
Installation support thread M12
13 12
22 10
12,5 22,5°
17 (12x)
18 19/21
30°
E 8x E
12x
45
6 7 °
Rz4 60
Ø730 bore in bulkhead recomm.

16
Oberflächenhärte/ 5 15
43
Surface Hardness 
15°
150-200HB
Ø250h6
Ø260
Ø790
Ø525
D D
20/21 Ersatzteilliste
Pos. Anzahl Benennung
C 8xM12-21tief 1 3 Dichtring/Seal Ring C
11 2 3 Spiralzugfeder/Garter Spring
87 38 3 3 Mitnehmer/Detent Plate
23 6 9 Federlasche/Spring Plate
10 1 Hochtemperaturflachdichtung/High Temperature Gasket
11 1 Hochtemperaturflachdichtung/High Temperature Gasket
(125) A 12 14 Isolierhülse/Isulation Sleeve
13 14 Isolierscheibe/Isolation Washer
15 6 Zylinderstift/Pin
Einsatzgrenzen / Operating Limits: 16 6 Zylinderkopfschraube/Cyl.Head Bolt
Radiale Beweglichkeit / Allowed Radial Movement: max.+/-5mm 17 9 Zylinderkopfschraube/Cyl.Head Bolt
B Druck / Pressure: max 2 bar 18 6 Zylinderkopfschraube/Cyl.Head Bolt B
1,5 A Temperatur / Temperature -5....+950 °C 19 8 Gewindestift/Stud
Gleitgeschwindigkeit / Gliding Speed max. 40m/s 20 8 Gewindestift/Stud
A 21 16 Hutmutter/Cup Nut
Anzugsmoment / Tightening Torque 22 14 Unterlegscheibe
23 8 Zylinderkopfschraube/Cyl.Head Bolt
A4-70 M5 M6 M8 M10 M12 M16 24 1 Hochtemperaturflachdichtung/High Temperature Gasket
Nm 3,5 5,9 14,5 30 50 121 Gewicht/Weight: ca.130kg
Schrauben gleichmäßig anziehen ISO 2768-m

mit Drehmomemtschlüssel Anzugsmoment kontrollieren Datum Name
Tighten screws uniformily Gezeichnet 03.09.2018 A.Dietsch
Feuerfeste Schottabdichtung D=250mm auf D=465mm
03.09.2018 T.Müller
A Check tightening torque with a torque wrench A
Kontrolliert
Norm
Fireresistent Bulkhead Seal D=250mm OD=465mm
0,75 A
05.250.01A 1
Zeichnung unterliegt nicht dem Änderungsdienst A2
Status Änderungen Datum Name
8 7 6 5 4 3 2 1
VL106525 Longitudinal section and piping arrangement. CW and CCW Gearboxes
215 101 96 44 45 74 100 73 120
210 212 250 241 52 112 251 1 268 99 12 142 39 92 12 268 70 99 84 277 69 54 78
110 114
34 36 35 55
Section B-B
291 Scale 1:5
101 252
Section C-C
Scale 1:5
91
29
141
27 14
104
292 221
227 228 70
290
87 28
F G
111
15 92
C
25
B
26
292
E 106
114
113
B
41
C
41
F G
97
70 44 53
219
28
62 64 63 60 61
31 33 29 83
83 30
A
32
40 232 324 92 220 99 11 2 3 42 99 10

Section A-A C Detail E
Scale 1:5 Scale 1:2.5
C 21424 13.11.2019 MWS

B 21129 05.07.2019 MK
A 21043 14.05.2019 MK
REV DESCR. DATE APP.
REVISION TABLE
DRAWN APPR. DATE
MK 11.01.2019
Brunvoll Volda AS
Tel: +47 70059000 Fax: +47 70059001
LONGITUDINAL SECTION
DWG.NO. REV.
& PIPING ARR. AG600 VS 106525 C
Section F-F Section G-G
REF. SHEET
Scale 1:5 Scale 1:5 Copyright of Brunvoll Volda as, whose property this document remains. No part of the document may
216 BLEED FROM
COOLING WATER IN(OUT)
273 PUMP 1
8 320 77 17 16 157
COOLING WATER OUT(IN) 321 211 300
301
265
243
242
242
TO PRESSURE SWITCH
PANEL, PS1B
302 168 167 166
264 BLEED FROM

PUMP 2
177 273
244
TO PRESSURE SWITCH
252 PANEL, PS1A
280 214
242
170 169 253 244
T
264
180 FROM PUMP 2 163 254 222

175 242
FROM PUMP 1
155
221
243 B 98
180 200
FROM PUMP 1 180
23 155 46
140 6
B
152 4
253 46
180 TS11 TS13
260 261 263
247
600
247
140 A 207 203 TO PUMP 1
152
TS2
4 TS1 TO PUMP 2
172
204 203 152
TS10
262
208 202 262 270

To pressure switch panel,
PS2, PS3A, PS3B, PS26
207 To pressure gauge panel,G1
273
256
254
152
1500
1275
171 173 183
236 241
5
217
230
220
224 202 236 174 253
208 246 175 169
249 176 170

DRAWN APPR. DATE
MK 11.01.2019
Brunvoll Volda AS
Tel: +47 70059000 Fax: +47 70059001
DWG.NO. REV.
141 320 8 19 139 179 180 7 13 255 242 140 18
F
249
239 162 170
9 172 253
268
245
251
254
270
207
253
261 260
A P
206
236
E 203
205 T
258
265
322
182 181
241
MA To pressure gauge panel, G2

To pressure switch panel, PS4, PS20
271 213 276 216 272 276 87 275
View 11
Scale 1:5
PS11
301 300 301 300 219
221 253 218 221 265 236 322 241

DRAWN APPR. DATE
MK 11.01.2019
Brunvoll Volda AS
Tel: +47 70059000 Fax: +47 70059001
DWG.NO. REV.
View F
323 212 Scale 1:4 REF. Copyright of Brunvoll Volda as, whose property this document remains. No part of the document may SHEET
307 306 164 210 249 180
152
180
247
246
236 D
A 140 4
C
TS13 A
152
46
TS1
140
141 163
252
Detail D
Scale 1 : 4 A
252 152 256 140 A

46 254
to PS2, PS3A, PS3B, PS26

View View 1 to G1
A 163
Scale 1:10 TS13
View View 2
Scale 1:10
273
268 253 270
222
253
Detail F
A
Scale 1 : 4
B
310
155 243 79 308 311 309 301 322
206 F
205
305 303
257
View View 3
79 TS10 Scale 1:10
304 305
B 140 4 TOLERANCE: ISO 2768m. THREADS: 6g/6H 1:5
Detail C DRAWN APPR. DATE
MK 11.01.2019
Brunvoll Volda AS
Scale 1 : 4 AM N-6101 Volda, NORWAY
311 310 308 301 322 Tel: +47 70059000 Fax: +47 70059001
DWG.NO. REV.
79 155 79
Detail E & PIPING ARR. AG600 VS 106525 C
Scale 1:2.5
268 253 268 268 253 REF. Copyright of Brunvoll Volda as, whose property this document remains. No part of the document may SHEET
604473BV BVo2232 Part list Gear VL106525
18.11.2019
604473BV GEAR LONGITUDE AG600 10:52:06

604473BV GEAR LONGITUDE AG600 V106525

001 106530 G600 GEARHOUSING 1,00 pcs V106530
002 106332BV SERVO MOTOR SHAFT 1,00 pcs V106332
003 106314 GEARWHEEL G600 1,00 set V106314
010 206456 BEARING SHELL 1,00 pcs V206456
015 207158 OPERATING HOUSING G600 1,00 pcs V207158
023 502616 THERMOSTATIC VALVE 1,00 pcs
025 309145 EAG600K SERVO OIL INLET ARR. 1,00 pcs V309145
026 500963 HEX. BOLT 6,00 pcs DIN 931
028 200429 PACKING GLAND FOR S.M.SHAFT 1,00 pcs V200429
029 400146 STOP PIECE FOR SEK.THRUST G600 1,00 pcs V400146
030 400879 STOP PIECE THRUST 2,00 pcs V400879
031 200206 THRUST PAD 9,00 pcs V200206
032 200207 THRUST PAD 7,00 pcs V200207
033 300153 THRUST PAD 1,00 pcs V300153
034 501061 PIN 1,00 pcs DIN 7
035 300097 THRUST PAD 1,00 pcs V300097
036 300096 THRUST PAD 6,00 pcs V300096
037 401943 HOLDING RING FOR PRIM.THRU.PAD 2,00 pcs V401943
038 400134 COVER G600 1,00 pcs V400134
039 400133 COVER G600 1,00 pcs V400133
040 404594 BUSHING FOR SERVOMOTOR PISTON, G680 1,00 pcs V404594
041 500633 SNAP RING 2,00 pcs DIN 472
042 309571 INNER+OUTER OIL PIPE G600 ASSEMBLY. 1,00 pcs V309571
044 309387 GUIDE RING EACG600K 1,00 pcs V309387
045 500124 SET. SCREW 1,00 pcs DIN 915
053 309388 ADAPTER PLATE 1,00 pcs V309388
054 406881 COVER 1,00 pcs V406881
055 207377 COVER 1,00 pcs V207377
060 405166 EACG600K PACKING RING 1,00 pcs V405166
061 500637 SNAP RING 1,00 pcs DIN 472
063 404151 PACKING RING 1,00 pcs V404151
064 505507 O-RING 1,00 pcs BS 1806
078 500938 HEX. BOLT 6,00 pcs DIN 931
084 200393 COVER 1,00 pcs V200393
091 501874 SET.SCREW 1,00 pcs DIN 916
092 501872 HEX.BOLT 40,00 pcs DIN 933
096 302460 OIL SPRAYER S600H 1,00 pcs V302460
097 507763 O-RING 1,00 pcs BS 1806
098 300098 OIL SPRAYER G600 1,00 pcs V300098
099 501064 PIN 4,00 pcs V405545
100 401692 COVER G500-600-680 1,00 pcs V401692
101 501049 PIN 2,00 pcs DIN 6325
104 500316 TUBE FITTING 1,00 pcs DIN 2353-STEEL
112 509522 BREATHER 1,00 pcs
120 106498 OPERATING ARM ARR. EACG600K 1,00 pcs V106498
139 506167 FITTING 2,00 pcs
140 402881 Ø35 ERMETO PLUG 5,00 pcs V402881
141 503148 FITTING 3,00 pcs DIN 908 MF
142 502850 PLUG 1,00 pcs DIN 908 MF
155 500649 TUBE FITTING 2,00 pcs
162 502352 PIPE CLAMP 3,00 pcs
164 501898 HEX.BOLT 12,00 pcs DIN 933
165 501848 WASHER 12,00 pcs DIN 125
166 502188 PIPE CLAMP RAPE 3,00 pcs
18.11.2019

167 502196 PIPE CLAMP COVER PLATE 6,00 pcs
168 503619 HEX.BOLT 6,00 pcs DIN 931
169 502353 PIPE CLAMP 10,00 pcs
176 500933 HEX.BOLT 4,00 pcs DIN 931
180 504228 FITTING 6,00 pcs DIN 2353-STEEL
182 502714 FITTING 1,00 pcs
183 506206 HEX.BOLT 4,00 pcs DIN 931
200 402432 SUCTION STRAINER 2,00 pcs V402432
202 502069 SUCTION FLANGE 2,00 pcs
203 500954 HEX.BOLT 16,00 pcs DIN 931
204 300092 OIL DISTRIBUTOR 1,00 pcs V300092
205 401681 DIP STICK TUBE G500-600-680 1,00 pcs V401681
206 401901 DIP STICK 1,00 pcs V401901
207 501910 HEX.NUT 16,00 pcs DIN 934
208 502070 PACKING 2,00 pcs
210 501848 WASHER 16,00 pcs DIN 125
211 502628 DUPLEX FILTER 1,00 pcs
212 406716 BRACKET 1,00 pcs V406716
213 406717 BRACKET 1,00 pcs V406717
215 309215 BRACKET 1,00 pcs V309215
217 509758 TUBE 2,00 m DIN 2391
223 300693 SUCTION FLANGE 2,00 pcs V300693
224 501893 HEX.BOLT 8,00 pcs DIN 933
225 501913 PLUG 1,00 pcs DIN 908 MF
227 401709 SIGN 1,00 pcs V401709
228 502124 Nail 4,00 pcs
230 501902 SEAMLESS STEELB. 2,00 pcs
232 502068 PACKING 0,25 m2
236 501700 TUBE 4,00 m DIN 2391
239 501696 TUBE 8,00 m DIN 2391
241 501702 PRECURE TUBE 5,00 m DIN 2391
242 501703 TUBE 4,00 m DIN 2391
247 502705 FITTING 1,00 pcs
253 501697 TUBE 6,00 m DIN 2391
254 501698 TUBE 0,56 m DIN 2391
255 500695 VALVE 1,00 pcs
256 500703 VALVE 1,00 pcs
260 502157 PACKING 2,00 pcs
261 402509 FLANGE 2,00 pcs V402509
262 506368 PLUG 2,00 pcs DIN 908 MF
263 506444 PLUG 2,00 pcs DIN 908 MF
264 500693 VALVE 2,00 pcs
265 500690 VALVE 4,00 pcs
269 502661 FITTING pcs
18.11.2019

276 503428 TUBE 0,50 m
277 401620 NIPPLE GE8PLR W/NOZZLE Ø 2.0 1,00 pcs V401620
280 604461 OIL FILTER 2,00 pcs
290 506505 PROPORTIONAL VALVE PVG120 1,00 pcs
291 309374 BRACKET 1,00 pcs V309374
292 502764 HEX.BOLT 8,00 pcs DIN 933
300 502877 FITTING 6,00 pcs
303 501602 FLANGE 1,00 pcs SE J518C
304 506637 SAE FLANGE 1,00 pcs
305 502022 O-RING 2,00 pcs BS 1806
307 504818 GASKET FOR FLANGE 3,00 pcs
308 405123 SAE FLANGE 2,00 pcs V405123
310 500743 O-RING 2,00 pcs BS 1806
311 508479 FITTING 2,00 pcs
321 509641 FITTING G 2,00 pcs DIN 2353-STEEL
324 407018 COVER G600 1,00 pcs V407018
604474BV BVo2233 Part list Gear VL106625
18.11.2019

604474BV GEAR LONGITUDE AG600 V106525

001 106530 G600 GEARHOUSING 1,00 pcs V106530
002 106332BV SERVO MOTOR SHAFT 1,00 pcs V106332
003 106314 GEARWHEEL G600 1,00 set V106314
015 207158 OPERATING HOUSING G600 1,00 pcs V207158
023 502616 THERMOSTATIC VALVE 1,00 pcs
025 309145 EAG600K SERVO OIL INLET ARR. 1,00 pcs V309145
026 500963 HEX. BOLT 6,00 pcs DIN 931
028 200429 PACKING GLAND FOR S.M.SHAFT 1,00 pcs V200429
029 400146 STOP PIECE FOR SEK.THRUST G600 1,00 pcs V400146
030 400879 STOP PIECE THRUST 2,00 pcs V400879
031 200207 THRUST PAD 9,00 pcs V200207
032 200206 THRUST PAD 7,00 pcs V200206
033 300151 THRUST PAD 1,00 pcs V300151
034 501061 PIN 1,00 pcs DIN 7
035 300096 THRUST PAD 6,00 pcs V300096
036 300097 THRUST PAD 1,00 pcs V300097
037 401943 HOLDING RING FOR PRIM.THRU.PAD 2,00 pcs V401943
038 400134 COVER G600 1,00 pcs V400134
039 400133 COVER G600 1,00 pcs V400133
040 404594 BUSHING FOR SERVOMOTOR PISTON, G680 1,00 pcs V404594
041 500633 SNAP RING 2,00 pcs DIN 472
042 309571 INNER+OUTER OIL PIPE G600 ASSEMBLY. 1,00 pcs V309571
044 309387 GUIDE RING EACG600K 1,00 pcs V309387
045 500124 SET. SCREW 1,00 pcs DIN 915
053 309388 ADAPTER PLATE 1,00 pcs V309388
054 406881 COVER 1,00 pcs V406881
055 207377 COVER 1,00 pcs V207377
060 405166 EACG600K PACKING RING 1,00 pcs V405166
061 500637 SNAP RING 1,00 pcs DIN 472
063 404151 PACKING RING 1,00 pcs V404151
064 505507 O-RING 1,00 pcs BS 1806
078 500938 HEX. BOLT 6,00 pcs DIN 931
084 200393 COVER 1,00 pcs V200393
091 501874 SET.SCREW 1,00 pcs DIN 916
092 501872 HEX.BOLT 40,00 pcs DIN 933
096 302460 OIL SPRAYER S600H 1,00 pcs V302460
097 507763 O-RING 1,00 pcs BS 1806
098 300098 OIL SPRAYER G600 1,00 pcs V300098
099 501064 PIN 4,00 pcs V405545
100 401692 COVER G500-600-680 1,00 pcs V401692
101 501049 PIN 2,00 pcs DIN 6325
112 509522 BREATHER 1,00 pcs
120 106498 OPERATING ARM ARR. EACG600K 1,00 pcs V106498
139 506167 FITTING 2,00 pcs
140 402881 Ø35 ERMETO PLUG 5,00 pcs V402881
141 503148 FITTING 3,00 pcs DIN 908 MF
142 502850 PLUG 1,00 pcs DIN 908 MF
164 501898 HEX.BOLT 12,00 pcs DIN 933
165 501848 WASHER 12,00 pcs DIN 125
18.11.2019

168 503619 HEX.BOLT 6,00 pcs DIN 931
169 502353 PIPE CLAMP 10,00 pcs
176 500933 HEX.BOLT 4,00 pcs DIN 931
182 502714 FITTING 1,00 pcs
183 506206 HEX.BOLT 4,00 pcs DIN 931
200 402432 SUCTION STRAINER 2,00 pcs V402432
202 502069 SUCTION FLANGE 2,00 pcs
203 500954 HEX.BOLT 16,00 pcs DIN 931
204 300092 OIL DISTRIBUTOR 1,00 pcs V300092
205 401681 DIP STICK TUBE G500-600-680 1,00 pcs V401681
206 401901 DIP STICK 1,00 pcs V401901
207 501910 HEX.NUT 16,00 pcs DIN 934
208 502070 PACKING 2,00 pcs
210 501848 WASHER 16,00 pcs DIN 125
211 502628 DUPLEX FILTER 1,00 pcs
212 406716 BRACKET 1,00 pcs V406716
213 406717 BRACKET 1,00 pcs V406717
215 309215 BRACKET 1,00 pcs V309215
217 509758 TUBE 2,00 m DIN 2391
224 501893 HEX.BOLT 8,00 pcs DIN 933
225 501913 PLUG 1,00 pcs DIN 908 MF
227 401709 SIGN 1,00 pcs V401709
228 502124 Nail 4,00 pcs
230 501902 SEAMLESS STEELB. 2,00 pcs
232 502068 PACKING 0,25 m2
236 501700 TUBE 4,00 m DIN 2391
239 501696 TUBE 8,00 m DIN 2391
241 501702 PRECURE TUBE 5,00 m DIN 2391
242 501703 TUBE 4,00 m DIN 2391
247 502705 FITTING 1,00 pcs
253 501697 TUBE 6,00 m DIN 2391
254 501698 TUBE 0,56 m DIN 2391
255 500695 VALVE 1,00 pcs
256 500703 VALVE 1,00 pcs
260 502157 PACKING 2,00 pcs
261 402509 FLANGE 2,00 pcs V402509
262 506368 PLUG 2,00 pcs DIN 908 MF
263 506444 PLUG 2,00 pcs DIN 908 MF
264 500693 VALVE 2,00 pcs
265 500690 VALVE 4,00 pcs
18.11.2019

276 503428 TUBE 0,50 m
277 401620 NIPPLE GE8PLR W/NOZZLE Ø 2.0 1,00 pcs V401620
280 604461 OIL FILTER 2,00 pcs
290 506505 PROPORTIONAL VALVE PVG120 1,00 pcs
291 309374 BRACKET 1,00 pcs V309374
292 502764 HEX.BOLT 8,00 pcs DIN 933
300 502877 FITTING 6,00 pcs
303 501602 FLANGE 1,00 pcs SE J518C
304 506637 SAE FLANGE 1,00 pcs
305 502022 O-RING 2,00 pcs BS 1806
307 504818 GASKET FOR FLANGE 3,00 pcs
308 405123 SAE FLANGE 2,00 pcs V405123
310 500743 O-RING 2,00 pcs BS 1806
311 508479 FITTING 2,00 pcs
321 509641 FITTING G 2,00 pcs DIN 2353-STEEL
324 407018 COVER G600 1,00 pcs V407018
VS305258 Pressure Switch panel - 8 valves
10 20 30 40 50 60 70 80
12 22 32 42 52 62 72 82
3 3 4 4 1 7
6 6 6 6
7 7 7 7
NOTES:
1. Sign plate see next sheet
TOLERANCE: ISO 2768m. THREADS: 6g/6H 1:2.5
DRAWN APPR. DATE
HO AM 18.09.2015 Scana Volda as
Tel: +47 70059000 Fax: +47 70059001
PRESSURE SWITCH PANEL

DWG.NO. REV.
8 VALVES VS 308736
REF. Copyright of Scana Volda as, whose property this document remains. No part of the document may SHEET
be disclosed, copied, duplicated, or in any other way made use of, except with approval of Scana Volda as. 1 /2
5 10 11 51 50 5
5 20 21 61 60 5
5 30 31 71 70 5
5 40 41 81 80 5

DRAWN APPR. DATE
HO AM 18.09.2015 Scana Volda as
Tel: +47 70059000 Fax: +47 70059001
PRESSURE SWITCH PANEL

DWG.NO. REV.
8 VALVES VS 308736
REF. Copyright of Scana Volda as, whose property this document remains. No part of the document may SHEET
be disclosed, copied, duplicated, or in any other way made use of, except with approval of Scana Volda as. 2 /2
604398 Part list V308736v - Pressure Switch panel

01.12.2017
604398 PRESSURE SWITCH PANEL 8 valves 08:36:27

604398 PRESSURE SWITCH PANEL 8 valves V308736

001 403408 PRESSURE SWITCH PLATE (6-9PCS) 1,00 pcs V403408
002 403392 SIGN PLATE (8-PCS) 1,00 pcs V403392
003 504992 PRESSURE BLOCK 2,00 pcs
004 504993 PRESSURE BLOCK 2,00 pcs
005 502124 Nail 16,00 pcs
010 506331 SIGN:PS1A 2,00 pcs V303292
011 502213 SIGN, AUTOSTART PUMP NO2 1,00 pcs V300372
012 504977 PRESSURE SWITCH 1,00 pcs
020 506332 SIGN:PS1B 2,00 pcs V303292
021 502212 SIGN AUTOSTART PUMP NO1 1,00 pcs V300372
030 505273 SIGN: PS 2 2,00 pcs V303292
031 502206 SIGN, ALARM LOW LUB.OIL PRESS. 1,00 pcs V300372
032 504979 PRESSURE TRANSMITTER 1,00 pcs
040 506338 SIGN:PS3A 2,00 pcs V303292
041 512229 SIGN EXTRA LOW LUB OIL PRESSURE STOP 1,00 pcs V300372
050 505325 SIGN:PS3B 2,00 pcs V303292
051 512229 SIGN EXTRA LOW LUB OIL PRESSURE STOP 1,00 pcs V300372
060 505275 SIGN: PS 4 2,00 pcs V303292
061 502218 SIGN LOW SERVOOIL PRESS. ALARM PUMP2 1,00 pcs V300372
070 505289 SIGN:PS20 2,00 pcs V303292
071 502232 SIGN, INTERLOCK REMOTE CONTROL 1,00 pcs V300372
080 505290 SIGN:PS21 2,00 pcs V303292
081 511703 INTERLOCK START EL. MOTOR 1,00 pcs V300372
VS403525 Pressure Gauge Panel
8 8
7 6 6 7
2 1 4 5 3
120
140
170 4xn9 THRU
190
7 8 9 10
View A
B
B 18122 19.11.2014 ØF
A 4002 27.01.2000
REVISION TABLE
DATE DRAWN SCALE
07.05.1996 KHT 1:2.5 Scana
Tel: +47 70059000 Fax: +47 70059001
PRESSURE GAUGE PANEL DWG.NO.
2 GAUGES VS 403525 B
REF. Copyright of Scana Volda as, whose property this document remains.No part of the document may SHEET
be disclosed, copied, duplicated, or in any other way made use of, except with approval of Scana Volda as.
1/1
604399 Part list V403525 Pressure Gauge panel

01.12.2017
604399 PRESSURE GAUGE PANEL 2 08:36:56

604399 PRESSURE GAUGE PANEL 2 V403525

000 V403525 1,00 pcs
001 403524 PRESSURE GAUGE PLATE 1,00 pcs V403524
002 504972 PRESSURE GAUGE 1,00 pcs
003 504973 PRESSURE GAUGE 1,00 pcs
004 502214 SIGN, LUB. OIL PRESSURE 1,00 pcs V300372
005 502216 SIGN, SERVO OIL PRESSURE 1,00 pcs V300372
006 502124 Nail 4,00 pcs
008 507043 HEX.NUT 6,00 pcs
009 502589 FITTING 2,00 pcs
012 501004 HEX. NUT 2,00 pcs DIN 934
VS202867 St-Ru-Si Valve Assembly
FROM OIL PUMP
1 2 3 4 14 6 8 9 10 11 7 5
13 12 14
DRAIN FROM SAFETY VALVE TO SERVO PRESSURE GAUGE

TO SERVOMOTOR
Section A-A 2 FITTING GE 35 PLR 14 500325
B 1 FITTING GE 28 PLR 13 500324
14
FROM OIL PUMP 11 2 FITTING GE 12 PL-R 1/4 12 500316
A 2 HEX.BOLT NS5720 M12X140 11 506206
1 O-RING 64,5X3 10 500847
1 PISTON 9 401031
1 CHOKE VALVE 8 300636
1 SPRING 7 401116
C 1 BUSHING 6 401036 1 kg
1 SPRING HOUSING CHOKE 5 401030 2 kg
VALVE
1 STRU-SI VALVE HUS 4 200903 25 kg
1 O-RING 54.3X5.7 3 500844
A A 1 ADAPTER FOR VALVE 2 302835 2 kg
12 1 SAFETY VALVE SUN 1 504497 1 kg
13 12 14 QT DESCRIPTION PO ART.N MATERIAL WEIGHT
DRAIN FROM SAFETY VALVE TOLERANCE: ISO 2768m. THREADS: 6g/6H 1:1
DRAWN APPR. DATE
Scale 1 : 2.5 TO SERVO PRESSURE GAUGE EM 13.05.2015 Scana Volda as
Tel: +47 70059000 Fax: +47 70059001
STRU-SI VALVE
TO SERVOMOTOR
DWG.NO. REV.
C 18521 13.05.2015 ØF
DRAIN FROM CHOKE VALVE B 16481 09.03.2013 DD ASSEMBLY VS 202867 C
A 6911 09.12.2005 RSH
REV DESCR. DATE APP. REF. Copyright of Scana Volda as, whose property this document remains. No part of the document may SHEET
REVISION TABLE be disclosed, copied, duplicated, or in any other way made use of, except with approval of Scana Volda as. 1 /1
VS402432 Suction strainer with flange outlet
C 21200 30.08.2019 TKF

105 B 14807 23.05.2011 LAA
A 11800 20.10.2008 HO
45
REVISION TABLE
A B
A
~82
~Ø194
465
Ø60
Ø60
C
C
B
100
A
18
A ( 1 : 2,5 )
4xn18 THRU
1 FLANGE ND40-Ø61 2 402509 Steel 2 kg
1 SUCTION FILTER EX 1 301485 16 kg
OUTLETFLANGE
TOLERANCE: ISO 2768m. THREADS: 6g/6H 1:2,5
DRAWN APPR. DATE
PH 03.10.1991
Brunvoll Volda AS
Tel: +47 70059000 Fax: +47 70059001
SUCTION STRAINER
DWG.NO. REV.
WITH FLANGE OUTLET VS 402432 C
A 105 2
4 4 8 5
5 8
2
VS301485
45
7
7
6 3
3 1
Ø193,7
~172
75
420
7
1
B
Suction strainer ex. flange outlet
1 WASHER M12 NS961 8 501854 Steel 8.8 0 kg

2 FELTRING Ø090/61X10 7 502767 Felt 0 kg
7 1 O-RING 179.5X3.0 6 500867 Rubber 0 kg
A A 1 WASHER Ø25/Ø12X5 G380 5 402087 Polyamid 0 kg
100
1 SUCTION STRAINER 3 301486 0 kg
1 COVER W/HAND GRIP FOR 2 401942 2 kg

18
STRAINER
1 SUCTION FILTER HOUSING 1301513 Welded Steel 13 kg
Mild
5 QT DESCRIPTION PO ART.N MATERIAL WEIGHT
12
DATE DRAWN SCALE
TF 1:2,5 Scana
Tel: +47 70059000 Fax: +47 70059001
4x18 THRU 165 www.scana.no e-mail: [email protected]
SUCTION STRAINER DWG.NO.
B 11799 20.10.2008 HO ex. FLANGE OUTLET
A 4574 05.02.2001
VS 301485 

REVISION TABLE 1/1
Chapter 8 - Page 65
506740 Pick-Up - for Brunvoll Mar-El
506505 Danfoss PVG 120 Drawing
513216 Flexible shaft coupling Gear-Engine
513256 Oil Cooler Data Sheet
Specification sheet
Bloksma compact cooler - P series

Client Brunvoll Volda AS Date specification 27-sep-2017
Service Oil cooler Our reference P173249-01-C
Your reference inst. 2232-33 Drawing P13-27-0000
Cooler type Bloksma P13-2P-L=1000 PF/IV
General
Heat exchanged 28.00 kW
Fouling (extra surface) 20 %
Number of tube passes 2 -
Weight empty cooler 37.3 kg
Shell side
Fluid Oil ISO VG 150
Inlet temperature 52.00 °C
Outlet temperature 43.97 °C
Fluid flow 7.38 m3/h
Pressure drop 0.22 bar
Operating pressure 16.00 barg
Connection 2" BSP -
Content 8 ltr
Design temperature 110.00 °C
Design pressure 16.00 barg
Tube side
Fluid Circulation water without glycol -
Inlet temperature 38.00 °C
Outlet temperature 40.44 °C
Fluid flow 10.00 m3/h
Pressure drop 0.16 bar
Velocity 2.14 m/s
Operating pressure 10.00 barg
Connection 1½" BSP -
Content 4 ltr
Design temperature 80.00 °C
Design pressure 10.00 barg
Materials
Tubes Mat.nr 2.0872 - CuNi10Fe1Mn
Tubeplates Mat.nr 2.0540 - CuZn35Ni
Baffle(s) / fins Aluminium / Aluminium
Shell C.Steel / Nodular cast iron
Bonnet(s) / cover Nodular cast iron (without anodes)
Remarks
Design and inspection: Kelvion
513256 Oil Cooler Drawing
513256 Bloksma Compact Cooler, Manual
Instruction Manual
Instruction manual. Version: 2015-12-09
BLOKSMA
COMPACT COOLER
Instruction Manual - IM-P-EN Rev.E – 200022301 - 2015-12-09
TABLE OF CONTENTS
1 Introduction 5
1.1 Notes for the customer 5
1.2 Responsibilities of the owner/operator 5
1.3 Guarantee and liability 5
1.4 Environment 6
1.5 Safety 6
1.6 Materials 7
1.7 Inhibitors 7
2 Installation and start-up 8
2.1 Receipt 8
2.2 Installation 8
2.3 Start-up 9
3 Maintenance 10
3.1 Cleaning and inspection intervals 10
3.2 Galvanic protection 10
3.3 Cleaning of the heat exchanger 10
3.3.1 Mechanical cleaning of the tubeside 11
3.3.2 Chemical cleaning of the shell-/tubeside 11
3.4 Shut down periods 11
3.5 Assembly and disassembly of the bundle 12
Step 1: Dissasembly 13
Step 2: Removing the tube bundle 13
Step 3: Assembly 14
3.6 Instructions for gaskets and bolting 16
3.6.1 Gaskets 16
3.6.2 Bolting 16
4 Troubleshooting & repairs 17
4.1 Insufficient thermal performance 17
4.2 Leaking tubes / tube-to-tubesheet connection 17
5 Spare parts & tools 18
6 Instructions for storage 19
6.1 Standard storage (controlled conditions) 19
6.2 Advice for conservation (uncontrolled conditions) 19
7 Cleaning of the heat exchanger 20
7.1 Chemical cleaning 20
7.2 Post cleaning 20
8 Validation 21
9 Glossary 22
Appendix 23
The P-type heat exchanger can be divided into four sizes: P10, P13, P20 and P28. The
number indicates the shell size in centimetres. The construction of the P10 is slightly different
from the others. When applicable in this manual the difference will be highlighted with the text
“(for P10 Only)“.
The P-type heat exchanger comes in three executions: the IV (Industrial Version), the MV
(Marine Version and the RV (Refrigeration Version). The main difference is the fact that the
MV comes equipped with anodes in the tubeside circuit of the heat exchanger to protect the
cooler in unconditioned cooling water conditions. The RV version coolers are thermo syphon
coolers with the refrigeration medium in the tube. When there are differences between the
models, this is pointed out in the text.
Please note that the P10-type is only available in MV version.
In addition, this manual applies to P-type heat exchangers with plain tubes (PT-type) as well.
Chapter 1 Introduction
1 Introduction
1.1 Notes for the customer

• Read this instruction manual before proceeding.
• Being familiar with the basic safety rules given in the ‘Safety’ chapter of this manual is
a prerequisite for safe and trouble free installation and operation.
The instructions given in this manual must be observed. Disregard

may endanger persons, cause damage to the heat exchanger and
lead to warranty and liability claims becoming forfeited.
1.2 Responsibilities of the owner/operator

• If you are in doubt how to proceed, contact Kelvion.
• The owner/operator is responsible for proper installation of the product.
• The design pressures and design temperatures as stated in the specification sheet
and on the nameplate may never be exceeded.
• Maintenance of the product is the responsibility of the product owner/operator.
• The product should be maintained according the maintenance instructions in this
manual.
• This Instruction Manual is part of the consignment. To guarantee professional handling
of the product, it should be preserved in a way, that installation-, maintenance- and
operating personnel have access to it.
• The owner is held to supplement this manual by including any provisions required by
applicable accident prevention and environmental protection rules and regulations.
• The owner is held to observe the generally accepted rules governing safe and skilled
working practices.
• The owner is to observe the skill level and authorizations of the persons installing and
operating this product.
1.3 Guarantee and liability

The “General sales conditions of Kelvion Machine Cooling B.V.” are applicable.
Also refer to the order confirmation for possible additions.
Liability and warranty claims are excluded:
• If the instructions in this manual are not observed.
• If the heat exchanger is incorrectly operated or handled incorrectly.
• If the heat exchanger is used for a different than the intended application.
• If operating conditions deviate from those, used for the thermal calculation.
• If the heat exchanger is being used outside the design limits, including deviation from
used media as defined in the specification.
• If the heat exchanger is modified.
• If protective guards are left unused or taken out of service as a whole or partly.
• If equipment functions are changed without Kelvion’s prior written consent.
• If applicable safety provisions are not observed.
• If the heat exchanger including pertinent accessories are maintained inexpertly
(timewise/expertise).
• In case of use of non-original parts.
• In case of any kind of corrosion.
1.4 Environment
Always respect the environmental laws and rules of the area where the heat exchanger is
installed.
If applicable the rules of the classification societies have to be respected.
Always be alert to the possibility of leakage!
1.5 Safety
Some symbols are used in the text to underline safety aspects:
Danger: risk of injury or danger to life.
Danger: risk of damage to the heat exchanger.
Warning that injuries may occur due to suspended loads. Only

employ suitable and approved lifting equipment. Secure loads
to prevent slipping and overturning during lifting.
Warning against burning hazards caused by hot surfaces.
Warning that personal protective means must be worn when

carrying out work on the heat exchanger. Protective clothing,
safety goggles, safety shoes, safety gloves, ear protection
and/or hard hat should be used depending on the situation,
otherwise there will be a risk of injuries.
Warning that safety goggles must be worn when carrying out

work on the heat exchanger, otherwise there will be a risk of
eye damage/loss of vision.
Warning that compliance with (local) waste disposal

regulations is required.
Chapter 1 Introduction
Important information.
Maintenance and repair: cool down to ambient temperature

and depressurize the heat exchanger before any work is done
on the cooler.
General Note:
Most heat exchangers contain media, which can be irritating or

dangerous to humans. These media may cause problems in case of
leakage. Since the medium in the heat exchanger is at a raised
temperature level, any leaks may cause burns of the skin.
A heat exchanger is a pressure vessel designed for operation at

certain specific limits of pressure and temperature. All operating
personnel should be made aware of this specific design pressure
and temperature, which is stated on the name plate.
1.6 Materials
Always check if the media that flowing through the heat exchanger is consistent with the
materials used. Kelvion makes its material choices on the basis of the media types specified
by the client, but is often not informed of possible contamination, higher/lower acid levels
than normal, additives and other aspects relevant to the choice of materials.
1.7 Inhibitors
Inhibitors may be added to the cooling medium in the heat exchanger. Contact the supplier of
the inhibitor to check for compliance of the inhibitor with the materials of the heat exchanger
(see specification sheet). Without proper prevention, micro organisms may grow excessively
in the cooling medium and can cause corrosion of metals. Bacteria also give an accumulation
of slurry / mud, forming a viscous film on the tube wall and blocking the flow and heat flux,
causing insufficient cooling.
Follow the instructions of the supplier for use of the inhibitor and
maintenance procedures.
2 Installation and start-up
2.1 Receipt
Upon reception of the heat exchanger check the packaging and the product:
• Report any damage to Kelvion.
• Compare the data on the nameplate, the drawing and the Kelvion order
confirmation/packing list.
• Check whether or not the correct instruction manual is present by comparing the
article number on the cover sheet with the article number of the instruction manual on
the order confirmation/packing list.
• Always store the heat exchanger in its original packing in a dry room at constant
temperature. When the heat exchanger is not being put into operation immediately
after receipt, follow the “Instructions for storage” (Chapter 6, Instructions for storage).
Kelvion reserves the right to plug off a maximum 1% of the tubes (as per TEMA RGP-RCB-2)
(not applicable for parts used in nuclear installations).
2.2 Installation
Corrosion preventive fluid is present inside the heat exchanger.

Before installation drain the heat exchanger to remove this fluid.
When complete removal of the conservation fluid is necessary, it
may be removed by flushing with a mineral solvent like petroleum.
Only use tools and lifting equipment suitable for the task to be
performed. Load carrying equipment should be approved, of
adequate size and undamaged. Make sure no person pass or stay
under the goods lifted during handling.
Chapter 2 Installation and start up
2.3 Start-up
Do not exceed the design temperature and pressure as specified on
the nameplate, specification sheet and/or drawing. Avoid abrupt
temperature fluctuations; these may cause leaking of the tube-to-
tubesheet connections or other connections.
• Make sure that the cold medium circulation is established first, followed by the gradual
introduction of the hot medium.
• Vent both circuits.
• Vent both circuits again when the operating temperatures and pressures are reached.
• Check for leakage.
Respect the flow as specified on the specification sheet. Lower/higher

speeds may cause corrosion/erosion.
Avoid standstill: in non-conditioned circuits this may cause corrosion. In

case of standstill follow the instructions for shut down periods.
3 Maintenance
If necessary refer to “Assembly and disassembly of the bundle” for (dis-)assembly

instructions.
3.1 Cleaning and inspection intervals

The end user is responsible for (preventive) maintenance.
Because the degree of fouling strongly depends on the operating conditions we recommend
the following:
• Inspect the tubeside at least quarterly.
• Inspect the shellside at least twice a year.
With the results of these inspections you will be able to determine the required cleaning
intervals. Always keep performing regular inspections.
3.2 Galvanic protection

Not applicable for IV models (without anodic protection).
The MV models of P-type heat exchangers are fitted soft iron anodes on the tubeside. When
inspecting the tubeside of the heat exchanger, also inspect the condition of the anodes
(always drain the tubeside circuit before removing the anodes).
The consumption of the anodes strongly depends on the operating conditions. If most of the
anode material is dissolved, they need to be replaced. For spare parts, contact our Service
Department at [email protected].
For example only:
The anode 1 is a new one (for comparison), anode 2 should be replaced if a high
consumption of the anodes has been determined. Anode 3 and anode 4 should be replaced
immediately. Please note that the above example is indicative only, the user should estimate
when the anodes need replacement.
3.3 Cleaning of the heat exchanger
3.3.1 Mechanical cleaning of the tubeside

The tubes can be cleaned with a tube brush. Use original Kelvion brushes only; these have
the correct dimensions and are of a suitable material. Other brushes may damage the
protective layer that is in the normal course of events present on the tube walls.
3.3.2 Chemical cleaning of the shell-/tubeside

Cleaning of the shellside is normally seldom necessary.
The shell- as well as the tubeside can be cleaned by circulating a chemical solution through
the heat exchanger. Another possibility is disassembling of the bundle and submerging the
tubebundle in a tank filled with a chemical solution.
There are various international companies (please refer to Appendix B) which can deliver
products for the chemical cleaning. They have world-wide offices in many countries and can
give you cleaning advice or can clean the heat exchanger for you.
Chemical cleaning can damage the heat exchanger. Let the supplier of
the chemical cleaning agent determine whether the agent is suitable in
combination with the materials of the heat exchanger (see specification
sheet).
3.4 Shut down periods
Avoid the heat exchanger standing still in freezing conditions: this

may cause damage to the tubes. Check for the proper glycol content
to prevent freezing.
During shut down periods longer than a week the heat exchanger
has to be drained completely and dried by means of preheated
compressed air.
When a corrosive medium is used in the heat exchanger: during

shut down periods longer than 24 hours. After draining a corrosive
medium, the heat exchanger has to be rinsed with fresh water.
When not used continuously, the heat exchanger should be drained,

rinsed with fresh water and dried for periods longer than 24 hours.
Stopping of the flows, cooling down and draining of the heat

exchanger has to be done in a manner to minimize thermal stresses
on the heat exchanger.
Never stop one of the flows of the heat exchanger while the other
one stays in operation, because of the risk of boiling.
11
3.5 Assembly and disassembly of the bundle
The circumference of one of the tubesheets is fitted with three grooves (fixed tubesheet). The
two outer grooves carry O-rings (sealing between shell- and tubeside). The middle groove of
the fixed tubesheet is for the fixation of the position of the tubebundle by means of ‘fixation
plates’.
1 Tubesheet 4 Shell
2 O-ring 5 Tubes
3 Fixation plate
Figure 1: Schematic drawing of tubesheet construction
The other tubesheet (floating tubesheet) will be not fixed and is supposed to slide according
to thermal extension.
For P10 only: instead of fixation plates the P10

has a metal spring ring in the middle groove of the tube sheet. As soon as the bolts are
loosened of the tube bundle is no longer fixated. Tubeside inspection or cleaning remains
possible, but extra attention is required because the tube bundle is not fixed anymore. Except
when performing a pressure test, we recommend to drain both circuits.
Step 1: Disassembly
Cool down to ambient temperature and depressurize the heat
exchanger before any work is done on the cooler.
• Depressurize both circuits.

• Drain the tubeside circuit, by opening the drain in the lowest point and the vent in the
highest point.
• Mark the position of all parts that will be disassembled, so they can be re-assembled in
the correct position later on.
In case the heat exchanger is placed vertically, take care the

bundle is supported before proceeding with untightening the
nuts (fixation plates come loose as well).
• Remove the waterboxes by untightening the nuts (the fixation plates come loose as well)
• Assemble the fixation plates again with the nuts (not necessary when the tubebundle is
going to be removed (see step 3))
• 2- or 3-pass heat exchangers have composite (or optional Brass) partitions on the tubesheet(s) for
dividing the tubeside circuit; mark their position and remove them
• Remove the outer O-ring from both tubesheets
• Only for a pressure test: pressurize the shellside again. Depressurize the shellside again
after the pressure test.
For P10 only: Remember that the tube bundle is not fixed!
Step 2: Removing the tube bundle

• Drain the shellside circuit, by opening the drain in the lowest point and the vent in the
highest point.
• Mark the position of the tube bundle.
• Move the tube bundle to one side until the inner O-ring shows (do not move the tube
bundle further than necessary) and remove the O-ring.
• Move the tube bundle to the other side and remove the outer O-ring on this side as well.
• Carefully pull the tube bundle from the shell.
• Support the tube bundle under the baffle(s) or support sheet(s) when lifting it, be careful
not to bend the baffles (this would affect the thermal performance of the heat exchanger).
The fins are very fragile parts of the heat exchanger and should be
handled with care.
13
For casting design with a blind side, bundle is designed with a small
and a big tubesheet. The small tubesheet is inserted at first in the
casting with the 4 o-rings already mounted. The fixed tubesheet has
to be placed always at the channel side (for 2 pass execution).
Step 3: Assembly
• Push the tube bundle in the shell. Do not push it completely into the shell. For big
bundle sizes, it is preferable (when possible) to insert the bundle vertically in the shell.
The tube bundle can be lifted vertically with the help of threaded holes in the
tubesheets (1). For horizontal assembly the bundle should be supported under the
baffle or support sheet.
• Check the position of the (optional) baffle(s). The position of the first baffle should
always be at the same side as oil inlet.
• Assemble the inner O-ring on the first tubesheet.
• Move the tube bundle gently inwards until both O-ring grooves in the other tubesheet
are accessible.
• Assemble the inner O-ring on the second tubesheet.
Hint: when it is difficult to move the tube bundle through the shell,
you can use a strip between tubesheet and channel and then
tighten bolts and nuts.
Figure 2: use of tool
• Move the tube bundle in its final position.
Tubeside assembly:
• Assemble the outer O-rings on both sides
• Assemble the composite (or optional Brass) partition(s) on the tubesheets of 2- or 3-
pass models.
• Position the fixation plates (3) to secure the bundle in the shell. Note that the fixation
plates of the cooler with an even number of tube passes should always be mounted on
the same side as the channel.
• Assemble the waterboxes and all connections
• Start-up the heat exchanger again:

• Make sure that the cold medium circulation is established first, followed by the gradual
introduction of the hot medium
• Vent both circuits
• Vent both circuits again when the operating temperatures and pressures are reached
• Check for leakage.
15
3.6 Instructions for sealings and bolting
3.6.1 Sealings
One type of sealing is being used in this heat exchanger:
O-rings: After disassembly of the heat exchanger never use the old O-rings again. Replace
them with new and original O-rings.
Warning: The O-rings have to be lubricated with a special O-ring

lubricant (O-ring silicone paste or Parker O-lube) for easy
assembly and a good sealing capacity. Lubricants not suited for
O-rings can affect the sealing capacity of the O-ring (for instance
never use Vaseline).
3.6.2 Bolting
Check bolts and nuts for damages. Tighten the bolts crosswise (see figure 3).
Figure 3: (Un-)bolting sequence
Chapter 4 Troubleshooting & repairs
4 Troubleshooting & repairs
4.1 Insufficient thermal performance

In case of insufficient thermal performance check the following items:
• Whether all connections have been made according to the drawing.

• Whether the heat exchanger and the system have been properly vented.
• Whether the flows are according to the specification (check all valves, pipelines and
pumps, as well as the flow directions).
• Whether the shell- as well as the tubeside have been cleaned recently (fouling can cause
a drop in performance and an increased pressure loss; an increased pressure drop is a
good indication that cleaning is necessary).
• Whether the heat exchanger has been re-assembled properly after disassembly. The
position of the tube bundle may accidentally be mounted rotated 180° around its axis.
4.2 Leaking tubes / tube-to-tubesheet connection

It is often very hard to determine whether leakage occurs because of a leaking tube or
because of a leaking tube-to-tubesheet connection. The shellside of the heat exchanger can
be hydrotested, after disassembly of the tubeside. Follow the instructions in” Assembly and
disassembly of the bundle“. Subsequently pressurize the shellside. After hydrotesting
depressurize and drain the shellside again. Assemble the heat exchanger again.
The tubes are expanded into the tubesheet. It is either not possible (finned tubebundles) or
relatively complicated (plain tube bundles) to replace a leaking tube, but it can be plugged
with soft copper Kelvion plugs (other materials are too hard and may cause leakage of the
adjacent tube-to-tubesheet connections) in both tube ends. Contact Kelvion for support when
plugging off tubes is necessary.
17
5 Spare parts & tools
Available spare parts and tools for this type of heat exchangers:
• Set of sealings (four O-rings)

• Set of soft metal rings for drains/vents
• Soft copper plugs
• Nylon tube brush
• Bolts / nuts
• Complete tube bundle
• For P10 only: Metal spring ring
• Fixation plates (for types > P10)
• Composite (or optional Brass) partitions (not for 1-pass heat exchangers)
• Waterbox
• Cover
• Anode
When placing orders please specify all data as stated on the

nameplate.
Sealings are subject to ageing. Expected lifetime of spare

sealings is approx. 5 years when stored according to the rules
below.
Rules for storage:

Dry, non-freezing environment at a constant temperature of
about 20°C
Constant humidity level
Keep away from direct sunlight
Horizontally stored (not hanging on hooks)
Sealing material should be correctly disposed, observing the

environmental needs and regulations. Any national rules and
directives should be adhered to.
For updated spare parts lists of each Bloksma heat exchanger, please visit www.kelvion.com in order
to download an original parts list or contact your local Kelvion supplier.
Chapter 6 Instructions for storage
6 Instructions for storage
6.1 Standard storage (controlled conditions)

Every Kelvion quality product is pressure tested before leaving the factory. The test is
performed using a conservation fluid, thus ensuring adequate protection against corrosion
during a maximum of six months after delivery. This fluid will protect the heat exchanger
when it is stored at controlled conditions, i.e. inside, in a dry room at constant
temperature. The conservation fluid is a petroleum based fluid.
6.2 Advice for conservation (uncontrolled conditions)

When the above mentioned storage conditions are not met, all openings have to be closed
airtight and you will have to fill the heat exchanger with an inert gas at a slight overpressure
(additionally silica gel can be added to absorb liquids). Attach a pressure gauge and check
the pressure at regular intervals. Alternatively, the heat exchanger can be treated with a rust
preventive liquid of a type suited for long term conservation.
When necessary contact a specialised company. Take the materials of the heat exchanger
(see specification sheet) into consideration. Be aware that in uncontrolled storage conditions
large amounts of water can accumulate in the heat exchanger as a result of condensation.
19
7 Cleaning of the heat exchanger
7.1 Chemical cleaning

For chemical cleaning several companies offer a comprehensive solution. The table below
lists a number of applicable cleaning agents that may be used for chemical cleaning.
manufacturer product
Drew HDE-777
Nalfleet MaxiClean 2
Unitor Aquabreak
Vecom Ultrasonic Multi Cleaner
Please refer to the manufacturer’s datasheet for specific properties,

concentration, duration of cleaning, temperature, etc.
7.2 Post cleaning

After cleaning work on the product has been done:
• Check the condition of the tube surfaces and coating.
• Check and clean all gasket surfaces.
• Replace damaged parts.
• Install new gaskets.
Chapter 8 Validation
8 Validation
This is to certify this manual has been validated internally by the Kelvion Engineering
department.
The validation comprised of checks by a group of engineers, service personnel and users
whether the instructions in this manual comply with the tasks to be done by the owner and
relevant personnel.
The manual is validated against NEN 5509.
Almere, The Netherlands
M.J. Pieters
Manager Engineering / R&D
21
9 Glossary
Refer to the figure(s) in the paragraph “ Assembly and disassembly of the bundle” for an
explanation of the designation of parts of the heat exchanger in the text.
Conditioned circuit Closed circuit with a non-corrosive medium.
Unconditioned circuit Open circuit (for instance seawater) or a closed

circuit with a corrosive medium.
Coating Composite polymer layer that protects the material

on which it is applied against corrosion.
Inhibitor Additive to a medium flowing through the heat

exchanger which –expressly tailored to that
medium- reduces the speed of chemical reactions
like corrosion.
Anodes / galvanic protection Introducing a soft iron anode in the tubeside circuit
that is more reactive to the corrosive medium
flowing through the heat exchanger. The anode
slowly dissolves and is leaving a corrosion
protective layer on the inside of the tubes.
Appendix
Appendix: Constructional directions for mounting a P-type heat exchanger in a piping design.
Pay attention to the following points:

• Level (horizontal) and square mounting possibility.
• Bends in the piping must be located at a distance of at least three times the nominal
diameter of the pipe from the inlet of the heat exchanger.
• When a vaporizing cryogenic medium is used, the heat exchanger has to be placed
under an angle of 3° - 10°, in order for the vapour to be able to exit the heat exchanger,
aided by natural circulation. For a proper thermosyphon functioning, the height between
the oil cooler and the condenser should be at least 3 meters.
• Check if vent and drain connections are present in both circuits of the heat exchanger
(when not present on the heat exchanger, then construct them in the piping).
• Put a filter (with a permeability of 3 mm) before the inlet of both circuits of the heat
exchanger.
• Stress- and vibration free mounting possibility of the connections and the supports (fit
expansion bellows and/or silencer blocks when necessary).
• Disassembling possibility of the tube bundle (and other parts like drain and vent plugs).
• Expansion possibility of lockable liquid circuits.
• Danger of freezing of liquid circuits.
• The design data of the heat exchanger on the specification sheet1 and the drawing.
E.g. the flows: deviating from these can cause unacceptable high or low velocities.
A (temporary) lower flow in a conditioned circuit is acceptable when caused by a
temperature control valve in the conditioned circuit. Avoid standstill (unless the heat
exchanger is drained and flushed according to Kelvion instructions at 3.4).
• When adding an inhibitor to one of the fluids in the heat exchanger, always check
whether this inhibitor can be harmful for the materials of the heat exchanger (see
specification sheet).
• Make sure that in case of flow control (with conditioned circuits only) this is done
gradually (no ‘on-off-control’).
• To prevent leakages at cold start-ups (especially PF-type oil coolers) the shellside of
the heat exchanger must always be completely filled with the operating fluid before
start up.
• Kelvion reserves the right (according to TEMA RGP-RCB-2) to plug a maximum of 1%
of the tubes.
• When selecting a heat exchanger, Kelvion’s choice for use of materials is based and
judged on the fluids specified by the customer at the time of selection.
However, if possible contaminations, higher or lower than normal pH-values and other
important properties are exceeding levels as specified at the time of the selection of the
heat exchanger, Kelvion cannot be held responsible. Therefore please always check
whether both fluids are compatible with the materials of the heat exchanger.
• Check whether the materials of the connecting piping are compatible with the materials
of the heat exchanger to prevent galvanic corrosion. E.g. the combination of stainless
steel piping running to and from the heat exchanger when CuNi 90/10 tubes are used,
might lead to a faster corrosion process than normal.
1
In connection with the applied materials the instruction manuals refer to the specification sheet of the heat
exchanger. Therefore always keep the specification sheet at your documentation.
23
503717 Sika 174B - 1/2” L0 40 mm- Thermometer for oil cooler pipelines
Casing 110x30 mm * Gold-colored anodized

0-100° C
Connection thread
G 1/2
REV REVISION RECORD DATE REVISED APPROVED
A1 16.02.2018 ADL HSL
A2 Changed to bigger motor 05.03.2018 ADL HSL
513369
Suction: 2" SAE3000
350
>> CW >>
Pressure:
1 1/2" SAE3000
Approx. 533
Electrical by Pump
A A
35 279 35 23 400 23
Approx. 349
615,6 204
Approx. 1069
4x 18 A-A ( 1:8 )

446
2x 423
This drawing / the design belongs to Servi AS, and must not be disclosed to any third person without our permission.
Ikke spesielt toleransesatte mål / Tolerances when not specified
2x 23 Maskinering: Sveising:
0 Machining: NS-ISO 2768-mk Welding: NS-EN-ISO 13920 BF
Dato/Date Konstr./Design Kontrollert/Checked Godkjent/Approved
Servi Ulsteinvik AS
0
16.02.2018 ADL
349
Tittel/Title
2x 35
General Arrangement
2x 314
Tegn. nr./Drwg. no. Rev.
Pumpe Unit 137lpm 55bar 15kW 400/690V
HMC2 180L GP265A1H-1EA-25C-6EMT 771405 A2
U652394 Brunvoll Volda Anlegg 2232-33. revidert.
Kanter fases/Chamfer 45° x 0.5 Skala/Scale Vekt/Weight Projek./Projec. Art. nr. Ark/Sheet
Hulkiler/Fillet rad. R = 0.5 1:8 A3 1 /1

Chapter 8 - Page 94
502628 High Pressure Duplex Filters - Models 22PD, 32PD
High Pressure Duplex Filters - Models 22PD, 32PD 107
INSTALLATION DETAILS :-
PREMIER
PRODUCTS
A
FLANGE FACE DETAIL
IN OUT B
PLUG PIN CODE
1 N. OPEN
2. N. CLOSED
3. COMMON
22PD
LENGTH 1 - 236
LENGTH 2 - 345
32PD
LENGTH 1 - 317
L BOTH 22PD & 32PD LENGTH 2 - 437
M12x1.72 PITCH
x20 DEEP
K HEXAGON
22PD
24 A/F
32PD C BOWL REMOVAL
36 A/F 100mm
D
INDICATOR LOCATION
E
G
J
H
4 MOUNTING HOLES
22PD: M8x1.2 PITCHx12 DEEP
32PD: M10x1.5 PITCHx15 DEEP 2 BLEED F
HOLES
G1/8
CHANGEOVER BLEED VALVE

HANDLE BALANCE VALVE
DIMENSIONS (mm)
MODEL A B C D E F G H I J K L
22PD 240 35 92 18 55 150 32 96 192 60 30 59
32PD 306 42 130 20 78 165 33 120 240 75 36 70
Indicator Detail
ELECTRICAL INDICATOR (E) VISUAL INDICATOR (V)
62
36
THE APPLIANCE SOCKET

MAY BE SET IN ANY ONE
37 OF 4 POSITIONS
(90˙ increments from
position shown)
34
APPLIANCE SOCKET TO DIN 43650
Filter Division Europe

Churwell Vale, Shaw Cross Business Park
Dewsbury, West Yorkshire WF12 7RD
Telephone: +44 (0) 1924 487000 Fax: +44 (0) 1924 487001
32PD Duplex Filter
Yellow Filter
Operating Instructions
Warning: When the filter is not in use the yellow valve must remain open by
turning anticlockwise.
To change the element in this filter:
1. Ensure this filter is not in use.

2. Remove the filter bowl and change the element.
3. Replace the filter bowl and fully open the red valve by turning anticlockwise to fill the
filter system fluid.
4. Close the red valve
To bring this filter into use:

1. Close the yellow valve.
2. Fully open the red valve by turning anticlokwise.
3. Turn the black changeover handle 90° by turning anticlockwise.
4. Close the red valve.
5. Open the blue valve by turning anticlockwise.
Blue Filter
Operating Instructions
Warning: When the filter is not in use the blue valve must remain open by
turning anticlockwise.
To change the element in this filter:
5. Ensure this filter is not in use.

6. Remove the filter bowl and change the element.
7. Replace the filter bowl and fully open the red valve by turning anticlockwise to fill the
filter system fluid.
8. Close the red valve
To bring this filter into use:

6. Close the blue valve.
7. Fully open the red valve by turning anticlokwise.
8. Turn the black changeover handle 90° by turning clockwise.
9. Close the red valve.
10. Open the yellow valve by turning anticlockwise.
502628 SVO Sparepart numbers, Parker High Pressure Duplex Filters
ref. Description 501884 502628 505782

1 Bowl 509307 507494 508442
2 Element 501885 502629 505783
3 Balance valve assy 503749 503749 503749
5 Diverter handle 504719 504719 504719
6 Indicator 504563 504563 504563
7 Drain plug 509308 509308 509308
14 Seal Kit - Contains items 15 to 24 504645 504645 504645
1 7
Chapter 9 Remote control. Manual and drawings
Chapter 9 Remote control. Manual and drawings
SYSTEM MANUAL
System manual
Neptune-II-CPP
Propulsion control system
Brunvoll Mar-El plant no.: 3744-45
Customer: Brunvoll Volda

2312-13
Vessel: China Merchants Heavy

Industry (Jiangu) Co. LTD
(CMHI)
CMHI-196-2
Brunvoll Mar-El AS, Storvegen 48, NO-3880 Dalen, Norway

DT: +47 35 07 58 00 F: +47 35 07 58 01 E: [email protected] W: brunvoll.no E No: 914 192 137 VAT B: DNB Bank ASA

1 General Information
2 System description
3 Installation and Interface Manual
4 User`s Manual
5 Service Manual
6 Commissioning manual
7 System Drawings
8 Miscellaneous
10
1 General Information

System manual
Neptune-II-CPP - Plant no. 3744-45
System manual contents and revisions
Neptune-II-CPP Propulsion control system - Plant no. 3744-45
Documents Rev./Date Comment

Main Parts List _
Factory Acceptance Test
Program Version
DnV-GL Type Approval Certificate TAA00000SM _1 Valid until 2021-01-22
EMC Test Report 2009-3549 Neptune-II _01
Additional descriptions Neptune-II-CPP, plant no. 3744-45 _

Installation and Interface manual Neptune-II-CPP _C
User manual Neptune-II-CPP _C
Service manual Neptune-II-CPP _C
PA0076 Dipswitch settings 28.12.2005
Commissioning manual _B
Drawing list _B
Revision history
Rev. Description Initials Date

- Initial release M.B. 10.10.2019
A As delivered M.B. 12.11.2019
B
C
3744-45 System manual_A 12.11.2019
Brunvoll Mar-El AS
Main parts list - Brunvoll Mar-El Remote Control System
Brunvoll Mar-El plant no: 3744-45
Brunvoll Mar-El type: Neptune II
Main parts:
Item: Type: No.'s Comments:
CPU Cabinet 800x600x210 2

PSU Other 2
I/O cabinet
Main panel Advanced double panel 1

Slavepanel
ECR panel
Pitch actuator -
Shaft rpm pickup - 2
Fuel pick up
Local ctrl box - 2
Interfaces: Modes:
Pitch interface Interface to Danfoss valve Indivdual pitch/rpm No

Rpm interface Standard 4-20mA Combinator Yes
DP No Limit rpm No
Joystick Yes Constant rpm 1 No
VDR No Constant rpm 2 No
Loadsignal 4-20mA
Operation modes:
Other
3744‐45 Main Parts list

Program version - Programmable components
Brunvoll Mar-El type: Brunvoll Mar-El plant no: Customer Customer ref.
Neptune-II 1.09 3744-45 Brunvoll Volda Ulstein Sunstone CMHI 196-2
Card no. Card Designator Purpose Revision Date / Sign. Revision Date / Sign. Revision Date / Sign. Comment
Electronic cabinet
C4 FX3UC Main Controller Program Main Controller 01.09 280619 / Bsva P7

C5 FX3UC Backup/ind controller Program Backup Controller 01.07 280619/ BSVA P7
C4Y FX3U-ENET Ethernet Parameter 01.02 100314 /LES
C3 MPP110 Power/monitoring U3 Alarm logic 03.00 061015 / JA

C7 MPB200 Pitch & RPM driver U6 Controller logic 02.00 020515/ LES
C6 / C16 MPS430 Communication U4 Communication program 01.04 151217 / HAL
C12 MPS431 Communication NMEA Communication Controller 01.02 220116/LES P6
Panels
Card no. Card Designator Purpose Revision Date / Sign. Revision Date / Sign. Revision Date / Sign. Comment
C1 MPS160 Panel Controller U19 Program Main Panel Controller 280916 / LES Patch 9
Main
01.06
C1 MPS160 Panel Controller U21 Program Backup/indication contr. 01.06 010319 / LES Patch 11
C1 MPS160 Panel Controller U4 Program IO-Logic 01.03 180215 / LES

Programversjon Neptune-II 3744-45
Certificate No:
TAA00000SM
TYPE APPROVAL CERTIFICATE Revision No:
1
This is to certify:
That the Remote Control System, Controllable Pitch Propeller
with type designation(s)

Neptune-II CPP
Issued to
Brunvoll Mar-El AS
DALEN, Norway
is found to comply with

DNV GL rules for classification – Ships, offshore units, and high speed and light craft
Application :
Product(s) approved by this certificate is/are accepted for installation on all vessels classed
by DNV GL.
Location classes:
Temperature B
Humidity B
Vibration A
EMC B
Enclosure Required protection according to the Rules to be provided upon installation
onboard
Issued at Høvik on 2019-01-23

for DNV GL
This Certificate is valid until 2021-01-22.
DNV GL local station: Sandefjord
Approval Engineer: Sergey Gilmiyarov Jan Tore Grimsrud

Head of Section
This Certificate is subject to terms and conditions overleaf. Any significant change in design or construction may render this Certificate invalid.
The validity date relates to the Type Approval Certificate and not to the approval of equipment/systems installed.
Form code: TA 251 Revision: 2016-12 www.dnvgl.com Page 1 of 4
© DNV GL 2014. DNV GL and the Horizon Graphic are trademarks of DNV GL AS.

Job Id: 262.1-008188-5
Certificate No: TAA00000SM
Revision No: 1
Product description
Neptune_II CPP Propulsion Control System consisting of:
– Control cabinet
– Bridge manoeuvre panel
– ECR manoeuvre panel
– IO expansion cabinet
A manoeuvre panel may be for one or two propulsion lines.

A bridge panel may be standard (with Noritake GU256x128 display) or advanced (with Exter T70 Touch
panel display or X2 HMI Panel family).
CPU / IO-cabinets
Mitsubishi FX3U Series,
Programmable Logic Controller with IO modules
(refer to DNV GL certificates TAA0000038 and TAA00000A0)
Mitsubishi MELSEC iQ-F Series,

MELSEC Programmable Logic Controller with IO modules
(refer to DNV GL certificates TAA00000SE)
Mitsubishi FX2NC-CNV-IF expansion adapter
Brunvoll Mar-El
MPP110 Power control & monitoring, dual 24VDC power isolation.
MPP300 Power monitoring with single DC/DC power isolation
MPS431 NMEA interface for VDR/alarm system.
MPT140 Analogue galvanic isolation.
MPT460 General analogue and digital I/O-module with serial RS-485 and CANbus interfaces.
PA0076 Step motor driver.
MPB200 Backup pitch controller
MPS430 Communication controller
MPT250 I/O interface card
Exter T70 Touch screen (ECR panel) (TAA00000TZ)

Exter T70 SR BL Touch screen Sun Readable (Adv. Bridge panel) (TAA00000TZ)
Beijer X2 HMI (TAA00000N8)
IE-SW-BL05-5TX Ethernet switch (refer to DNV GL certificate TAA0000112)

MINI MCR-2-XXXX Signal converter (refer to GL certificate 1444515 HH)
Brunvoll Mar-El
ICP-DAS 7000 Decentralised IO connection
MCL2 Control/order lever
MPS160 Panel controller with Modbus serial interface
MPS161 Panel card
Brunvoll Mar-El
MACxxx-Dyyyyy Pitch actuator with pitch feedback sensor
RPM Actuator Control Unit
Software is identified by <version no.>.<revision no>, where <version no.> is updated for major
changes and <revision no.> for minor changes. All revisions are backward compatible.
System is equipped with VPN solution which is meeting requirements set by DNV GL Rules Pt.4 Ch.9 with
regarding remote access to vessels control systems.

Job Id: 262.1-008188-5
Revision No: 1
sw modules included in Neptun CPP 1.09 sw version

FX3UC-16/32MT controller 01.09
- FX3U-ENET Ethernet controller 01.02
FX5U/FX5UC xx/xx Main controller 2.00
MPS431 NMEA interface for VDR/alarm system 01.02
MPT460 General analogue and digital I/O-module 01.04
with serial RS-485 and CANbus interfaces
MPB200 Backup pitch controller 02.00
MPS430 Communication controller 01.04
MPP110 Power & Alarm card 03.00
Exter T70 SR BL Touch screen Sun Readable 01.07
MPS160 Main panel controller with Modbus serial 01.06
interface
MPS160 Backup panel controller with Modbus serial 01.06
interface
FX3UC Backup/indicator controller 01.07
FX5U/FX5UC xx/xx Backup controller 2.00
MPS430 Communication controller 01.04
MPS431 Communication controller Modbus 01.00
PA0076 Stepper motor driver 01.30
MPS160 IO controller 01.03
X2 Marine 7 Touch screen 02.00
ICP-DAS Serial IO converter 01.01
Application/Limitation
The means to emergency stop the propulsion from the navigating bridge are to be arranged separately
to this remote control system, ref. DNV GL Rules Pt.4 Ch.1 Sec.4 [1.4.3] (SOLAS Reg. II-1/31.2.3).
Approval conditions
The Type Approval covers hardware and software listed under Product description.
When the type approved software is revised (affecting all future deliveries) DNV GL is to be informed by
forwarding updated software version documentation. If the changes are judged to affect functionality for
which rule requirements apply a new function type test may be required and the certificate may have to
be renewed to identify the new software version.
For each system intended to be installed in a DNV GL classed vessel the following documentation of the
actual application is to be submitted for approval:
- Reference to this Type Approval Certificate
- System block diagram
- Power supply arrangement (may be part of the System block diagram)
- Main parts list
- Layout of bridge control panels with legible labels for alarms and pushbuttons
and, if updated since this Type Approval Certificate was issued:

- Software revision history document
- Test program for certification
- Main parts list
- Layout of bridge control panels with legible labels for alarms and pushbuttons

Job Id: 262.1-008188-5
Revision No: 1
Product certificate
Each delivery of the application system is to be certified according to Pt.4 Ch.9 Sec.1. The certification
test is to be performed at the manufacturer of the application system before the system is shipped to the
yard. After the certification the clause for application software control will be put into force.
Clause for application software control

All software modifications made after the certification test and as long as the system is in use onboard,
are to be recorded. The records, together with the software version(s) in use are to be available for
evaluation at request by DNV GL. Major software changes are to be approved before being installed
onboard.
Type Approval documentation

Title Rev.
Plant 2795 drawings <24.09.09
lant 2795 FAT report 2009-10-22
Plant 2795 system manual 25. september 2009
FMEA Neptune-II CPP system 19. oktober 2009
Hardware description Neptune-II CPP system 19. oktober 2009
Software description Neptune-II CPP system 7. september 2009
Software revision history Neptune-II CPP system, SW version 1.07 04.07.2014
EMC and environmental testing of maritime control panel 2009-10-19
EMC and environmental testing of manoeuvre panel and CPU cabinet 2011-12-19
TA Assessment Report by DNV GL Sandefjord dated 2018-09-21
Tests carried out

Applicable tests according to DNV GL Class Guidelines DNVGL-CG-0339.
Periodical assessment
The scope of the periodical assessment is to verify that the conditions stipulated for the type are
complied with, and that no alterations are made to the product design or choice of systems, software
versions, components and/or materials.
The main elements of the assessment are:
• Ensure that type approved documentation is available
• Inspection of factory samples, selected at random from the production line (where practicable)
• Review of production and inspection routines, including test records from product sample tests and
control routines
• Ensuring that systems, software versions, components and/or materials used comply with type
approved documents and/or referenced system, software, component and material specifications
• Review of possible changes in design of systems, software versions, components, materials and/or
performance, and make sure that such changes do not affect the type approval given
• Ensuring traceability between manufacturer’s product type marking and the type approval certificate
A renewal assessment will be performed at renewal of the certificate.
END OF CERTIFICATE

TECHNICAL REPORT
SCANA MAR-EL
EMC AND ENVIRONMENTAL TESTING OF MARITIME
CONTROL PANEL
REPORT NO. 2009-3549

REVISION NO. 01

DET NORSKE VERITAS
Report No: 2009-3549, rev. 01

TECHNICAL REPORT
Date of first issue: Project No.:

2009-10-19 44341199
Approved by: Organisational unit:
Einar Richter Jordfald Compliance Testing & Field
Head of section Measurement
Client: Client ref.:

Scana Mar-El Odd Arne Gaarder
Summary:
A Single Bridge Panel, type Neptune II, manufactured by Sacna Mar-EL AS, has been EMC
and environmentally tested according to the specifications given by the classification societies
and bodies listed in chapter 1.
The tests were carried out in the Environmental Test Laboratory at Det Norske Veritas, Høvik,
Norway in the time period 17.08.2009 to 12.10.2009.
With the notes/comments described in conclusive summary, chapter 2, the EUT passed all the
tests.
Report No.: Subject Group:

2009-3549 R1 Indexing terms
Report title: Key words Service Area
EMC and Environmental Testing of Maritime Electromagnetic Verification
Control Panel compatibility
Environmental tests Market Sector
General
Industry
Work carried out by:
Stian Mong, Huu Dung Dinh No distribution without permission from
the client or responsible organisational
unit
Work verified by: No distribution without permission from
Jonas Beverfjord, Tor Heiestad (env.)
( ) the client or responsible organisational
unit (however, free distribution for
internal use within DNV after 3 years)
Date of this revision: Rev. No.: Number of pages:
Strictly confidential
01 42
Unrestricted distribution
© 2002 Det Norske Veritas AS
All rights reserved. This publication or parts thereof may not be reproduced or transmitted in any form or by any means,
including photocopying or recording, without the prior written consent of Det Norske Veritas AS.
Page i
This test report may not be reproduced other than in full.
Test Report 2009-3549.doc

2 System description

SYSTEM MANUAL
System description -
3744-45
Neptune-II


3744-45
Neptune-II CPP
Ownership
All information, including drawings, pictures etc., contained in this document is the sole property of
Brunvoll Mar-El AS. It must not be copied or reproduced wholly or partially in any form or by any
means, and the information contained within must not be communicated to a third party, without prior
written permission of Brunvoll Mar-El AS.
Liabilities
Brunvoll Mar-El AS strains to ensure that all information in this document are correct and precise, but
disclaims liability for any errors or omissions.
Warning
The equipment to which this manual applies must only be used for the purpose for which it was
designed. Improper use or maintenance may cause damage to the equipment and/or injury to
personnel. The user must be familiar with the contents of the appropriate manuals before attempting
to operate or work on the equipment.
Brunvoll disclaims any responsibility for damage or injury caused by improper installation, use or
maintenance of the equipment.
Improvements
To assist us in making improvements to the product and to this manual, we welcome comments and
constructive criticism. Please send all such in writing to:
Mar-El AS
Att: Product improvement E-mail: [email protected]
Storvegen 48 Telephone: +47 35 07 58 00
N-3880 Dalen Telefax: +47 35 07 58 01
Norway Web: www.mar-el.no / www.Brunvoll.no
Revision history

- Initial release. M.B. 27.03.18
A
B
Introduction Page I
3744-45 NEPTUNE-II CPP - SYSTEM DESCRIPTION
3744-45
Neptune-II CPP
Table of Contents:
1 Introduction .......................................................................................................................................................................1
2 Power mode.......................................................................................................................................................................1
3 Start drive ...........................................................................................................................................................................1
Introduction Page II
3744-45
Neptune-II CPP
1 Introduction
This document only describes features and details that differs from standard systems, or in other ways
needs clarification. For general information see Neptune-II User manual and Neptune-II Service manual.
2 Power mode
This mode allows the frequency converter to let the propeller RPM fluctuate to maintain a constant
power load. I.e. better operating conditions for generators and better fuel economy. This mode is
manually activated/deactivated with the "POWER MODE" button in main panel on bridge.
3 Start drive
To be able to start drive, the CPP control lever must be set to zero, servo pump must be started and the
shaft lock must be disengaged.
When these conditions are fulfilled a closed contact (Start Interlock) is sent to frequency converter.
If frequency converter is ready a closed contact (Ready to Start) is sent to CPP control system.
Operator is now able to start the drive from CPP control panel by pushing the START button.
Introduction Page 1
3 Installation and Interface Manual

SYSTEM MANUAL
Installation and
Interface manual
Neptune-II CPP

DT: +47 35 07 58 00 F: +47 35 07 58 01 E: [email protected] W: brunvoll.no E No: 914 192 137 VAT B: DNB Bank AS

Installation and Interface manual
Neptune-II CPP
Ownership
Liabilities
Warning
Improvements
Brunvoll Mar-El AS
N-3880 Dalen Telefax: +47 35 07 58 01
Norway Web: www.mar-el.no / www.brunvoll.no
Revision history

- Initial release. SL 25.09.2009
A Design update. Some additions and corrections. HOK 08.12.2010
B Corrected error in pitch interface. SL 24.03.2011
C Update to Brunvoll design (temporary version) BR 6.07.2017
Neptune-II CPP - Installation and Interface manual en_C 23.11.2017
Brunvoll Mar-El AS External connections Page 1

Neptune-II CPP
Table of Contents
1 Introduction .................................................................................................................................................... 3
2 General description ....................................................................................................................................... 3
3 Mounting ......................................................................................................................................................... 3
3.1 CPU-cabinet and I/O-cabinets ............................................................................................................... 3
3.2 Manoeuvre panels .................................................................................................................................. 3
4 Power and alarm connections...................................................................................................................... 4
4.1 Power supply ........................................................................................................................................... 4
4.2 Alarm outputs ......................................................................................................................................... 4
5 Internal connections ...................................................................................................................................... 5
5.1 CPU-cabinet and manoeuvre panel interconnections ...................................................................... 5
5.1.1 Between CPU-cabinet and bridge panels ................................................................................... 5
5.1.2 Between CPU-cabinet and ECR panel .......................................................................................... 5
5.1.3 Modbus RS-485 network ............................................................................................................... 5
5.1.4 Ethernet network ........................................................................................................................... 6
5.2 Manoeuvre panel extensions................................................................................................................ 6
5.2.1 Command transfer control output unit ...................................................................................... 7
5.3 CPU-cabinet and I/O-cabinet(s) interconnections (if present) .......................................................... 8
5.3.1 Profibus-DP I/O-cabinet(s) ............................................................................................................ 8
5.3.2 Serial interface I/O-cabinet(s) ....................................................................................................... 8
6 External connections ..................................................................................................................................... 9
6.1 Gear and propeller system ................................................................................................................... 9
6.1.1 Servo and propeller control system ............................................................................................ 9
6.1.2 Clutches ......................................................................................................................................... 10
6.2 Main engine(s) / prime mover ............................................................................................................ 11
6.2.1 General interfaces ........................................................................................................................ 11
6.2.2 Standard additions for MaK-interface ....................................................................................... 11
6.3 Main switchboard (shaft generator interface) .................................................................................. 11
6.4 Joystick-system (joystick interface) ..................................................................................................... 12
6.5 DP-system (DP interface) ..................................................................................................................... 13
6.6 Voyage data recorder (VDR) ................................................................................................................ 13
6.7 GPS interface for Speed pilot .............................................................................................................. 13
6.8 Serial interface to alarm/monitoring system .................................................................................... 14
6.9 Miscellaneous ....................................................................................................................................... 14

Neptune-II CPP
1 Introduction
Important documentation and drawings for installing the Neptune-II CPP propulsion control system
are:
1. The installation and interface manual - this manual.
2. Installation guidelines Neptune-II CPP.
3. Cable plan Neptune-II CPP, drawing no. 016-XXXX (individual for each system).
4. Mechanical drawing CPU-cabinet Neptune-II CPP, drawing no. 058-XXXX (different versions exists).
5. Mechanical drawing manoeuvre panel Neptune-II CPP, drawing no. 058-XXXX (different versions exists).
6. Mechanical drawing I/O-cabinet Neptune-II CPP, drawing no. 058-XXXX, if present (different versions
exists).
All installations, mechanical and electrical, are to be done according to these documents. Note that all
vessels are normally not equipped with all propulsion and manoeuvring units and functions/options
described in the general Neptune-II documentation (in such cases connect all that exists/are specified).
To fully comply with EMC-standards all cables must be screened and it is very important to follow the
'Installation guidelines Neptune-II CPP'.
Note that this document is for general help, and is not intended as the detailed installation documentation
for the system. The installation shall be done according to the cable plan, which is the most important
installation document. In case of disagreements between the cable plan and other documentation, the cable plan
is prevailing.
2 General description
The Neptune-II CPP propulsion control system controls main engine RPM, propeller pitch and clutches.
Different operating modes to suit the vessels different operating conditions may be implemented. Up
to seven control stations can be included.
The Neptune-II CPP propulsion control system consists of the following main units:
1. CPU-cabinet.
2. Manoeuvre panels (one or more, up to seven).
3. I/O-cabinet(s), if present.
4. Miscellaneous sensors and actuators.
3 Mounting
All units must be mounted according to general requirements and classification society requirements
for equipment on-board vessels. Se also 'Installation guidelines Neptune-II CPP'.
3.1 CPU-cabinet and I/O-cabinets

The CPU-cabinet and eventual I/O-cabinets must be mounted indoor, and are normally mounted easily
accessible in the engine control room (ECR).
Pay special attention to grounding of cable screens to the ground terminal at the inside of each cabinet.
3.2 Manoeuvre panels

The manoeuvre panel(s) are designed for fixed mounting. See cut-out dimensions in the mechanical
drawing for mounting. No drilling, screwing etc. into the unit is allowed.
The connectors must be easily accessible.

Neptune-II CPP
Access to the Ethernet connector in the main and ECR manoeuvre panels is necessary during system
set-up and tuning.
4 Power and alarm connections

Two completely independent power supplies must be provided for the CPU-cabinet, i.e. two separate
sources and separate circuits are required.
Alarm outputs are normally connected to the vessels alarm system.
4.1 Power supply

Power supplies:
Neptune-II Signal Term. Sign. Term. Signal Power supply
CPU-cabinet specification no. dir. no. specification
Max load
L1-1 24VDC (+)
24VDC power input 1 depends on ←
L1-2 24VDC (-)
configuration.
Max load
L1-3 24VDC (+)
24VDC power input 2 depends on ←
L1-4 24VDC (-)
configuration.
The two supplies must be capable of delivering min. the required continuous rating each (the required
min. ratings are given in the cable plan, drawing no. 016-XXXX).
4.2 Alarm outputs

The system has the following alarm outputs:
Neptune-II Signal Term. Sign. Term. Signal Alarm system
24VDC max
Voltage Failure Alarm
L2-1 10W. Surge
(open when alarm is → Voltage failure input.
L2-2 suppression
triggered)
required.
24VDC max
System Failure Alarm
L2-3 10W. Surge
(open when alarm is → System failure input.
L2-4 suppression
triggered)
required.
Other alarm outputs may be present. See cable plan, drawing no. 016-XXXX.

Neptune-II CPP
5 Internal connections
Connection of internal signals. Connect as described in the cable plan. Note that the internal Modbus
network has a theoretical maximum cable length of 1200 meters. Also note that there are two
independent networks, each with its own power supply (one main network and one back-up network).
5.1 CPU-cabinet and manoeuvre panel interconnections
5.1.1 Between CPU-cabinet and bridge panels

The cabling starts in the CPU-cabinet and ends in the last panel in chain, except the Ethernet cable. This
shall only be cabled to the panel defined as the “Main manoeuvre station”.
Neptune-II Signal Term. Sign. Term. Signal Bridge manoeuvre

CPU-cabinet specification no. dir. no. specification panels
L3-1 X1-1 24VDC (+)
Power 1 24VDC max 3A → Power input.
L3-2 X1-2 24VDC (-)
Communication1 Modbus RS-485 L3-3 → X1-3
Main communication.
Modbus RS-485 twisted pair L3-4 ← X1-4
L3-9 X2-1 24VDC (+)
L3-10 X2-2 24VDC (-)
Communication2 Modbus RS-485 L3-11 → X2-3 Backup/indication
Modbus RS-485 twisted pair L3-12 ← X2-4 communication.
Industrial
RJ45 RJ45 Only to the main
Ethernet Setup Ethernet →
Male Male manoeuvre station.
Cat5 (S/FTP)
5.1.2 Between CPU-cabinet and ECR panel
Neptune-II Signal Term. Sign. Term. Signal ECR manoeuvre

CPU-cabinet specification no. dir. no. specification panel
L3-5 X1-1 24VDC (+)
L3-6 X1-2 24VDC (-)
Communication1 Modbus RS-485 L3-7 → X1-3 Main
L3-13 X2-1 24VDC (+)
L3-14 X2-2 24VDC (-)
Communication2 Modbus RS-485 L3-15 → X2-3 Backup/indication
Industrial
Ethernet RJ45 → RJ45 Setup
Ethernet
communication Male ← Male communication.
Cat5 (S/FTP)
5.1.3 Modbus RS-485 network

The cabling must be performed with shielded twisted pair.
The internal network must be terminated at each end, at the manoeuvre panels. It must be guided as
one line, i.e. no branches are allowed.

Neptune-II CPP
The figure below shows the network schematically:
The network termination consists of two 120 resistors, one connected between X1-3 and X1-4, the
other between X2-9 and X2-10.
5.1.4 Ethernet network

The cabling must be performed with at least a Cat5 (S/FTP) shielded cable, maximum 100 meters
without repeaters/fibre switches. Repeaters/fibre switches are not Brunvoll Mar-El delivery.
The internal Ethernet network must be terminated in a shielded (S/FTP) male RJ45 plug in each end of
the cables.
Note: It is very important that the cable-connector connection is according to the ANSI TIA/EIA-568-B
standard, T568A connection, i.e. each signal is connected in the same twisted pair etc.
T568A connection, ANSI TIA/EIA-568-B standard:
The figure below shows the network schematically:

CPU-cabinet
Manoeuvre panel Manoeuvre panel

(ECR) “Main manoeuvre
station”
5.2 Manoeuvre panel extensions

Intended for internal use in Brunvoll Mar-El delivered systems only. If connected to external
equipment/systems, all inputs and outputs in the connected equipment/systems must be potential free
or galvanic separated and written approval must be obtained from Brunvoll Mar-El.
Note that some I/O are multi-used, i.e. if one function is used another one may be impossible. Check
carefully in each individual case.

Neptune-II CPP
External button panel. See cable plan (drawing no. 016-XXXX) for terminal numbers:
Manoeuvre panel Signal Term. Sign. Term. Signal Button panel
specification no. dir. no. specification
Button inputs 0VDC common J4-2
← Push buttons.
Main Input 1 to 6 J1-1 to 6
Button inputs 0VDC common J4-3
← Push buttons.
Backup Input 1-4 J1-7 to 10
Button LED outputs +24VDC J4-1
→ Max. load 60mA Button indicators.
Main Output 1-6 J2-1 to 6
Button LED outputs +24VDC J4-1
→ Max. load 60mA Button indicators.
Backup Output 1-4 J2-7 to 10
External lever. See cable plan (drawing no. 016-XXXX) for terminal numbers:
Manoeuvre panel Signal Term. Sign. Term. Signal Lever panel
0VDC common J4-2
In command button ← Push button.
Input 1 J1-1
In command +24VDC J4-1
→ Max. load 60mA Button indicator.
indication Output 1 J2-1
J3-8 Toward Ahead Order
±5VDC from
Lever order J3-9 ← Wiper potentiometer.
potentiometer
J3-10 Toward Astern Normally 5k.
External instruments. See cable plan (drawing no. 016-XXXX) for terminal numbers:
Manoeuvre panel Signal Term. Sign. Term. Signal Instruments
Propeller pitch 0VDC common J3-1
→ Max. load 10mA Analogue instrument.
feedback ±10VDC J3-2
0VDC common J3-1
Propeller shaft RPM → Max. load 10mA Analogue instrument.
0-10VDC J3-3
Configurable 0VDC common J3-1
analogue output ±10VDC J3-4
3 configurable 0VDC common J3-1
analogue outputs 0-10VDC J3-5 to 7
External illumination. See cable plan (drawing no. 016-XXXX) for terminal numbers:
Manoeuvre panel Signal Term. Sign. Term. Signal External unit
+24VDC J4-1
Max. load Instruments, lever.
Illumination +5VDC J4-6 →
60mA NB! Only LEDs.
0VDC dimmer J4-7
5.2.1 Command transfer control output unit

Interconnection between manoeuvre panel and command transfer control output unit:

Neptune-II CPP
Manoeuvre panel Signal Term. Sign. Term. Signal Command output

specification no. dir. no. specification unit
Power (internal +24VDC J4-1 L1-1 24VDC (+)
→ Power input.
supply) Note: *) 0VDC at J3-1 to J4-4 L1-2 24VDC (-)
Main in command
Output 1 J2-1 L2-1 Max. load 60mA
ECR in command
Output 2 J2-2 L2-2 each.
Port slave in cmd
Output 3 J2-3 L2-3
Starboard slave in
Output 4 J2-4 → L2-4 Sink input (i.e. Command signals.
cmd
Output 5 J2-5 L2-5 connect units
Aft slave in cmd
Output 6 J2-6 L2-6 commonly to
Fore slave in cmd
Output 7 J4-5 L2-7 +24V)
Slave in command
*) Power supply (select either internal or external supply):

Internal supply: Connect 024V at J3-1 to J4-4 and +24VDC at J4-1 to command output unit term. no. L1-1.
External supply: Connect external 024V to J4-4 and external +24V to command output unit term. no.
L1-1.
Former denotation slave panels: Port - Slave 1, Starboard - Slave 2, Aft - Slave 3, Fore - Slave 4, Slave - Slave
5.
External outputs from command output unit; see cable plan (drawing no. 016-XXXX) for terminal
numbers.
5.3 CPU-cabinet and I/O-cabinet(s) interconnections (if present)
5.3.1 Profibus-DP I/O-cabinet(s)

Normally mounted on the gearbox.
Neptune-II Signal Term. Sign. Term. Signal Profibus DP
CPU-cabinet specification no. dir. no. specification I/O-cabinet
L14-1 L1-1 24VDC (+)
Power 24VDC max 3A → Power input.
L14-2 L1-2 24VDC (-)
9-pin 9-pin
Communication Profibus DP
Dsub → Dsub
Profibus DP twisted pair
C4Z C1
Use a certified Profibus DP cable suitable according to industrial environment (e.g. Miltronic profibus
(L2/FIP-DP). The cable must be guided as one line, i.e. no branches are allowed. The termination shall
be done in standard Profibus 9-pin female D-sub.
5.3.2 Serial interface I/O-cabinet(s)

E.g. NMEA communication, VDR-signals, alarm system.
Neptune-II Signal Term. Sign. Term. Signal Serial interface
CPU-cabinet specification no. dir. no. specification I/O-cabinet
L15-1 L1-1 24VDC (+)
Power 24VDC max 3A → Power input.
L15-2 L1-2 24VDC (-)
Communication Modbus RS-485 L15-3 L1-3
→
Modbus RS-485 twisted pair L15-4 L1-4
The cables must be screened twisted pair. The internal network must be terminated at each end, at the
manoeuvre panels. It must be guided as one line, i.e. no branches are allowed.

Neptune-II CPP
6 External connections
The propulsion control system interfaces sensors and actuators and other systems (e.g. main engine
RPM control, main switchboard, joystick-/DP-system etc.).
All external equipment and units are connected to connection terminals in the CPU-cabinet or the I/O-
cabinet. Below are all external connections described in detail (actuators, sensors etc. within the scope
of supply are internal connections).
Note that all connections are not necessarily present on all systems, see the systems cable plan for
details (drawing no. 016-XXXX). The descriptions below are given as guidelines. In case of other
description than in the cable plan, e.g. different terminal numbers etc., the cable plan is valid.
See installation requirements in the installation guidelines and the cable plan. Note specially that
connected units must not generate transients, e.g. connected solenoids, relay coils etc. must have
transient arrester in addition to be potential free. All inputs to the Neptune-II from external
equipment/systems (i.e. outputs from these) must be potential free or separately galvanically isolated.
This may also apply to inputs. Check carefully in each individual case. Detailed requirements are also
given below.
Interfaces marked with grey colour might be connected to I/O-cabinet if present. See the cable plan
(drawing no.016-XXXX) for terminal numbers.
6.1 Gear and propeller system
6.1.1 Servo and propeller control system

Interface signals to the pitch servo unit:
Neptune-II Signal Term. Sign. Term. Signal Pitch servo unit
Pitch driver alt. 1. Phase B(-) (24V) L5-1
Stepper motor Phase B(+) (24V) L5-2 24VDC max 5A Stepper motor on
→
output from stepper Phase A(-) (24V) L5-3 each phase pitch actuator.
motor driver. Phase A(+) (24V) L5-4
Pitch driver alt. 2. 24VDC (+) L5-1
Danfoss proportional Control output L5-2 Danfoss proportional
→ 24VDC max 0,5A
valve. Power, output Failure feedback L5-3 valve.
and fail. 24VDC (-) L5-4
24VDC (+) L5-5 Release electrical
Local control pitch
Local control L5-6 ← fields on pitch driver.
servo
24VDC (-) L5-7 Local alarm lamp.
L4-1 Toward Ahead Pitch feedback
Pitch control ±10VDC from
L4-2 ← Wiper potentiometer.
feedback alt. 1. potentiometer
L4-3 Toward Astern Normally 1k to 5k.
Pitch feedback
L4-4 Toward Ahead
Pitch indication ±10VDC from potentiometer.
L4-5 ← Wiper
feedback alt. 1. potentiometer Normally 1k to
L4-6 Toward Astern
5k.
Pitch control 4-20mA from L4-1 + signal Pitch feedback
←
feedback alt. 2. transmitter L4-2 - signal sensor.
Pitch indication 4-20mA from L4-4 + signal Pitch feedback
←
feedback alt. 2. transmitter L4-5 - signal sensor.

Neptune-II CPP
Neptune-II Signal Term. Sign. Term. Signal Pitch servo unit

On/Off pickup for
24VDC max L6-1
Shaft RPM pick-up ← detecting RPM of the
100mA L6-2
propeller shaft.
24VDC max L6-3 Servo oil pressure
Servo oil pressure ←
100mA L6-4 switch.
6.1.2 Clutches
Interface signals to standard clutches. See cable plan (drawing no. 016-XXXX) for terminal numbers:
Neptune-II Signal Term. Sign. Term. Signal Clutch interface
Pressure switch
sensing the clutch
0VDC common L6-?
Clutch Indication ← pressure (Closed
Indication L6-?
when clutch
engaged).
24VDC (-) Com L6-?
Clutch solenoid Max load Clutch engage and
24VDC (+) IN L6-? →
valves 50W/solenoid disengage valves.
24VDC (+) OUT L6-?
Interface signals to Brunvoll Volda Softclutch. See cable plan (drawing no. 016-XXXX) for terminal
numbers:
Neptune-II Signal Term. Sign. Term. Signal Clutch interface
Pressure switches
0VDC common L6-?
Clutch indication sensing the clutch
Indication L6-? ←
status pressures (Closed
Soft indication L6-?
when pressure OK).
24VDC (-) Com L6-?

24VDC (+) IN L6-?
Clutch solenoid Max load Clutch engage and
24VDC (+) OUT L6-? →
valves 50W/solenoid disengage valves.
24VDC (+) FLUSH L6-?
24VDC (+) SOFT L6-?
Misc interlock signals to clutches. See cable plan (drawing no. 016-XXXX) for terminal numbers:
Neptune-II Signal Term. Sign. Term. Signal Clutch/engine/MSB
CPU-cabinet specification no. dir. no. specification interface
Interlock Clutch IN 0VDC common L6-? Potential free
←
General Feedback L6-? contact.
Interlock Clutch OUT 0VDC common L6-? Potential free
←
General Feedback L6-? contact.

Neptune-II CPP
6.2 Main engine(s) / prime mover

Interface signals to the main engine(s) (governor, diesel control, safety system).
6.2.1 General interfaces

See cable plan (drawing no. 016-XXXX) for terminal numbers:
Neptune-II Signal Term. Sign. Term. Signal Main engine(s)
Speed setting signal 4-20mADC L7-? + signal 4-20mA To governor(s) speed
→
(isolated output) Max load 500 L7-? - signal 4-20mA setting input.
24VDC (+) L7-? Power to sensor Fuel rack position
Load signal from
Signal L7-? ← + signal 4-20mA (galv. isolated
engine(s)
GND L7-? - signal 4-20mA output).
Engine RPM
RPM indication Signal L7-? + signal 4-20mA
← (galv. isolated
(to instrument) GND L7-? - signal 4-20mA
output).
Interlock clutch in 0VDC common L7-? Potential free
←
high RPM Feedback L7-? contact.
0VDC common L7-? Potential free
Emergency clutch out ←
Feedback L7-? contact.
Slowdown 0VDC common L7-? Potential free
←
(Pitch limit 1) Feedback L7-? contact.
L7-? NC
Interlock start main Interlock start main
L7-? → Common
engine output engine.
L7-? NO (wirebreak)
6.2.2 Standard additions for MaK-interface

Special interface MaK engines, others do also exist. See cable plan (drw. no. 016-XXXX) for terminal
numbers:
Neptune-II Signal Term. Sign. Term. Signal Main engine(s)
Remote RPM control 0VDC common L7-? Potential free contact
←
request Feedback L7-? (pulse).
Remote RPM control 0VDC common L7-? Potential free contact
←
selected Feedback L7-? (change over).
Remote RPM control L7-? Potential free Confirm the remote
→
accepted L7-? contact RPM control request.
0VDC common L7-? Potential free
Overload ←
Feedback L7-? contact.
6.3 Main switchboard (shaft generator interface)


Neptune-II CPP
Neptune-II Signal Term. Sign. Term. Signal Main switchboard

CPU-cabinet specification no. dir. no. specification (MSB) interface
Potential free
Shaft generator 0VDC common L8-? contact.
←
engaged Feedback L8-? Interlock constant
RPM.
Constant RPM L8-? Potential free Interlock shaft
→
engaged L8-? contact generator.
Electronic speed
+ signal 4-
setting
20mA
Signal L8-? potentiometer.
External RPM setting ← - signal 4-
GND L8-? Galvanically isolated
20mA
and noise protected in
(or 0-10V)
MSB.
Potential free
0VDC common L8-? contact.
Increase RPM setting ←
Feedback L8-? Step increase
constant RPM setting.
Potential free
Reduce RPM setting ←
Feedback L8-? Step reduce constant
RPM setting.
E.g. positive signal as
generator and
+ signal 4-20mA
Shaft generator load Signal L8-? negative signal as
← - signal 4-20mA
signal GND L8-? motor. Galvanically
(or 0-10V)
isolated and noise
protected in MSB.
6.4 Joystick-system (joystick interface)

Neptune-II Signal Term. Sign. Term. Signal Joystick interface
Potential free
Joystick call ←
Feedback L9-? Request from
joystick.
L9-? Potential free CPP ready for joystick
Joystick ready →
L9-? contact control.
+ signal 4-20mA
Signal L9-? Joystick pitch order
Joystick pitch order ← - signal 4-20mA
GND L9-? (galvanic isolated).
(or ±10V)
+ signal 4-20mA
Signal L9-? Joystick RPM order
Joystick RPM order ← - signal 4-20mA
(or ±10V)

Neptune-II CPP
6.5 DP-system (DP interface)

Neptune-II Signal Term. Sign. Term. Signal DP interface
Potential free
0VDC common L9-?
DP call ← contact.
Feedback L9-?
Request from DP.
L9-? Potential free CPP ready for DP
DP ready →
L9-? contact control.
+ signal 4-20mA
Signal L9-? DP pitch order
DP pitch order ← - signal 4-20mA
(or ±10V)
+ signal 4-20mA
Signal L9-? DP RPM order
DP RPM order ← - signal 4-20mA
(or ±10V)
Pitch feedback 4-20mADC L9-? + signal 4-20mA
→ Pitch position.
(isolated output) Max load 500 L9-? - signal 4-20mA
Pitch order (isolated 4-20mADC L9-? + signal 4-20mA
→ Pitch order.
output) Max load 500 L9-? - signal 4-20mA
Propeller shaft RPM 4-20mADC L9-? + signal 4-20mA
→ Propeller shaft RPM.
6.6 Voyage data recorder (VDR)

Neptune-II Signal Term. Sign. Term. Signal VDR interface
Pitch feedback 4-20mADC L10-? + signal 4-20mA
→ Pitch position.
Pitch setting (isolated 4-20mADC L10-? + signal 4-20mA
→ Pitch setting.
Propeller shaft RPM 4-20mADC L10-? + signal 4-20mA
→ Propeller shaft RPM.
RPM setting (isolated 4-20mADC L10-? + signal 4-20mA
→ RPM setting.
6.7 GPS interface for Speed pilot

Signal interface to GPS for the Speed pilot:
Neptune-II Signal Term. Sign. Term. Signal GPS
NMEA 0183
L3-? A
(or IEC 61162-1). NMEA 0183
GPS input L3-? ← B
Galvanically (or IEC 61162-1)
L3-? Sign. GND
isolated input.
The GPS interface is according to the NMEA 0183 version 2.00 (or IEC 61162-1) VTG-sentence.

Neptune-II CPP
6.8 Serial interface to alarm/monitoring system

Two alternatives exists, Modbus and NMEA 0183 version 2.00 (or IEC 61162-1). The connections may
either be in the Neptune-II CPU-cabinet (L? in the table below is then L3) or in a separate unit/cabinet.
Signal interface to alarm/monitoring system:
Neptune-II Signal Term. Sign. Term. Signal Alarm/monitoring
specification no. dir. no. specification system
L?-? D+ Modbus RS-485.
Modbus RS-485
Interface alternative 1 L?-? → D- Galvanically
twisted pair
L?-? Sign. GND isolated input.
NMEA 0183
NMEA 0183 L?-? A (or IEC 61162-1).
Interface alternative 2 →
(or IEC 61162-1) L?-? B Galvanically
isolated input.
The telegram definition is given in separate documentation, and may be system dependent.
6.9 Miscellaneous
Several more inputs and outputs may be available. See project specific documentation (specially the
cable plan, drawing no. 016-XXXX) for more information.

4 User`s Manual

SYSTEM MANUAL
User manual
Neptune-II CPP


User manual
Neptune-II CPP
Ownership
Liabilities
Warning
Improvements
Brunvoll Mar-El AS
N-3880 Dalen Telefax: +47 35 07 58 01
Revision history

A Minor additions. NW 06.10.2009
B Design update and some minor alterations. HOK 08.12.2010
C Update to Brunvoll design (temporary version) BR 06.07.2017
D
Neptune-II CPP - User manual en_B 23.11.2017
Brunvoll Mar-El AS Alarms Page 1

User manual
Neptune-II CPP
Table of contents
1 Overview.......................................................................................................................................................... 4
2 General ............................................................................................................................................................ 4
3 Manoeuvre stations ....................................................................................................................................... 5
3.1 Different manoeuvre stations / control panels .................................................................................. 5
3.2 Control and status units ........................................................................................................................ 6
3.2.1 Manoeuvre lever ............................................................................................................................ 6
3.2.2 Graphic display (standard bridge panels) ................................................................................... 6
3.2.3 High-resolution colour touch screen (ECR panel and advanced bridge panels) ................... 7
3.2.4 Push-buttons and indicators ...................................................................................................... 11
3.2.5 Indicator LED's .............................................................................................................................. 13
3.3 Command transfer ............................................................................................................................... 13
4 Pitch control .................................................................................................................................................. 14
4.1 Pitch output ........................................................................................................................................... 14
4.2 Pitch measurement .............................................................................................................................. 14
4.3 Pitch control methods.......................................................................................................................... 14
4.4 Ramp functionality ............................................................................................................................... 15
4.5 Automatic load control ........................................................................................................................ 15
4.6 Other pitch reductions and gains ....................................................................................................... 15
4.7 Miscellaneous ....................................................................................................................................... 15
4.7.1 Wrong way detection ................................................................................................................... 15
5 RPM control .................................................................................................................................................. 16
5.1 RPM output ........................................................................................................................................... 16
5.2 RPM control methods .......................................................................................................................... 16
5.3 Ramp functionality ............................................................................................................................... 16
5.4 Miscellaneous ....................................................................................................................................... 16
6 The clutch control system ........................................................................................................................... 16
6.1 Operation of clutches .......................................................................................................................... 16
6.2 Interlocks ............................................................................................................................................... 16
6.3 Valve outputs ........................................................................................................................................ 17
6.4 Indication of clutch state ..................................................................................................................... 17
6.5 Miscellaneous ....................................................................................................................................... 17
6.6 Special clutch/gearbox options .......................................................................................................... 17
7 System modes .............................................................................................................................................. 17
7.1 Normal ................................................................................................................................................... 17
7.2 Backup ................................................................................................................................................... 18
8 Operating modes ......................................................................................................................................... 18
8.1 Operation mode ................................................................................................................................... 18
8.1.1 Local control ................................................................................................................................. 18

User manual
Neptune-II CPP
8.1.2 Standard panel control ................................................................................................................ 18

8.1.3 Joystick mode ................................................................................................................................ 18
8.1.4 DP mode ........................................................................................................................................ 19
8.1.5 Speed pilot mode ......................................................................................................................... 19
8.2 RPM modes ........................................................................................................................................... 19
8.2.1 Combinator ................................................................................................................................... 19
8.2.2 Separate ........................................................................................................................................ 19
8.2.3 Constant RPM ............................................................................................................................... 19
8.2.4 Limit RPM ...................................................................................................................................... 20
9 Alarms ............................................................................................................................................................ 20
9.1 Voltage failure alarm ............................................................................................................................ 20
9.2 System failure alarm ............................................................................................................................ 20
9.3 Project dependant alarms ................................................................................................................... 20

User manual
Neptune-II CPP
1 Overview
Neptune-II CPP is a propulsion control system for safe and secure vessel control. It has various
operating modes to suit the vessels different operating conditions. There can be up to seven
manoeuvre stations.
Functions:
• Control of pitch main propulsion propeller(s).
• Control of main engine(s) RPM.
• Control of clutch(es).
• Automatic load control for protection of the main engine(s).
Main units:
• 1 CPU-cabinet (2 off for duplex systems).
• 1 to 6 bridge manoeuvre stations (bridge panels).
• 0 or 1 ECR manoeuvre station (ECR panel).
• I/O-cabinet(s) (if present, system dependent).
• Miscellaneous sensors and actuators.
Documentation:
• Installation and interface manual Neptune-II CPP.
• Installation guidelines Neptune-II CPP.
• User manual Neptune-II CPP (this manual).
• Service manual Neptune-II CPP.
• System drawings.
• Special documentation referred to in the individual manuals.
System drawings:
• See drawing list.
2 General
The total system consists of one or more manoeuvre station(s), a CPU-cabinet with electronic cards, and
miscellaneous sensors and actuators. The manoeuvre station(s) are the system's operating unit(s), they
are the only units used during normal operation (also called panels, e.g. bridge panel, ECR panel).
All system settings and adjustments are carried out from a standard MS-Windows PC running a special
program called MarWin-II (available from Brunvoll Mar-El) or from the touch screen on the ECR panel
(or in advanced bridge panel). Connections to peripheral units, sensors, actuators and other systems
are via the CPU-cabinet or I/O-cabinet(s) if present.
The vessel's propulsion units are controlled from the manoeuvre stations order lever and push-buttons.
Operating information (e.g. propeller pitch, RPM etc.), warning and error messages are shown on the
operating stations graphic display.
Optimal safety is obtained by a main system and an independent backup and indication system.
Different versions of the backup systems are available, from the standard push-button operated
system to a sophisticated hot backup system.

User manual
Neptune-II CPP
3 Manoeuvre stations
All user interaction during normal operation is through units on the manoeuvre station(s). They are
equipped with push-buttons, order lever, graphic display etc. necessary for system control and status.
3.1 Different manoeuvre stations / control panels

Standard single and double bridge panels:
Advanced double bridge panel:
Single and double ECR panels:

User manual
Neptune-II CPP
3.2 Control and status units

The manoeuvre stations are equipped with an order lever on the bridge panels (rotary controls on the
ECR panels), a graphic display, push-buttons, and indicators. There are back-lighting in all units,
including the lever, display and push-buttons. The back-lighting and the light in the indicators may be
adjusted to suit the surrounding lighting conditions.
3.2.1 Manoeuvre lever

The manoeuvre lever is the primary unit for controlling the vessel's propulsion, main engine RPM and
propeller pitch. Either a single lever can control both pitch and engine RPM, in a 'combinator mode', or
two separate levers can be used to independently control pitch and RPM, in an 'individual mode'.
Normally systems with separate levers for pitch and RPM also have the 'combinator mode', in which
case the pitch lever becomes the only operational lever and the RPM lever has no function.
The pitch and RPM order signals can be programmed to follow various curves in relation to the lever
position. In 'combinator mode' it is most often correct to have non-linear 'combinator curves' while in
'individual mode' the curves are often linear and follows the levers (e.g. 75% lever position equals 75%
RPM and/or pitch).
3.2.2 Graphic display (standard bridge panels)

The graphic display is the system's information centre. Operating and status information like propeller
pitch, RPM and other relevant information is shown. Guiding and helping information is shown when
useful for the operator. The graphic display serves as the output unit for the extensive warning and
error checking system. The push-buttons adjacent to the display ('+', '-' and '') navigates through the
different available views.

User manual
Neptune-II CPP
3.2.3 High-resolution colour touch screen (ECR panel and advanced

bridge panels)
Same as above but with extended information and features like trends, alarm log, set-up and
adjustment functionality, and export/import of system data and parameters. Navigation is by soft-
buttons in the touch panel instead of push-buttons.
Menu access depends on current password level:
• Level 0: Normal user level.
• Level 1: Extended user menus.
• Level >1: Only for authorised service personnel.
Standard information in the display:
Speedometer and Speedometer and

numeric indication numeric indication
of engine RPM of propeller shaft
RPM
Misc info like Bar graph and

- Operating mode numeric indication
- Command station of actual propeller
- Load & reductions pitch (i.e. feedback)
Information within
the red area
depends on
the menus
Go to Adjust
previous menu illumination
(In all menus)
Go to Go to Go to E.g. go to E.g. go to
Home user menu Alarm menu Setup menu next project Trend
(In all menus) (In all menus) (In all menus) menu menus

User manual
Neptune-II CPP
Menu dependant display area:

• 'HOME' - Project menu 1, 2 ,3....:
Visualisation of
engine, gear and
shaft generators
Visualisation of
Operating buttons operating mode
and other user
input devices
• 'TREND' - Trend menu 1, 2....:
Numeric indication
of the trended data
Trend curve area
Buttons to navigate
in the history trend
• 'ALARM' - Alarm list:
Alarm history
See Service manual
for detailes

User manual
Neptune-II CPP
• 'MENU' - Main navigation menu:
User calibration
Misc status info
menus
menus
Export and import

Login buttons
menus via USB
to new levels
Service and setup

menus View the control
curves (combinator,
load, ramp)

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Neptune-II CPP
The menu navigation tree:

User manual
Neptune-II CPP
3.2.4 Push-buttons and indicators

During change of state, the light in the corresponding push-button will flash (if the change of state time
is long enough). 75% duty cycle indicates it is going from on to off and 25% from off to on.
3.2.4.1 Standard and most common push-buttons

• IN COMMAND
Push-button with light for command transfer. Green continuous light in the button indicates that the
panel is in service (only lit at one panel at a time). Flashing yellow or green light indicates a command
transfer is activated.
• TRANSFER COMMAND
Push-button with light for command transfer to another panel. Flashing yellow light indicates that a
command transfer is activated.
• EMERGENCY ECR COMMAND TRANSFER
Function on the ECR panel. Push and hold both 'In Command' and 'Transfer Command' buttons in
this panel for at least two seconds and the engine room will receive control.
• BACKUP ON/OFF
Push-button integrated in the "backup circle" for activation and deactivation of the backup system.
Light in the "backup circle" indicates that the backup system is active.
• PITCH (Arrow UP)
Push-button integrated in the "backup circle". Only active while the backup system is on. The
propeller pitch moves in the arrow direction as long as the button is pushed.
• PITCH (Arrow DOWN)
Push-button integrated in the "backup circle". Only active while the backup system is on. The
propeller pitch moves in the arrow direction as long as the button is pushed.
• ACKNOWLEDGE (Silence symbol)
Push-button for acknowledging alarms. Further information is given in the graphic display.
• LIGHT UP/DOWN (In ECR/advanced bridge panels the buttons are located in the touch screen)
Increases (+) and decreases (-) the light in the indicators, display,levers and the back lighting. Lamp
test if both '+' and '–' are pressed together. The back lighting is increasing while dimming of
indicators and display is reducing. The back lighting will also be turned off in daylight.
• ACTIVATE (with 'Enter' symbol, '')
The 'Activate' button is used to confirm operation of other critical functions (push-buttons) to avoid
accidental operation of these functions. The functions that require 'Activate' can be set by
programming parameters and some are by default used with 'Activate'. The button light is on/flashes
as long as the function is active.
• CLUTCH IN
Push-button with light for engaging the clutch, used with 'Activate' button. Steady green light
indicates that the clutch is engaged, flashing yellow light indicates that engaging sequence is active.
• CLUTCH OUT
Push-button with light for disengaging the clutch, used with 'Activate' button. Steady green light
indicates that the clutch is disengaged, flashing yellow light indicates that disengaging sequence is
active.

User manual
Neptune-II CPP
• CLUTCH IN/OUT
Push-button with light for toggling the clutch in and out, used with 'Activate'. Steady green light
indicates that the clutch is engaged while light off indicates that the clutch is disengaged. Flashing
yellow light indicates that an engaging or disengaging sequence is active.
• COMBINATOR
Push-button with light for activation and deactivation of the combinator mode. Green light indicates
that the combinator mode is active. In the combinator mode the pitch lever is the combinator lever
and the RPM lever has no function.
• CONSTANT RPM
The engine speed will be set to a pre-set speed in the system or controlled from an input from the
main switchboard. Green light indicates that the constant RPM mode is active.
3.2.4.2 Push buttons for most common options and extended functions
• LIMIT RPM
The engine speed can be varied between two pre-set limits with the RPM lever. Normally shaft
generator mode, then the limits correspond to 50 and 60Hz. Green light indicates that the limit RPM
mode is active.
• RPM CONTROL
Push-button with light to confirm and indicate that the RPM is controlled from the remote control
system. Green light when local/remote switch on main engine panel are at the remote position.
Flashing yellow light indicates a request from local RPM control to transfer RPM control to
manoeuvre station. Press button to confirm.
• FEATHER MODE
Push-button with light for setting the pitch in feathering position. Green light indicates that the
feather mode is active.
• ACTUATOR PITCH RELEASED (LOCAL CONTROL PITCH)
Push-button with light that switches off the electrical field in the stepping motor. The pitch actuator
can then be operated by hand. The light is also lit when the actuator field is switched off caused by
too low servo oil pressure.
• LOAD INCREASE
Push-button with light for increasing the max. load up to the max. limit pre-set in the system. Green
light as in the 'Load Reduce' button.
• LOAD REDUCE
Push-button with light for reducing the max. load below the max. limit pre-set in the system. Green
light if the load has been reduced with this button. Use the load increase button to reset the manual
load limit.
• SET SPEED
Push-button with light for activating the Speed pilot functionality. Green light indicates active
functionality. See separate description.
• INCREASE SPEED
Push-button with light for increasing speed set point in the Speed pilot functionality. Green light
when button is pressed.
• REDUCE SPEED
Push-button with light for reducing speed set point in the Speed pilot functionality. Green light when
button is pressed.
Push-buttons may be used to toggle on and off other various functions like Fi-Fi-pumps, standby-
pumps, motors etc. Green light indicates that the function is active.

User manual
Neptune-II CPP
3.2.5 Indicator LED's

Only in standard bridge panels. Text in touch screen in the ECR panel and advanced bridge panels.
Project dependent indicators. Red light indicates a failure or warning while green light indicates running
or active applications.
Following indications are most common:
• SYSTEM FAILURE
Indicating serious failure in the main or backup control system. Red light indicates that it is not
possible to switch between backup on or off. Extended alarm information in the display.
• OVERLOAD
Indicating main engine overload. The automatic load control of the system will operate the pitch in
order to not prevent dangerous overload of the main engines. The load control may be disabled from
the ECR panel. WARNING!! This may cause engine damage. Disabling of load control is time logged in
the system.
• SLOWDOWN
Indicating a slowdown condition due to e.g. an engine failure. The slowdown may be disabled from
the ECR panel. WARNING!! This may cause engine damage. Disabling of slowdown is time logged in
the system.
3.3 Command transfer

The Neptune-II supports up to seven manoeuvre stations but only one manoeuvre station can at any
time be in command. The command can be transferred between any stations.
The panels have an 'In Command' push-button with light which is lit on the panel in service/command
and off on all other stations.
Responsibility change between the panels is carried out with the push-buttons 'In Command' and
'Transfer Command'. The order levers must be in the same position before command is transferred.
When power is applied to the system, no panel is in service. Press 'In Command' at any panel to take
command. The RPM will then be set to the settings (order lever positions) at the manoeuvre station that
is given the command. The pitch will still be controlled by the backup system. Deactivate the backup
system with the 'Backup On/Off' button to control the pitch with the main system. If a message is still
shown on the graphic display, acknowledge it by pressing the 'Ack' push-button.
The command is transferred to other stations according to the procedure below:
1. Press the 'In command' push-button on the manoeuvre station where the command is wanted.
The light in the 'In command' push-button starts flashing yellow indicating that a command transfer is
in progress.
2. At the same time the 'Transfer Command' button in the manoeuvre station which is in service
also start flashing yellow. Confirm command transfer from this panel by pressing this button. (The
"transfer command" action is not needed between panels which are located nearby each other on the
bridge.)
3. The indicators will now flash green. If necessary move the order lever to the same position as
the one on the station in service. Help for finding the position is given in the display.
4. When the two orders are within limits the command is transferred. The light in the 'In
Command' push-button is lit on the new panel in service, and switched off on the panel which was in
service.

User manual
Neptune-II CPP
Alternatively point 1 and 2 above may be done in reverse order:

1. Press the 'Transfer Command' push-button on the manoeuvre station in service in order to give
away the command. The light in the 'Transfer Command' push-button starts flashing yellow indicating
that a command transfer is in progress.
2. At the same time the 'In Command' button in all the other manoeuvre stations will start flashing
yellow. Confirm command transfer to another panel by pressing this button in wanted panel.
3. Equalise orders as above.
Since the command is only transferred at identical orders, the risk for giving unwanted manoeuvres are
completely eliminated. The procedure for transferring the command is also very easy and quick to carry
out.
In case of an emergency, the ECR can take control without the bridge acknowledging.
Emergency take over procedure:
1. On the ECR panel press and hold down both 'In Command' and 'Transfer Command' for at least two
seconds. Because this is an emergency takeover, the ECR will get the command independently of
bridge pitch lever position and the pitch will move to the ECR pitch order position.
4 Pitch control
4.1 Pitch output

The propeller pitch deflection is achieved by an electromechanical actuator or hydraulic proportional
valves. The actuator is driven by a stepping motor and has built-in feedback unit for pitch position
sensing. Servos using hydraulic valves have the feedback unit placed on the gear.
4.2 Pitch measurement

The propeller pitch is measured with two separate sensors inside the feedback unit, one for control and
one for indication. The pitch indicators are scaled in percent. Neutral pitch is displayed as 0%,
maximum pitch ahead 100% and maximum pitch astern -100%.
4.3 Pitch control methods

The order lever on the manoeuvre station in command controls the pitch from full astern to full ahead.
The maximum ahead and astern pitch positions, which corresponds to the ±100% range, are set during
sea trial.
Alternatively an analogue external input from e.g. a joystick- or DP-system may control the pitch.
If a system failure occurs, an alarm light will be lit and a buzzer will sound. At the same time the
command will automatically be transferred to the push-button operated backup system. The backup
system can also be activated by a push-button. Note that the backup system can drive the pitch to the
mechanical end-stops, which is often past the +/-100% limits, with corresponding risk for overloading
the main engine etc.
If it is necessary to operate the pitch manually at the gear, the actuator can be de-energized by
operating the 'Local Control Pitch' push-button on the ECR panel. Some systems may also have backup
control from the levers, as a part of a 'Hot backup' system. In case see separate description.

User manual
Neptune-II CPP
4.4 Ramp functionality

The propeller pitch can follow various curves from -100% to +100% (i.e. full astern to full ahead) and
vice versa in relation to the lever position. The curves are set according to optimum performance.
Several curves can be used for various conditions. For instance some conditions may require the pitch
to approach maximum before the engine RPM and vice versa. Any type of pitch curve can be
implemented.
4.5 Automatic load control

The engine load is monitored by the automatic load control. The propeller pitch is automatically limited
to prevent overload situations.
The load control consists of three main features:
1. An advanced PID controller will keep the pitch reduced to the maximum calculated allowed load of
the engine(s). The calculated load is based on the load signal from the engine(s) and the RPM.
2. A dynamic overload controller will prevent the propeller pitch from oscillating e.g. if the vessel is
sailing in rough sea.
3. A pitch ramp up slowdown function reduces the pitch speed as it approaches max. load.
4.6 Other pitch reductions and gains

Several pre-adjustable or analogue pitch reductions are available. These may be operated by external
units like engine control system or the main switchboard. Normally the reductions would be activated
as a slowdown, in advance of a known increase in engine load or a reduction in available power.
A boost function is available. E.g. if a PTI clutch is engaged, the maximum load can increase. Makes it
possible to achieve e.g. 110% pitch. Can also be used to reduce the pitch operating span, i.e. if higher
resolution of the lever movement is desired.
The ECR panel has a function for pitch/load reduction of 20% from max. pitch ('Load Reduce' and 'Load
Increase'). The amount of available pitch reduction can be set to other values than the default 20%. This
is used with heavily loaded vessel, rough weather conditions or if the engine needs enhanced
protection.
4.7 Miscellaneous
4.7.1 Wrong way detection

If the pitch is moving in the wrong direction due to system failure, it will be detected as a runaway
situation. If the pitch is not moving when a new order is given, its a stall situation.
A pitch runaway situation will cause the system to enter the backup mode and give alarm. A stall
situation will give an alarm.

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Neptune-II CPP
5 RPM control
5.1 RPM output

The system gives a RPM order to the main engine(s), hereafter called 'RPM output'. The system has
several interfaces for the RPM output depending on the engine type etc.
5.2 RPM control methods

The RPM can be controlled from all panels. The RPM varies from idle to full with combinator lever
movement from mid-position to full ahead or full astern or from a separate order lever/ potentiometer.
Alternatively analogue external input from e.g. a joystick- or DP-system may control the RPM output.
Some systems may have backup control of the RPM output. In combinator mode the RPM output will
be calculated according to pitch position and actual combinator curve. When changing the pitch, the
RPM will follow up. Otherwise in 'Hot backup' the RPM will be controlled by the levers.
5.3 Ramp functionality

A set of RPM ramp curves makes it possible to control the RPM speed output change.
5.4 Miscellaneous
The RPM control system can be set up to automatically increase the idle RPM when the clutch is
engaged. The value of the idle rise is adjustable. It is used specially on engines with low power at low
RPM.
A crash stop function will reduce the RPM output if the combinator lever is moved fast from ahead to
astern (and vice versa) until the propeller pitch has passed through the zero position.
6 The clutch control system

Control of up to six clutches available.
6.1 Operation of clutches

May be operated by either:
• Push-buttons on the manoeuvre station (one push-push button or separate engage/disengage
buttons). For safety reasons the clutch buttons require an additional 'Activate' button.
• Automatic engaging / disengaging sequences (as a part of a special clutch sequence).
6.2 Interlocks
The main clutch may be interlocked with 'Zero Pitch' and 'High RPM' as standard.
Other external interlock conditions may be included. The system will not engage the clutch during an
interlock situation.

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Neptune-II CPP
6.3 Valve outputs

The system has outputs to astable or bistable potential free solenoid valves. Output: 24VDC, max. 2A.
Analogue output to soft-clutches controlled by analogue operated valves is also available (as a part of a
special clutch sequence).
6.4 Indication of clutch state

To get a true indication of the clutch state, the system requires a potential free NO contact from a
pressure switch sensing the clutch pressure. The switch should be configured to close when the clutch
is engaged.
An analogue signal from the clutch pressure can also be used (as a part of a special clutch sequence).
6.5 Miscellaneous
The system has an output from a potential free contact giving information about the clutch state.
Normally used to prevent starting of the main engine if the clutch is engaged. This is called 'Interlock
Start Engine'.
The system has an input for disengaging of the clutch from a potential free contact, 'Emergency Clutch
Out' which is used if the engine suddenly stops unintentionally.
6.6 Special clutch/gearbox options

The emergency clutch out function may also demand monitored circuits with alarm outputs to comply
with the DP2 classification requirements.
Special clutch sequences can be implemented, like electrically controlled soft-clutches, advanced
interlock systems and automatic engage/disengage sequences.
It is also possible to gather more information at the gearbox, like temperatures and pressures, witch
can be trended and logged together with already existing system information in the touch screen or in
the commissioning software. This is a useful tool for service and maintenance of the gear and propeller
system. This depends on the actual system.
7 System modes
The Neptune-II has two system modes:
1. Normal.
2. Backup.
Switching between these modes are carried out by toggling the 'Backup On/Off' button in the panel in
command.
7.1 Normal
In this mode the main controllers of the system will control all functionality of the system except
handling and indication of system variables. This is always carried out by the backup/indication
controllers.

User manual
Neptune-II CPP
7.2 Backup
The ‘Backup’ mode takes over control of the basic functionality of the main controllers for propeller
pitch position. The 'Backup' has separate backup/indication controllers and is independent of the main
controllers.
This mode is entered either manually with the 'Backup On/Off' button or automatically in case of a
serious system error in the main control system.
8 Operating modes
The system controls the vessel's propulsion units by input from the operator via levers, push-buttons
and external inputs.
Note that during all normal operation the main engine must be running. It is not possible to control the
propeller pitch unless the main engine or the standby pump is running.
Depending on the actual system, several modes are available. They are divided into two types:
1. Operation mode.
2. RPM mode.
8.1 Operation mode

These modes are handling different kinds of pitch and RPM control inputs:
1. Local control.
2. Standard panel control.
3. Joystick mode.
4. DP mode.
5. Speed pilot mode.
8.1.1 Local control

If the servo oil pressure is low and the clutches are disengaged, the pitch servo will be electrically
disconnected to ensure that the pitch control system is interlocked.
An external contact from a servo pressure switch is needed. The pressure switch is delivered from the
gear supplier. The switch is mounted to sense the pressure both from the main pump and from an
auxiliary pump.
An optional manual on-off switch beside the gearbox will also release the pitch electrically to make it
possible to move the pitch servo by hand in an emergency situation.
8.1.2 Standard panel control

Pitch and RPM are controlled from the manoeuvre station in service as described in chapters '' and ''.
8.1.3 Joystick mode

Pitch (and eventually RPM) order are received from an external joystick-system. To enter the joystick
mode the manoeuvre station in service must be on the bridge and a call signal from the joystick-system
must be active.

User manual
Neptune-II CPP
8.1.4 DP mode
Pitch (and eventually RPM) order are received from an external DP-system. To enter the DP mode the
manoeuvre station in service must be on the bridge and call signal from the DP-system must be active.
8.1.5 Speed pilot mode

A speed over ground signal must be received from a speed sensing device in operation, e.g. a GPS
system, to be able to enter the mode.
The Speed pilot mode is entered by pressing the 'Set Speed' button. The actual speed is then saved as
the wanted speed and an automatic controller starts to regulate the pitch in order to keep constant
speed. The 'Increase Speed' and 'Reduce Speed' buttons in the panel will change the actual speed
setting accordingly.
The mode is left and the command transferred back to the order lever by changing the lever position.
8.2 RPM modes

These modes are handling the relations between the pitch and RPM control outputs:
1. Combinator.
2. Separate.
3. Constant RPM.
4. Limit RPM.
8.2.1 Combinator
One order lever controls both the RPM and the pitch according to the active combinator curve.
Four sets of combinator curves are available to make an optimal ratio between pitch and RPM when
running in combinator mode, e.g. depending of number and type of engines/motors connected to the
shaft.
If the system is equipped with separate order levers for pitch and RPM, when selecting 'combinator
mode', the pitch lever will be the combinator (order) lever, and the RPM lever will have no function.
8.2.2 Separate
The system is equipped with separate order levers for pitch and RPM for independent control.
8.2.3 Constant RPM

The engine is set to a pre-set RPM. The pitch/combinator lever controls only the propeller pitch, the
RPM lever has no function.
The mode is activated from the engine room panel. In this mode the RPM is controlled from the main
switch board or as a fixed speed in the system.
When the 'Constant RPM' mode is chosen and the constant RPM setting is achieved, the system gives a
closed contact to the main switch board. The main switch board sends back a closed contact when the
shaft generator is engaged. It is not possible to disengage the 'Constant RPM' mode when the shaft
generator is engaged. This handshake logic prevents damaging the generator.

User manual
Neptune-II CPP
8.2.4 Limit RPM

The pitch lever controls the propeller pitch. The RPM lever controls the RPM between two pre-set RPMs
and thus 'limited RPM' settings, normally corresponding to 50 and 60 Hz from the shaft generator.
9 Alarms
The system has two alarm outputs:
1. Voltage failure alarm.
2. System failure alarm.
These are normally connected to the vessels main alarm system.
In addition alarms and warnings that are not critical for the system are given internally. Both these and
the system failure alarm are controlled by the internal fault monitoring system.
Internal alarms and warnings are given at the control panels by flashing the alarm light and sounding
the buzzer. The display will also show a list of the alarms and warnings.
Alarms are acknowledged by pressing the acknowledge button on the panel which has command.
9.1 Voltage failure alarm

The system is equipped with voltage failure alarms, both the 24VDC supply voltages and the internal
operating voltages are monitored.
If any of the voltages should fail, an alarm is given via an open potential free contact (normally
connected to the vessels alarm system).
The LED's in front of the filter and voltage monitoring card (mounted in the CPU-cabinet) shows status
of the voltages.
9.2 System failure alarm

The system is equipped with a fault monitoring system which continuously monitors the systems and
reacts in case of malfunction. The external output of the fault monitoring system is the 'System Failure'
alarm.
In case of a serious system failure, an alarm via an open potential free contact is given (normally
connected to the vessels alarm system), and the control is transferred to the backup system.
See the service manual for an overview of failures causing system failure.
The pitch indication system will still be working, since it is a part of the backup system and also has its
own independent track on the feedback potentiometer.
9.3 Project dependant alarms

The system may include other alarm outputs to external systems if required. See the system drawings.

5 Service Manual

SYSTEM MANUAL
Service manual
Neptune-II CPP


Service manual
Neptune-II CPP
Ownership
Liabilities
Warning
Improvements
Brunvoll Mar-El AS
N-3880 Dalen Telefax: +47 35 07 58 01
Revision history

A Design update and some alterations and corrections. HOK 08.12.2010
B Update to Brunvoll design (temporary version) SL 22.06.2017
C Add. 4.4 Remote connection for diagnostics and service access HAL 23.08.2017
Neptune-II CPP - Service manual en_C 23.11.2017
Page I
Service manual
Neptune-II CPP
Table of Contents
1 Introduction .................................................................................................................... 1
2 General description ........................................................................................................ 1
3 Tuning and adjustments ................................................................................................ 1
3.1 General ...................................................................................................................... 1
3.2 Using the touch screen in the ECR panel/advanced bridge panel ...................... 2
3.2.1 User available menus ........................................................................................ 2
3.2.2 Pitch offset adjustments ................................................................................... 2
3.2.3 RPM output calibration ..................................................................................... 4
3.2.4 Load signal adjustments ................................................................................... 5
4 Special procedures ......................................................................................................... 7
4.1 Manoeuvre panels ................................................................................................... 7
4.1.1 Calibrate order units for the panel computer ................................................ 7
4.2 Export of system parameters and data using USB memory stick (flash drive) .. 7
4.2.1 Export of alarm and trend log .......................................................................... 7
4.2.2 Export of set-up parameters ............................................................................ 7
4.3 Import of system parameters using USB memory stick (flash drive) ................. 8
4.3.1 Import of set-up parameters............................................................................ 8
4.4 Remote connection for diagnostics and service access. ...................................... 9
5 Troubleshooting ........................................................................................................... 10
5.1 Power failure alarm ................................................................................................ 10
5.2 System failure alarm .............................................................................................. 10
5.3 Overview of internal alarms and warnings .......................................................... 12
5.3.1 !!SERIOUS ERROR!! - Alarms causing 'System failure' ................................. 12
5.3.2 !!WARNING!! - Alarms caused by an abnormal situation ........................... 12
5.3.3 !CAUTION! - Messages caused by operating interlocks ............................. 13
Page II
Service manual
Neptune-II CPP
1 Introduction
This manual describes basic tuning/adjustments and troubleshooting of the Neptune-II CPP propulsion
control system.
In addition to this manual the following documentation are available and essential:
1. Installation and interface manual Neptune-II CPP.
3. User manual Neptune-II CPP.
4. System drawings.
5. Special documentation referred to in the individual manuals.
The individual hardware modules included are described in the system drawings.
2 General description
Neptune-II CPP is a propulsion control system for safe and secure vessel control. It controls main
engine RPM, propeller pitch and clutches. Different operating modes to suit the vessel's different
operating conditions may be implemented. Up to seven control stations can be included.
The Neptune-II CPP consists of the following main units:
1. CPU-cabinet.
3. I/O-cabinet if present.
Further description regarding the functionality, different modes etc. of the Neptune-II CPP are given in
'User manual Neptune-II CPP'.
3 Tuning and adjustments

Most adjustments must be performed by authorised service engineers. However some adjustments
may be carried out by trained personnel. This section describe these procedures.
All the system settings, tunings and adjustments of the Neptune-II CPP propulsion control system are
carried out from the touch screen in the ECR panel/advanced bridge panel or from a PC. If using a PC,
the Neptune-II CPP PC software MarWin-II is needed. The following describes the operation and
procedures using the touch screen in the ECR panel/advanced bridge panels.
3.1 General
It is assumed that the system is in operation and working properly apart from needed
tuning/adjustments.
The normal procedure for tuning and adjustments is:
1. Tune the parameters as good as possible alongside the dock.
2. Do the final parameter tuning (load adjustments etc.) during sea trial.
3. Test the different operating modes etc. from each control position.
Brunvoll Mar-El AS Troubleshooting Page 1

Service manual
Neptune-II CPP
3.2 Using the touch screen in the ECR panel/advanced bridge panel
All set up and tuning parameters are available for editing from the touch screen in the ECR
panel/advanced bridge panel. Access to the parameters depends on the login level via password. Some
parameters are restricted to Brunvoll Mar-El's service engineers.
At start-up the parameters at access level 0 are available for editing.
To get access to more parameters enter the password level in the 'Main Menu':
Access level Password Access
0 None, automatically entered when Standard user access.
powering the panel.
1 MAR-EL Export of system data and some user
commissioning parameters.
2 For service engineers only. All above, plus vital system parameters.
3 For service engineers only. Brunvoll Mar-El service engineer level.
Customers/users log in at level 1 for adjustments.
3.2.1 User available menus

Log in at level 1. Thereafter choose 'User' under the 'Edit' heading. From this menu it's possible to do
user calibrations and function overrides.
'USER MENU' - Extended user functionality:
Misc. user menu

Pitch calibration (set-up, tuning
menu etc.)
OVERRIDE
RPM calibration SLOWDOWN
menu (The action will
be
logged and give
Load calibration an alarm)
menu OVERRIDE
LOADCONTROL
(The action will
Go to
be
previous menu
logged and give
an alarm)
Go to
Go to Go to Adjust
Home user
Alarm menu Set up menu illumination
menu
3.2.2 Pitch offset adjustments

There may sometimes be a need for small adjustments of pitch position. The ship may behave
differently through different loading conditions, there might have been work done on the pitch servo
system, mechanical wear and tear etc. This procedure makes it possible to store an offset for each of
the zero pitch-, full ahead- and full astern positions. The actual parameter-values are not changed. The
maximum offset is limited to ±15% from the actual parameter-value. There are no limits on how often
the procedure can be repeated. It would normally be a good idea to clear the offset-values the next
time a full set-up is made.
If it is not possible to trim the pitch satisfactory with the pitch offset adjustments, a mechanical
adjustment of the pitch feedback sensor or a new complete feedback calibration must be performed.
Contact authorised service personnel before doing either.

Service manual
Neptune-II CPP
Caution: The following procedures involve changing the pitch while the engine is running. This may be
dangerous unless done properly. Always check with equipment suppliers before doing changes.
The procedure is basically the same for all three positions. Find the (new) correct position by adjusting
the offset values, and afterwards save the new value.
To access the pitch menu in the ECR panel:
• 'MAIN MENU' → Login level 1 (see password above) → 'USER MENU' → 'Pitch menu'
In order to enter new offset values you may either touch the value and enter a new number with the
graphic numeric keyboard or use the '+' OR '–' buttons to increase or reduce the value.
'PITCH MENU' - User pitch calibration:
Tuning of Synchronise indication

max. pitch ahead of max. pitch ahead

zero pitch of zero pitch

max. pitch astern of max. pitch astern
3.2.2.1 Adjusting zero pitch

The zero pitch is best adjusted next to a stationary object, with no water currents and calm weather.
Loosely tied to the dock is often the best situation for this adjustment. Usually the propeller wake
around zero pitch is so little that an increase in engine RPM is necessary to notice movements. Observe
the propeller water and movement of the vessel.
1. Put the pitch lever in zero position.
2. Do small adjustments to the 'Zero Offset adjustment' value (steps of 0,1 - 0,5%).
3. Observe the movement of the ship and re-enter new values until “zero pitch” is achieved.
4. Press 'Save Zero Indication' and confirm with 'OK' in order to get the pitch indication feedback equal
to the pitch control feedback.
3.2.2.2 Adjusting maximum pitch ahead

The maximum pitch is always adjusted at lever full ahead to get optimum engine and propeller
performance. The engines must be able to reach maximum RPM for this procedure. If engine RPM must
be adjusted go to chapter 3.2.3. Maximum pitch is the pitch deflection that gives maximum allowed
engine conditions such as RPM, fuel load, charge air pressure, exhaust temperature, etc. Always check
with engine supplier.
If it is a twin screw vessel, i.e. the ship has a dual system (port and starboard) both systems must be
tuned simultaneously.
1. Press the 'Load control' override button in the 'User Menu'.
2. Put the pitch lever in full ahead position if possible. Take care not to overload the engine.
Always check with engine supplier.
3. If the engine gets overloaded before the lever is at 100%, retard the lever and reduce the 'Max
Offset adjustment' value to -15%. Then set the lever to full ahead position. Since the engine

Service manual
Neptune-II CPP
will be running at full steam it is best to approach maximum pitch from a too low than a too
high deflection.
4. Do small adjustments of the 'Max Offset adjustment' value. As the pitch approaches
maximum carefully increase with smaller steps (0,1 - 0,5%).
5. Observe the engine RPM, loads, turbo charger pressures and exhaust temperatures and re-
enter new values until wanted maximum pitch is achieved.
6. Press 'Save Max Indication' an confirm with 'OK' in order to get the pitch indication feedback
equal to the pitch control feedback.
7. Enable the automatic load control again.
3.2.2.3 Adjusting maximum pitch astern

If it is a twin screw vessel, i.e. the ship has a dual system (port and starboard) both systems must be
tuned simultaneously.
1. Press the 'Load control' override button in the 'User Menu'.
2. Put the pitch lever in full astern position if possible. Take care not to overload the engine. Always
check with engine supplier.
3. If the engine gets overloaded, first reduce the 'Min Offset adjustment' value to -15%. Then set the
lever to full astern position.
4. Do small adjustments of the 'Min Offset adjustment' value (steps of 0,1 - 0,5%).
5. Observe the engine load and re-enter new values until wanted “min pitch” is achieved.
6. Press 'Save Min Indication' and confirm with 'OK' in order to get the pitch indication feedback equal
to the pitch control feedback.
7. Enable the automatic load control again.
3.2.3 RPM output calibration

Sometimes it may be necessary to adjust the RPM setting output to the engines. This procedure makes
it possible to store new maximum and idle settings for the RPM output signal to the engine(s). The
actual parameter-values are not changed. The setting is limited to ±30% from the actual parameter-
value. There are no limits on how often the procedure is repeated.
Caution: The following procedures involve changing the maximum engine RPM. This may be dangerous unless
done properly. Always check with equipment suppliers before doing changes.
This adjustment should always be taken into consideration when maximum pitch is adjusted after
engine commissioning is performed.
To access the RPM menu in the ECR panel:
• 'MAIN MENU' → Login level 1 (see password above) → 'USER MENU' → 'RPM menu'

Service manual
Neptune-II CPP
'RPM MENU' - User RPM calibration:
Correction of
maximum RPM
See guidance Correction of internal
below constant RPM set-point
Correction of
idle rpm
3.2.3.1 Adjusting maximum RPM

1. The maximum engine RPM should be adjusted before sea trial with the clutches disengaged. If there
is a problem with RPM drop (smaller engines) at maximum pitch ahead at sea trial, the RPM output
setting may be adjusted simultaneously with the maximum pitch ahead adjustment.
2. Observe the engine RPM.
3. Do small adjustments of the 'RPM Offset adjustment' value in order to achieve maximum RPM on
engine(s) (steps of 0,1 - 0,5%).
3.2.4 Load signal adjustments

NB! Only to be done when maximum pitch and RPM are properly adjusted.
There may sometimes be a need for small adjustments of maximum load. There might f.ex. have been
work done on the engines or load sensors. This procedure makes it possible to store an offset for each
of the load signals coming from each engine. The offset is limited to ±30% of the Voltage/mA input
signal calibration. There are no limits on how often the procedure can be repeated.
Caution: The procedure involve changing the load/pitch while the engine is running at full load. This may be
dangerous unless done properly. Always check with equipment suppliers before doing changes.
The procedures is the same for all load signals, one for each engine, but they will affect each other. Use
the system specific documentation to find out which engine is connected to each load signal. Find the
(new) correct maximum load by adjusting the offset values.
To access the load menu in the ECR panel:
• 'MAIN MENU' → Login level 1 (see password above) → 'USER MENU' → 'Load menu'

Service manual
Neptune-II CPP
'LOAD MENU' - User load signal adjustments:
Adjustment of
max. load signal If present, up to four
from engine 1. separate engine
Use numeric input load signals may
or the '+' and '-' be adjusted
buttons.
See guidance below.
Observe the effect

while adjusting
3.2.4.1 Adjusting maximum load

1. The load signal may be adjusted at sea-trial when maximum pitch is adjusted and achieved.
2. The ship must have a stable speed and course with not to rough sea at maximum pitch ahead.
3. The automatic load control must be enabled.
4. Observe the turbo charger pressure and exhaust temperatures of the engines in order to achieve
maximum load of all engines. If there is unbalance between engines due to RPM drop or other load
sharing problems, maximum load correction will not be properly done.
5. Do small adjustments of the 'Load Offset adjustment' values in order to achieve about 99,5% load
on all engines (steps of 0,1 - 0,2%).
6. If the ship has a dual system (port and starboard) both systems must be tuned simultaneously.
7. When all active load signals are approximately 99,5% (not above 100%) the load offset calibration is
finished.

Service manual
Neptune-II CPP
4 Special procedures
4.1 Manoeuvre panels
4.1.1 Calibrate order units for the panel computer

If the order potentiometers have been replaced or mechanically adjusted, they have to be re-calibrated.
Carry out the appropriate procedure below.
Standard bridge panels:
1. Press the '' button in abt. five seconds to enter the set-up menu.
2. Enter the order calibrating menu according to guidance.
3. Move all levers and potentiometers first to maximum, then to minimum and then to zero (if
present). The sequence is important, otherwise the values will be inverted.
4. Save the settings according to the guidance.
ECR panel and advanced bridge panels:
1. Enter 'Main Menu'.
2. Login to level 2.
3. Enter 'Service Menu'.
4. Enter 'Panel Menu'.
5. Enter the order calibrating menu according to guidance.
6. Move all levers and potentiometers first to maximum, then to minimum and then to zero (if
present). The sequence is important, otherwise the values will be inverted.
7. Save the settings according to the guidance.
4.2 Export of system parameters and data using USB memory stick
(flash drive)
In order to achieve easy help from authorised service personnel, the system can save the alarm- and
trend logs and set up/tuning parameters to a USB memory stick. The USB connector is located on the
side of the touch screen unit on the ECR panel. Either lift up the ECR panel if possible or access the USB
connector from the back side. These data may be e-mailed to authorised service personnel who can
evaluate them.
4.2.1 Export of alarm and trend log

Procedure for exporting the alarm and trend log:
1. Get access to the back side of the ECR panel.
2. Put in a USB memory stick into the slot on the right side of the touch screen unit.
3. Observe that the touch screen recognize the USB memory stick and confirm that a file structure
shall be created.
6. Enter 'File Manager Menu'.
7. Press the button 'Save alarm and log to USB flash drive'.
8. Remove the USB memory stick when saving is completed. The file can be copied and sent as an
attachment in an e-mail.
4.2.2 Export of set-up parameters

Procedure for export of set-up parameters:

Service manual
Neptune-II CPP

2. Put in a USB memory stick into the slot on the right side of the touch screen unit.
shall be created.
7. Enter 'Export Parameter Menu'.
8. Select destination directory using the 'Select USB directory: #Param' button and select '#Param'.
9. Save the file using the button 'Export set up to USB flash'. A name must be entered for the file.
10.Remove the USB memory stick when saving is completed. The file can be copied and sent as an
attachment in an e-mail.
4.3 Import of system parameters using USB memory stick (flash drive)
WARNING! This will affect all the set-up and tuning of the system! Only do this when the ship is out of
operation and securely moored and in agreement with authorised service personnel!.
4.3.1 Import of set-up parameters

Procedure for import of set-up parameters:
2. Put in a USB memory stick with the file structure and the set-up file into the slot on the right side of
the touch screen unit.
shall be created.
7. Enter 'Import Parameter Menu'.
8. Select destination directory using the 'Select USB directory: #Param' button and select '#Param'.
9. Press the button 'Import set up from USB flash'.
10.Press the green 'OK' button and select the correct file to import.
11.Remove the USB memory stick when import is finished.
12.Leave the 'Import Parameter Menu'.
13.Test the system with the new parameters.

Service manual
Neptune-II CPP
4.4 Remote connection for diagnostics and service access.

The system may be delivered with VPN cabinet for remote connection between Brunvoll Mar-El
control systems and server at our service department.
It requires use of the vessel’s IT system and the Internet.

The device needs a DHCP server to supply it with DNS, gateway, subnet mask and IP.
If this is not available or preferred, Brunvoll Mar-El AS must be informed of this along with DNS
server IP, gateway, subnet mask and IP before the system is shipped.
Once installed it needs access to the following:

* Access to DNS server
* NTP access to one of the server at 0.no.pool.ntp.org
* TCP & UDP access to vpn.mar-el.no (FQDN) at port 65261)
Internet speed requirement:

* 5Mbs
* 50ms max ping time to vpn.mar-el.no
The device needs to be able to use the following services

Service Ports Comment
DNS TCP & UDP port 54 IP normally supplied by the external DHCP server
NTP UDP port 123 One of the servers at 0.no.pool.ntp.org
OpenVPN TCP & UDP port 65261¹ Server at vpn.mar-el.no
¹Only TCP or UDP will be used.

Service manual
Neptune-II CPP
5 Troubleshooting
Note that during troubleshooting the LEDs in the systems are giving a lot of information. There are LED
indication on all digital inputs and outputs in addition to voltage monitoring etc. The internal alarm
handling system will also give useful information.
5.1 Power failure alarm

The LED's on the side of the filter and voltage monitoring card (mounted in the CPU-cabinet) shows
status of the voltages, both the external power supplies and the internal.
Possible faults and actions:
Symptom Cause Correction
Voltage failure alarm. One of the 24VDC power supply Check fuses F1-F4 in the CPU-cabinet.
The system is OK. circuits is out. Check the power supply (24VDC).
Voltage failure alarm. One of the internal circuits are Check fuses F5 -> in the CPU-cabinet.
Part of the system is "dead". out. Check the internal power supply voltages.
Voltage failure alarm. Both 24VDC power supply Check the fuses in the CPU-cabinet and in the I/O-cabinet.
The system is "dead". circuits are out. Check the power supply (24VDC).
Any of the internal voltages are Check if there is a short circuit on the 24VDC supply
missing. internally in the system.
Check the internal power supply voltages.
5.2 System failure alarm

The system failure alarm is activated when the fault monitoring system discovers a serious internal
error. In addition to the audible and visual alarms externally, the system failure is indicated with an LED
inside the CPU-cabinet. The system failure LED is located on the side of the filter and voltage-
monitoring card mounted in the CPU-cabinet.
The system failure alarm will automatically transfer the command to the backup system.
The 'normal' and 'backup' systems are independent. If a serious failure in the backup system occurs it
will not be possible to put the system into backup mode.
The system failure alarm is only related to control of propeller pitch and engine RPM. It will not trigger if
a failure is related to other functions such as generator, clutch, engine functions other than RPM, etc.
The first thing to do is to check the error message in the manoeuvre panels and also check the pitch
related hardware carefully. Further troubleshooting may be necessary if the display message is not
enough.
Conditions that will trigger the system failure alarm:
• Loss of communication to the control panel in command.
• Failing order lever on control panel in command, (pitch and/or RPM).
• Missing connection between CPU-cabinet and actuator (position feedback).
• Faults on electronic cards in CPU-cabinet related to pitch control.
• Pitch moving in the wrong direction.
Possible system failure causes and actions:
Symptom Cause Checkpoints Correction
The LED's in panel are No communication Are any LED's on YES Check connection of the panel cable (the cable
flashing or will start to between the main communication with multi-plugs) and the cable itself.
flash when button is controllers in the module C4A in the Check the wiring, connection terminals etc.
pressed. panel and the CPU- CPU-cabinet flashing? Check the network termination.
cabinet. Check the panel itself.
NO Check the main controller (C4) in the CPU-cabinet.

Service manual
Neptune-II CPP
Symptom Cause Checkpoints Correction

The message “NO No communication Are any LED's on YES Check connection of the panel cable (the cable
COMMUNICATION between the communication with multi-plugs) and the cable itself.
WITH BACKUP“ in the backup controllers module C5A in the Check the wiring, connection terminals etc.
panel display. in the panel and CPU-cabinet flashing? Check the network termination.
the CPU-cabinet. Check the panel itself.
NO Check the backup controller (C5) in the CPU-

cabinet.
The system is Broken pitch Is the failure present YES Check the wiring, connection terminals etc.
transferred to backup control feedback during the whole Replace the feedback sensor.
and the message sensor or cabling. range of pitch servo
NO Replace the feedback sensor.
“Pitch feedback failure movement?
Main controller”
appears in the panel
display.
The message “Pitch Broken pitch Is the failure present YES Check the wiring, connection terminals etc.
feedback Indication indication feedback during the whole Replace the feedback sensor.
failure” appears in the sensor or cabling. range of pitch servo
NO Replace the feedback sensor.
panel display or movement?
feedback indication is
wrong and not
possible to calibrate.
The system is Broken pitch order Is the failure present YES Check the wiring, connection terminals etc.
transferred to backup sensor or cabling in during the whole Replace the order sensor.
and the message the panel or device range of pitch order
NO Replace the order sensor.
“Pitch order failure” (e.g. DP/Joystick) in movement?
appears in the panel command.
display.
The system is Broken RPM order Is the failure present YES Check the wiring, connection terminals etc.
transferred to backup sensor or cabling in during the whole Replace the order sensor.
or RPM output is the panel or device range of RPM order
NO Replace the order sensor.
frozen and the (e.g. DP/Joystick) in movement?
message “RPM order command.
failure” appears in the
panel display.
The system is Broken pitch servo Is it possible to re- YES Check the wiring, connection terminals etc. of the
transferred to backup motor or cabling. enter main control pitch servo motor for loose wires.
and the message command and run the Reduce the sensitivity of the runaway detection.
“Pitch runaway pitch servo?
NO See next checkpoint.
condition” appears in
the panel display. Is it possible to YES Check outputs from the main controller to pitch
operate the pitch from driver.
backup control? Contact authorised service personnel.
NO Check the pitch servo. Is it possible to move the

pitch locally.
Check the wiring, connection terminals etc. of the
pitch servo motor for breakage.
Check pitch actuator or valve.

Service manual
Neptune-II CPP
5.3 Overview of internal alarms and warnings
5.3.1 !!SERIOUS ERROR!! - Alarms causing 'System failure'

!!SERIOUS ERROR!! - Alarms causing 'System failure'. See chapter 5.2.
Alarm text Further description
Main Controller Error - Check error in ECR panel More detailed alarms may appear in the ECR panel.
Contact authorised service personnel.
Backup Controller Error - Check error in ECR panel More detailed alarms may appear in ECR panel.
Contact authorised service personnel.
Power failure Main Controller - Check fuses See chapter 5.1.
Power failure Backup Controller - Check fuses See chapter 5.1.
Panel IN COMMAND NOT responding Main controller See chapter 5.2.
Panel IN COMMAND NOT responding Backup controller See chapter 5.2.
Pitch Order Failure Main Controller See chapter 5.2.
Pitch Order Failure Backup Controller See chapter 5.2.
Pitch Feedback Failure Main Controller See chapter 5.2.
Pitch Feedback Failure Backup Controller See chapter 5.2.
Pitch Feedback Failure Indication See chapter 5.2.
Pitch Runaway condition Main Controller See chapter 5.2.
Pitch Runaway condition Backup Controller See chapter 5.2.
Panel IN COMMAND NOT responding Backup controller See chapter 5.2.
Pitch Order Failure Main Controller See chapter 5.2.
RPM Order Failure Main Controller See chapter 5.2.
RPM Order Failure Backup Controller See chapter 5.2.
IO Communication Failure! See chapter 5.2.
5.3.2 !!WARNING!! - Alarms caused by an abnormal situation

!!WARNING!! - Alarms caused by an abnormal situation.
Emergency Command transfer to ECR Panel The command was taken to ECR without confirming on
bridge.
Pitch Stall condition The pitch is not moving. Servo failure?
Local Control Pitch Activated Local control of pitch is taken.
Local control RPM activated Local control of RPM is taken.
Main Engine Slowdown An input has activated the slowdown function.
Slowdown Override The slowdown function has been deactivated.
Clutch engaged abnormally The clutch indication input has been activated without a
clutch engage sequence. Sensor failure?
Clutch indication failure? Request Clutch Out The clutch indication input has been deactivated without a
clutch disengage sequence. Sensor failure?
Time-out when engaging clutch Too long clutch engage sequence time before indication input
has been activated.
Time-out when disengaging clutch Too long clutch disengage sequence time before indication
input has been deactivated.

Service manual
Neptune-II CPP

Soft clutch engaged too fast Too short clutch engage sequence time before indication
input has been activated.
Clutch disengaged! Emergency clutch Out The emergency clutch out input has been activated.
Engine stopped! Pitch to Zero! Move lever to reset pitch. If no shaft clutch is present, the input above will activate this
alarm and function.
5.3.3 !CAUTION! - Messages caused by operating interlocks

!CAUTION! - Messages caused by operating interlocks.
Alarm text
Command transfer not possible - Change mode first
Activate Feather mode Not possible! - Clutch engaged
Engage Const. RPM Not possible! - External Interlock!
Disengage Const. RPM Not Possible! - External Interlock!
Disengage Const. RPM Not Possible! - Shaft Generator Engaged
Disengage Const. RPM Not Possible! - No RPM Lever on panel in cmd.
Disengage Const. Limit RPM Not Possible! - No RPM Lever on panel in cmd.
Engage Limit RPM Not possible! - External Interlock!
Disengage Limit RPM Not Possible! - Shaft Generator Engaged
Disengage Limit RPM Not Possible! - External Interlock
Engage Limit RPM Not Possible! - No RPM Lever on panel in cmd.
Combinator Mode Not Possible! - Const. RPM Mode Engaged
Combinator Mode Not Possible! - Limit RPM Mode Engaged
Separate Mode Not Possible! - Const. RPM Mode Engaged
Separate Mode Not Possible! - Limit RPM Mode Engaged
Separate Mode Not Possible! - No RPM Lever on panel in cmd.
Engage clutch Not Possible! Emergency Clutch Out interlock
Engage clutch Not Possible! RPM too high
Engage clutch Not Possible! External Interlock
Engage clutch Not Possible! Pitch not in neutral
Disengage clutch Not Possible! External Interlock
Disengage clutch Not Possible! Shaft Generator Engaged

1. 4 D ipsw it ch set t ings
Dip-Switch layout PA0076 step motor driver
ON 1 2 3 4 5 6 7 8 9 10
Standby Current Speed Adjustment

DIP1 DIP10
ON 80% Standby ON Internal Pot.
OFF 50% Standby OFF External Pot.
Current Scale Motor Phase Current

DIP2 DIP7 DIP8 DIP9
ON 50% Reduction ON ON ON 2.0A
OFF 100% Normal OFF ON ON 2.5A
ON OFF ON 3.0A
OFF OFF ON 3.5A
ON ON OFF 4.0A
Steps/revolution
OFF ON OFF 4.5A
DIP3 DIP4 DIP5 ON OFF OFF 5.0A
ON ON ON 200 step/rev. OFF OFF OFF External (32A)
OFF ON ON 400 step/rev.
ON OFF ON 1000 step/rev. TT0701GB
OFF OFF ON 2000 step/rev.
Motor Energise
ON ON OFF 4000 step/rev.
OFF ON OFF 4000 step/rev. DIP6
ON OFF OFF 4000 step/rev. ON Always Energised
OFF OFF OFF 4000 step/rev. OFF Remote energised (ENRG input)
1. 4. 1 D IP1 - S t andby C urrent

This switch controls the phase current for the motor when the motor is stationary.
The absolute value of the current is determined by DIP7, 8 and 9. Also DIP2 has an influence
since DIP2 in general is reducing the current to 50% of the value set by DIP7-9.
DIP1 set in the ON position will decrease the motor current to 50% when the motor is sta-
tionary. If DIP1 is set in the OFF position this value will be 80%.
Example :
DIP7, 8 and 9 is set in a combination which will setup the full scale current to 5.0A.
DIP2 is set to OFF which means that it has no influence. DIP1 is set to OFF which means
that the phase current for the motor will be 2.5A when the motor is stationary.
1. 4. 2 D IP2 - C urrent S cale

If small motors are used it can be convinient to reduce the motor current full scale.
DIP2 set in position ON will reduce the current scale with 50%.
Example :
If DIP7, 8, and 9 is set to 5.0 A DIP2 set in position ON it will decrease this value to 2.5A.
DIP2 also have an influence at the standby current (when motor is stationary).
LB0045-02GB Revised 28.12.2005

1. 4 D ipsw it ch set t ings
1. 4. 3 D IP3-5 - S t eps/revolution
The step resolution can be adjusted with these switches.
The resolution can be set in the range 200 to 4000 steps/revolution based at a standard
hybrid step motor with 200 full steps per revolution.
A standard rule is to set the step resolution to highest possible value since mechanical res-
onances is reduced to a minimum.
1. 4. 4 D IP 6 - M ot or E nergise
The motor can be permanently energised if DIP6 is set in the ON position.
If DIP6 is set in the OFF position the input ENRG will determine wheather the motor should
be energised or not. The ENRG input can typically be used to release the motor if it should
be moved manually from its position.
1. 4. 5 D IP7-9 - M otor Phase C urrent .

The phase current for the motor can be set-up at these switches. The value specified is ex-
pressed as peak values during movement. When the motor is stationary the current will be
decreased to 50% or 80% of the setup value.
Notice that DIP2 set in position ON will decrease the specified values by 50%.
1. 4. 6 D IP10 - S peed Adjust m ent .

If the FAST or SLOW inputs are used it means that the internal step generator is used the
speed for either FAST or SLOW can be adjusted at the internal potentiometers (DIP10=0) or
by using the external inputs FADJ or SADJ (DIP10=1).
LB0045-02GB Revised 28.12.2005

1. 5 O pt ion set up
SW2
1
SW2: Option setup 2
DIP1:
ON=Board setup w/software V1.1
OFF=Newest software
DIP2:
ON=Speed range reduced 4 times
OFF=Speed range normal
SW2 default settings =

Both switches in position “OFF” TT0704GB
1. 5. 1 O pt ion set up sw it ch (S W 2)
(Only available at PA0076 version 1.4 or newer)
The first switch makes it possible to be backward compatible with boards containing soft-
ware version 1.1 since certain features have been changed in newer versions in order to
comply with major customer demands.
The second switch can be used to reduce the speed range for both the inputs “slow” and
“fast” by 4 times. This can be usefull for applications where a very low speed is desired.
Please notice that this feature only take effect when using the internal step generator.
LB0045-02GB Revised 28.12.2005

6 Commissioning manual

SYSTEM MANUAL
Commissioning manual
Neptune-II CPP


Neptune-II CPP
Ownership
Liabilities
Warning
Improvements
Brunvoll Mar-El AS
N-3880 Dalen Telefax: +47 35 07 58 01
Revision history

- Initial release. HAL 19.05.2010
A Design update. Some additions, alterations and rearrangements. HOK 08.12.2010
B Update to Brunvoll design (temporary version) BR 6.07.2017
C
Neptune-II CPP - Commissioning manual en_B 19.12.2017
Brunvoll Mar-El AS Introduction Page 1

Neptune-II CPP
Table of Contents
1 Introduction .................................................................................................................................. 4
1.1 General .................................................................................................................................. 4
1.2 Commissioning, set-up and tuning procedures ..................................................................... 4
2 Mechanical and electrical installation checks .............................................................................. 5
2.1 Mechanical checks ................................................................................................................ 5
2.1.1 CPU-cabinet ................................................................................................................... 5
2.1.2 I/O-cabinet ..................................................................................................................... 5
2.1.3 Manoeuvre panels .......................................................................................................... 6
2.1.4 Sensors and actuators ..................................................................................................... 6
2.1.5 Cables and electrical conductors .................................................................................... 6
2.2 Electrical checks with no power applied ............................................................................... 7
2.2.1 24VDC power supplies .................................................................................................. 7
2.2.2 Earth fault external 24VDC system ............................................................................... 7
2.2.3 Earth fault internal 24VDC system ................................................................................ 7
2.2.4 Internal connections ....................................................................................................... 7
2.2.5 External connections ...................................................................................................... 8
3 System checks and pre-adjustments ............................................................................................. 8
3.1 Applying power ..................................................................................................................... 8
3.2 Basic system checks and operation ....................................................................................... 8
3.2.1 Panel set-up checks ........................................................................................................ 8
3.2.2 Backup mode operation ................................................................................................. 9
3.2.3 Normal mode operation ................................................................................................. 9
3.3 The pitch system .................................................................................................................... 9
3.3.1 Pitch movement and direction........................................................................................ 9
3.3.2 Pitch feedback mechanical limits ................................................................................... 9
3.3.3 Pitch control ................................................................................................................... 9
3.3.4 Pitch speed ................................................................................................................... 10
3.4 The clutch system ................................................................................................................ 10
3.4.1 Clutch interface ............................................................................................................ 10
3.5 The RPM system ................................................................................................................. 10
3.5.1 RPM order signal ......................................................................................................... 10
3.5.2 RPM feedback .............................................................................................................. 10
3.6 Operating curves.................................................................................................................. 11
3.6.1 Pitch and RPM combinator curves............................................................................... 11
3.6.2 Load curves .................................................................................................................. 11
3.6.3 Ramp curves ................................................................................................................. 11
3.7 Operating modes.................................................................................................................. 11

Neptune-II CPP
3.7.1 Pitch and RPM modes .................................................................................................. 11

3.7.2 Special modes .............................................................................................................. 11
3.8 The automatic load control system ...................................................................................... 11
3.8.1 Engine load signals ...................................................................................................... 11
3.8.2 Load control parameters............................................................................................... 12
3.9 Alarms ................................................................................................................................. 12
3.9.1 Power failure ................................................................................................................ 12
3.9.2 System failure .............................................................................................................. 12
3.9.3 Custom specific alarms ................................................................................................ 12
4 Adjustments alongside quay ...................................................................................................... 13
4.1 Zero pitch calibration .......................................................................................................... 13
4.2 Propeller shaft RPM ............................................................................................................ 13
4.3 Idle and maximum RPM settings ........................................................................................ 13
4.4 RPM modes and settings ..................................................................................................... 13
5 Sea trial ...................................................................................................................................... 14
5.1 Maximum pitch ahead calibration (max. pitch) .................................................................. 14
5.2 Maximum pitch astern calibration (min. pitch) ................................................................... 14
5.3 Load signal calibration ........................................................................................................ 15
5.4 Combinator curve optimization ........................................................................................... 15
5.5 Ramp curve optimization .................................................................................................... 15
5.6 Load curve optimization...................................................................................................... 15
5.7 The automatic load controllers ............................................................................................ 16
5.7.1 PID-controller .............................................................................................................. 16
5.7.2 DO-controller ............................................................................................................... 16
5.7.3 Loadspeed controller .................................................................................................... 16
6 Commissioning report ................................................................................................................ 17

Neptune-II CPP
1 Introduction
This manual describes the start-up and sea trial procedures of the Neptune-II CPP propulsion control
system.
In addition to this manual the following documentation is available and essential:
2. Installation and interface manual Neptune-II CPP.
3. Service manual Neptune-II CPP.
4. User manual Neptune-II CPP.
5. System drawings.
6. Special documentation referred to in the individual manuals.
The individual hardware modules included are described in the system drawings. Block diagram and
miscellaneous details are given in the cable plan, drawing no. 016-XXXX.
1.1 General
Neptune-II CPP is a propulsion control system for safe and secure vessel control. It controls main
engine RPM, propeller pitch and clutches. Different operating modes to suit the vessel's different
operating conditions may be implemented.
The Neptune-II CPP consists of the following main units:
1. CPU-cabinet.
3. I/O-cabinet(s) if present.
Neptune-II CPP is equipped with one main controller and an independent indication and backup
controller. The main controller handles everything regarding operation and control etc., while the
indication controller handles the indication of vital functions like propeller pitch and RPM in addition to
backup of propeller pitch and eventual other optional functions.
Descriptions of functionality, various modes etc. are found in the 'User manual Neptune-II CPP'.
1.2 Commissioning, set-up and tuning procedures

Control of the installation and interfaces to other equipment/systems must be carried out before the
sea trial, while the tuning and adjustments are carried out during the sea trial. If all necessary
information is known, the system set-up and configuration is done during the factory set-up and tests..
The normal procedure for inspection, set-up and tuning is:
1. Carry out the mechanical and electrical installation checks, incl. signals to connected
equipment.
2. Carry out the system checks and pre-adjustments.
3. Tune the parameters as good as possible alongside the quay.
4. Do the final parameter tuning (load adjustments etc.) during sea trial.
5. Check the different control positions, operating modes etc.
WARNING! Note that power shall not be applied to the system before the checks and procedures in chapter '2
' are carried out successfully and it is specifically written that power shall be applied! Otherwise serious
damage may occur!

Neptune-II CPP
The system settings, tunings and adjustments of the Neptune-II CPP propulsion control system are
carried out from the touch screen in the ECR manoeuvre panel/advanced bridge panel or from a MS-
Windows PC. To use a PC, the Neptune-II CPP PC software MarWin-II is needed.
2 Mechanical and electrical installation checks

This section describes checkpoints and procedures for commissioning the Neptune-II CPP. The first
points to check out during commissioning is to verify that all installation requirements are fulfilled, see
the systems installation documentation and go carefully through this.
Check that all fuses from the power supplies, the main fuses, are removed/open. Normally F1 to F4 in
the Neptune-II CPP, but others or more may be present in the individual system, check the cable plan
(drawing no. 016-XXXX).
2.1 Mechanical checks

The mechanical and visual checks must be carried out to ensure proper installation of the system in
regards of vibrations, EMC consideration etc.
2.1.1 CPU-cabinet
The CPU-cabinet is normally mounted easily accessible in the engine control room. In the lower end of
the CPU-cabinet there are connection terminals for connections to both system internal units and other
equipment.
Checkpoints that require special attention:
1. Check that the cabinet is rigidly mounted regarding fastening and vibrations. Vibrations must be
kept at the lowest possible level, the cabinet must be mounted so further vibrations do not
occur.
2. If the temperature might rise above 55°C a cooling fan must be mounted.
3. Electrical sources of disturbance nearby (VHF, intercom etc.) must be shielded.
4. Check that there are no waste from drilling etc. inside the cabinet and on the electronic
modules/cards.
5. Check that all cables and conductors are well fastened, that they do not touch any sharp edges,
and that they do not have sharp bends.
6. Check that all conductors into the terminal block are labelled with correct numbers and that the
fastening screws are well tightened.
7. Check that all cable screens are properly grounded.
2.1.2 I/O-cabinet
The I/O-cabinet may in some instances be a part of the CPU-cabinet. It is normally mounted in the
engine control room. In the lower end of the cabinet there are connection terminals for connections to
both system internal units and to other equipment.
1. Check that the cabinet is rigidly mounted regarding fastening and vibrations. Vibrations must be
kept at the lowest possible level, the cabinet must be mounted so further vibrations do not
occur.
2. Electrical sources of disturbance nearby (VHF, intercom etc.) must be shielded.
3. Check that there are no waste from drilling etc. inside the cabinet and on the electronic
modules/cards.
4. Check that all cables and conductors are well fastened that they do not touch any sharp edges
and that they do not have sharp bends.

Neptune-II CPP
5. Check that all conductors into the terminal block are labelled with correct numbers and that the
fastening screws are well tightened.
2.1.3 Manoeuvre panels

The manoeuvre panels are mounted at selected places according to the required/wanted control
positions.
Checkpoints that require special attention (to be carried out for all control stations):
1. Check that the manoeuvre panel is securely mounted regarding fastening and vibrations.
2. Check that there is no waste from drilling etc. inside the cover nor on and the screw
terminals/connectors.
3. Check that all cables and conductors are well fastened and that they do not touch any sharp
edges and that they do not have sharp bends.
4. Check that all conductors into the screw terminals/connectors are marked with correct
numbers and that the fastening screws are well tightened.
6. Check that the network is only terminated at the last manoeuvre panel and here only.
2.1.4 Sensors and actuators

The checkpoints must be carried out for all sensors and actuators, e.g. RPM pick-up, pitchactuator etc.
See the systems cable plan (drawing no. 016-XXXX) to find what's included.
Checkpoints to pay special attention to for each sensor/actuator:
1. Check that the sensors/actuators fastening bracket is mechanically strong. It must be so rigid
that vibration and fractures do not occur.
2. Check the actuators fastening, that it is well mounted regarding the fitting, links to the
connected arm, the stroke length, and that there is no lateral forces in any position.
3. Check that sensors are mounted correctly regarding sensing distance, mechanical movement
etc. The range is normally stamped onto the sensor.
2.1.5 Cables and electrical conductors

1. Check that all cables used are according to the requirements.
2. Check that all cables and conductors are well fastened, that they do not touch any sharp edges
and that they do not have to sharp bends.
3. Check that all conductors not in use are individually isolated and properly secured.
4. Check that the cables are not mounted nearby electrical sources of disturbance.
5. Check that all conductors into the terminal connectors are labelled with the correct numbers.
6. Check that shielded cables between different equipment have the screen connected to ground
in accordance with the installation requirements and the cable plan.
7. Check that the screen is guided unbroken through connection boxes, terminal lists etc.
8. Check that there are no waste from drilling etc. inside or outside connection boxes, terminal lists
etc.
9. Check that pigtails are no longer than 50mm for any screen.

Neptune-II CPP
2.2 Electrical checks with no power applied

Before power is applied to the system check carefully that all connections are correct. Damage to the
system may occur if an incorrect connection exits when power is applied. Potentiometers and sensors
must be checked especially carefully.
The system has two different 24VDC power systems, the external 24VDC power system (from the ships
distribution system) and an internal 24VDC system which is galvanically isolated from the external.
Most of the measurements are done inside the system, on the connection terminals/connectors in the
CPU-cabinet or the I/O-cabinet(s) (if present), or units/equipment connected to this.
2.2.1 24VDC power supplies

Check that the required power supplies (normally two) are completely separate and independent, and
that each of them is capable of delivering the required power (current) (see the cable plan for details).
Measurements that must be done on each of the power supply circuits before connection:
1. Check that the supply voltage is within the range 24VDC -10%/+20% (21,6VDC - 28,8VDC).
2. Measure between each of the power supplies and the hull using a voltmeter. Check that the
reading counts upward to infinity or downward to zero, if a steady voltage is measured it
indicates earth fault in the power supply circuit.
2.2.2 Earth fault external 24VDC system

The measurements are carried out on the terminal block in the CPU-cabinet with all fuses in the power
supply connection terminals removed (F1-F4). They are done on the inside of the fuse connection
terminals, on the consumer side, for all the external 24VDC power supply circuits (normally two
separate). Note that external consumers like clutch solenoids are connected to this system.
If an earth fault is discovered, one and one lead connected to the external 24VDC power supply circuit
with the earth fault is removed until the fault disappears. The earth fault is then in connection with the
lead last removed. Be aware of that more than one earth fault may occur.
Checks to be carried out (easiest measured on the consumer side of F1 to F4 with the fuses removed):
1. Measure between 024V and the hull using an ohm-meter. The reading should be more than
3MΩ. Lower value indicates an earth fault.
2. Measure between +24V and the hull using an ohm-meter. The reading should be more than 3M.
Lower value indicates an earth fault.
2.2.3 Earth fault internal 24VDC system

The 24VDC used internally in the Neptune-II are galvanically isolated from the external 24VDC power
supplies.
To check the internal 24VDC supply, remove the fuses in the power supply connection terminals (F1-F4).
Then measure the resistance between the hull and the test points on the MPP110 power module
marked Bat1, Bat2 and GND1. The reading should be more than 3MΩ. Lower value indicates an earth
fault.
If an earth fault is discovered, remove one of the remaining fuses at the time (F5, F6 and so on) until the
fault disappears. The earth fault is then associated with the parts connected to the fuse last removed.
Be aware that more than one earth fault may occur.
2.2.4 Internal connections

Check carefully that all connections between the units listed below are correct:
1. CPU-cabinet and manoeuvre panels (including terminal resistors).
2. Between each control station.

Neptune-II CPP
3. CPU-cabinet and I/O-cabinet(s) (if present).

4. CPU-cabinet (I/O-cabinet) and sensors and actuators.
Check that all network terminations are correctly mounted.
2.2.5 External connections

Check carefully all connections to external equipment, i.e. gearbox, engine control system, main switch
board, joystick-system, DP-system etc.
Check carefully the requirements listed below:
1. Digital inputs: connections to digital inputs shall be potential free contacts only.
2. Digital outputs: potential free contacts. Maximum ratings resistive load are 24VDC/1A,
220VAC/1A (considerably less when load is not purely resistive). If connected to a relay coil or similar
(inductive) load, a spark quenching device/transient arrester (protection diode) must be installed on
the consumer side.
3. Analogue inputs: Check that the signals are galvanically isolated into the system (must be
galvanically isolated from all other systems). Check that the signal range is within the range for
the input.
4. Analogue outputs: ±10VDC max. output current 1mA; 4-20mA min. load 600Ω; galvanically isolated.
5. Communication port to GPS: NMEA 0183 Version 2.00, i.e. EIA-422 (RS-422) hardware
requirements.
3 System checks and pre-adjustments

These are procedures for system/function checks, and pre-adjustment of the most important functions.
WARNING! The clutches shall be disengaged and/or the prime movers stopped during these procedures!
3.1 Applying power

When all the checks in the chapter '2 ' above are carried out successfully, power can be applied to the
system. I.e. inserting the main fuses, normally F1 to F4.
WARNING! Be absolutely certain that all connections are checked and found correct before applying power,
otherwise serious damage may occur!
3.2 Basic system checks and operation

Procedures for checking basic system set-up and operation.
3.2.1 Panel set-up checks

Check the settings in the panel set-up menu for all panels:
• Mounting direction: Ahead / astern *)
• Mounting side: Starboard / port / single
• Panel address: Main / ECR / Slave1...5
• Lamp test: All indications, background lights and buzzers shall be active.
Standard panels: press '+' and '-' on the 'Light' button simultaneously.
ECR panel/advanced panels: press 'Light' then 'Lamp test' in the touch screen.
To enter the set-up menu in the standard panels push the '' in approximately five seconds. Use the '+'
or '-' buttons to enter the password (0145). In the ECR/advanced panels go to main menu and login at
level > 1, choose the set-up menu and then the panel set-up menu.

Neptune-II CPP
*) The end-connections of the pitch lever order potentiometer must be interchanged and the
potentiometer re-calibrated if this is changed. Remove the back cover of the panel, interchange the
wires on Jx-1 and Jx-3 and carry out the calibration procedure for the order potentiometer (described in
the service manual).
3.2.2 Backup mode operation

The system shall be in 'Backup mode'. Note that 'Normal mode' may not be available yet since the pitch
feedback is not calibrated.
Check that the command can be transferred to all control panels and that they are operating in 'Backup
mode'.
3.2.3 Normal mode operation

The system shall be in 'Normal mode'. Note that it may be required to adjust the pitch feedback
mechanically before it is possible to enter 'Normal mode', see '3.3.2 '.
Check that the command can be transferred to all control panels and that they are operating in 'Normal
mode'.
3.3 The pitch system

If the engine is not running, start the emergency servo pump to get servo oil pressure.
3.3.1 Pitch movement and direction

Use the buttons on MPB200 in CPU cabinet to check pitch controller direction (ahead/astern).
Alternatively the backup buttons pitch (up arrow and down arrow) on the panel in command may be
used if the pitch feedback has not been connected. Observe the movement, direction and deflection.
Tip: Check the mounting direction of panel in the panel display menu to find out if the arrow upwards
on the panel is ahead or astern.
If the pitch moves in wrong direction, swap wire 1 and 2 to the pitch actuator. If it is proportional valve
controlled pitch, increasing signal will "always" be ahead, but may be inverted in the analogue output
menu.
3.3.2 Pitch feedback mechanical limits

Adjust the feedback according to the mechanical limits of the pitch servo. Activate the function in the
'pitch feedback menu' and move the pitch servo to extreme limits and then press save.
Evaluate the extreme values. Are they acceptable or should the mechanical arrangement be adjusted?
3.3.3 Pitch control

It shall now be possible to enter 'Normal mode'. Check the pitch movement from the lever in all panels.
The pitch should now move from approximately +70 to -50% of mechanical limits.
Tip: If the pitch moves in wrong direction in normal mode, the end points of feedback control
potentiometer is swapped. Interchange wires L4-1 and L4-3. If the pitch indication goes in wrong
direction, the end points of feedback indication potentiometer is swapped. Interchange wires L4-4 and
L4-6. Repeat the pitch feedback adjustment afterwards.

Neptune-II CPP
3.3.4 Pitch speed

Adjust the maximum pitch speed of the system. The movement of the pitch actuator must not be faster
than the hydraulic servo, otherwise mechanical damage may occur. Use the parameter 'Max frequency'
of the pitch actuator to adjust this.
Default speed should be 450Hz for the MAC-102/103-Dxxxxx and 250Hz for the CRAB-12.
If the pitch system has valves (instead of actuator), the maximum and minimum valve output (opening)
must also be optimised in order to have a good regulation.
3.4 The clutch system
3.4.1 Clutch interface

Activate clutch outputs to check that the engage and disengage signals are connected to the correct
clutch valves and that the corresponding indication signals from clutch and servo pressures are correct.
This must be correct before starting the engines. Be sure to leave the clutch(es) disengaged.
3.5 The RPM system
3.5.1 RPM order signal

Check that the output signal to the engine control system / governor (RPM order signal) follows the
order when operating the RPM order potentiometer in the ECR panel.
Start the engine and carefully increase the RPM order while observing that the engine RPM is increasing
accordingly. WARNING! The clutches must be disengaged!
Enter the RPM set-up menu in the ECR panel to adjust the idle and maximum RPM order (Login level > 2
/ Setup menu / Parameter menu / RPM menu).
It may not be allowed to run at maximum engine RPM at this point. The maximum RPM order
parameter may therefore need to be calculated/predicted.
3.5.2 RPM feedback

Indication of engine RPM may be based on either an analogue signal from the engine control system or
a calculated RPM based on the propeller shaft RPM and the gear ratio.
The propeller shaft RPM is calculated based on pulses from the propeller shaft RPM sensor. Check the
distance between sensor and all bolts on the propeller shaft. (2-5 mm) The sensor must point at an
even surface on the head or end of the bolts.
The number of bolts and the gearbox ratio(s) must be entered in the GEAR set-up menus (one ratio for
each engine connected to the gear). The propeller shaft RPM in the main controller is used in the load
control system (Login level > 2 / Setup menu / Parameter menu / Gear menu).
In order to visualise the propeller shaft RPM, the same parameters must be added into the backup
controller. Copy the parameters from main controller to the backup controller or manually insert the
same values into the backup gear set-up menu. If the engine RPM is received as an analogue signal, set
the maximum value according to the analogue input scaling (Login level > 2 / Setup menu / Backup
menu / Gear menu / AnalogIO menu).

Neptune-II CPP
3.6 Operating curves
3.6.1 Pitch and RPM combinator curves

The optimal combinator curves should be inserted, depending of engine type, propeller curves etc.
• Check the curves in the system. May be corrected during sea trial.
3.6.2 Load curves

The optimal load curves should be inserted, depending of engine type etc.
3.6.3 Ramp curves

The optimal ramping curves of pitch and RPM should be inserted, depending of engine type etc.
3.7 Operating modes
3.7.1 Pitch and RPM modes

Check mode shift, pitch movement and engine RPM output signal for as many modes as possible:
• Separate pitch/RPM (from ECR panel).
• Combinator (from any bridge panel).
• Local control pitch (on the gearbox - activates the alarm 'Pitch released').
• Local control RPM (indication/handshaking of where the engine RPM is controlled).
• Constant/limit RPM (analogue/fixed setpoint - handshaking signals from the MSB).
3.7.2 Special modes

• Speed control: Check the speed signal (NMEA communication / analogue input).
Landing mode:
• Check eventual interlocks and activate the mode.
3.8 The automatic load control system
3.8.1 Engine load signals

Each engine (max. four) connected to the gear may have an analogue load signal input to the system.
Each load signal are input to a corresponding load curve which calculate a load value for each engine
relative to the propeller shaft (respective engine) RPM.
Checks to be carried out for each engine:
• Check the load signal from the engine control system (or from the sensor on the fuel rack). As default
the load signal is 4-20mADC, where 16-18mA should be max. load of engine. 20mA must be more
than full load as the system needs this for adequate control.
• Disconnect the load signals and observe that a local alarm is present in panel displays.
Adjust the curves if needed (Login level > 2 / Setup menu / Load curves / Load curve 1-4).

Neptune-II CPP
3.8.2 Load control parameters

Checks to be carried out for each engine:
• Check the Minimum pitch limit for enabling the load control.
• Check the Minimum RPM limit for enabling the load control.
• Check that the dynamic load control is enabled.
• Check that the PID-control is enabled and the PID-parameters.
• Check the Ramp gain parameters (overload/always and the parameters of the enabled sets).
Adjust parameters if needed (Login level > 2 / Setup menu / Parameter menu / Load menu).
3.9 Alarms
The system have several alarm outputs. Normally these are connected to the vessels main alarm
system. Check the cable plan (drawing no. 016-XXXX) for details.
3.9.1 Power failure

A power failure is given (open contact) when a power supply is missing, an internal fuse is broken or an
internal voltage is missing.
Open a fuse or disconnect a power supply and observe that a power failure alarm is given.
3.9.2 System failure

A system failure is given (open contact) at serious errors in the system.
Simulate a system failure and observe that a system failure alarm is given.
Serious errors are:
• Main controller failure (PLC-stop).
• Backup controller failure (PLC-stop).
• Pitch feedback failure (signal failure).
• Pitch order failure (signal failure).
• Pitch driver failure (step-motor driver or proportional valve driver).
• Communication failure with panel in command.
• I/O communication failure.
3.9.3 Custom specific alarms

Other alarm outputs may be present to the alarm plant, like f.ex. softclutch failure.
Check the system specific documentation and test all present alarms.

Neptune-II CPP
4 Adjustments alongside quay

These are procedures that are normally carried out with the vessel securely moored alongside quay
when all system checks and pre-adjustments are done.
NB! Clarify with the person in charge onboard the vessel, the gear/propeller supplier and the engine supplier
before starting the tests and adjustments in the procedures below. There might f.inst. be work going on in
conjunction with or nearby the propeller shaft. Do not activate any thing nor do any adjustments etc. before
permission is clearly given by the person in charge!
During all adjustments etc. the vessel must be securely moored. Be very careful with engine RPM and
propeller pitch. Generally no quick movements with the lever must be done.
The main engine must be started. Run at idle speed if not otherwise specified.
4.1 Zero pitch calibration

The pitch must be calibrated accurate to get an optimal adjustment of the system.
Procedure for adjusting the zero pitch:
• Check that all 'Pitch Offset' adjustments are 0. (These are only for easy adjustments for trained
crew/chief).
• Start the main engine and clutch in the propeller (if twin screw only one by one).
• When the propeller shaft is running (preferable at max. speed), move the pitch lever on the panel in
command until the vessel is as steady as possible and there is least possible propeller wake. When
this is achieved, save the 'Zero pitch' setting by pressing the 'Save' and 'OK' buttons.
WARNING! When the system is in normal mode and the 'OK' button is pressed, the pitch will move to the
actual lever position. To avoid this, the system should be in backup mode when the 'OK' button is pressed.
When setting the lever to zero, both control and indication feedback settings will be correct.
It is also possible to enter the correction value manually and then press save to adjust the indication. In
this way it is not necessary to control the pitch from panel in command. (Login level > 2 / Setup menu /
Parameter menu / Pitch feedback menu.)
It is best to adjust the zero pitch next to a stationary object, with no water currents and with calm
weather. Loosely tied to the dock is often the best situation for this adjustment. Usually the propeller
wake around zero pitch is so little that an increase in engine RPM is necessary to notice movements.
Observe the propeller water and movement of the vessel.
4.2 Propeller shaft RPM

Check that the propeller shaft RPM is correct relative to the engine RPM. Use a stroboscope if any
doubt. A wrong detection of a shaft bolt will give wrong RPM calculation. See chapter '3.5.2 ' above.
4.3 Idle and maximum RPM settings

Check and adjust if necessary:
• Idle speed/RPM.
• Maximum speed/RPM.
•
4.4 RPM modes and settings

Check 'Combinator', 'Separate', 'Constant RPM', 'Limit RPM (Floating frequency)' modes and settings.
Check that there are correct RPM setting values in the different RPM modes. These adjustments may

Neptune-II CPP
already have been checked out during the system check procedures, but may possibly be corrected to
give the proper set-up during full speed at sea trial. Adjust if necessary.
5 Sea trial
These are procedures that shall be carried out during sea trial at full speed and load of the vessel after
the adjustments alongside quay are done. During these the final adjustments of the system are done.
First adjust the propeller pitch (load) and the engine RPM, then the automatic load control system (if
equipped with).
The tests shall be carried out in all present modes of the system, i.e. with each possible mode of the
clutches engaged etc. All details about the actual system must be known in order to be able to set up
the system correctly. Necessary information is given in the system specific documentation.
The final adjustments are done when the vessel can be operated at full speed and full load. To get as
good settings as possible the adjustments should be done in smooth water.
5.1 Maximum pitch ahead calibration (max. pitch)

To do this the load control must not interfere the pitch control. The easiest way is to disable the
automatic load control by pressing the 'Override load control' button (Login level > 0 / User menu / ).
It is possible to have several max. and min. feedback parameter sets (1-4), depending on the actual
configuration. Only enabled parameter sets are accessible. This depends on the active mode.
Check the activation conditions of the feedback parameter sets in the system specific documentation.
Normally the parameter sets will follow the combinator curves, i.e. Combinator curve 1 active →
feedback parameter set 1 active. (Login level > 2 / Setup menu / Parameter menu / Pitch feedback
menu)
Do the maximum pitch ahead adjustment for each parameter set:
• Cooperate with the ship officers and achieve the maximum pitch ahead (speed) of the vessel. Take
into consideration the engine loads (RPM, temperatures, load indications, turbo pressures). Use the
pitch levers in normal mode or put the system in backup mode and use the buttons to achieve the
wanted pitch.
• When it is achieved, save the 'Max. pitch' setting by pressing the 'Save' and 'OK' buttons.
WARNING! When the system is in normal mode and the 'OK' button is pressed, the pitch will move to the
actual lever position. To avoid this, the system should be in backup mode when the 'OK' button is pressed.
It is also possible to enter the correction value manually and then press save to adjust the indication. In
this way it is not necessary to control the pitch from the panel in command.
'Max pitch parameter 1' is usually used in "normal mode", which generally is when only the main clutch
is engaged. Min pitch parameters 2 to 4 are usually used in "boost modes" or "reduction modes", e.g.
when two engines/motors are clutched in, like twin-in single-out or a PTI/PTO/PTH mode. Check with
the system specific documentation in each case.
5.2 Maximum pitch astern calibration (min. pitch)

Same presumptions as maximum pitch ahead (max. pitch). Normally not necessary to achieve 100%
possible pitch astern, but it must be enough to give the vessel good manoeuvrability. The exception is
when the vessel is equipped with a joystick- and/or a DP-system. Then it is important that the
maximum pitch astern is calibrated optimally.

Neptune-II CPP
Save the 'Min pitch' setting (i.e. max. pitch astern) by pressing the 'Save' and 'OK' buttons.
'Min pitch parameter 1' is usually used in "normal mode". Min pitch parameters 2 to 4 are usually used
in "boost modes" or "reduction modes". See the corresponding Max pitch parameter above, and check
with the system specific documentation in each case.
5.3 Load signal calibration

The load signals were set up during system check procedures, but the maximum load of each engine
must be adjusted during sea trial. Usually this is done once the maximum pitch ahead (max. pitch) is
calibrated.
Load signal calibration:
• Increase the pitch in order to achieve maximum load of all engines (one by one if possible) at 100%
speed. (max. engine RPM).
• Adjust the maximum load of each engine until the load of respective engine is indicating 99-100%
(Login level > 2 / Setup menu / Load curves / Load curve 1-4).
Remember to repeat this for each active curve (depending of number of engines/modes).
'Load signal prime mover 1' is the load signal from prime mover (engine or electric motor) 1. 'Load
signal prime mover 2' is the load signal from prime mover (engine or electric motor) 2, and so on up to
4.
5.4 Combinator curve optimization

Move the lever in steps and observe speed, temperatures, turbo pressures and fuel consumption.
Eventually try to reduce/increase the RPM relative to the pitch and check if it is an improvement.
Consult the ship officers and engine/gear suppliers.
Remember to repeat this for each active curve (depending of mode).
'Combinator curve 1' is usually used in "normal mode". 'Combinator curve 2 to 4' are usually used in
"boost modes" or "reduction modes". The active combinator curve often follows the max./min. pitch
parameters, i.e. 'Combinator curve 1' is used when 'Max/min pitch parameter set 1' is active,
'Combinator curve 2' when 'Max/min pitch parameter set 2' is active, and so on. This is not necessarily
always correct and must be checked with the system specific documentation.
5.5 Ramp curve optimization

Ramp curve optimization:
• Accelerate/decelerate the vessel to/from full speed ahead and full speed astern. Observe the load of
the engines (temperatures, turbo pressures etc.) Consult the chief and/or the engine supplier. Adjust
if necessary.
Remember to repeat this for each active curve (depending of mode).
Ramp curve 1: "Normal mode". Normally only this one is in use.
Ramp curve 2: "Special mode". May be used in special modes like "Landing mode".
5.6 Load curve optimization

The load control system is using the engine load signals and propeller shaft RPM to calculate an
eventual pitch reduction in order not to overload the engine(s).
To have correct adjusted load curves relative to the propeller shaft RPM, check them as follows:

Neptune-II CPP
• Reduce the propeller shaft RPM in steps of about 10% and adjust the pitch (use separate or backup)
to the highest wanted value (check temperatures, etc.). Observe the calculated load of each engine
(value in “moving dot” in the curves) and adjust the curves in order to achieve about 100% in all
steps.
Remember to repeat this for each curve. If several engines are present in the system, they might be run
one by one in order to achieve 100% load. Each engine have separate load curve.
'Load curve 1' is the load curve related to the load signal from prime mover (engine or electric motor) 1.
'Load curve 2' from prime mover 2, and so on up to 4.
5.7 The automatic load controllers

The automatic load controllers should be checked when the load is approximately 100% at full speed.
Check that the automatic load control is active and that all three load controllers are enabled (PID, DO
and Loadspeed).
5.7.1 PID-controller
Make a note of the settings from chapter '5.3 ' and temporarily increase one of these settings in order
to achieve 102-103% load of the system (highest load signal is used). Observe that the PID-controller
will reduce the pitch and try to hold the load between 99-100%. If necessary adjust the P or I in order to
achieve as stable pitch as possible.
5.7.2 DO-controller
To test the dynamic load control it is necessary to have a pulsing load around 100%. In normal
circumstances this happens in heavy sea. The pitch will then be reduced in small steps until the load is
continuously below 100%. If possible try to achieve this pulsing load and observe the dynamic load
reduction. Adjust the reduce and increase value to change the reduction speed. The test button in the
load control menu may be used in order to achieve this pulsing.
5.7.3 Loadspeed controller

Thereafter reinsert the correct max. load signal settings and reduce the pitch to about 50% with the
lever and increase it again fast. Observe that the pitch (and load) are increasing slower than normal, so
that the system does not enter an overload situation. Both the D-parameter (derivative) in the PID-
controller and the Ramp gain will work in order to prevent this overload situation. Adjust if necessary.

Neptune-II CPP
6 Commissioning report
Plant no: ___________________________ Date: ___________________________
Vessel: ___________________________ Service engineer: ___________________________
Installation and system checks
Mechanical and electrical installation checks OK - N/A Comment
2.1 Mechanical 2.1.1 CPU-cabinet

installation
2.1.2 I/O-cabinet
2.1.3 Manoeuvre panels
2.1.4 Sensors and actuators
2.1.5 Cables and electrical conductors
2.2 Electrical checks 2.2.1 24VDC power supplies

with no power applied
2.2.2 Earth fault internal 24VDC system
2.2.3 Internal connections
2.2.4 External connections
System checks OK - N/A Comment
3.1 Applying power 3.1 Applying power
3.2 Basic system set- 3.2.1 Panel set-up/test

up and operation
3.2.2 Backup mode operation
3.2.3 Normal mode operation
3.3 The pitch system 3.3.1 Pitch movement and direction
3.3.2 Pitch feedback mechanical limits
3.3.3 Pitch control
3.3.4 Pitch speed
3.4 The clutch system 3.4.1 Clutch interface
3.5 The RPM system 3.5.1 RPM order signal
3.5.2 RPM feedback
3.6 Operating curves 3.6.1 Pitch and RPM combinator curves
3.6.2 Load curves
3.6.3 Ramp curves
3.7 Operating modes 3.7.1 Pitch and RPM modes
3.7.2 Special modes
3.8 The automatic 3.8.1 Engine load signals

load control system
3.8.2 Load control parameters
3.9 Alarms 3.9.1 Power failure

Neptune-II CPP
System checks OK - N/A Comment
3.9.2 System failure
3.9.3 Customer specific alarms

Neptune-II CPP
Sea trial procedures
Adjustments alongside quay OK - N/A Comment
4.1 Zero pitch Zero pitch calibration

calibration
4.2 Propeller shaft Propeller shaft RPM

RPM
4.3 Idle and maximum Idle RPM setting

RPM settings
Maximum RPM setting
4.4 RPM modes and Combinator

settings
Separate
Constant RPM
Limit RPM (Floating frequency)
Sea trial procedures (at high/full speed) OK - N/A Comment
5.1 Maximum pitch Max pitch parameter 1

ahead calibration
Max pitch parameter 2
(max. pitch)
5.2 Load signal Load signal prime mover 1

calibration
Load signal prime mover 2
5.3 Maximum pitch Min pitch parameter 1

astern calibration
Min pitch parameter 2
(min. pitch)
5.4 Combinator curve Combinator curve 1

optimization
Combinator curve 2
Combinator curve 3
Combinator curve 4
5.5 Ramp curve Ramp curve 1

optimization
Ramp curve 2
5.6 Load curve Load curve 1

optimization
Load curve 2
Load curve 3
Load curve 4
5.7 The automatic PID-controller

load controllers
DO-controller
Loadspeed controller

Neptune-II CPP
Notes:
......................................................................................................................................................................................
......................................................................................................................................................................................
......................................................................................................................................................................................
......................................................................................................................................................................................
......................................................................................................................................................................................

7 System Drawings

DRAWING LIST Page 1 of 1
Customer / Cust. plant no. Yard / Yard plant no. Ship's name Other
Brunvoll Volda China Merchants Heavy
Industry (Jiangu) Co. LTD
(CMHI)
2312-13 CMHI-196-2 BV: 36870D
Mar-El Propulsion Thruster Rudder Joystick Other
Type no Neptune-II
CPP
Plant no 3744-45
Text Drawing number Rev. Information
CPU Cabinet,
002 Neptune CPP
002-10217 H
Panel bridge,
003 propulsion
003-10278
Panel ECR,
005 propulsion
Alarm plant
011 Connections
011-10925 A
Cableplan,
016 propulsion
016-10926 A
Layout rack front / Neptune CPP cabinet
043 043-10219
cabinet, B
adjustments etc.
Panel layout(s) Bridge panel(s)
045 (general)
045-10220 A
Mechanical drawings Cabinet outline, Neptune-II CPU
058 058-7594 A
Mechanical drawings Panel outline, Bridge (double,
058 058-7687 A advanced)
Mechanical drawings PSU cabinet
058 058-7984 B
Terminal box, gear
076 076-10927 A
Electrical connections Service connection for PC
077 077-8579 C
Electrical connections PSU cabinet, outline
077 077-11133
w:\anl\a-3700 .. 3799\3744-45\30 - hw\10 - txt\3744-45 drawing list_b.docx 07.11.19

8 Miscellaneous

Chapter 10 Manual from Sub Suppliers and Notes

Chapter 10 Manual from Sub Suppliers and Notes

513183-84
513183-84 Lagersmit - Supreme STA-STF Stern tube Manual

Lagersmit
Postbus 176, 2950 AD Alblasserdam
Nieuwland Parc 306, 2952 DD Alblasserdam
T +31 88 0216 200

F +31 88 0216 249
[email protected]
www.lagersmit.com
SUPREME® STA-STF seals
Installation and maintenance manual
Date Reference Version Status

October 28th, 2016 STA-STF 8 Final
Order number :
Vessel name :
Serial number of SUPREME STA seal :
Size :
Assembly drawing : Xxxxxxxxxxxxx
Serial number of SUPREME STF seal : XxxxxxF
Size : XXXX
Assembly drawing : Xxxxxxxxxxxxx
PID : PID-STA-STF
Size:
Aft/Outer: Forward/Inner:
400/380 330/290
513183-84
Date Reference Version Status Page

October 28th, 2016 STA-STF 8 Final 2 van 36
Table of contents
INTRODUCTION........................................................................................................................................................ 3
1 PRODUCT DESCRIPTION ................................................................................................................................ 4
1.1 Equipment checks and precautions before installation ............................................................................... 4
2 THE SUPREME STA SEAL ................................................................................................................................ 5
2.1 General ........................................................................................................................................................ 5
2.2 Installation precautions ................................................................................................................................ 5
2.3 Assembling of the SUPREME STA seal ..................................................................................................... 6
2.4 Placement of the SUPREME STA seal ..................................................................................................... 10
2.5 Zero wear-down measurement .................................................................................................................. 15
3 THE SUPREME STF SEAL .............................................................................................................................. 16
3.1 General ...................................................................................................................................................... 16
3.2 Installation precautions .............................................................................................................................. 16
3.3 Assembly of the SUPREME STF seal ....................................................................................................... 17
3.4 Placement of the SUPREME STF seal ..................................................................................................... 21
4 OIL TANKS ....................................................................................................................................................... 26
4.1 Oil tanks location ....................................................................................................................................... 26
4.2 Oil lubrication option .................................................................................................................................. 26
4.3 Stern tube oil tank unit ............................................................................................................................... 26
4.4 Forward seal circulation tank ..................................................................................................................... 27
4.5 Oil specifications ........................................................................................................................................ 27
5 START-UP PROCEDURE ................................................................................................................................ 28
5.1 Preparation and checks before use ........................................................................................................... 28
6 PERIODIC MAINTENANCE ............................................................................................................................. 29
6.1 Weekly checks ........................................................................................................................................... 29
6.2 Half yearly maintenance ............................................................................................................................ 29
6.3 Each docking ............................................................................................................................................. 29
6.4 Points of interest during overhaul .............................................................................................................. 30
6.4.1 Overhaul of the SUPREME STA seal ................................................................................................ 30
6.4.2 Overhaul of the SUPREME STF seal ................................................................................................ 31
7 DISASSEMBLY AND REPAIR OF THE SEALS .............................................................................................. 32
7.1 Disassembly .............................................................................................................................................. 32
7.2 Repair ........................................................................................................................................................ 32
8 TROUBLESHOOTING ...................................................................................................................................... 33
9 OPTIONAL EXTRAS ........................................................................................................................................ 34
APPENDIX A SERVICE & SPARE PARTS ....................................................................................................... 35
APPENDIX B WEAR-DOWN LOG SHEET ....................................................................................................... 36
513183-84

INTRODUCTION
This manual gives guidance for the professional installation, maintenance and disassembly of SUPREME STA
and SUPREME STF seals.
The instructions in this manual are accompanied, where necessary, by special symbols indicating particular
hazards.
: Danger to the body and/or health
: Danger to the product and/or other machines
These hazardous situations can arise when:

 Inadequately trained staff service the product;
 The product is inexpertly installed, maintained or disassembled;
 The product is used for purposes other than those for which it was originally designed.
In addition to the above hazard symbols, additional information is accompanied by the following symbol:
: Extra information
All persons responsible for installation, maintenance or disassembly of the product must:
 Be familiar with the contents of this manual;
 Possess adequate technical skills.
Although the information in this manual has been composed and verified as accurately as possible and the
descriptions are as clear as possible, no liability can be accepted for errors and/or deficiencies in the work
done during maintenance, installation or startup procedures.
This document remains the property of Lagersmit. All rights reserved. This document or any part thereof may
not be made public or disclosed, copied or otherwise reproduced or used in any form or by any means, without
prior permission in writing from Lagersmit.
DOCUMENT HISTORY
Release date Version Comment

08-01-2014 6 Lay-out changed.
06-03-2015 7 Company name changed
28-10-2016 8 Filling the chambers between lip seals page 14
Table P.1 Document history
513183-84

1 PRODUCT DESCRIPTION
The SUPREME stern tube seal system consists of a SUPREME aft seal, an aft bearing bush, a forward
bearing bush and a SUPREME forward seal. The SUPREME stern tube seals are used for sealing the stern
tube at the points where the shaft penetrates. Fig. 1.1 shows an example of a complete stern tube system.
Fig. 1.1 Example of a complete stern tube system (actual situation on board may vary)
1.1 Equipment checks and precautions before installation
 All assemblies and components supplied by Lagersmit. have been carefully inspected before shipment.
 Each component is suitably packed and protected to prevent damage or deterioration during shipment,
transit or storage. Any specific storage or handling requirements will be clearly identified on the package.
 Goods should be examined on receipt to verify the contents and their condition.
 Lagersmit should be immediately advised of any damage or discrepancy in the range of products supplied.
Damage which is clearly caused by handling in transit should be notified to the carrier.
 Keep goods in their original packing until just prior to installation in order to protect them optimally. Pipe
fittings/connections will be protected with tape plugs; do not remove them until necessary, just before
installation.
 Care must be taken during handling to prevent any mechanical damage occurring due to dropping, crushing
etc., especially on products containing electronic components.
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2 THE SUPREME STA SEAL
2.1 General
The SUPREME STA seal consists of three lip seals which are clamped in housing parts. The lip seals run to a
corrosion resistant liner. The purpose of the SUPREME STA seal is to prevent (sea) water penetration into the
stern tube (lip seal #1 and #2) and lube oil leakage out of the stern tube (lip seal #3). The lip seals can be
replaced by IHC Sealing Solutions engineers, without removing the propeller or withdrawing the propeller
shaft.
Fig. 2.1 SUPREME STA seal (Actual seal might differ slightly from this example)
In order to protect the liner against corrosion, Lagersmit recommends a grounded propeller
shaft.
2.2 Installation precautions
The following precautions must be taken before commencing the installation of the SUPREME STA seal:
1. Check the shaft and stern tube for damage and contamination;
 Clear the shaft and stern tube of deficiencies such as dirt and/or damage/burrs.
2. Check the goods for transit damage and for completeness;
 If transport damage and/or shortages is/are noticed, please contact Lagersmit.
3. Check the connection dimensions and tapped holes;
 The connection must correspond with measures on the assembly drawing, for the sealing unit to be
fitted. If not, please consult Lagersmit.
 The thread in the tapped holes must be the correct size and the holes must be undamaged.
4. Centring of the housing component:
 Arrange the housing components as shown in the assembly drawing.
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2.3 Assembling of the SUPREME STA seal
A new SUPREME STA seal is delivered completely assembled; for installation, please refer to the next section.
Before the SUPREME STA seal can be placed on the shaft, it must first be assembled for example, after
overhaul. The assembly must be carried out as shown in fig. 2.2 and 2.3.
Fig. 2.2 Assembly of the SUPREME STA seal (Actual seal might differ slightly from this example)
Clean your working area before proceeding with the following steps. Rubber lip seals are
sensitive to dirt.
1. Fit the coil springs (116 and 119) around the lip seals (118);
 The water-repellent lip seal #1 must be fitted with a Hastelloy coil
spring (116), which is marked with paint.
The length and appearance of the coil springs

can differ slightly. However, the pre-load
generated by the coil spring is verified
according the specifications.
513183-84

2. Place the flange ring (104) on a flat surface;
3. Place the lip seal (118) with coil spring (119) in the recess of the flange
ring (104);
 Ensure that the tip of the lip seal is oriented correctly.
4. Fit the intermediate supporting ring (103) against the flange ring (104)
using spring rings (112) and HSH screws (111);
 Tighten the opposing HSH screws evenly.
5. Place the lip seal (118) with coil spring (119) in the recess of the
intermediate supporting ring (103);
6. Fit the end supporting ring (102) against the intermediate supporting
ring (103) using spring rings (112) and HSH screws (111);
7. Place the lip seal (118) with the Hastelloy coil spring (116) in the
recess of the end supporting ring (102);
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8. Fit the end ring (101) against the end supporting ring (102) using spring
rings (112) and HSH screws (110);
9. Screw the plugs (114) with sealing rings (115) in the supporting ring
(103) and end supporting ring (102).
10. Fill the space between lip seal #1 and #2 and the space between lip seal #2 and #3 with multipurpose mineral
grease.
Fig. 2.3 Assembly of the liner in the SUPREME STA seal (actual seal might differ slightly from this example)
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11. Place the assembled part of the seal on blocks;
12. Lubricate the outside surface of the liner (106) with oil and
slowly lower it from the side of the end ring (101);
 Guide the liner so that the lip seals will not be damaged.
13. Mount the liner (106) with brackets (120) to the end ring
(101);
 Tighten the HH bolts (121) of the brackets evenly to
prevent damage of the liner and lip seals.
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2.4 Placement of the SUPREME STA seal
The SUPREME STA seal is delivered completely assembled, including brackets. In order to prevent damage
to the liner or the lip seals, the complete seal must slide onto the propeller shaft as a unit, including the
brackets.
Do not drive the shaft when work is done to the seal.
Do not use the mounting brackets for lifting purposes.
These steps only apply to standard executions. For each and every deviating execution consult
the applicable assembly drawing.
Fig. 2.4 Placement of the SUPREME STA (actual seal might differ slightly from this example)
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1. Take the precautions outlined in section 2.2;
2. Oil the shaft;
3. Slide the complete SUPREME STA seal, including the gaskets (108
and 117), O-ring (126) (if applicable) and brackets (120) onto the
shaft;
4. Fit the complete seal against the stern tube;

 Pay heed to the correct positioning of the gaskets and plugs.
 For the purposes of alignment, do not yet secure the collar bolts (113) of
the flange ring (104) yet.
5. Remove the brackets (120) and HH screws (121) in the liner (106) and end ring
(101).
If the mounting brackets are not removed, they

will cause damage when the seal is put into
operation.
The mounting brackets do not determine the

built-in length.
6. Fit the liner (106) against the propeller using the collar bolts (109);
 Pay heed to the correct positioning of the gasket (108)
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7. Check the alignment of the seal as shown in fig. 2.5;
In case of a dirt barrier In case of no dirt barrier (saw cut end ring)
Fig.2.5. Checking the alignment
When a saw cut end ring (101) is used, which is standard for seals without sand barrier (126), the static
eccentricity should be measured according to the following procedure:
 Remove the end ring (101) and lip seal (118) with coil spring (116) according step 7 and 8 in the description
in section 2.3, but in reverse order.
 Take measurements in horizontal and vertical direction on the end support ring (102).
 Mount the lip seal (118) with coil spring (116) and the end ring (101) back in place according step 7 and 8 in
the description in section 2.3.
The maximum allowable margin of difference in measurement A – B will depend on the size of the SUPREME
seal, as given in table 2.1. Minimising the alignment error will maximise seal life.
SUPREME STA size Max. allowable difference in measurements

A1-B1 and A2-B2
155 to 300 0.35 [mm]
330 to 500 0.40 [mm]
530 to 710 0.45 [mm]
750 to 850 0.50 [mm]
Tab. 2.1 Alignment measurements
8. Check the built-in length as shown in fig. 2.6;
Fig. 2.6. Checking the built-in length
The built- in length depends on the size of the SUPREME STA seal and is shown in the assembly drawing.
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9. If propeller shaft can be coupled, check the run-out of the liner (102) as shown in fig. 2.7;
 If propeller shaft cannot be coupled, this procedure cannot be done until first dry dock.
Fig 2.7 Checking the run-out
The maximum allowable shaft movement will depend on the size of the SUPREME seal. Minimising the run-out
will maximise seal life. Table 2.2 gives the maximum allowable clock gauge deflections.
SUPREME STA size Maximum allowed clock gauge deflection

155 to 300 0.10 [mm]
330 to 500 0.15 [mm]
530 to 850 0.20 [mm]
Table 2.2 Maximum allowable clock gauge deflection
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10. Fasten and secure the collar bolts (109 and 113);
 Table 2.3 shows the tightening torques. Tightening the collar bolts must be done in the order given in fig.
2.8.
 The collar bolts must be secured using securing wire as shown in fig. 2.8.
Bolt Tightening torque

M8 20 [Nm]
M10 45 [Nm]
M12 75 [Nm]
M16 120 [Nm]
M20 205 [Nm]
M24 350 [Nm]
Table 2.3 Tightening torques
Fig. 2.8. Tightening order
11. Fill the chambers between the lip seals;

 In case mineral oil is used, the STA must be equipped with 80 NBR lip seals:
o The chamber between the lip seals need to be filled with oil or grease. New seals are
already filled with mineral multi-purpose grease, so with new seals skip this step and go on
to the next step. After maintenance of the seals, first fill the stern tube, then the seal
chambers. Seal chambers must not be filled to the brim, to prevent high pressure while
installing the plug.
 In case EAL is used inside the stern tube, the STA must be equipped with 85 FKM-EAL lip seals:
o The chambers between the lip seals needs to be filled with the same EAL as used inside the
stern tube. First fill the stern tube, then the seal chambers. Seal chambers must not be filled
to the brim, to prevent high pressure while installing the plug. Follow the same procedure
during maintenance.
At all times, the seals must be protected against grinding dust and/or welding spatter.
Wrapping of the seals, for example with fibreglass cloths, is recommended by Lagersmit.
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2.5 Zero wear-down measurement
The wear-down of the aft bearing bush can be determined without removing the aft seal by carrying out a zero
wear-down measurement. This measurement has to be carried out before launch. The value has to be
recorded on the wear-down log sheet in appendix B or on the stickers in the box containing the vernier
callipers. This measurement has to be carried out regularly, e.g. at dry-dockings. By comparing the values to
the zero wear-down value, it can be determined whether the bearing clearance is still acceptable.
The following procedure is also valid for IWS (In Water Survey). Some oil might leak from the
camber between lip seals #1 and #2. Check with local authorities if this is allowed.
Carrying out the zero wear-down measurement:
The bearing wear-down is to be determined with the use of the vernier callipers and the measuring plug as
shown in fig. 2.9. These tools are equipped with the new aft seal.
Fig. 2.9 Zero wear-down measurement
1. Set the propeller blade #1 to TOP position;

2. Remove the plug and sealing ring from the end supporting ring;
3. Screw the measuring plug into the thread hole;
4. Determine dimension A using the vernier callipers;
5. Record the value measured in the wear-down;
6. Remove the measuring plug and replace the sealing ring and plug.
Use a new sealing ring after each wear-down measurement!
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3 THE SUPREME STF SEAL
3.1 General
The SUPREME STF seal consists of two lip seals which are clamped in housing parts. The lip seals run to a
corrosion resistant. This liner is connected to the shaft with the aid of a split clamp ring. The purpose of the
SUPREME STF seal is to prevent lube oil from leakage out the stern tube (lip seal #4 and #5). The lip seals
are lubricated with oil from a circulation tank. A combination of temperature difference and rotation of the
propeller shaft, together with the presence of a scraper in the seal, forces the oil to circulate.
Fig. 3.1. The SUPREME STF seal (actual seal might differ slightly from this example)
3.2 Installation precautions
The following precautions must be taken before commencing the installation of the SUPREME STF seal:
1. Check the shaft and stern tube for damage and/or dirt;
 The shaft and stern tube should be free of imperfections such as dirt and/or damage/burs.
2. Check the goods for transport damage and/or incompleteness;
 If any transport damage is noted and/or anything is missing, contact IHC Lagersmit.
3. Check the connection sizes;
 If the connection sizes do not match with those in the drawing, the stern tube seal cannot be fitted. In
this case, consult Lagersmit.
4. Check the pipes and oil tank(s) for damages or leaks, and purge the pipes to remove any internal dirt;
 The pipes and tank(s) should be free of imperfections such as dirt, damages and leaks.
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3.3 Assembly of the SUPREME STF seal
A new SUPREME is delivered completely assembled; for installation, please refer to the next section. Before the
SUPREME STF seal can be placed on the shaft, it must first be assembled. The assembly must be carried out
as shown in fig. 3.2 and 3.3.
Fig. 3.2 Assembly of the SUPREME STF seal (actual seal might differ slightly from this example)
Clean your working area before proceeding with the following steps. Rubber lip seals are
sensitive to dirt.
1. Fit the coil springs (215) around the lip seals (214);
The length and appearance of the coil springs

can differ slightly. However, the pre-load
generated by the coil spring is verified
according the specifications.
2. Place the flange ring (203) on a flat surface;
flange ring (203);
 Ensure that the nose of the lip seal is oriented correctly.
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4. Fit the support ring (202) against the flange ring (203) using spring rings
(209) and HSH screws (208);
 Tighten the HSH screws evenly.
5. Grease the scraper (223) and fit this in the G3/8 hole in the support ring
(202).
support ring (202);
 Ensure that the nose of the lip seal is oriented correctly.
7. Fit the lock up ring (201) against the support (202) ring using the HH
screws (210);
 Tighten the HSH screws evenly.
8. Screw the plug (216) with sealing ring (217) in the flange ring (203);
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9. Screw the plug (218) with sealing ring (219) in the support ring (202);
Fig. 3.3 Assembly of the liner in the SUPREME STF seal (Actual seal might differ slightly from this example)
10. Place the assembled part of the seal on blocks;
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11. Lubricate the outside surface of the liner (204) with oil and
slowly lower it from the side of the lockup ring (201);
 Guide the liner so that the lip seals will not be
damaged.
12. Mount the liner (204) with the brackets (221) to the
lockup ring (201);
 Tighten the HH bolts (211 and 222) of the
brackets evenly in turn to prevent damage of the
liner and lip seals
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3.4 Placement of the SUPREME STF seal
The SUPREME STF seal is delivered in a pre-assembled cartridge design, including brackets. In order to
prevent damage to the liner or the lip seals, the complete seal must slide onto the propeller shaft as a unit,
including the brackets.
Do not drive the shaft when work is done to the seal.
Do not use the mounting brackets for lifting purposes.
These steps only apply to standard executions. For each and every deviating execution consult
the applicable assembly drawing.
Fig. 3.4 Assembly of the SUPREME STF seal (Actual seal might differ slightly from this example)
1. Take the precautions outlined in section 4.2;
2. Oil the shaft;
3. Slide the complete stern tube seal, including the gasket (206), brackets
(221) and O-ring (205) onto the shaft;
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4. Fit the seal against the stern tube;

 Take heed of the correct positioning of the gasket and the bleed plug.
 For the purpose of alignment do not yet fasten the HH screws (207) of
the flange ring (203).
5. Couple the propeller shaft;
6. Remove the brackets (221);
If the mounting brackets are not removed, they will cause

damage when the seal is put into operation.
The mounting brackets do not determine the

build-in length.
7. Adjust and mount the clamp ring (213) onto the propeller shaft using
the spring rings (231) and HSH screws (230);
 The adjustment value is given on the assembly drawing.
 Do not use excessive force when tightening the HSH screws.
Fig. 3.5 Adjustment value
To allow for the possibility of shunting the liner aside to the stern tube, the maximum
adjustment value should be achieved/ensured at new-build stage.
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8. Fit the liner (204) against the clamp ring (213) using the HH screws
(211);
 Tighten the HH bolts evenly.
9. Check the alignment of the liner (204);
Fig. 3.6 Checking the alignment
Measurements must be taken in horizontal and vertical direction. The maximum allowable margin of difference
in measurement A – B will depend on the size on the SUPREME seal, as given in table 3.1. Minimizing the
alignment error will maximize seal life.
Max. allowable difference in measurements

SUPREME® size
A1 – B1 and A2 – B2
155 to 300 0.35 [mm]
330 to 500 0.40 [mm]
530 to 710 0.45 [mm]
750 to 850 0.50 [mm]
Tab. 3.1: Alignment measurements
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10. Check the run-out of the liner (204);
Fig. 3.7 checking the run-out
The maximum allowable shaft movement will depend on the size of the SUPREME seal. Minimizing the run-
out error will maximize seal life. Table 3.2 gives the maximum allowable clock gauge deflections:
SUPREME® size Max. allowable clock gauge deflection

155 to 300 0.10 [mm]
330 to 500 0.15 [mm]
530 to 850 0.20 [mm]
Table 3.2: Maximum allowable clock gauge deflections
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11. Fasten the HH screws (207);

 Table 3.3 shows the tightening torques. Tightening the HH screws must be done in the order given in
fig.3.8:
HH
Tightening torque
screws
M8 20 [Nm]
M10 40 [Nm]
M12 70 [Nm]
M16 110 [Nm]
M20 160 [Nm]
M24 250 [Nm]
Table 3.3: Tightening torques
Fig. 3.8 Tightening order
12. Fit and connect the forward seal oil tank in accordance with the piping & instrumentation diagram;
At all times, the seals must be protected against grinding dust and/or welding spatter.
Wrapping of the seals, for example with fibreglass cloths, is recommended by Lagersmit.
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4 OIL TANKS
4.1 Oil tanks location
No Item name Location

1 Stern tube lube oil tank Approx. 2 to 4 [m] above the deep loaded waterline.
2 Circulation tank 0.3 to 0.6 [m] above the seal.

Tab. 4.1: Location of the oil tanks
4.2 Oil lubrication option
If the SUPREME STA seal is equipped with extra oil lubrication, the aft seal tank will need to be connected
with a pipe to the space between lip seal #2 and #3. This pipe runs through the stern tube and must have an
internal diameter of at least Ø10 [mm]. The valve in this pipe must be closed when the vessel is not in water,
because the oil needs water pressure to remain in place between the lip seals.
4.3 Stern tube oil tank unit
Install the lube oil tank in the location given in table 4.1. To prevent vibration of the components in the lube oil
tank unit, be sure to provide vibration isolating support for the mounting fixtures.
Install oil supply pipe and return pipe between tank unit and stern tube, in accordance with the piping &
instrumentation diagram. An example PID can be seen in fig.5.1.
Fig. 4.1 Stern tube oil tank unit
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4.4 Forward seal circulation tank
Install the circulation oil tank in the location given in table 4.1.
Install oil supply pipes between tank unit and the SUPREME STF seal, in accordance with the piping &
instrumentation diagram.
Fill the forward seal circulation tank up to just below the upper sight glass. Rising and falling oil levels will then be
clearly visible through the sight glass.
Fig. 4.2 Forward seal circulation tank
4.5 Oil specifications
Mineral lubrication oil may be used, provided it meets the following specifications:
 The oil must be a mineral oil. (i.e.: no synthetic oil)
 Viscosity between ISO VG68 ~ ISO VG320 (at 40 [°C])
 Temperature range: -20 [°C] to 120 [°C].
 Rubber friendly
VGP approved environmentally acceptable lubricants may be used, provided it is compatible with the Supreme
lip seals. Please check the document “Heading towards VGP compliance” on www.lagersmit.com/eal or
contact Lagersmit for further consult.
Mixing different oils is not allowed!
When the use of particular oil, for example bio-degradable oil, is desired, please contact the oil supplier
concerned.
The installation is ready for start-up after removal of the protection cloths on the seal.
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5 START-UP PROCEDURE
5.1 Preparation and checks before use
To put the propulsion installation into operation, see the relevant manuals from the supplier(s) of the
propulsion installation. As regards the stern tube seals and bearings, the following steps must be taken:
1. Check that the SUPREME STA and STF seals are correctly fitted and placed;
 For the correct fitting and placement, see sections 2.3, 2.4, 3.3 and 3.4 and the assembly drawings.
2. Fill the stern tube and stern tube tank with lubrication oil;
 See section 4.4 for oil specifications.
3. Fill the circulation tank of the SUPREME STF seal with lubrication oil;
 Check for contamination in the tank before filling. Any contamination will damage the lip seals.
4. Fill the additional lubrication oil tank(s). (if applicable)
Observe safety and environmental regulations while filling tank.
During start-up, keep well clear of the shaft!
Fig.5.1 Piping & instrumentation example diagram
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6 PERIODIC MAINTENANCE
Periodical Act
Weekly Check the oil levels
Half-yearly Refresh the lubrication oil in the circulation tank of the forward seal
Each docking Measure the wear-down
Overhaul of the aft Remove the distance ring (if fitted)
Points of interest at seal (6.4.1) Machine the liner
overhaul Overhaul of the Adjust the liner
forward seal (6.4.2) Machine the liner
If performance is unsatisfactory, refer to chapter 8 – Trouble shooting.
6.1 Weekly checks
Check weekly that the oil level is at an acceptable level and the colour of the oil is normal. In case of any
increase or decrease in oil level in the stern tube header tank, drain or refill tank to normal level. If any
abnormal change in oil level has occurred, then resolve the cause before draining or refilling.
At normal operating conditions, seals will consume little oil. This consumption depends on a large number of
factors: For instance, the size, peripheral velocity, misalignment, viscosity of the oil, temperature and
conditions of the lip seals/liner all have a great influence. The oil levels in the circulation tank of the SUPREME
STF seal, the stern tube tank and additional oil tanks need to be checked weekly and filled as necessary. As a
rule of thumb, a maximum oil consumption of 0.5% of seal size in litres per day should be allowed for. For
example, a seal type 200 can use 1 [l/day].
6.2 Half yearly maintenance
Refresh the lubrication oil in the circulation tank of the forward seal every 6 months.
6.3 Each docking
Measuring the wear-down:

Before starting the work; the wear-down on the bearing bush needs to be measured. The method of
measuring this is the same as the zero wear-down measurement as described in section 2.5.
For the maximum allowable bearing wear, contact the relevant classification society. After this work, the zero
wear-down measurement needs to be undertaken again.
Optional:
If the seal is equipped with an additional aft seal lubrication tank, the valve in the pipe between the aft seal
tank and the stern tube must be closed before the vessel is going into dry dock.
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6.4 Points of interest during overhaul
The lip seals can be replaced without removing the propeller or withdrawing the propeller shaft.
Gluing the lip seals in situ can only be done if the stern tube is free of oil.
In the event of repairs, Lagersmit recommends renewing the lip seals and other “soft”
materials such as rubber rings and gaskets.
Overhauling SUPREME seals demands specialist skills / tools and as such needs to be done
by a service engineer from Lagersmit or by a service engineer from a service station
recognized by Lagersmit.
6.4.1 Overhaul of the SUPREME STA seal
In the event of running spurs at the liner there are several options:
 Removing the distance ring (if fitted)

After removing the distance ring, the housing of the aft seal can be shunted aside to the stern tube. This way
the lip seal will run on a new running surface.
 Machiningthe liner
Once the distance ring has been removed, the running surface of the liner can be turned and/or ground
down. The finish should be pitch-free. The roughness (Ra) must be between 0.2 and 0.8 [μm]. Table 6.1
shows the maximum diameter reduction.
Fig. 6.1 machining the liner
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SUPREME size Pmax

(Dnominal) (Max. diameter reduction)
155 to 200 1.5 [mm]
220 to 240 1.6 [mm]
260 to 280 1.6 [mm]
300 to 355 1.6 [mm]
380 to 450 1.7 [mm]
480 to 530 1.8 [mm]
560 to 600 1.9 [mm]
630 to 710 2.0 [mm]
750 to 850 2.1 [mm]
Tab. 6.1: maximum diameter reduction of the liner
6.4.2 Overhaul of the SUPREME STF seal
It is not necessary to put the ship into dock in order to overhaul the forward seal. Before such an overhaul can
take place, be sure that the aft seal is watertight.
In the event of running spurs at the liner, there are several options:
 Adjust the liner

After removing the clamping ring, the liner can be shunted aside to the stern tube. This way, the lip seals will
run on a new running surface. After adjusting the liner, fit the liner back against the clamp ring.
Fig.6.2. Adjusting the liner
 Machining the liner

Once the liner has been adjusted, the running surface of the liner can be turned and/or ground down. The
finish should be pitch-free. The roughness (Ra) must be between 0.2 and 0.8 [μm]. Table 6.1 shows the
maximum diameter reduction.
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7 DISASSEMBLY AND REPAIR OF THE SEALS
This chapter describes the actions that may be necessary during disassembly and/ or repair of the seals.
While work is being done on the seal unit, the shaft must not be powered up.
7.1 Disassembly
To disassemble the SUPREME STA seal, the instructions set out in sections 2.3 and 2.4 should be followed in
reverse order.
To disassemble the SUPREME STF seal, the instructions set out in sections 3.3 and 3.4 should be followed in
reverse order.
7.2 Repair
Depending on the nature of the fault, the SUPREME seal unit may be repairable. This will primarily be the
case with replacement of those parts that are subject to wear.
In the event of repairs, Lagersmit recommends renewing the lip seals and other “soft”
materials such as rubber rings and gaskets.
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8 TROUBLESHOOTING
SUPREME STA SUPREME STF
Alarm Check Probable cause Action

Mostly water Lip seals #1 and #2 Replace lip seals #1 and #2
High level of Drain oil from tank down to normal

Recently overfilled level
stern tube oil tank
Mostly oil
Pumping from fwd seal
tank Check run-out of liner fwd seal
Oil spillage to marine

Lip seal #3 Replace lip seal #3
environment
Low level of High level fwd seal tank Replace lip seal #4 and drain tank
Lip seal #4
stern tube oil tank to normal level
O-ring between fwd seal
Oil inside engine room Replace the O-ring
liner and clamping ring
O-ring between fwd seal
Low level of Replace the O-ring
Oil inside engine room liner and clamping ring
circulation tank
Lip seal #5 Replace lip seal #5
Replace lip seal #4 and drain tank
Lip seal #4
High level of to normal level.
High oil level
circulation tank Drain oil from tank down to normal
Recently overfilled
level.
When the cause of an anomaly is unknown or the countermeasures would be difficult, please contact the
service department of Lagersmit.
When contacting us, please submit all relevant data, e.g. serial no., and operating conditions.
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9 OPTIONAL EXTRAS
SUPREME 2/2 4 Net cutter

Enjoy the comfort of replacing the distance ring, lip Protect your seal from damage from fishing nets.
seals, liner and/or housing parts without having to Stainless steel net cutters can be fitted on the rope
pull out the propeller shaft. SUPREME seals are guard.
available in a fully divisible ‘2/2’ design. 5 Dirt barrier
Service and commissioning Avoid damage to the aft seal caused by sand and
Our service engineers offer ongoing consultancy debris. Dirt barriers also prevent small fishing lines
24/7. In addition to service and repair, our engineers from entering the seal. Dirt barriers can be delivered
play a supervisory role in ensuring the proper either with or without protective cover.
installation of sealing systems. 6 Lip seal springs
Hastelloy® lip seal springs offer greater resistance to
1 Distance ring corrosion. All lip seal springs can be delivered in
Extends the lifetime of a liner. A divisible distance Hastelloy® models.
ring can be fitted with the SUPREME design. Over
time, the rubber lip seals wear down the liner. By 7 Liner: wear resistant coatings
removing or adding a distance ring, the house parts Reduce wear and invest in a more durable product.
can be repositioned. After repositioning, the lip seals When sailing in shallow waters, the rubber lip seals
run on a new surface and the lifetime of the seal is run into the liner. By applying a hard metal layer or
extended. ceramic coating, wear is reduced, guaranteeing a
2 Cathodic protection longer lifetime for the liner.
Placing anodes on the seal ensures improved
corrosion protection for the liner. 8 Lip seal material
3 Wire winder Basic SUPREME seals are equipped with NBR lip
Protect your seal from damage caused by (fishing) seals. Depending on the operating conditions
lines. A wire winder can be mounted on the (speed; draught), FKM lip seals may have to be
propeller hub. used instead of NBR lip seals.
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APPENDIX A SERVICE & SPARE PARTS
Lagersmit offers an appropriate spare parts service. Lagersmit recommends that a spare parts order be
placed several weeks before the dry dock (if possible). This way, the company can guarantee that spare parts
will be delivered on schedule. If necessary, the Lagersmit Service Engineers are available to deliver service
where needed worldwide.
To ensure that the correct parts are supplied, the following information must be provided on the order:
 The information on the data sheet of this manual
 Description of the required parts
 Part number and/or code number of the required parts
 Quantity, desired delivery time and delivery details for the parts required
In addition to the required information for ordering spare parts, the following information should be provided
when ordering a service engineer:
 Place of docking;
 Desired starting date.
Orders for spare parts and/or a service engineer should be addressed to:
Lagersmit
P.O. Box 176
2950 AD Alblasserdam
The Netherlands
Telephone : +31 (0)88 0216 200

Service telephone : +31 (0)88 0216 300 (available 24/7)
Fax : +31 (0)88 0216 249
E-mail : [email protected]
Website : www.lagersmit.com
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APPENDIX B WEAR-DOWN LOG SHEET
Single Twin screw Single Twin screw

Date screw Date screw
1 PS SB 1 PS SB
Propeller blade #1 at TOP
513221 SRP LSB2 Installation & Maintenance Manual
Manufacturing of bearings, stern tube bearings and stern

tube seals, propeller shaft lines, rudder system lines,
hydraulic couplings and industrial bearings, manufacturing
and repair of white metal bearings. Production of welded
steel elements for marine and land based industry.
Document standard: DTMN.LSB2.01 A

Reference: ---
File name: ---
Distribution to: ---
Distribution date: 04-09-2017
LSB2
SRP Installation & maintenance manual
COMERCIAL IN CONFIDENCE
Written: Reviewed: Authorized:
David Vidal Laura Lois Jose Antonio Vázquez
Date: 17-07-2017 Date: 04-09-2017 Date: 04-09-2017
V1.00
Copyright © 2017 Wärtsilä Ibérica, S.A.
This document and the information contained herein is the Intellectual property of Wärtsilä Ibérica, S.A. and must not be
copied or disclosed in whole or in part to any unauthorized person without Wärtsilä Ibérica, S.A. prior written consent.
LSB2
MODIFICATION RECORD:
Revision Description of Change Date
A Document creation. 2017-07-17
B ---
C ---
D ---
E ---
F ---
V1.00 Page 2 of 41
Chapter 10 Page 40
LSB2
INDEX
1 DESCRIPTIONS. .......................................................................................................................... 4
1.1 Subject................................................................................................................................... 4
1.2 Application. ............................................................................................................................ 4
2 INSTALLATION PROCEDURE .................................................................................................... 5
3 MAINTENANCE SCHEDULE. .................................................................................................... 20
3.1 SRP Seal system recommended schedule: ........................................................................ 20
ANNEX
I. SRP Seal - Installation schema ................................................................................................... 22

II. PTFE oil scraper installation. ...................................................................................................... 24
III. Approved grease type ................................................................................................................. 26
IV. Sealing joints information. ........................................................................................................... 29
V. Joining instructions for sealing joints........................................................................................... 32
NOTES
V1.00 Page 3 of 41
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1 DESCRIPTIONS.
1.1 Subject.
The reason of this document is provide the detailed technical instructions to install the sealing SRP
(Safe Return to Port) of Wärtsilä Linesafe Shaft Bearings.
The SRTP seal include a radial lip seals that close against the shaft and permit that the bearing can
work in flooded conditions.
To ensure the best performance, Wärtsilä recommends the study of this guide before the installation
of the SRP seal.
1.2 Application.
These instruction/ indications are only for the Wärtsilä Linesafe Shaft Bearings.
V1.00 Page 4 of 41
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2 INSTALLATION PROCEDURE
SRP Seal assembly – Installation procedure
Detail view of the seal assembly.
Exploded view.
Important note:
As a recommendation and in order to

prevent oil leakages, seal both bodies of
seal housing with CURIL‐T or similar
universal jointing compound, during the
assembly process.
General view of the seal assembly.
With all components.
WATER OIL
PRESSURE PRESSURE
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General view of the seal housing.
For mounting the seal housing in the

position, check the two PTFE oil scrapers
are located in its grooves before the
installation in the bearing housing.
Note that the PTFE oil scrapers cannot

be assembled with the seal housing
installed.
With PTFE
Detail of the PTFE oil scraper positioned

in the grooves.
The assembly process of the PTFE oil

scraper is indicated in the Annex III.
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General view of the seal housing.
With internal spacer
Install the spacer in its position.
Screw the spacer against the seal

housing.
For mounting the seal housing in the

position, check that the internal spacer
is posited in its place.
Detail view of the seal housing.
With internal spacer.
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General view of the OPSQ‐F.
Detail of the unit, before installation of

the seal housing.
Apply CURIL T Standard or similar

jointing compound on bearing housing,
in the surface where the seal housing
will be mounted.
Detail view of the OPSQ‐F.
With the lower seal housing.
Install the lower seal housing in its

position.
Screw the seal housing against bearing
housing without ever fully adjusted.
Do this process in both sides.
Apply CURIL T Standard or similar

jointing compound on the split line of
seal housing.
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With the seal housing.
Mount the upper seal housing.
Install the screws between both parts of

seal housing.
Important note:
Make sure to be precisely centred the
seal housing over the shaft.
For this, it is recommended check the
clearance with gauges along the shaft
perimeter.
Tighten all the screws against bearing

housing (corresponding to the lower and
upper seal housings) an apply Curil‐T or
similar compound in the threads of the
bolts that join them together, in order to
prevent leakages.
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With internal sealing joint.
Vulcanize the internal sealing joint type

D6, following the manufacturer
indications.
Important note:
Check the orientation of the joint (see

ANNEX I).
With internal sealing joint.
Locate the sealing joint type D6 in its

position.
Use grease for an easy manipulation.
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With the lower part of the lantern ring.
Use grease for an easier manipulation.
With the lower part of the lantern ring.
Locate the lower part of the lantern ring

in the seal housing.
Use grease for an easier manipulation
Important note:

ANNEX I).
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With the upper part of the lantern ring.
Use grease for an easier manipulation.
With the lantern ring.
Locate the upper part of the lantern ring

in the seal housing.
Use grease for an easier manipulation
Important note:

ANNEX I).
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With the lantern ring.
Locate the lantern ring its position.
The final position of the lantern ring is

determined when it is in contact with
the internal sealing joint type D6.
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With external sealing joint.
Vulcanize the external sealing joint

type D6, following the manufacturer
indications.
Important note:

ANNEX I).
With external sealing joint.
Locate the external sealing joint type

D6 in its position.
Use grease for an easy manipulation.
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With retaining plate and external

spacer.
Independently, mount and screw the

spacer against retaining plate.
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With retaining plate and external spacer.
Before installation, clean carefully these

components.
Locate the upper and lower assembly of

retaining plate and external spacer.
With retaining plate and external spacer.
Tighten the both halves of retaining

plate against the sealing housing.
Check that the screws are tight.
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Detail view of the inspection plate.
With the inspection plate installed.
Note: Before inspection plate

installation, apply CURIL T Standard or
similar jointing compound on the
surface of the housing where to be
placed.
Exploded view ‐ Inspection plate.

1.
1. Oil inlet plug.
2.
2. Screw DIN912.
3.
3. Washer DIN125.
4. Stainless steel frame.
5. Inspection plate.
4.
5.
V1.00 Page 17 of 41
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Detail view of the aeration male stud

coupling.
With the aeration male stud coupling

and the bonded seal.
The male stud coupling is provided to

permit the installation of the aeration
system, composed of a stainless steel
pipe whose end must reach the height
of 1 meter above the water level in
flooded conditions.
Detail view of the aeration coupling.
With local thermometer and the bonded

seal.
Detail view of the Dipstick and adapter.
Note: Before Dipstick adapter

installation, apply CURIL T Standard or
similar jointing compound on the
surface of the housing where to be
placed.
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Detail view of the aeration coupling.
With the PT‐100, male stud coupling and

the bonded seal.
General view of the OPSQ‐F.
With the seal assemblies.
Universal jointing compound – Where to apply.
Picture of CURIL T
With the universal jointing compound CURIL T.
Apply CURIL T standard or similar universal jointing

compound in the following components, during the assembly
process:
‐ Between the two bodies of the bearing housing.

‐ Between the two bodies of the seal housing.
‐ Between the bearing housing and the inspection plate.
‐ Between the bearing housing and the seal housing, and on
the threads of the bolts that join them together.
‐ On the thread of the dipstick adapter.
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3 MAINTENANCE SCHEDULE.
3.1 SRP Seal system recommended schedule:
Seal inspections schedule.
Check for not oil leakages.

Daily
Check that NO noise.
Supply 1.5 cm3 of grease **.

Check for not oil leakages.
Check that NO noise.
Weekly
** The quantity of grease is as reference and it
must be checked and corrected with the
experience if is necessary, in order to keep a good
performance of the unit.
Manual grease lubrication of the sealing joints – Installation procedure.

With grease nipples.
For supplying grease to the sealing

joints, use the grease nipples located
in three points of the seal housing.
ATTENTION:
Grease for seal lubrication has to be compatible with the oil of the bearing.
Also the grease has to be compatible with the material of the joints (NBR).
Use the recommended grease CASTROL SHEEROL SX 2 or similar (see ANNEX III).
V1.00 Page 20 of 41
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OPTIONAL INSTALLATION
Automatic grease lubrication of seal joints‐ Installation procedure
As option, an automatic grease lubrication system can be installed for supplying continuous lubrication to
the sealing joints. This system will be installed in the place of the grease nipples.
Change of the seal joints position‐ Installation procedure.
Detail view of the Seal.
By varying the position of the

spacers, the sealing elements
can be accurately
repositioned to run on the
shaft, when it is necessary.
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ANNEX
I. SRP Seal - Installation schema
V1.00 Page 22 of 41
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Seal – Installation schema.
V1.00 Page 23 of 41
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ANNEX
II. PTFE oil scraper installation.
V1.00 Page 24 of 41
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PTFE oil scraper – Installation procedure.
Step 1.
Clean carefully the groove of

the PTFE oil scraper.
The PTFE oil scraper will be

positioned, manually, into its
groove. Note that the PTFE
oil scraper has to protrude
around 5 ÷ 10 mm over the
seal housing.
Note:
Only if it is necessary, a
nylon hammer can be of
helpful to locate the PTFE
joints in their grooves.
Step 2.
In order to get the best

adjustment possible, glide a
small cylinder of soft material
(plastic or wood) over the
PTFE oil scraper doing a
light pressure over it.
Step 3.
Finally, cut the excess of the

PTFE oil scraper, using for
this a cutter or similar.
V1.00 Page 25 of 41
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ANNEX
III. Approved grease type
V1.00 Page 26 of 41
Chapter 10 Page 64
PRODUCT &
TECHNICAL DATA
CASTROL SPHEEROL SX 2
Calcium complex grease
DESCRIPTION
Spheerol SX2 is a complex calcium sulphonate grease providing superior performance benefits in the highly aggressive conditions
experienced in the marine environment.
APPLICATIONS
Spheerol SX 2 is a true multipurpose ships machinery lubricant In addition to the excellent protection provided for wire ropes and
specifically developed to provide enhanced lubrication and open gears, Spheerol SX 2 is also suitable for use on a wide range
protection for bearings, wire ropes and open gears found usually of deck equipment where it will protect and lubricate hinges,
in marine environments. turnbuckles, screws, fair leads etc.
Spheerol SX 2 is suitable for most journal bearings, wire ropes and For multipurpose applications, a grease gun may be used with
open gears used in marine deck equipment and can be considered Spheerol SX 2. Alternatively, traditional application methods can
for roller, ball and needle bearings, generally used in engine room be used for wire ropes and open gears. (Please see also
equipment. “Additional Information”).
FEATURES/BENEFITS
Spheerol SX2 is proven to offer: Extensive evaluation in adverse climatic conditions has confirmed
• High drop point. the outstanding qualities of Spheerol SX 2 as a true multipurpose
• Excellent protection against corrosion. ships machinery lubricant. Service intervals between re-lubrication
• High resistance to sea water wash off. are extended, reducing the time spent on preventative maintenance.
• Strong adhesion to surfaces.
• A lubricant which is solvent free containing no heavy metals or
harmful constituents.
CARE AND HANDLING

Avoid prolonged or repeated contact with skin. Wash thoroughly Care should be taken to ensure that only a thin film of grease is
after handling. applied to the external surfaces of the wire ropes as excessive
greasing could potentially lead to contamination of surrounding areas.
PACKAGING AND STORAGE

All packages should be stored under cover. Where outside storage Products should not be stored above 60°C, exposed to hot sun or
is unavoidable drums should be laid horizontally to avoid the freezing conditions.
possible ingress of water and the obliteration of drum markings.
Page 1 of 2
Chapter 10 Page 65
PRODUCT &
TECHNICAL DATA
ADDITIONAL INFORMATION
Whilst traditional ways of applying grease on wire ropes can be utilised, use of a proprietary pressurised grease applicator in accordance
with manufacturer's instructions may assist in applying the appropriate quantity of grease and may also help to protect the core of the
wire rope.
TECHNICAL DATA
TYPICAL CHARACTERISTICS UNIT TEST METHOD VALUE
Spheerol SX 2
NLGI Classification - ASTM D217 2
Base Complex Calcium Sulphonate
Penetration, Worked (0.1mm) ISO 2137 265-295
Oil viscosity @ 40°C cSt ISO 3104 / ASTM D445 180
Drop point °C ASTM D566 >280
Flash point °C ISO 2176 >250
Operating temp, min/max °C -20 /150
Colour Pale Brown
Four ball EP Weld Point kg 400
The above figures are typical of those obtained with normal production tolerance and do not constitute a specification.
GENERAL ADVICE
Further information on all Castrol Marine lubricants is available from any Castrol Marine office or from:
Castrol Marine www.castrolmarine.com
Technology Centre
Whitchurch Hill
Pangbourne
Reading RG8 7QR
United Kingdom
This data sheet and the information it contains is believed to be accurate as of the date of printing. However, no warranty or representation, express or implied, is made as to
its accuracy or completeness. Data provided is based on standard tests under laboratory conditions and is given as a guide only. Users are advised to ensure that they refer to
the latest version of this data sheet.
It is the responsibility of the user to evaluate and use products safely, to assess suitability for the intended application and to comply with all applicable laws and regulations.
Material Safety Data Sheets are available for all our products and should be consulted for appropriate information regarding storage, safe handling, and disposal of the product.
No responsibility is taken by either BP plc or its subsidiaries for any damage or injury resulting from abnormal use of the material, from any failure to adhere to recommendations,
or from hazards inherent in the nature of the material.
All products, services and information supplied are provided under our standard conditions of sale. You should consult our local representative if you require any further information.
Castrol and the Castrol logo are the trade marks of Castrol Limited, used under licence.
© 2009 BP Marine Limited. All rights reserved.
17th Sept 2009 Produced by BP Marine Limited.

Version 3.0 Registered office: Chertsey Road, Sunbury-on-Thames,
Spheerol SX 2 Middlesex. TW16 7BP United Kingdom.
Page 2 of 2 Registered in England & Wales, no 01214291.
Chapter 10 Page 66
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ANNEX
IV. Sealing joints information.
V1.00 Page 29 of 41
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Walkersele® Ultraglide.
 Description:
Ultraglide is a reformulated hydrogenated nitrile (HNBR) material with optimised
properties that greatly extend the working life of Walkersele® radial lip seals when
running for long periods under hot and abrasive conditions.
Walkersele® Ultraglide is the result of a five-year research programme by James Walker
Technology Centre. In field trials on the intermediate stand of a hot rolling mill,
Walkersele Ultraglide® has given six times the maintenance-free life of a traditional
nitrile (NBR) seal.
This operational success is backed by comparative test results that show our Ultraglide
grade reformulated-HNBR matches the strength of fluoroelastomer FKM and nitrile NBR,
and provides far lower friction plus vastly superior thermal conductivity and abrasion
resistance.
 Special features:
 Far greater abrasion resistance for highly extended sealing life.
 Low coefficient of friction for improved running at higher surface speeds.
 Better heat dissipation to keep the lip cooler for high efficiency sealing.
 Construction: flexible back of HNBR-proofed synthetic fibres, lip of Ultraglide reformulated-
HNBR.
 Typical applications:
V1.00 Page 30 of 41
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Radial lip seal for transmission systems, gearboxes and rotary plant in metallurgical
industries, power generating industry, cement works, mining and quarrying, rail traction
systems, etc. Walkersele® Ultraglide is suitable for use with ceramic shafts.
Media compatibility:
Excellent resistance to all lubricating oils, fuels, air, hot and cold water, dilute acids and
alkalis.
 Seal construction:
Flexible back of HNBR-proofed aramid/glass fibre, with lip of Ultraglide reformulated-
HNBR.
 Maximum under-lip temperature:

150°C constant: but note that under-lip temperature can often be substantially higher (eg,
by 30°C) than fluid media temperature.
 Maximum surface speed:

30m/s in abrasive environments with Walkersele® D6 design.
 How supplied:
Walkersele® Ultraglide is manufactured to order in Walkersele® D6 and D7 designs.
Both designs are supplied in endless form, and are also available as Walkersele® OSJ-2
for On-Site Joining using our patented technique.
V1.00 Page 31 of 41
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ANNEX
V. Joining instructions for sealing

joints.
V1.00 Page 32 of 41
Chapter 10 Page 70
Chapter 10 Page 71
Chapter 10 Page 72
Chapter 10 Page 73
Chapter 10 Page 74
Chapter 10 Page 75
Chapter 10 Page 76
Chapter 10 Page 77
Chapter 10 Page 78
LSB2
NOTES
V1.00 Page 41 of 41
Chapter 10 Page 79
513221 LSB2 Värtsilä Intermediate bearings Customer Manual
Manufacturing of bearings, stern tube bearings and stern

tube seals, propeller shaft lines, rudder system lines,
hydraulic couplings and industrial bearings, manufacturing
and repair of white metal bearings. Production of welded
steel elements for marine and land based industry.
Document standard: DTMN.LSB2.00 A

Reference: ---
File name: ---
Distribution to: ---
Distribution date: 23-05-2017
LSB2
CUSTOMER MANUAL
Written: Reviewed: Authorized:
Borja Gago Laura Lois Jose Antonio Vázquez
Date: 15-06-2017 Date: 18-06-2017 Date: 20-06-2017
V1.01
Copyright © 2017 Wärtsilä Ibérica, S.A.
This document and the information contained herein is the Intellectual property of Wärtsilä Ibérica, S.A. and must not be
copied or disclosed in whole or in part to any unauthorized person without Wärtsilä Ibérica, S.A. prior written consent.
LSB2
CUSTOMER MANUAL
MODIFICATION RECORD:
Revision Description of Change Date
A Document creation. 2017-05-01
B ---
C ---
D ---
E ---
F ---
V1.01 Page 2 of 77
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INDEX
1 DESCRIPTION. ............................................................................................................................ 5
1.1 Subject................................................................................................................................... 5
1.2 Application. ............................................................................................................................ 5
1.3 Product brief description........................................................................................................ 5
2 CONSIDERATIONS FOR USE. ................................................................................................... 7
3 SAFETY INSTRUCTIONS............................................................................................................ 8
4 TOOLS AND EQUIPMENT REQUIRED. ..................................................................................... 9
5 INSTALLATION. ......................................................................................................................... 10
5.1 Assembly preparation.......................................................................................................... 10
5.2 Assembling the unit. ............................................................................................................ 10
5.3 Dismounting procedure ....................................................................................................... 39
5.3.1 Material / tools required................................................................................................ 39
5.3.2 Dismounting the bearing support unit. ......................................................................... 39
6 EMERGENCY OPERATION ...................................................................................................... 40
6.1 Description........................................................................................................................... 40
6.2 Lubrication failure. ............................................................................................................... 40
6.2.1 Force lubrication system failure. .................................................................................. 40
6.2.2 Self-lubrication system failure. ..................................................................................... 41
6.3 White metal damage. .......................................................................................................... 42
7 MAINTENANCE.......................................................................................................................... 46
7.1 Description........................................................................................................................... 46
7.2 Temperature monitoring. ..................................................................................................... 46
7.3 Maintenance schedule. ....................................................................................................... 47
7.3.1 General inspections ..................................................................................................... 47
7.3.2 Oil inspections.............................................................................................................. 47
7.3.2.1 Time for oil replacement: ......................................................................................... 47
7.3.2.2 Oil inspections schedule: ......................................................................................... 47
7.3.3 Bearing inspections...................................................................................................... 48
7.4 Spare parts .......................................................................................................................... 48
8 HANDLING, STORAGE AND PRESERVATION. ...................................................................... 49
8.1 Description........................................................................................................................... 49
8.2 Recommendations. ............................................................................................................. 49
8.2.1 Handling ....................................................................................................................... 49
8.2.2 Storage......................................................................................................................... 49
9 ADDRESSES, CONTACTING.................................................................................................... 50
9.1 Manufacturer address ......................................................................................................... 50
9.2 Identification details............................................................................................................. 50
V1.01 Page 3 of 77
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ANNEX
I. Approved oil types....................................................................................................................... 51
II. Base bolts torque. ....................................................................................................................... 59
III. Bearing dimensions..................................................................................................................... 61
IV. Shaft installation. ......................................................................................................................... 63
V. Installation schemas.................................................................................................................... 66
VI. PTFE oil scrapper installation. .................................................................................................... 69
TROUBLESHOOTING
NOTES
DRAWINGS
V1.01 Page 4 of 77
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1 DESCRIPTION.
1.1 Subject.
The reason of this manual is to provide detailed technical instructions for installation, setup,
dismounting, care, and maintenance for LSB2 line shaft bearings.
To ensure the best performance and reliability, it is necessary to recommend the study of this manual
before the installation and follow the instructions provided carefully.
1.2 Application.
This instruction manual will be applicable only for Wärtsilä Line shaft bearings LSB2 type, with
standard self-lubrication by means of oil ring method.
1.3 Product brief description.

The LSB2 line shaft bearings are composed of several parts mounted in a housing manufactured in
two bodies. The most important parts are described in the next paragraphs:
A. Bearing housing – It is a cast structure divided in two halves, named upper and lower.
The lower halve is the part of the cast structure that rigidly fix the housing to the
foundation, and provide the spherical seat for the bearing. The lower halve is also
provided with the necessary locations for PT-100 and cooling water doorways. It also
includes an oil sump, which provides the necessary oil to the bearing for operation.
The upper halve close the unit, support the bearing shell and allows the bearing self-
aligning at same time due to the internal spherical geometry. This halve is also
provided with the lifting eye bolts, the inspection cover plate to check the correct oil
lubrication and the rest of the standard locations for thermometer and oil level gauge.
The bearing housing is ready to connect a forced lubrication unit, if necessary.
B. The bearing shell – It is a ring manufactured in two halves with one inner layer of soft
tin base white metal, machined with the proper geometry and clearances to create the
oil sliding surfaces.
The ring outer surface is spherical and matches the housing. This geometrical
configuration allows the free self-aligning during the bearing installation as well as the
bearing self-aligning according to the shaft movement during the shaft line operation.
This special geometric configuration makes possible a uniform load repartition over
the bearing inner surface.
The bearing free movement is limited by the anti-rotation pin that is installed in the
upper bearing shell.
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C. Lubrication system - Composed by an oil ring and an oil scrapper.
This is the standard lubrication method, and consists in one ring that picks up the oil
stored at the lower bearing housing and lift it over the outer surface up to the oil
scraper located at the bearing top.
The oil scraper picks the oil from the ring outer surface and distributes it into the
bearing.
The amount of oil delivered to the bearing by this system is enough to create a good
oil film and maintain the unit in operation within a wide speed range.
D. Shaft pass cover – It is installed on both sides of the bearing shell.
The unit is equipped with two shaft pass cover, with integrated PTFE seals and with
an internal chamber where deflection rings are positioned.
E. Cooler – Using fresh water or sea water as refrigerant.
It contributes to cool down the oil stored in the bearing and avoid excessive warm-up
of the unit.
The cooler is jacket type: The water flows through the lower bearing housing. The
cooler connections are located at port and starboard sides of bearing housing.
Standard flanges are used as jacket type cooler connections.
V1.01 Page 6 of 77
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2 CONSIDERATIONS FOR USE.

The instructions given in this manual are addressed to qualified technical personnel (Fitters, mechanic
installers, mechanical engineers). Also, whilst it is our policy to allow the Installation and Maintenance
of this equipment to be carried out by 3rd parties (in accordance with the guidance contained within
this Technical Manual), we would always recommend that one of our Service Engineers is present to
oversee any Installation or Maintenance.
Read these instructions carefully before starting the bearing installation.
When using this manual, refer to the general arrangement drawing(s) referenced in last section, which
give the dimensions and data for the correct assembly and operation of the equipment.
There is no automatic provision to up-date this manual. However, the supply of a complete new
assembly will be accompanied by the latest revision/issue Manual and Drawing(s).
Following indications should be observed when reading these instructions:
Danger!
Warning of dangers for personnel.
Example: Warning of injury
Attention!
Warning of damage for the bearing installation
Useful recommendations and additional information are framed.
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3 SAFETY INSTRUCTIONS.
Danger!
The installation, maintenance and inspection of the line shaft bearings should be
carried out by:
• Persons nominated by the safety representative.
• Persons correspondingly trained and instructed.
• Persons with knowledge on appropriate standards, regulations and accident
prevention rules
• Persons with knowledge on first-aid measures and local rescue centers.
Warning of injury!
Before install/uninstall the line shaft bearing:
• Switch off the installation.
• Make sure the installation is not in operation.
Warning of injury!
When handling the line shaft bearing:
• Make sure the lifting equipment can support the bearing weight.
• Lift and move the bearing using the proper lifting points.
Warning of injury!
As a recommendation, keep the areas in front of and behind the bearing clear of
personnel.
Attention!
In case:
• The admissible temperature exceeds 12ºC.
• Inadmissible vibrations occur.
• Unusual noises or odours are noticed.
• Monitoring equipment triggers alarm.
Shut down the installation and inform the maintenance personnel in charge.
Attention!
In order to ensure the correct performance the following indications are to be followed:
• Avoid the heavy water presence or excessive humidity and corrosive atmospheres.
• Keep the bearing away from the action of chemical products.
• Keep the bearing away from direct action of fire.
• Avoid the excessive heating.
• Do not use the bearing as base or work table for hammering or welding.
• Do not make drills or modifications in the unit without the manufacturer / society agreement.
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4 TOOLS AND EQUIPMENT REQUIRED.

For the manipulation and installation/uninstallation of the line shaft bearing, the following tools and
equipment are necessary
• Allen key set.

• Wrenching key set.
• Open-jawed spanner set.
• Dynamometric key to ensure the correct torque application.
• Bolts, nuts, level screws and pins to fix the bearing shell to the foundation.
• Nylon hammer.
• Small cylinder of soft material.
• Cutter or similar.
• Feeler gauges (up 0,05 mm).
• Dial indicator.
• Caliber gauge.
• Emery paper, plain scraper.
• Oil stone.
• Lifting equipment.
• Clean rags (close weave) and cleaning paper.
• Oil with a viscosity degree according to the general arrangement drawing.
• Detergents.
• Sealing compound (CURIL-T recommended).
• Locking compound (Loctite 401 or similar quality product suitable for nitrile rubber bonding).
• MoS2 or grease (Molikote P-37 recommended).
• Teflon tape.
• An empty jerry can or other kind of recipient.
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5 INSTALLATION.
5.1 Assembly preparation.

Unpack the bearing support, disassemble all the elements, and carefully wipe away all the
transportation grease. Also the upper / lower housing internal surfaces must be carefully inspected in
order to ensure the cleaning of packing wastes.
ATTENTION:
Be sure to remove the joints from the shaft pass cover

before lifting the upper part of the housing, otherwise they
may break.
5.2 Assembling the unit.
Bearing position.
Detail view of the LSB2.
Locate the unit following the

recommended orientation indicated in
the General Arrangement Drawing.
Note:
As recommendation, install the unit
following the position indicated in the
bearing housing.
ATTENTION:
In sloped shafts, the units must be installed always with the oil ring facing the
slope (usually to FWD side).
Bearings are designed for a standard max shaft inclination of 4°.
For installation procedure, the flooring, framework or structure to which the bearing is to be secured,
must be prepared in advance. It must be:
• Positioned so that, when secured to it, the bearing is able to be correctly aligned to the
installed shaft.
• Machined, ready to accept the main securing screws, jacking screws and knock pins that fit
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Lower bearing housing – Installation procedure.
General view of the LSB2.
Over the foundation.
Locate the lower bearing housing

over the foundation and make a
preliminary alignment referenced to
the shaft line.
Check that all the surfaces are

cleaned, specially the spherical
faces and the bearing oil sump.
With the fixing bolts and levelling

bolts.
Following the preliminary alignment

of the lower bearing housing, use the
alignment bolts to level the unit.
(Depending on the size the
necessary level screws are 2 or 4.)
The main objective of this

preliminary installation must be to
ensure that the foundation position is
correct and final installation will be
possible.
For levelling the unit, use level

screws DIN561 or DIN933.
Installation note (as optional):
After the unit is aligned, and if required, dowel or tapered pins can be installed in order to guarantee the
position of the unit. It depends on the shipyard procedure.
Once the lower bearing housing preliminary installation is done and its alignment over the foundation is
correct, fix the lower bearing to the foundation using the bolts.
Follow the torques indicated in the Annex II.
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Bearing shell (360º) – Installation procedure.
With the lower bearing shell.
Clean carefully all the spherical faces

of the bearing housing and bearing
shell.
For lifting the lower bearing shell,

use eye bolts threaded to bearing
shell.
Check the assembly position.

Note that the bearing has only one
assembly position. It is determined
by the anti-rotation pin location on
the upper housing and the upper
bearing shell. Also you can find the
correct mounting position in a mark
located on the upper bearing (FWD
side)
Carefully get down the bearing shell.
When the spherical faces are in

contact, remove the eye bolts.
It is important that the split faces of

the bearing shell are aligned with the
bearing housing.
Now, the unit is prepared to install the shaft on the bearing.

Before the shaft installation, check that the bearing shell is completely cleaned and it is lubricated with
a film of oil (see approved oils in the Annex I).
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With the shaft.
Get down the shaft softly over the

bearing, in order to prevent damages
in the white metal of the bearing
shell.
Finally place the shaft on the

bearing.
With the shaft.
Clean carefully and lubricate with oil

the zone of the shaft where the
upper bearing will be located, in
order to prevent damages in the
white metal of the bearing shell.
ATTENTION:
See Annex IV to check the unit alignment, in order to ensure that the unit is
correctly aligned by checking the clearances between bearing housing and shaft.
The clearances must be as per in the specifications.
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With the lower bearing shell and the

dowel pins.
Before assembling the upper

bearing shell, the dowel pins should
be placed in their position. These will
be situated diagonally.
Detail view of the upper bearing.
For lifting the upper bearing shell,

use a male eye bolt.
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With the upper bearing shell.
Remember that the bearing shell has

only one assembly position. It is
defined by the dowel pins located in
the split faces of the bodies.
So before getting down the upper

bearing shell, make sure the drills
are correctly aligned with the pins.
Carefully get down the upper bearing

shell over the shaft.
Check that the inner surface is

completely cleaned, and lubricated
with oil.
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Remove the male eye bolts.
Check that the holes of the split

faces are well aligned, in order to
make the assembly easier.
Now the two bodies of the bearing

shell have to be fixed.
For this fasten the bolts against the

lower bearing.
ATTENTION:
See Annex IV to check the unit alignment, in order to ensure that the unit is
correctly aligned by checking the clearances between bearing housing and shaft.
The clearances must be as per in the specifications.
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Oil ring – Installation procedure
With the oil ring.
Locate the oil ring in its place.
The oil ring has two windows to

permit an easier tightening of the
bolts.
Note that the oil ring can rotate

around the shaft in order to get the
best comfortable position to locate
the bolts.
With the oil ring.
Locate the bolts and nuts in their

positions.
Fasten the bolts, but not completely,

in order to get a small clearance
between the oil ring and the shaft.
This will permit a later adjustment of
the oil ring into the oil scrapper.
With the oil ring.
Guide the oil ring to its position.
Keep the distance between the

bearing shell and the oil ring (Dist. 1)
according to the General
Arrangement drawing.
Once the oil ring is in position, start

with the alignment of it.
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ALIGNMENT OF THE OIL RING:
Make a previous alignment of the oil ring. For such task, use a square between the shaft and the oil
ring. The axial oscillation alignment tolerance will be of 0.5 mm as maximum.
Once the oil ring is aligned, tighten the bolts of the split faces.
Important notes:
The aligning of the oil ring must be checked with the shaft in rotation. This is rotating the shaft very
slowly and using a dial indicator comparator.
Check again that the alignment tolerance is 0.5 mm as maximum.
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Upper bearing housing – Installation procedure.
Using the eye bolts, lift the upper

bearing housing.
Detail view of the upper bearing

housing.
With the antirotation pin
Before the installation of the upper

bearing housing in the unit, check
that the anti-rotation pin is in its
position.
As recommendation and in order to

prevent oil leakages between the
mating surfaces, seal both bodies
with CURIL-T or similar universal
jointing compound.
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With the upper bearing housing.
Using the eye bolts, get down the

upper bearing housing carefully.
Note that the upper bearing housing

has to be positioned easily over the
lower bearing housing.
Important note:
Note that the bearing housing has
only one assembly position. This
position is indicated in the bearing
housing.
Check this matter before starting the

assembly process.
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Install the dowel pins in position.

They are located diagonally opposite
in the lugs of the bearing housing.
Fitting the bolts and washers.
Tighten the bolts of the bearing

housing using the recommended
torque shown on the part list.
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Oil scrapper – Installation procedure.
With the oil scrapper.
Note that the clearance between the

outer oil ring diameter and the oil
scrapper must be below 0.3 mm, in
order to maximize the unit oil
feeding.
For checking the clearance, use a

set of gauges between the oil ring
and oil scrapper.
The recommended clearance of 0.3 mm could be increased at the installation in case that the oil ring
makes contact with the scrapper.
If the clearance increases up to 0.5 mm, it is mandatory to confirm during a trial test that the oil flow is
still acceptable at low rotation speed in warm conditions.
ATTENTION:
See the Annex V to check the oil scrapper installation.
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Exploded view - Oil scrapper.
1. 1. Screw DIN6921.
2. Washer NORD-LOCK.
3. Oil scrapper.
2. 4. Set of levelling plates.
3. The set of levelling plates is

composed of three washers with a
0.5, 0.3 and 0.2 mm thickness.
4.
With the oil scrapper.
After the installation, check the

lateral clearance between the oil ring
and the oil scrapper. This distance
must be 3 mm approx.
In order to prevent any contact

between the oil ring and the oil
scrapper, rotate the shaft (if
possible) to check that the lateral
clearance is correct.
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PTFE oil scrapper – Installation procedure.
General view of the shaft pass

cover.
For mounting the shaft pass cover in

its position, check that the two PTFE
oil scrappers are positioned in its
grooves before the installation in the
bearing shell.
This is important because the PTFE

oil scrappers cannot be assembled
with the shaft pass cover installed.
Detail view of the shaft pass

cover.
Detail of the PTFE oil scrapper

positioned in the grooves.
The assembly process of the PTFE

oil scrapper is indicated in the
Annex VI.
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Lower shaft pass cover – Installation procedure.
With the shaft pass cover plain joint.
Install the plain joint keeping the cut

at the top.
With the shaft pass cover plain joint.
Check the correct match between

the holes in the plain joint and the
drills in the bearing housing.
With the lower seal housing.
Install the lower shaft pass cover in

its position.
Screw the seal housing against
bearing housing without ever fully
adjusts.
Do this process in both sides.
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Deflection ring – Installation procedure.
With the deflection ring.
Install the deflection ring around the

shaft, passing it on the inside of the
shaft pass cover.
Glue both ending faces of the

deflection ring with Loctite 401 or
another product with similar quality,
suitable for nitrile rubber bonding.
After the deflection ring is glued,

install the spring around the
deflection ring, in order to prevent
axial movements of it when the shaft
is in movement.
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With the shaft pass cover.
Mount the upper shaft pass cover.
Install the screws between both parts

of shaft pass cover.
Make sure to be precisely centred

the shaft pass cover over the shaft.
For this, it is recommended check
the clearance with gauges along the
shaft perimeter.
Tighten the screws against bearing

housing.
Important note:
As the shaft pass cover are not
completely screwed against the
bearing housing, tighten all the bolts
(corresponding to the lower and
upper shaft pass covers), in order to
prevent leakages.
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Cooler - Installation procedure.
A jacket type cooling system is used to reduce oil temperature.

All the coolers are suitable for fresh and sea water.
Notes:
The standard connection of the cooler is a flange for a pipe whose nominal diameter is according to
flanges range 10A-50A.
For other special connection, the mounting and dismounting details have to be agreed with customer.
Cooler installation procedure.
With the cooler connections and

cover.
The cooling water is introduced in

the journal bearing by means of a
pipe connected by a flange in one
side and it comes out on the other
side, where another pipe is
connected.
Note: Flanged pipes will be supplied
by shipyard.
A cover is mounted at the bottom of

the lower bearing housing for the
cooling system maintenance
operations.
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With the cooler cover.
Tighten the cooler cover against the

lower bearing housing using the
bolts and the washers.
Check that all bolts are completely

screwed in order to prevent
leakages.
Exploded view of the cooler cover

1.
With the cooler cover.
1. Plain joint.
2. Cooler cover.
3. Screws and washers.
3.
2.
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With the cooler in/out flange.
Tighten the cooler blind flange

against the lower bearing shell, using
bolts and washers.
Check all bolts are completely

screwed, in order to prevent
leakages.
Note: Flanged pipes will be supplied
by shipyard.
Exploded view – blind flange

installation.
4. Plain joint.
5. Cooler cover.
6. Screws and washers.
1. 2.
3.
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Dipstick - Installation procedure.
As standard, the dipstick is located in the upper bearing housing at the right side of the unit, as the next
schema shows.
It is used for measuring the oil level in the carter of the bearing.
Dipstick installation procedure from LSB2-165 to LSB2-590.
With the dipstick.
Note:
The dipstick and the thermometer
can be changed from port side to
starboard side, depending on the
shipyard requirements.
Dipstick installation procedure from LSB2-630 to LSB2-800.
With the dipstick.
The dipstick is lodged in a pipe, and

the pipe is connected to the carter of
the bearing through a coupling.
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Measure process:
• Take off the dipstick and clean it.
• Introduce the dipstick in its position.
• Take off again the dipstick and check that the oil level is between the marks.
Note: The measure process must be checked once the shaft has stopped. For this condition, the oil
level must be in the MAXIMUM mark.
Detail view – Dipstick oil levels.
The dipstick has two marks in the

wire.
The upper mark corresponds with

the MAXIMUM oil level and the lower
mark with the MINIMUM oil level.
IMPORTANT NOTE:
With the bearing in operation, the oil
level must be between the two
marks.
Attention!
Before turning the shaft, remove the inlet plug located on the inspection plate, and
feed a small quantity of lubrication oil to the top of the upper bearing.
The oil viscosity grade must be in accordance with the indicated in the General
Arrangement drawing.
Due the importance of a good lubrication, it is strongly recommended the use of
one of the oils from the approved oil types (Annex I)
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Thermometer - Installation procedure.
The thermometer is located on the upper bearing housing on the left side of the unit, as standard.
It is used to measure the oil temperature in the bearing oil sump.
ATTENTION:
The thermometer is screwed as follows:
Bring the thermometer closer to its position, and then give it a quarter of a round.
Thermometer procedure.
With the thermometer.
Note:
The dipstick and the local

thermometer location can be
exchanged from one side (port side)
to the other (starboard) depending
on the shipyard requirements, thanks
to the adaptor by means of which the
dipstick is installed on the bearing
housing.
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Dial thermometer installation - Optional item.
The dial thermometer gauge is screwed against the lower bearing housing in the unit oil sump.
The dial indicator is positioned in a support made of steel.
This dial type thermometer has a long wire that connects the gauge with the dial indicator.
With the dial thermometer.
Note:
The thermometer location can be
changed from one side to the other,
depending on the shipyard
requirements.
It also can be installed out of the

bearing, depending on the length of
the wire and on the shipyard
requirements.
Exploded view – Dial

thermometer.
1. 1. Dial.
2. Wire.
3. Gauge.
2.
3.
ATTENTION:
When the dial thermometer installation takes place, it is necessary to check the connections in
order to avoid oil sump leakages.
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PT-100 temperature sensor - Installation procedure.

It is used to measure the bearing temperature through remote access.
ATTENTION:
The PT-100 sensor must be mounted in its position according to the shaft rotation, (see the
indication on General Arrangement Drawing).
Only the manufacturer can approve the installation of the PT-100 sensor in other position than the
recommended.
PT-100 temperature sensor installation procedure for LSB2 bearings.
With the PT-100 temperature sensor.
Exploded view – PT-100

1. temperature sensor.
2.
1. Male stud coupling.

2. PT-100 temperature sensor.
PT-100 installation.
a. Install the male stud coupling in the side hole of the lower bearing housing.
b. Insert the PT-100 sensor till it makes contact with the side hole of the lower bearing shell.
c. Separate the gauge 2 mm approx. of the side hole of the lower bearing shell.
d. For fixing the gauge, use the nut of the male stud coupling.
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Inspection cover - Installation procedure.
Without the inspection plate.
As recommendation and in order to

prevent oil leakages, seal both
bodies with Curil-T or similar
universal jointing compound.
With the inspection plate.
Note that the inspection plate has

only one assembly position.
This position is determined by the

hole for oil inlet, which is
positioned over the bearing.
Tighten the bolts against the

bearing shell using the washers, in
order to prevent damages on the
inspection plate surface.
Now fill the bearing with oil taking into account the levels of the dipstick, checking that the drain plug is
installed in the oil sump of the bearing.
Note that the oil levels have to be checked with the bearing in operation.
The oil viscosity grade used must be in accordance with the indicated in the General Arrangement
Drawing, to ensure the best performance.
Due to the importance of a good lubrication, it is strongly recommended the use of first quality oils and
recognized manufacturers (see Annex I).
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With the inlet plug.
Now the bearing is completely installed and the installation is finished.
Verifications.
With the LSB2 in operation, check the following parameters:
• Make a visual inspection through the inspection plate, checking the correct operation of the oil ring
and oil scrapper system.
• Check that the PT-100 temperature sensor for radial bearing is continuously monitoring the
temperatures.
• Check the oil carter temperature indicated in the local thermometer.
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IWS Gauge – Installation procedure – Optional Item.
With the wear down gauge.
Wear down gauge use.
a. Remove the plug M16x1.5
b. Install the gauge in the threaded

hole.
c. Take measure.
d. Stamp the initial measure in the

housing and take note in an
appropriate book for this.
e. Remove the gauge.
f. Install the plug.
For future measurements, make this

procedure and take note of the
measurements, in order to make a
control of the wear down.
Check the General Arrangement

drawing.
Detail view of the wear down

gauge.
Wear down measurement:
Turn the micrometre until the gauge

is in contact with the shaft.
IMPORTANT NOTE:
Note that the wear down gauge will
be installed ONLY during the
inspections. Then must be remove
and a plug must be installed in the
hole.
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5.3 Dismounting procedure
5.3.1 Material / tools required.
The material required for the dismounting process is the same as indicated in chapter (4) for the unit
mounting process.
5.3.2 Dismounting the bearing support unit.
Dismounting process must be realized using a reverse process as indicated at chapter (5.2).
A. Remove the measurement control devices, to avoid damages in the next dismounting
process.
B. Unscrew both halves of the shaft pass cover.
C. Unscrew the shaft pass covers from the upper bearing housing, clean the joining faces,
and protect them conveniently.
D. Remove the shaft pass cover joints.
E. Unscrew the upper have of bearing housing, remove using the lifting points.
F. Unscrew the oil scrapper from the housing, and protect it conveniently.
G. If required, unscrew the oil ring, clean and protect it conveniently.
H. Unscrew the upper halve of the bearing shell, clean and protect with oil or grease.
I. Lift and support the shaft with jacks to liberate the lower bearing halve, remove it from the
bearing housing by making it rotate around the shaft, and then using the lifting points to
raise it. Clean and protect with oil or grease.
J. If required, unscrew the shaft pass cover from the lower bearing housing, clean the
joining faces, and protect them conveniently.
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6 EMERGENCY OPERATION
6.1 Description.
LSB2 design offer different solution for emergency operation, which could maintain the unit working
until the vessel reaches a port, where it can perceive the necessary reparations and spare parts.
In this section these situations as well as their repair procedure will be described.
Attention!
The procedures described in this section are ONLY for EMERGENCY cases.
Wärtsilä advise against its continuous use because it could damage the bearing.
6.2 Lubrication failure.

If the lubrication system fails, the LSB2 design is ready to install a temporary lubrication pump or
spare oil ring / oil scupper in order to maintain the proper oil feed.
6.2.1 Force lubrication system failure.
If for some reason the pump interrupted its operation, or if the flow it provided is not enough, it is
possible to proceed with the installation of a self-lubrication system:
A. Dismount the upper bearing housing (Section 5.3.2).
B. Install an oil ring and oil scrapper (Section 5.2).
C. Fit the upper housing (Section 5.2).
Attention!
Contact with Wärtsilä (Section 9) to know the range of rpm in which the bearing
can operate as a self-lubricated way.
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6.2.2 Self-lubrication system failure.
In case that the self lubrication system interrupts its operating, it is possible to connect a pump directly
to the bearing in order to maintain the oil flux:
Oil pump – Installation procedure.
Connect the oil exit of the pump with

the upper house bearing, through the
flanged connection located on the
top.
Check the flange dimension on the

General Arrangement drawing.
Connect the oil exit of the lower

house bearing with the oil tank
pump, through the flanged
connection located on the lower
forward side.
Check the flange dimension on the

General Arrangement drawing.
Attention!
Contact Wärtsilä (Section 9) to know the required oil flow for proper running of the
bearing.
Make sure that the pump is running before starting the shaft rotation.
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6.3 White metal damage.

For emergency condition, if the white metal is damaged, it is possible to exchange the upper and
lower haves of bearing shell, provided a fast and reliable temporary solution.
Bearing exchange procedure.
First, the upper shaft pass cover, the

bearing housing, the upper bearing
shell, the shaft and the lower bearing
shell should be disassembled
following the procedure described in
section 5.3.2.
Clean carefully all the spherical faces

of the bearing housing and bearing
shell.
For lifting the upper bearing shell, use

eye bolts threaded to bearing shell.
Check the assembly position.
Note that the bearing has only one

assembly position. It is determined
by the anti-rotation pin location on the
upper housing and the upper bearing
shell.
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With the upper bearing shell and the

dowel pins.
Before assembling the lower bearing

shell, the dowel pins should be
placed in their position. These will be
situated diagonally.
Now, the unit is prepared to install the shaft on the bearing.

Before the shaft installation, check that the bearing shell is completely cleaned and it is lubricated with
a film of oil (see approved oils in the Annex I).
With the shaft.
Get down the shaft softly over the

bearing, in order to prevent damages
in the white metal of the bearing shell.
Finally place the shaft on the bearing.
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With the shaft.
Clean carefully and lubricate with oil

the zone of the shaft where the upper
bearing will be located, in order to
prevent damages in the white metal
of the bearing shell.
Detail view of the upper bearing.
For lifting the lower bearing shell, use

a male eye bolt.
With the upper lower shell.
Remember that the bearing shell has

only one assembly position. It is
defined by the dowel pins located in
the split faces of the bodies.
So before getting down the lower

bearing shell, make sure the drills are
correctly aligned with the pins.
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Carefully get down the lower bearing

shell over the shaft.
Check that the inner surface is

completely cleaned, and lubricated
with oil.
Remove the male eye bolts.
As an emergency case, the bearing

shell can operate without its screws
of split line.
Once you arrive at this assembly point, continue assembling the rest of components according to
section 5.2.
Note that in this case the upper bearing mark "TOP FWD" must be at the bottom.
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7 MAINTENANCE
7.1 Description.
Line shaft bearings are designed on a low maintenance basis, yet regular maintenance service and
surveillance will be necessary to ensure the best performance and lifetime of the units.
7.2 Temperature monitoring.

The bearing shell temperature can be checked by remote devices. Lower halve bearing shell has the
necessary holes to install PT-100 sensors for the temperature control.
Temperature monitoring devices, which use the PT-100 data received, should be adjusted initially to
alarm and shutdown at 80ºC and 85ºC respectively. After the normal operating conditions are
stabilized, the set points can be re-adjusted if necessary.
Therefore, the alarm and shutdown temperatures will be approximately 7ºC and 12ºC respectively
above the stabilization temperature.
Bearing shell temperatures setting values

Initial condition
Stabilized condition
(Trial tests)
Alarm 80ºC Normal bearing temperature + 7ºC
Shutdown 85ºC Normal bearing temperature + 12ºC
The oil temperature (shown in the local thermometer) must not exceed 65ºC. The oil temperature can
be checked thanks to the local thermometer that is located on the top of the bearing.
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7.3 Maintenance schedule.

7.3.1 General inspections
Routine checks that should be conducted daily:

• Check the oil flow in the bearing through the inspection plate, located in the top of housing.
• Check and record the bearing temperature.
• Check operation of cooling water circuit (if it is required).
7.3.2 Oil inspections.
The presence of wearing metallic elements is considered normal when operating with white metal
bearings.
The generation of wearing particles in a normal installation is due to:

• Frequent start-stop operations.
• Operation at very low speeds when the oil is hot.
7.3.2.1 Time for oil replacement:
The general recommendation is to replace the oil every 3000 operating hours or two years maximum.
Important notes:
- When the installation is new, it is required shorter times to replace the oil until the installation
and the bearings bed-in.
- Note that this manual recommends replacing the oil every six months for average
operational conditions (see the table below).
7.3.2.2 Oil inspections schedule:
Oil inspections schedule (for average operational conditions)
Daily Levels visual inspection using dipstick.
Weekly Check for not normal colour or oil viscosity.
Half-yearly Check oil quality, and replace if necessary.
Attention!
If the oil is checked when the shaft is turning, the oil level may show slightly below
the min. Mark on the dipstick because of the lubricant being circulated through the
bearing and partly retained in the upper part of the bearing, As long as oil flow is
noted at the top of the upper bearing housing through the inspection plate, there is
no problem.
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Change of the oil – Procedure.
Detail view of the ITB.
For replacing the oil, unscrew the

drain plug.
When the bearing carter is dry,

install the drain plug again.
Check the General Arrangement

Drawing.
7.3.3 Bearing inspections.
Bearing inspections.
Check the bearing clearances in order to control the wear of the white metal.
These inspections can be done during the programmed inspections of the shaft line in the
vessel.
Check the Annex III to determine the bearing clearance (H) of the unit.
It is recommended to repair, but is not

1.5 × H < High clearance < 2 × H
mandatory.
Reparation limit ≥ 2 × H It is mandatory to repair or replace.
7.4 Spare parts

The requirements for spare parts for al line shaft bearing are extremely limited. They are basically the
wearing components (The white metal bearing shells and the rubber components).
These are:
• Upper and lower white metal bearing shells.
• PTFE scrappers.
• Nitrile rubber deflection rings.
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8 HANDLING, STORAGE AND PRESERVATION.
8.1 Description.
Due to the importance of a correct storage and manipulation of the bearing supports, we recommend
special attention to storage or manipulation conditions before the final installation, in order to avoid
corrosion problems in the materials and also damages during the transport process due to a bad
manipulation.
8.2 Recommendations.
8.2.1 Handling
 Use suitable equipment for handling.
 Care must be taken during handling to prevent any mechanical damage occurring due to
dropping, crushing, etc.
 Lift and move the unit using the proper lifting points in order to prevent damages or falls of
some components or the complete unit.
 Lift and move every component using the proper lifting points.
 Particular care and attention should be paid to the white metal surfaces of the bearing.
 All machined surfaces must be supported by wood or other soft material to avoid
damages. Special care is to be used with the split surfaces and the spherical parts.
 Do not touch the spherical parts of the bearings.
8.2.2 Storage
 Before the installation, if the bearings are to be stored for a long period of time, we
recommend keeping goods in their original packing until just prior to installation in order to
give them the best protection.
 It is also recommendable a regular inspection in order to check if exists external damages

in the box and water effects.
 For spare parts, if they are to be stored for a long period, we recommend they are suitably
protected.
 Bearings.
a. Protect from rain and falls, storing it in a wooden box.
b. Protect from corrosion, using TECTYL 502 C or similar product.
c. Do not touch the spherical parts.
 Other metallic parts.

a. Protect from rain and falls, storing it in a wooden box.
b. Protect from corrosion, using TECTYL 502 C or similar product.
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9 ADDRESSES, CONTACTING
9.1 Manufacturer address

Wärtsilä Ibérica S.A.
Seals & Bearings Product Company Spain
Polígono Industrial “As Gándaras”
Parcela 206 – Nave B3
36475 O PORRIÑO – PONTEVEDRA – SPAIN
9.2 Identification details

Telephone: +34 986 344 048
Fax: +34 986 344 716
UNIT REFERENCE
Identification plate view: In case of contact, indicate the Line shaft bearing model and the references
indicated on the plate.
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ANNEX
I. Approved oil types.
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ATTENTION:
Due to the importance of a good lubrication, please use the approved oils defined
in the next tables. These oils were tested with the Wärtsilä bearings and the
experience with them is completely satisfactory.
Check the General Arrangement Drawing in order to select the oil grade indicated
in the drawing.
SUPPLIER OIL NAME GRADE CSt 40ºC
AVIATECH TURBINE OIL TP 46 VG 68 74.8
BP CASTROL CASTROL PERFECTO T-68 VG 68 64.0
COSMO OIL TURBINE SUPER 68 VG 68 68.1
EXXON - MOBIL - ESSO DTE OIL HEAVY / MEDIUM VG 68 65.0
HOUGHTON INTERNATIONAL HOUGHTOSAFE HE 130 VG 68 64.3
HOUGHTON INTERNATIONAL HOUGHTOSAFE HE 130N VG 68 64.3
IDEMITSU KOSAN CO., LTD. DAPHNE TURBINE OIL 68 VG 68 68.0
JAPAN ENERGY CORPORATION JOME RIX TURBINE 68 VG 68 64.3
JAPAN SUN OIL COMPANY. LTD. SUNVIS 968 VG 68 68.0
NIPPON OIL CORPORATION FBK TURBINE 68 VG 68 67.3
PETRO CANADA PURITY FG AW68 VG 68 66.2
SANKYO YUKA KOGYO KK SANLUBE SP-68 TURBINE OIL VG 68 68.0
SHELL TURBO T 68 VG 68 68.0
STATOIL HYDRAWAY HVXA 68 VG 68 63.0
VICKERS HYDROX BIO 68 VG 68 70.0
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BP CASTROL CASTROL 215 MXD VG 100 103,0
BP CASTROL CASTROL MARINE CDX 30 VG 100 103,0
BP CASTROL CASTROL MARINE HEAVY VG 100 99,0
BP CASTROL CASTROL MARINE MLC 30 VG 100 107,0
BP CASTROL CASTROL MHP 153 VG 100 105,0
BP CASTROL CASTROL MPX 30 VG 100 103,0
BP CASTROL CASTROL PERFECTO T-100 VG 100 96,0
BP CASTROL CASTROL TLX 203 VG 100 100,0
BP CASTROL CASTROL TLX 203 PLUS VG 100 105,0
BP CASTROL ENERGOL DL-MP 30 VG 100 100,0
BP CASTROL ENERGOL IC-HFX 203 VG 100 105,0
CALTEX RPM DELO 1000 MARINE OIL SAE 30 VG 100 110,0
CHEVRON TEXACO DELO 1000 MARINE SAE 30 VG 100 109,0
CHEVRON TEXACO GST OIL 100 VG 100 100,0
CHEVRON TEXACO REGAL OIL P&O 100 VG 100 91,7
CHEVRON TEXACO REGAL OIL R&O 100 VG 100 100,0
CHEVRON TEXACO TARO DP-30 VG 100 105,0
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CHEVRON TEXACO TARO XD-30 VG 100 105,0
CHEVRON TEXACO TURBINE OIL 105 TEP VG 100 105,0
CHEVRON TEXACO VERITAS MARINE R&O 30 VG 100 108,0
COGNIS CORP PROECO 100EP VG 100 101,8
COSMO OIL MARINE 3000 VG 100 95,0
COSMO OIL TURBINE SUPER 100 VG 100 95,4
EXXON - MOBIL - ESSO DTE OIL HEAVY VG 100 95,0
EXXON - MOBIL - ESSO EXXMAR 12TP30 VG 100 110,0
EXXON - MOBIL - ESSO EXXMAR XA VG 100 110,0
EXXON - MOBIL - ESSO EXXMAR XD-3 30 VG 100 110,0
EXXON - MOBIL - ESSO MOBILGARD 312 VG 100 108,0
EXXON - MOBIL - ESSO MOBILGEAR 627 VG 100 100,0
FUJI KOSAN CO, LTD FUKKOL SEA ACE 300 VG 100 105,0
IDEMITSU KOSAN CO., LTD. DAPHNE MARINE OIL SM-30 VG 100 107,0
IDEMITSU KOSAN CO., LTD. DAPHNE MECHANIC OIL 100 VG 100 100,0
JAPAN ENERGY CORPORATION JOME RIX TURBINE 100 VG 100 99,1
JAPAN ENERGY CORPORATION JOMO MARINE D13 VG 100 105,8
JAPAN ENERGY CORPORATION JOMO MARINE P30 VG 100 106,2
JAPAN ENERGY CORPORATION JOMO MARINE PD30 VG 100 108,0
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JAPAN ENERGY CORPORATION JOMO REDUCTUS 100 VG 100 99,0
JAPAN SUN OIL COMPANY. LTD. SUNFLEET MIL-B30 VG 100 102,0
NIPPON OIL CORPORATION MARINE S 30 VG 100 109,0
NIPPON OIL CORPORATION MARINE T 103 VG 100 95,2
PANOLIN AG HLP SYNTH 100 VG 100 100,0
PETROMIN PETROMIN PETROSHIELD SPL30 VG 100 92,8
SANKYO YUKA KOGYO KK SANLUBE 30P VG 100 100,0
SANKYO YUKA KOGYO KK SANLUBE MARINE 4030 VG 100 100,0
SANKYO YUKA KOGYO KK SANLUBE MARINE 5030 VG 100 100,0
SHELL ARGINA T 30 VG 100 104,0
SHELL BELA 30 VG 100 108,0
SHELL GADINIA 30 VG 100 104,0
SHELL MELINA 30 VG 100 103,0
SHELL MELINA S 30 VG 100 103,0
SHELL RIMURA OIL 30 VG 100 97,9
SK CORPORATION SUPERMAR AS VG 100 110,0
STATOIL MARWAY 1030 VG 100 106,0
TOTAL - ELF - GULF ATLANTA MARINE 30 VG 100 102,7
TOTAL - ELF - GULF ATLANTA MARINE D 3005 VG 100 105,0
TOTAL - ELF - GULF AURELIA 3030 VG 100 108,1
TOTAL - ELF - GULF BIOHIDRAN TMP 100 VG 100 100,0
TOTAL - ELF - GULF DISOLA M 3015 VG 100 110,0
VICKERS HYDROX 100 VG 100 100,0
VICKERS HYDROX BIO 100 VG 100 100,0
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BP CASTROL CASTROL 220 MXD VG 150 138,0
BP CASTROL CASTROL MDX 304 VG 150 138,0
BP CASTROL CASTROL MDX 404 VG 150 138,0
BP CASTROL ENERGOL DS3 154 VG 150 142,0
BP CASTROL ENERGOL IC-HF 254 VG 150 155,0
CHEVRON TEXACO MEROPA 150 VG 150 150,0
CHEVRON TEXACO TARO 50XL40 VG 150 150,0
CHEVRON TEXACO TARO DP-40 VG 150 140,0
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CHEVRON TEXACO TARO XD-40 VG 150 140,0
EXXON - MOBIL - ESSO DTE OIL EXTRA HEAVY VG 150 146,0
EXXON - MOBIL - ESSO MOBILGARD 412 VG 150 142,0
EXXON - MOBIL - ESSO MOBILGARD M440 VG 150 143,0
EXXON - MOBIL - ESSO MOBILGARD M50 VG 150 142,0
EXXON - MOBIL - ESSO MOBILGEAR 629 VG 150 136,5
IDEMITSU KOSAN CO., LTD. DAPHNE MARINE OIL SP-40 VG 150 164,0
IDEMITSU KOSAN CO., LTD. DAPHNE MARINE OIL SS-40 VG 150 165,0
JAPAN ENERGY CORPORATION JOMO REDUCTUS 150 VG 150 155,4
SHELL ARGINA T 40 VG 150 141,0
SHELL ARGINA X 40 VG 150 140,0
SHELL GADINIA 40 VG 150 150,0
SHELL STERN TUBE LUBRICANT VG 150 150,0
SK CORPORATION SUPERMAR 13TP40 VG 150 146,0
TERRESOLVE ENVIROLOGIC 215 VG 150 150,0
TOTAL - ELF - GULF AURELIA 4040 VG 150 140,0
TOTAL - ELF - GULF DISOLA M 4015 VG 150 145,0
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TOTAL - ELF - GULF DISOLA MT 40 VG 150 140,0
VICKERS HYDROX PO VG 150 150,0
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ANNEX
II. Base bolts torque.
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Bearing Bolt Bolt / Shell Torque Torque

Model dimension Quality Min (Nm) Max (Nm)
165 M24 8.8 / EN-GJL-250 420 500
210 M24 8.8 / EN-GJL-250 420 500
240 M30 8.8 / EN-GJL-250 830 1000
270 M30 8.8 / EN-GJL-250 830 1000
300 M30 8.8 / EN-GJL-250 830 1000
330 M36 8.8 / EN-GJL-250 1450 1700
360 M36 8.8 / EN-GJL-250 1450 1700
400 M36 8.8 / EN-GJL-250 1450 1700
430 M42 8.8 / EN-GJL-250 2300 2700
470 M42 8.8 / EN-GJL-250 2300 2700
510 M42 8.8 / EN-GJL-250 2300 2700
550 M48 8.8 / EN-GJL-250 4100 4800
590 M48 8.8 / EN-GJL-250 4100 4800
630 M48 8.8 / EN-GJL-250 4100 4800
670 M48 8.8 / EN-GJL-250 4100 4800
710 M48 8.8 / EN-GJL-250 4100 4800
750 M48 8.8 / EN-GJL-250 4100 4800
800 M48 8.8 / EN-GJL-250 4100 4800
ATTENTION:
The indicated torques are for the line shaft bearings

basement, and indicates the minimum / maximum
values recommended for their use with metallic
basement. The torque must be applied with grease or
MoS2 to reduce the friction.
In case of epoxy or elastic anti-vibratory systems the

torque must be agreed with the supplier of these
solutions.
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ANNEX
III. Bearing dimensions.
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Shaft range diameter Bearing

Bearing
clearance
Model
d min (mm) d max (mm) H (mm)
165 101 165 0.25
210 166 210 0.30
240 211 240 0.35
270 241 270 0.35
300 271 300 0.40
330 301 330 0.40
360 331 360 0.45
400 361 400 0.50
430 401 430 0.50
470 431 470 0.55
510 471 510 0.60
550 511 550 0.65
590 551 590 0.70
630 591 630 0.70
670 631 670 0.75
710 671 710 0.80
750 711 750 0.85
800 751 800 0.90
Bearing hole diameter D = d + H
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ANNEX
IV. Shaft installation.
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Shaft installation – Unit alignment.
MEASURE PROCESS:
Once the unit is completely aligned in the foundation, check that the dimensions comply the following
relations.
|A1 - B1| ≤ 0.50 mm
|A3 - B4| ≤ 0.50 mm
|A4 - B3| ≤ 0.50 mm
Unit alignment report (Final condition).

A1 A3 A4 B1 B3 B4
|A1 - B1| ≤ 0.50 mm

|A3 - B4| ≤ 0.50 mm
|A4 - B3| ≤ 0.50 mm
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Shaft installation – Bearing clearances.
MEASURE PROCESS:
Once the bearing is completely mounted in the unit and before continuing with the assembly process,
check the following clearances at both sides of the bearing (AFT and FWD).
d Shaft diameter
D Bearing hole diameter (d + H)
H Bearing clearance (see Annex VI)
Check with gauges (in the indicated points) that the following dimensions are as follows:
A=H
B = ½H
C=0
D = ½H
Bearing clearances report (Final condition).

Position A B C D
AFT
FWD
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ANNEX
V. Installation schemas.
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Seal – Installation schema.
Oil scrapper – Installation schema.
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Foundation – Installation schemas
BOLT BOLT
NUT NUT
BEARING HOUSING BEARING HOUSING
CHOCKLINER CHOCKFAST
WELDING LINER WELDING LINER
FOUNDATION FOUNDATION
THREADED ROD THREADED ROD
NUT NUT
HEAVY DUTY WASHER BEARING HOUSING HEAVY DUTY WASHER BEARING HOUSING
CHOCKLINER CHOCKFAST
FOUNDATION FOUNDATION
THREADED ROD
NUT
BEARING HOUSING
SPHERICAL WASHER
VIBRACON
STEEL CHOCK
FOUNDATION
NOTES:
The indicated schemas are only as reference. The shipyard must apply its procedure plan.
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ANNEX
VI. PTFE oil scrapper installation.
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PTFE oil scrapper – Installation procedure.
Step 1.
Clean carefully the groove of the

PTFE oil scrapper.
The PTFE oil scrapper will be

manually positioned into its
groove. Note that the PTFE oil
scrapper has to protrude around
5 - 10 mm over the shaft pass
cover.
Note:
Only if necessary, a nylon
hammer can be of help to locate
the PTFE joints in their grooves.
Step 2.
In order to get the best possible

adjustment, make a small
cylinder of soft material (plastic
or wood) roll over the PTFE oil
scrapper applying a light
pressure on it.
Step 3.
Finally cut the excess of the

PTFE oil scrapper using a cutter
or similar tool.
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TROUBLESHOOTING
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Troubleshooting
Problem Possible solution
High bearing temperature. • Check through the inspection plate that the
Alarm temperature lubrication is good.
to • Check the oil grade (according to the General

Alarm temperature + 10 ºC arrangement drawing).
• Check the bearing load is according with the
specification.
Very high bearing temperature. • Check the state of the bearing.

> Alarm temperature + 10 ºC • Replace the bearing if the white metal is
damaged.
• Check through the inspection plate that the
lubrication is good.
• Check the oil grade.
• Check the bearing load is according with the
specification.
Metallic particles in the oil sump. • Check the state of the bearing.
• Replace the bearing if the white metal is
damaged.
• Replace the oil and clean carefully the oil carter.
• Check that the oil ring and oil scrapper are not
in contact.
• Check through the inspection plate that the
lubrication is good.
Low lubrication. • Check the oil levels.

• Check that the oil ring and oil scrapper are not
loose.
• Check the clearance between the oil scrapper
and oil ring. It must be between 0.2 and 0.3
mm.
No electrical signal of the temperature sensor • Check the electrical connections of the
PT-100. temperature sensor PT-100.
• Replace the temperature sensor PT-100.
No indication of the oil temperature. • Replace the thermometer.
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Oil leakages
Between the upper and lower bearing housing. • Apply CURIL-T or similar universal jointing
compound.
Between the inspection plate and the upper • Apply CURIL-T or similar universal jointing
bearing housing. compound.
Through the shaft pass cover. • Check the oil levels.

• Check the deflection ring.
• Check the PTFE oil scrappers.
Other oil leakages. • Tighten all the covers and plugs.

• Check that the plain joints are installed in their
positions.
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NOTES
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NOTES:
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NOTES:
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DRAWINGS
V1.01 Page 77 of 77
513575 & 513639 Fire Resistant A60 Bulkhead Seal
ProfiSeal GmbH
Seal Technology for Shippming

Mühlerstraße 13
D - 55288 Schornsheim
Germany
Tel: +49 ( 0 ) 6732 / 961476
Fax: +49 ( 0 ) 6732 / 961477
E – Mail: [email protected]
Internet: www.profiseal.com
Installation -
and
Operation Instruction
for
ProfiSeal
Fire Resistant A60
Bulkhead Seal
Shaft Diameter 50 mm — 500 mm
completely split, dryrunning
File name: ProfiSeal_Installation Instruction BHS Fireproof_v03-00.docx
Version: December 2017
Please read this Instruction carefully and Observe the Information

contained as to:
• Safety • Storage • Installation • Start up • Maintenance • Repair
!!If there is any uncertainty please contact ProfiSeal by all means!!
ProfiSeal fire resistant A60 Bulkhead Seals must be
• Safety ⇒ page 2 operated, maintained or repaired by authorized,
trained and instructed personnel only.
• Manufacturer ⇒ page 2
• Declaration ⇒ page 2 Any person at the user’s facilities being involved in
assembly, disassembly, start up, operation and
• Operating Limits ⇒ page 3 maintenance of the ProfiSeal Bulkhead Seal must
• Materials ⇒ page 3 have read and understood this Installation- and
Operating Instruction and in particular the safety
• Drawings ⇒ page 3
notes. We recommend the user to have this
• Description ⇒ page 3 confirmed.
• Designated Use ⇒ page 3
Any work to be carried out on the ProfiSeal is only
• Dimensions ⇒ page 3 permitted when the seal is neither in operation nor
• Emissions ⇒ page 3 pressurized.
• Storage ⇒ page 3
Apart from the notes in this instruction , the general
• Preliminaries ⇒ page 4 regulations for workers protection and those for
• Auxiliaries ⇒ page 4 prevention of accidents have to be observed.
• Installation ⇒ page 4 - 7 Unauthorised modifications or alternations which

• Start Up ⇒ page 7 affect the operational safety of the ProfiSeal
Bulkhead Seals are not permitted.
• Troubles ⇒ page 7
•
•
Removal
Maintenance
⇒ page 7
⇒ page 7
• Manufacturer
• Repair ⇒ page 7
• Spare Parts ⇒ page 7
• After-Sales ⇒ page 8
• How to order ⇒ page8 ProfiSeal GmbH
Seals and Bearing Technology for Commercial- and
• Copyright ⇒ page8 Pleasure Craft
Mühlerstraße 13
D -55288 Schornsheim
• Safety Germany
Tel: +49 ( 0 ) 6732 / 961476
ProfiSeal fire resistant A60 Bulkhead Seals are Fax: +49 ( 0 ) 6732 / 961477
manufactured on a high quality level and have a high E – Mail: [email protected]
operation reliability. However, if not operated within Internet: www.profiseal.com
their intended purpose or handled inexpertly by
untrained personnel they may cause risks. • Declaration
(within the meaning of the EC–Directive „Machinery“)
The user is asked to check what effects a failure of
the mechanical seal might have to the environment A fire resistant A60 Bulkhead Seal does not function
and what additional safety measures have to be taken independently. It is intended to be incorporated into
to prevent personnel injury. or assembled with machinery.
Any operation mode that affects the operational

safety of the seal is not permitted.
Chapter 10 Page 158

Page 2 of 8 BVo Installation Manual No.: 2312-13. IMO No.: -. Date: 2019-11-18
• Operating Limit Operation under conditions lying outside those limits
stated in paragraph <Operating Limits> is
considered contrary to it’s designated use.
Shaft Diameter, max. : 500 mm
Medium to be sealed: Seawater Should the seal be operated under conditions other
Medium Temperature : Seawater: -5 – + 950° C than those recommended, ProfiSeal has to be asked
Operating Pressure: max. 2 bar for recognition as safe.
max. Sliding Speed: 40 m / s
The shaft surfaces which get in contact with the seal • Dimensions
rings should have a surface hardness of min. 150 to
200 HB. Decisive for the design of the seal housing is the
The lay-out of ProfiSeal fire resistant A60 Bulkhead ProfiSeal data sheet or the available mounting space
Seal (i.e. type, suitability, materials etc.) should be given by the user. The connecting dimensions are
done by ProfiSeal personnel or an authorized office. checked before shipment with regard to the respec-
ProfiSeal can not be held liable for wrong tive ProfiSeal drawing.
selection by unauthorized persons !
• Emissions
• Materials A labyrinth seal is a dynamic seal that can not be free
The materials of the fire resistant A60 Bulkhead Seal of leakage due to physical and technical reasons. The
depent on the application and the respective order. design of the seal, manufacturing tolerances,
They may vary from those stated in the general operating conditions, vibrations of the engine and
drawing. shaft system etc. mainly define the leakage value.
The seal ring material is designed for dry running and

• Drawings do not require any kind of lubrication.
The assembly drawing in the original scale and in it’s ▶▶▶ Components which get in contact with the
latest revision only is decisive for the design and the leakage have to be corrosion resistant or have to be
use in connection with this instruction. otherwise protected!
• Description • Storage
These instructions apply to all ProfiSeal fire resistant
♦ labyrinth seal A60 Bulkhead Seals which have been supplied and
♦ horizontally split stored in their undamaged original packaging, as well
♦ bi-rotational as to seals which have been installed allready into a
♦ seal rings split system but have not yet been put into operation.
♦ dry running
ProfiSeal Bulkhead Seals are super finished and
ProfiSeal fire resistant A60 Bulkhead Seal should be tested machine elements whose handling before and
used for sealing shafts, going through A60 bulkheads during the storage periode ( in particular of spare
of ships, boats and special craft’s. parts ) entails certain conditions. (for elastomeric
parts please refer also to DIN 7716).
The housing and the seal rings are split, to ease the
installation and replacement without pulling the Sliding materials and elastomers are subject to
shaftline. material-specific and time based alterations
(distortion, aging) which might reduce the full
• Designated Use efficiency of the seals. However, this may be avoided
by observing the following storage instructions.
This Bulkhead Seal is exclusively designed for the ProfiSeal can not be claimed liable with respect to
use in the specified application. A different their warranty for damages caused by improper
utilization or a utilization going beyond the storage!
specification is considered as contrary to it’s
designated use and excludes a liability of the
manufacturer.
Chapter 10 Page 159

The bulkhead seals have to be stored in a dry,
dustfree, moderately ventilated and tempered room.
We recommend: relative air humidity below 65 %, • Installation
temperature between 15° C and 25° C.
For reason of serviceability the installation should
Direct exposure of the seals to heat (sun, heating) as always be carried out by two persons.
well as ozone, present or produced by ultraviolet light
(halogen or flourescent lamps) must be avoided Never use unnecessary force during installation.
because of the risk of embrittlement of elastomeric
materials. • Unpack the seal and place on a clean surface.
A preservation of the ProfiSeal Bulkhead Seal is ♦ First Installation

not permitted.
ProfiSeal fir resistant A60 Bulkhead Seals are
The ProfiSeal fire resistant A60 Bulkhead Seals
delivered pre-assembled.
should be stored, lying on an even Surface.
Packaging should be checked periodically for any
 Split Housing with 2 Seal Rings, complete
damages.
 Housing with 1 Seal Rings, complete
We recommend a Check of the fire resistant A60
 Gasket and Insulation Sleeves and Washers
Bulkhead Seal:
 Insulation Covers and Insulation
• Unpack the seal and place on a clean surface.

• after a storage period of approximately 2 – 3 years
• after a damage of the packaging
• Remove the retaining bolts (9) of the housing (4)
• after a shock on the bulkhead seal (e.g. by dropping with two seal rings and of the housing (5) with one
the packed seal) seal ring and press the two halves carefully apart.
 at the manufacturers plant or at the nearest In order not to damage the parting surfaces when
authorized service facility pressing the housing halves apart with a
screwdriver, recesses are provided in the lower half
• Preliminaries of the housing.
 Tilling or lateral movements of the parting

Check Shaft for: surfaces during disassembly may result in
• all edges chamfered breakage of the seal rings.
• transitions sufficiently smooth
• O-ring fits should be finished to a surface • Remove the two seal rings (1) and place on a clean
roughness of 10 ym surface.
Check the surrounding • The parting surfaces have to be cleaned thoroughly

• damages of the installation surface with alcohol and tissue.
• connecting dimensions, right-angeled and
centricity of the shaft as per drawing
• clean all relevant parts with propyl alcohol and ♦ Installation of the fire resistant
cellulose-tissue
 Never place seal rings on their sliding faces
A60 Bulkhead Seal
without covering them adequately
The Installation starts with the one seal ring Housing
(5) onto the welded in bulkhead flange, as described
• Auxiliaries in the following (see Figure 1 and 2)
• Place the gasket (19) against the bulkhead flange

• propyl alcohol + cellulose-tissue
• (no rag, no cloth)
• Place the lower half of the housing with the
• spacing pieces ( e.g. wooden spacers )
insulation sleeves (15) from below the shaft.
• srew / bolt adhesive e.g. Loctite Nr. 243
• suitable measuring tools • The lower half of the housing is the half with the
• adequate cover to protect the sliding faces during thread holes for the housing retaining bolts (9).
installation Check that the cylinder pins (6) are placed in that
half of the housing.
Ensure that the surrounding area is clean, dust- and
chip-free.
Chapter 10 Page 160

• Carefully open the garter spring (3) of the first seal
ring and place the segments, garter spring and
detent (2) as one set aside, ready for reinstallation.
Caution: The garter spring is under preload. Make

sure the segments are not released uncontrolled to
prevent damage to the seal rings.
• Push the garter spring through the first seal ring

groove of the housing, pick up on the opposite side.
Place the detent onto the spring and close the garter
spring.
• Place the first seal ring segment onto the shaft and
allow the spring to engage in the seal ring groove.
Turn spring and segment until the segment
disappears into the housing groove. To ease the
movement of the segment event. Slightly pull the
spring plate (7). Place the next segments onto the
shaft in the same way and allow the spring to
engage. The detent (3) must engage in the detent
groove of the seal ring (see Figure 3).
• Make sure that the detent plates fit Figure 1

correctly into the groove provided in the
lower half of the housing, as shown on
the drawing overleaf.
• Always make sure that the segments of the two seal
• Align the seal ring with the groove in the housing rings are kept as one set.
and carefully place the upper housing half
vertically onto the lower half. • Do not mix segments of the two seal rings.
• Tighten the two halfs with the retaining bolts (9). • Continue the installation of the two seal rings as
described above.
• Check for rectangularity (± 1° maximum to the
shaft) and centricity with regards to the position • Align the seal rings with the grooves in the housing
to the shaft. and carefully place the upper housing half
vertically into the lower half.
• After complete Installation of the first housing,
continue as above with the second housing (4) • Tighten the halfs with the retaining bolts (9).
(see Figure 1 and 2).
• Check for rectangularity (± 1° maximum to the
• Please the Gasket (18) against the housing (4). shaft) and centricity with regards to the position
to the shaft.
• Place the lower half of the two seal ring housing
with the insulation sleeves from below the shaft. • For the installation of the Insulation (8) and the
covers (5+6) insert the threat pins (13) into the two
• The lower half of the housing is the half with the seal ring housing and threat pins (17) into the one
thread holes for the housing retaining bolts (9). seal ring housing (see Figure 4 and 1).
Check that the cylinder pin (6) are placed in that
half of the housing. • Cover the housings from the one side completely
with the precutted insulation material (8) and
install the split cover (6) with the cup nuts (14).
• Than cover the housing on the other side

completely inside the adapter flange with the
precutted insulation material (8) and install the
split cover plate (7) with the cap nuts (14).
Chapter 10 Page 161

• Make sure that the housings are
completely covered with insulations
material and that the cover plate (7)
does not have any contact with the
adapter flange. Make sur that distance
between cover plate (7) and flange is at
least 5 mm.
Figure 2
Figure 3
Chapter 10 Page 162

• Optional:
Fireproof bulkhead seal with angle adjustment
The fireproof bulkhead seal with angle adjustment

Fig. 4 allows the installation of the shaft at a defined
angle.
For this purpose, an angle adapter (20), a flat gasket
(19) and an adapter ring (21) are also included. The
adapter ring is welded to the bulkhead so that the
mark points upwards. Before the installation of the
fireproof bulkhead seal, first the gasket and then the
angle adapter, with the marking facing up, has to be
installed to the adapter ring.
Then install the fireproof bulkhead seal as described
above.
Figure 5
• Removal
The disassembly (removal) of the fire resistant A60
Bulkhead Seal is carried out in the reverse sequence
as described for Installation.
• Maintenance
When operating the seal following the instructions
in this manual, very few maintenance should be
necessary during the whole running time !
Figure 4 An inspection of the seal should be carried out during

regular revisions of the whole propulsion line.
For inspection remove all parts as described above

Figure 4 and check seal rings for damage and wear.
If you should be uncertain with regards to reusa-

• Start Up bility of the seal rings, please ask ProfiSeal, or let
the inspection be performed by authorized
If the operation limit values and the instructions ProfiSeal personnel !
given in this manual are observed, a trouble-free
operation of the ProfiSeal fire resistant A60 Bulkhead
Seal can be expected.
• Repair
If repair is necessary, the complete set of seal rings
• Troubles should be replaced.
Or sent the complete seal to the manufacturer, as this
Try to define the kind of failure and record it ! is the best way to find out which components can be
reconditioned or which parts must be replaced.
If there is a malfunction you cannot correct on your
own, or if the reason for malfunction is not clearly
recognizable please contact ProfiSeal immediately !
During the warranty period the seal must only be

disassembled or removed with the approval of the
manufacturer or when a representative of the
manufacturer is present!
Chapter 10 Page 163

• Spare Parts
♦ Only original ProfiSeal spare parts
should be used !
Not observing this rule could cause:
 Risk of seal failure endangering persons and
environment !!
 The ProfiSeal Warranty for the seal expires
automatically!!
♦ We recommend to store a complete set of seal
rings to react promptly if needed.
• After-Sales
The range of services offered by ProfiSeal not only
includes advice during the planning stage but also
technical support after commissioning.
ProfiSeal GmbH
Seals and Bearing Technology for Commercial and
Pleasure Craft
Mühlerstraße 13
D - 55288 Schornsheim
Germany
Tel: +49 (0) 6732 / 961476
Fax: +49 (0) 6732 / 961477
E – Mail: [email protected]
Internet: www.profiseal.com
• How to order
For enquiries and orders the following details are
required:
• Original Order or Sales-Order-Nr.
• Part/Item/Position Nr., designation, material,
number of pieces needed (please refer to the
respective parts-list ! )
• Copyright
This instruction was written for the installation,
operation and maintenance personnel.
Buyer, naval architects etc. and user of the product

are authorized for use in connection with further
documentation.
ProfiSeal reserves the right to carry out technical

modifications which might become necessary to
improve our products even if they are not
mentioned in this technical instruction.
Chapter 10 Page 164

513216 CX-50-78 GSS1-300 Mounting instruction
CENTAX-SEC Series G
Assembly and operating instructions
CX-50…78-GSS1-300
M20-002-EN
Rev. 1
Chapter 10 Page 165

Assembly and operating instructions M20-002-EN
CENTAX-SEC Series G Rev. 1
CX-50…78-GSS1-300
Contents
1 General remarks ..................................................................................... 5
2 Safety ..................................................................................................... 6
2.1 Safety remarks ............................................................................. 6
2.1.1 Signal words...................................................................... 6
2.1.2 Pictograms ........................................................................ 7
2.2 Qualification of deployed personnel.................................................. 7
2.3 Intended application...................................................................... 7
2.4 Application not in compliance with the intended use ........................... 9
3 Delivery, transport, storage and disposal ............................................. 10

3.1 Delivery..................................................................................... 10
3.2 Transport................................................................................... 10
3.3 Storage ..................................................................................... 10
3.3.1 Storage location ............................................................... 11
3.3.2 Storage of couplings / flexible elements............................... 11
3.4 Disposal .................................................................................... 11
4 Technical description ............................................................................ 12

4.1 Characteristics............................................................................ 12
4.2 Specifications ............................................................................. 12
5 Alignment of the units being connected................................................ 13

5.1 Axial alignment........................................................................... 13
5.2 Radial alignment ......................................................................... 14
5.3 Angular alignment....................................................................... 16
6 Mounting .............................................................................................. 17
6.1 General assembly instructions....................................................... 17
6.2 Mounting the hubs ...................................................................... 18
6.2.1 Mounting hub with feather key ........................................... 18
6.2.2 Mounting hub with oil interference fit .................................. 20
6.3 Aligning the units ........................................................................ 22
6.4 Positioning the membran ............................................................. 23
6.5 Pre-mounting of parts to a BG ...................................................... 24
6.6 Placing threaded ring into pre-mounted BG..................................... 25
6.7 Mounting pre-mounted BG to hub.................................................. 26
6.8 Mounting the threaded ring .......................................................... 27
6.9 Mounting the membran................................................................ 28
6.10 Connect BG rubber element to membran ........................................ 29
6.11 After completed mounting ............................................................ 30
CENTA Antriebe Kirschey GmbH 2 / 38

Chapter 10 Page 166
CX-50…78-GSS1-300
7 Operation.............................................................................................. 31
7.1 Operating faults, root causes and remedy....................................... 31
7.2 Admissible overall misalignment of the coupling .............................. 31
8 Care and maintenance .......................................................................... 32

8.1 Work to be performed.................................................................. 32
8.1.1 Cleaning the coupling........................................................ 32
8.1.2 Visual inspection of the coupling ......................................... 32
8.1.3 Visual inspection of the rubber elements / rubber segments ... 32
8.1.4 Inspection of the screw connections .................................... 32
8.2 Replacing defective parts ............................................................. 32
9 Dismantling .......................................................................................... 33
9.1 General dismantling instructions ................................................... 33
9.2 Dismantling the coupling.............................................................. 34
9.3 Dismantling the hubs................................................................... 34
9.3.1 Dismantling hub with feather key ....................................... 34
9.3.2 Dismantling hub with oil interference fit............................... 35
10 Wearing and spare parts....................................................................... 37
11 Annex ................................................................................................... 38
11.1 CENTA data sheet D13-013 (lubricated screw connections) ............... 38

Chapter 10 Page 167
CX-50…78-GSS1-300
Index of illustrations
Fig. 5-1 Axial misalignment 13
Fig. 5-2 Radial misalignment 14
Fig. 5-3 Angular misalignment 16
Fig. 6-1 Mounting hub with feather key 19
Fig. 6-2 Mounting hub with oil interference fit 20
Fig. 6-3 Positioning the membran 23
Fig. 6-4 Pre-mounting of parts to a BG 24
Fig. 6-5 Placing threaded ring into pre-mounted BG 25
Fig. 6-6 Mounting pre-mounted BG to hub 26
Fig. 6-7 Mounting the threaded ring 27
Fig. 6-8 Mounting the membran 28
Fig. 6-9 Connecting rubber element to membran 29
Index of tables
Table 2-1 Shape and size of ventilation holes 8
Table 5-1 Permissible radial alignment tolerance 15
Table 7-1 Troubleshooting table 31
Index of formulas
Formula 5-1Calculated dimension SW 16

Chapter 10 Page 168
CX-50…78-GSS1-300
1 General remarks
These assembly and operating instructions form a constituent part of the
coupling delivery and must be kept in an easily accessible place at all times.
CENTA products are developed and produced to quality standard

DIN EN ISO 9001:2000.
In the interests of further development, CENTA reserves the right to make

technical changes.
IMPORTANT
CENTA is unable to accept liability for damage and operating faults caused by failure to
observe the operating instructions.
These operating instructions are protected under copyright to CENTA Antriebe

Kirschey GmbH.
In case of technical questions, please enquire with our head office:
CENTA Antriebe
Kirschey GmbH
Bergische Strasse 7
42781 Haan
GERMANY
Phone +49-2129-912-0
Fax +49-2129-2790
[email protected]
www.centa.info

Chapter 10 Page 169
CX-50…78-GSS1-300
2 Safety
The purpose of these operating instructions is to enable users to:
• use the coupling safely and correctly
• maximize efficiency
• ensure that care and maintenance are carried out correctly
For this reason, these operating instructions must be thoroughly read and
understood prior to work on and with the coupling.
WARNING
Injury and material damage can occur as a result of:
Failure to adhere to the safety and accident prevention
regulations valid at the relevant installation site
The safety and accident prevention regulations valid at the
installation site in question must be adhered to when performing any
of the tasks described in these operating instructions.
2.1 Safety remarks

In these operating instructions, safety remarks are indicated by a pictogram and
a signal word.
2.1.1 Signal words

The following signal words are used in the safety remarks:
Denotes the immediate threat of danger.

DANGER If not prevented, fatal or extremely serious injuries can result.
Denotes a potentially dangerous situation.

WARNING If not prevented, fatal or extremely serious injuries can result.
Denotes a potentially dangerous situation.

CAUTION If not prevented, minor injuries and/damage to property may result.
Denotes application tips and particularly useful information. This is not

IMPORTANT a signal word denoting a dangerous or damaging situation.

Chapter 10 Page 170
CX-50…78-GSS1-300
2.1.2 Pictograms
Possible pictograms in the safety precautions:
Warning of a hazardous area
Do not switch
Use protective gloves
Use protective goggles
2.2 Qualification of deployed personnel

All the work described in these operating instructions may only be performed by
authorized persons with adequate training and instruction.
WARNING
Work at the coupling which is not described in these instructions
Only carry out work which is described in these operating
instructions.
2.3 Intended application
WARNING
Application not in compliance with the intended use
The couplings are intended exclusively for use in accordance with
the relevant design. They may only be used under the specified
conditions.

Chapter 10 Page 171
CX-50…78-GSS1-300
WARNING
Injuries can occur as a result of:
Contact with rotating parts
Shield the coupling in accordance with the applicable accident
prevention regulations with an enclosure.
Exception:
The coupling is encased by the driving and driven units.
The scope of delivery provided by CENTA does not include a protective

enclosure.
This enclosure must fulfil the following criteria:

• Provide protection against persons gaining access to rotating parts
• Restrain any rotating parts which may be work loose
• Guarantee sufficient ventilation for the coupling
This enclosure must be made of stable steel components. In order to ensure

adequate ventilation for the coupling, the enclosure must be fitted with regular
openings. For safety reasons, these openings must not exceed the dimensions
outlined in table 2-1.
Component Circular openings Rectangular openings

[mm] [mm]
Top of the enclosure Ø8 8
Side elements of the Ø8 8

enclosure
Table 2-1 Shape and size of ventilation holes
The enclosures must be positioned a minimum of 15 mm distant from rotating

parts. The enclosure must be electrically conductive and be included in the
equipotential bonding.
Before commencing long-term operation, the plant must successfully complete a

test run.

Chapter 10 Page 172
CX-50…78-GSS1-300
2.4 Application not in compliance with the intended use
WARNING
Inadmissibly high torque
Inadmissibly high or low speeds
Exceeding the specified ambient temperature
Inadmissible ambient medium
Inadmissible coupling enclosure
Exceeding the admissible overall misalignment values
Only use the coupling for the specified application.
CENTA bears no liability for damage resulting from application not in compliance
with the intended use of the equipment.
Should there be a change of plant parameters, the coupling design must be
reviewed by CENTA (address see chapter 1).

Chapter 10 Page 173
CX-50…78-GSS1-300
3 Delivery, transport, storage and disposal

3.1 Delivery
After delivery, the coupling:
• must be checked for completeness and correctness of the delivery.
• must be examined for possible transport damage (which must be reported
immediately to the carrier).
3.2 Transport
CAUTION
Incorrect transportation of couplings
Ensure that the coupling is correctly transported.
CAUTION
Material damage to coupling components can occur as a
result of:
Contact with sharp-edged objects
Protect coupling components for transportation.
Only hoist coupling components with nylon belts or ropes.
Always cushion parts when supporting them from below.
Following transportation damage:

• Check the coupling carefully for damage.
• Consult the manufacturer (Address see chapter 1).
3.3 Storage
CAUTION
Material damage to elastic elements and rubber parts can
occur as a result of:
Incorrect storage
These parts must be stored laid flat and so they cannot distort, and
protected from ozone, heat, light, moisture and solvents.
IMPORTANT
Rubber parts are marked where possible with their production date. From this date,
they may only be stored for a maximum of 5 years.

Chapter 10 Page 174
CX-50…78-GSS1-300
3.3.1 Storage location

Requirements imposed on the storage location:
• Moderately ventilated and low in dust
• Dry (max. 65% humidity)
• Temperature stabilized (-10°C to +25°C)
• Free of ozone-producing devices such as light sources and electric motors
• Free of UV light sources and direct sunlight
• Do not store solvents and disinfectants, fuels or lubricants, acids, chemicals
etc. in the same location
For more details, refer to DIN 7716.
3.3.2 Storage of couplings / flexible elements

¾ Unpack the parts.
¾ Check the packaging for damage. Replace if necessary.
¾ Check that the wax protection on steel components is intact. If necessary,
patch or renew.
¾ Package the parts (for prolonged periods of storage, enclose desiccant and
weld into film).
¾ Place the parts into storage.
3.4 Disposal
RECYCLING
Ensure safe, environmentally responsible disposal of operating
supplies and exchange parts. For this, locally provided recycling
facilities and regulations must be utilized.
For disposal, the coupling parts must be separated where possible and sorted
according to material type.

Chapter 10 Page 175
CX-50…78-GSS1-300
4 Technical description
4.1 Characteristics
CENTAX-SEC series G couplings have the following excellent characteristics:
• Sufficient elasticity to take up axial, radial and angular misalignment,

movements, installation errors and heat expansion in units with rigid or
elastic bearings.
• High torsional elasticity with linear curve. One or more elements with
different shore hardnesses can be used in series, in which case the necessary
torsional rigidity for optimal vibration behaviour of the unit can be ensured.
• All sides of the rubber element are ventilated all round in order to guarantee
good heat dissipation and high heat capacity.
• High dynamic capacity and balancing quality.
• Simple, cost-effective design with compact dimensions, low weight and mass
moment of inertia.
• Wear free, low maintenance, simple to install. In all the series, the elements
can be replaced radially – without having to move the connected machine
components. Suitable dimensioning of bolts and clamping forces for torque
transmission by friction.
• Available with or without failsafe device.
4.2 Specifications
The specifications can be found in the catalogue and the dimensions in the
installation drawing.

Chapter 10 Page 176
CX-50…78-GSS1-300
5 Alignment of the units being connected
IMPORTANT
• The units should be aligned during assembly.
• The overall misalignment is composed of the misalignment and the operating
misalignment. The permissible overall misalignment values can be found in the
catalogue and must not be exceeded.
Align the units that are to be connected as accurately as possible. In this way, a
long service life for the coupling and maximum operating misalignment values can
be achieved.
After completion of assembly, check the alignment of the coupling again and if
necessary correct.
5.1 Axial alignment

Determine the axial misalignment (see Fig. 5-1).
¾ Take installation length L from the installation drawing.

¾ Align the units (installation dimension = L±∆KA max).
Permissible axial alignment tolerance:

∆KA max=0,5 mm
Fig. 5-1 Axial misalignment

Chapter 10 Page 177
CX-50…78-GSS1-300
5.2 Radial alignment
CAUTION
Material damage to elastically installed motors can occur as a
result of:
Disregard during alignment of the extent by which the motor
bearing settles
During vertical alignment, take into account the extent by which the
motor bearing settles. Please enquire about specifications for the
degree of settling from the motor manufacturer or motor bearing
manufacturer.
Measure the radial misalignment with a dial gauge (see Fig. 5-2).
¾ Attach the dial gauge to the hub.

¾ Set the sensor of the dial gauge radially against the centering.
¾ Turn the hub with dial gauge and hub slowly by 360°.
¾ Align the units (calculated deviation ≤∆KR max).
The permissible radial alignment tolerance ∆KR max can be found in the following
table.
Fig. 5-2 Radial misalignment

Chapter 10 Page 178
CX-50…78-GSS1-300
Size Shorehardeness ∆KR max

[Shore A] [mm]
50 - 56 45 / 50 / 60 ±0,75
70 ±0,25
64 - 65 50 / 60 ±0,75
70 ±0,25
66 - 70 50 / 60 ±1,00
70 ±0,30
72 50 / 60 ±1,25
70 ±0,38
75 50 / 60 ±1,38
70 ±0,43
78 50 / 60 ±1,50
70 ±0,50
80 50 / 60 ±1,75
70 ±0,55
81 50 / 60 ±1,75
70 ±0,60
82 - 90 50 / 60 ±2,00
70 ±0,60
Table 5-1 Permissible radial alignment tolerance

Chapter 10 Page 179
CX-50…78-GSS1-300
5.3 Angular alignment

Measure the angular misalignment with a dial gauge (see Fig. 5-3).
¾ Attach the dial gauge to the hub.

¾ Position the sensor of the dial gauge radially against flat surface at a distance
R.
¾ Turn the hub with dial gauge and hub slowly by 360°.
The maximum dial gauge deflection must not exceed the value 2xSw at any
point. The permissible tolerance SW max should be calculated according to formula
below.
¾ Align the units (calculated deviation ≤∆KW max).
Permissible angular alignment tolerance:

∆KW max=0,05°
Fig. 5-3 Angular misalignment
Formula 5-1Calculated dimension SW

Chapter 10 Page 180
CX-50…78-GSS1-300
6 Mounting
6.1 General assembly instructions
Any work method which impairs the safety of the coupling is prohibited.
The user undertakes to notify the manufacturer immediately of any changes
occurring at the coupling which could impair safety (address see chapter 1).
WARNING
Before starting work at the coupling, switch off the plant and secure
against unintentional start-up.
WARNING
Assembly of the coupling in the wrong sequence
Only ever assemble the coupling in the described sequence.
WARNING
Falling coupling components
Secure coupling components against falling to the floor.
CAUTION
result of:
Contact with sharp-edged objects
Protect coupling components for transportation.
Only hoist coupling components with nylon belts or ropes.
Always cushion parts when supporting them from below.
CAUTION
Material damage can occur as a result of:
Soiled joint surfaces
The surfaces that are to be joined must be free of dirt, preservatives
and lubricants.

Chapter 10 Page 181
CX-50…78-GSS1-300
CAUTION
result of:
Anaerobic adhesives (e.g. Loctite) used for screw locking
This type of screw locking medium may not be in contact with
rubber parts.
IMPORTANT
• Screw preparation and tightening torque levels in accordance with CENTA data
sheet D13-013 (see chapter 11.1).
• Use suitable lifting devices for assembly.
• The following assembly stages are described for coupling CX-70-GSS1.
• Part illustration and marking may different slightly from installation drawing and
delivery state.
6.2 Mounting the hubs

¾ Mount the hubs as appropriate for the supplied design (see installation
drawing).
¾ Mounting hub with feather key, see chapter 6.2.1 .
¾ Mounting hub with oil interference fit, see chapter 6.2.2 .
6.2.1 Mounting hub with feather key
IMPORTANT
To ease assembly of the hubs/flange hubs, warm them to a temperature of
120° - 150° C.
CAUTION
Incorrect heating of the hubs/flange hubs
Heat the hubs/flange hubs steadily in an oil bath, a fan oven, on an
electric hot plate, either inductive or with a flame (ring burner).
CAUTION
Hot coupling components
Use suitable protective gloves.

Chapter 10 Page 182
CX-50…78-GSS1-300
CAUTION
Hot hubs/flange hubs
Before further mounting of hubs/flange hubs, allow them to cool to
ambient temperature.
Fig. 6-1 Mounting hub with feather key
Item Info Designation Remark
2 Hub
A Shaft Customer part
a Face of shaft (A)
b Face of hub (2)
¾ Push the hub (2) onto the shaft (A).
IMPORTANT
Face of shaft must not protrude to face of hub. Otherwise radial replacement of other
coupling parts is not guaranteed.

Chapter 10 Page 183
CX-50…78-GSS1-300
6.2.2 Mounting hub with oil interference fit
WARNING
Non-compliance with the operating instructions for the hydraulic
pumps
Before carrying out work with the hydraulic pumps, do not fail to
read their operating instructions. Only ever work with hydraulic
pumps as described in their operating instructions.
WARNING
Hydraulic fluid spraying out
Use protective goggles.
Fig. 6-2 Mounting hub with oil interference fit

Chapter 10 Page 184
CX-50…78-GSS1-300
2 Hub
4 Screw plug G1/4"
a Face of shaft (A)
b Face of hub (2)
c Thread 1/4"
IMPORTANT
We recommend the following mounting fluids:
• For mounting:
Oil with a viscosity 300 mm2/s at 20°C, e.g. SKF LHMF300
• For dismantling:
Oil with a viscosity 900 mm2/s at 20°C, e.g. SKF LHDF900
¾ Lightly oil the cone of the shaft (A).

¾ Push the hub (2) onto the shaft (A).
¾ Remove the screw plug (4) from the hub (3).
¾ Connect the pump for expanding the hub to the hub (2) at thread ¼“ (c).
¾ Screw the pump for pushing on the hub to the shaft.
¾ Build up the oil pressure to push on the hub.
WARNING
Too fast increase of the expanding pressure in the hub
The increase of the expanding pressure may not exceed 35
bar/minute.
WARNING
Insufficient expanding pressure in the hub
If the expanding pressure is too low, the necessary pushing pressure
is too high.
¾ Build up the oil pressure for expanding the hub slowly.

¾ Build up the oil pressure alternately until the lift path (p up) of the hub (2) is
reached (for p up and reference faces, see installation drawing).
¾ Decrease the oil pressure for expanding the hub.

Chapter 10 Page 185
CX-50…78-GSS1-300
¾ Remove the pump for expanding the hub from the hub (2).
¾ Maintain the oil pressure for pushing on the hub for one hour.
¾ Decrease the oil pressure for pushing on the hub.
¾ Remove the pump for pushing on the hub from the shaft.
¾ Turn the hub (2), allow the oil to run out of the thread (c) and dispose of it
correctly.
¾ Screw the screw plug (4) into the hub (2).
IMPORTANT
Do not place a load on the hub for 24 hours.
IMPORTANT
Face of shaft must not protrude to face of hub. Otherwise radial replacement of other
coupling parts is not guaranteed.
6.3 Aligning the units

¾ Align the units to be connected (see chapter 5).

Chapter 10 Page 186
CX-50…78-GSS1-300
6.4 Positioning the membran
Fig. 6-3 Positioning the membran
1.2.1 Membran
1.2.3 Locking ring
2 Hub
f Radius
¾ Place locking ring (1.2.3) and membran (1.2.1) on hub (2). The radius (f) of
the locking ring (1.2.3) must be on the side of the membran.

Chapter 10 Page 187
CX-50…78-GSS1-300
6.5 Pre-mounting of parts to a BG
Fig. 6-4 Pre-mounting of parts to a BG
1.1 Rubber element
1.3 Adapter ring
1.4 Screw
1.6 Washer
C Pre-mounted BG
¾ Push adapter ring (1.3) into centring of the rubber element (1.1).
¾ Screw the rubber element (1.1) with screws (1.4) and washers (1.6) to
adapter ring (1.3).

Chapter 10 Page 188
CX-50…78-GSS1-300
6.6 Placing threaded ring into pre-mounted BG
Fig. 6-5 Placing threaded ring into pre-mounted BG
1.2.2 Threaded ring
C Pre-mounted BG
g Radius
¾ Placing the threaded ring (1.2.2) into the pre-mounted BG. The radius (g)
must be directed outwards.

Chapter 10 Page 189
CX-50…78-GSS1-300
6.7 Mounting pre-mounted BG to hub
Fig. 6-6 Mounting pre-mounted BG to hub
1.2.1 Membran
2 Hub
3 Hub
10 Screw 1
C pre-mounted BG
¾ Push pre-mounted BG (C) onto centring of hub (3).

¾ Screw hub (3) with screws (1.5) to pre-mounted BG (C).

Chapter 10 Page 190
CX-50…78-GSS1-300
6.8 Mounting the threaded ring
Fig. 6-7 Mounting the threaded ring
1.2.1 Membran
1.2.2 Threaded ring
1.2.12 Screw
2 Hub
C pre-mounted BG
¾ Push threaded ring (1.2.2) onto centring of the hub (2).

¾ Screw hub (2) with screws (1.2.12) to the threaded ring (1.2.2).

Chapter 10 Page 191
CX-50…78-GSS1-300
6.9 Mounting the membran
Fig. 6-8 Mounting the membran
1.2.1 Membran
1.2.2 Threaded ring (covered by membran 1.2.1)
1.2.3 Locking ring
1.2.10 Screw
2 Hub
¾ Push membran (1.2.1) onto centring of the hub (2).

¾ Push locking ring (1.2.3) onto centring of the hub (2).
¾ Screw hub (2) and membran (1.2.1) with screws (1.2.10) to threaded ring
(1.2.2).

Chapter 10 Page 192
CX-50…78-GSS1-300
6.10 Connect BG rubber element to membran
IMPORTANT
Ensure during installation that the centring sleeves are in the right position. The hole
diameters depending on coupling size are: ø10H7 or ø18H7.
Fig. 6-9 Connecting rubber element to membran
1.1 Rubber element
1.2.1 Membran
1.2.4 Spacer
1.2.5 Centering sleeve 2x180°
1.2.6 Washer 2x2x180°
1.2.7 Nut 2x180°
1.2.8 Nut
1.2.9 Screw 2x180°
1.2.11 Screw
1.2.13 Washer
C Pre-mounted BG

Chapter 10 Page 193
CX-50…78-GSS1-300
¾ Turn the membran (1.2.1) to the rubber element (1.1) in such a way, that
the drillings for centering sleeves of both parts align.
¾ Push the centring sleeves (1.2.5) into the drillings of the rubber element
(1.1) and the membran (1.2.1 ; 2x180°).
¾ Screw the rubber element (1.1), centring sleeves (1.2.5) and membran
(1.2.1) with screws (1.2.9), washers (1.2.6) and nuts (1.2.7) (2x180°).
¾ Screw the rubber element (1.1) and membran (1.2.1) with screws (1.2.11),
washers (1.2.13), spacers (1.2.4) and nuts (1.2.8).
6.11 After completed mounting
WARNING
Loose screw connections
Before commissioning, the tightening torque levels of all screws
must be checked and corrected if necessary.
Before commencing long-term operation, the plant must successfully complete a

test run.

Chapter 10 Page 194
CX-50…78-GSS1-300
7 Operation
WARNING
Worn coupling components
If the running noises change and/or vibrations occur turn the plant
off immediately.
Determine the fault and its root cause, and remedy.

The troubleshooting process is simplified by the table in the next chapter.
On principle in case of a fault, an analysis of the entire plant should be
performed.
7.1 Operating faults, root causes and remedy
Faults Possible root Remedy

causes
Running noises or Alignment error 1. Switch off the plant

vibrations in the
2. Check alignment, correct if applicable
plant
3. Trial run
Loose bolts 1. Switch off the plant

3. Check screw torque levels and correct if
necessary
4. Trial run
Membrane or rubber Alignment error 1. Switch off the plant

element damaged
2. Replace defective parts
4. Trial run
Inadmissibly high 1. Switch off the plant

torque
2. Replace defective parts
4. Trial run
Table 7-1 Troubleshooting table
In case of uncertainty or if you have questions, please contact our head office
(address see chapter 1).
7.2 Admissible overall misalignment of the coupling

The overall misalignment values can be found in the catalogue.

Chapter 10 Page 195
CX-50…78-GSS1-300
8 Care and maintenance
WARNING
The coupling requires low maintenance. We recommend a visual inspection at

the regular scheduled maintenance intervals for the whole unit.
8.1 Work to be performed

8.1.1 Cleaning the coupling
¾ Remove any loose dirt from the coupling.
8.1.2 Visual inspection of the coupling

¾ Inspect the coupling for cracks, chips or missing parts.
¾ Replace faulty and missing parts.
8.1.3 Visual inspection of the rubber elements / rubber segments
IMPORTANT
Exchange the rubber elements / rubber segments in the event that:
• The wear specifications given in W00-002 are exceeded
¾ Assess the rubber elements / rubber segments as described in CENTA

guidelines W00-002.
8.1.4 Inspection of the screw connections

¾ Check the tightening torque levels of all screws and if necessary, correct.
8.2 Replacing defective parts

¾ Remove the coupling as described in chapter 9.
¾ Replace wearing parts.
¾ Mount the coupling as described in chapter 6.

Chapter 10 Page 196
CX-50…78-GSS1-300
9 Dismantling
9.1 General dismantling instructions
Any work method which impairs the safety of the coupling is prohibited.
The user undertakes to notify the manufacturer immediately of any changes
occurring at the coupling which could impair safety (address see chapter 1).
IMPORTANT
The coupling is dismantled in reverse order to the assembly process.
Please refer to the illustrations in chapter 6.
WARNING
WARNING
Falling coupling components
Secure coupling components against falling to the floor.
WARNING
Dismantling of the coupling in the wrong sequence
Only ever dismantle the coupling in the described sequence.
IMPORTANT
Use suitable lifting devices for dismantling.

Chapter 10 Page 197
CX-50…78-GSS1-300
9.2 Dismantling the coupling

¾ Loosen the screws (1.2.11) of the connection membrane (1.2.1) and rubber
element (1.1) and remove with spacers (1.2.4), washers (1.2.13) and nuts
(1.2.8 , see fig. 6-9).
¾ Loosen the screws (1.2.9) of the connection membrane (1.2.1) and rubber
element (1.1) and remove with centring sleeves (1.2.5), washers (1.2.6)
and nuts (1.2.7 , 2x180° , see fig. 6-9).
¾ Loosen and remove the screws (1.2.10) of the connection locking ring
(1.2.3), membrane (1.2.1) and threaded ring (1.2.2 , see fig. 6-8).
¾ Pull locking ring (1.2.3) and membrane (1.2.1) off the centring of the hub (2)
and place on the hub (see fig. 6-3).
¾ Loosen and remove the screws (1.2.12) of the connection hub (2) and
threaded ring (1.2 , see fig. 6-7).
¾ Push the threaded ring (1.2.2) off the centring of the hub (2) and place in
the pre-mounted BG (C , see fig. 6-7).
¾ Loosen and remove the screws (1.5) of the connection hub (3) and pre-
mounted BG (C , see fig. 6-6).
¾ Pull the pre-mounted BG (C) off the centering of the hub (3) and remove
(see fig. 6-6).
¾ Remove threaded ring (1.2.2) off the pre-mounted BG (C , see fig. 6-5).
¾ Loosen and remove the screws (1.4) of the connection adapter ring (1.3) and
rubber element (1.1 , see fig. 6-4).
¾ Pull adapter ring (1.3) off the centring of the rubber element hub (1.1) and
remove (see fig. 6-4).
¾ Remove the membrane (1.2.1) and locking ring (1.2.3 , see fig. 6-3).
If necessary:
9.3 Dismantling the hubs

¾ Dismantle the hubs as appropriate for the supplied design.
¾ For hubs with feather key, see chapter 9.2.1 .
¾ For hubs with oil interference fit, see chapter 9.2.2 .
9.3.1 Dismantling hub with feather key

¾ Remove the hub (2) from the shaft (A , see fig. 6-1).

Chapter 10 Page 198
CX-50…78-GSS1-300
9.3.2 Dismantling hub with oil interference fit
WARNING
Non-compliance with the operating instructions for the hydraulic
pumps
Before carrying out work with the hydraulic pumps, do not fail to
read their operating instructions. Only ever work with hydraulic
pumps as described in their operating instructions.
WARNING
Hydraulic fluid spraying out
Use protective goggles.
WARNING
Injuries and material damages can occur by:
Suddenly loosening hubs
Secure the hub with a hydraulic tool against sudden axial loosening.
IMPORTANT
We recommend the following mounting fluids:
• For mounting:
Oil with a viscosity 300 mm2/s at 20°C, e.g. SKF LHMF300
• For dismantling:
Oil with a viscosity 900 mm2/s at 20°C, e.g. SKF LHDF900
¾ Connect the pump to the thread G1/4” (c) of hub (2) to expand the hub (see
fig. 6-2).
¾ Screw the pump to the shaft (B), in order to hold the hub.
¾ Build up oil pressure in order to hold the hub.

Chapter 10 Page 199
CX-50…78-GSS1-300
WARNING
Too fast increase of the expanding pressure in the hub
The increase of the expanding pressure may not exceed 35
bar/minute.
¾ Slowly build up oil pressure to expand the hub (pmax= 1500 bar).
¾ Slowly reduce the oil pressure for holding the hub.
¾ Slowly reduce the oil pressure for expanding the hub.
¾ Repeat the above mounting section until the hub is completely released from
the shaft.
¾ Remove the pump for holding the hub on from the shaft (A).
¾ Remove pump for expanding the hub from the hub (2).
¾ Turn the hub (2), drain oil out of the thread (c) and dispose correctly.
The remounting of the coupling is carried out as described in chapter 6.

Chapter 10 Page 200
CX-50…78-GSS1-300
10 Wearing and spare parts
WARNING
Mounting and/or utilization of non-original CENTA parts
Never use parts from other manufacturers.
A stock of the most important wearing and spare parts is the most important
condition to ensure that the coupling is functional and ready for operation at all
times.
We only provide a warranty for CENTA original parts.
Wearing parts of this coupling:

• Rubber element
• Membrane
When exchanging, all screw connections must be renewed. These must be

ordered separately.
When ordering a spare, specify:

• Order no.
• Coupling order no.
• Drawing no.

Chapter 10 Page 201
CX-50…78-GSS1-300
11 Annex
11.1 CENTA data sheet D13-013 (lubricated screw connections)
Validity:
For all non-dynamically stressed screw connections with lubricated shank bolts
in accordance with ISO 4014, ISO 4017 and ISO 4762 (DIN 912) with metric
standard thread in accordance with DIN ISO 262, unless other specifications are
given on CENTA documents.
Preparation of parts that are to be screwed together:
The joining areas must be free of dirt, preservatives and lubricants.
Preparation of screws that ARE NOT secured with liquid screw locking
medium:
Give the screws extra lubrication with motor oil under the screw head and in the
thread.
Preparation of screws that ARE secured with liquid screw locking
medium:
Give the screws extra lubrication with motor oil under the screw head. Remove
all grease from the thread.
Screw tightening method:
Screw in (by hand with torque wrench).

Chapter 10 Page 202
NOTES
Date:
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NOTES
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NOTES
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NOTES
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NOTES
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Brunvoll VoldaBrunvoll
AS, Hamnegata
Volda AS,
24, Hamnegata
P.O. Box 205,
24,N-6100
P.O. Box
Volda,
205, Norway
T: +47 700 59 000,
T: +47
T: Emergency:
700 59 000, T:
+47Emergency:
47 8 24 365+47
(after
47 8office
24 365
hrs), E: [email protected],
(after office hrs), E: [email protected],
W: brunvoll.no,W:
E No:
brunvoll.no, E No:
917 225 702 VAT917 225 702 VAT
NOTES
Date:
Sign:
Page 6 of 10
NOTES
Date:
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NOTES
Date:
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NOTES
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Brunvoll Volda AS, Hamnegata

Brunvoll Volda AS, Hamnegata
24, P.O. Box
24,205,
P.O.N-6100 Volda,
Box 205, Norway
T: +47 700 T:
59+47 T: Emergency:
000,700 59 000, T: Emergency:
+47 47 8 24+4736547(after
8 24 office E: [email protected],
hrs),office
365 (after W: brunvoll.no,
hrs), E: [email protected], E No: 917 225
W: brunvoll.no, E No:
702 VAT
917 225 702 VAT
NOTES
Date:
Sign:
Page 10 of 10

Cmhi19602 634 VCD Uds 017 Main Propulsion and Gears

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Installation Manual Please discard this when the final instruction manual is available.

Brunvoll Volda Propulsion System

Yard: China Merchants Heavy Industry Co., Ltd DMHI

Chapter 2 Technical data 1

Chapter 3 Technical description 1

Chapter 4 Preparation and Installation 1

Sheet No. Content Page

GAP and SAG Open Condition for inst.: 2313 19

Chapter 5 Operating instruction and emergency 1

Chapter 7 Spare parts and tools (per ship set) 1

Chapter 8 Brunvoll Volda Drawings and Manuals from Sub-suppliers 1

Sheet No. Content Page

604477BV Part list CW - V307066 8

Sheet No. Content Page

Chapter 9 Remote control. Manual and drawings 1

Chapter 10 Manual from Sub Suppliers and Notes 1

General - about this manual

Manual created: Volda 2019-11-18

Safety alert notices

Brunvoll Volda AS Tel.: +47 700 59 000

Direct all correspondence to our address:

End of Life Disposal

The iron, steel and copper can now be recycled.

Items requiring specialist treatment

Forward the reclaimed materials for recycling.

Storage and preservation instruction for propulsion systems

After curing of the VpCI

Lifting instruction for propeller shaft

Use fiber slings, never metal lifting devices in

What you need:

Lifting yoke must be approved for the weight to

What you need:

Lifting bolts (Red painted).

Gear box - side views

Check that the chains are not in

Chapter 2 Technical data

Sheet No. Content Page

Sheet No. Content Page

Technical data - Brunvoll Volda Installation no.: 2312-13

Stern tube bearings

Bearing Clearance Min Max

Aft stern tube bearing (new) 0,65 0,839

Intermediate shaft bearings

Electric oil pumps

Main Gear AG600

Lubrication recommendation for Brunvoll Volda equipment - Biodegradable oils

* In addition - Gears with Ortlinghaus, HPC and LK clutches - the oil

Biodegradable oils can be used, see next page.

Bulkhead Seal -Oil Tank lubricated / Gas-tight Bulkhead Seal -None

Change of oil in service

* See Ch.6 Maintenance.

Biodegradable Oil list for Stern tube and Propeller hub

Klüberbio is the brand Brunvoll Volda AS has approved.

Klüberbio RM 2-100, 2-150

Product data Klüberbio RM 2-100 Klüberbio RM 2-150

Klüber Lubrication München SE & Co. KG /

Klüber Lubrication München SE & Co. KG /

Blade bolts: See propeller assembly drawing

if not anything specified in relevant documentation use standard torque according to