Wca-16 Rolls Royce - 250 TV Bow & Stern Tunnel Thrusters PDF

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SERVICE MANUAL
UNIT NO: I 8 2 5 3
TYPE: 250 TV
YARD: AUKRA INDUSTRIER
HULL NO: 110
r ----- . - - --
INFORMATION
1
SERVICE
DETAIL
2
DESCRIPTION
3 INSTALLATION
4 DRAWINGS
5 ENCLOSURES
Rolls-RoyceMarine AS
Dept. Propulsion - Ulstein
Sjogata 98, N-6065 Ulsteinvik, Norway
Te1.+477001 4000- Fax+477001 40 14 (adm.)
Fax +47 70 01 40 12 (service)
Service manual and part list for

Rolls-Royce Marine AS
Dept. Propulsion - Ulstein
250 TV
Type: ................................................................
T8253
Plant no:...........................;........ ...........................
ROLLS-ROYCE MARINE AS
Dep. propulsion - Ulstein
6065 ULSTEINVIK
1RolIs-Royce
lam
Teleph: 47 700 14000

Telefax: 47 700 14011
a- PAGE: 1 of 22
IMPORTANT
BOW AND STERN TUNNEL

THRUSTERS
IN ORDER TO PROTECT THE TUNNEL

THRUSTERS FROM EXTREME LOADS,
BOW AND STERN THRUSTERS SHOULD
NOT RUN WITH LOAD (PITCH) WHEN
SHIP SPEED EXCEEDS
- 6-7 KNOTS .
6065 ULSTEINVIK
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I ROLLS-ROYCE MARINE AS - SERVICE MANUAL I

This manual contains a technical description of installation, operation and maintenance of a
KAMEWA ULSTEIN TRANSVERSE THRUSTER TYPE 250 TV-D.
The manual has been compiled to assist personnel responsible for the operation and
maintenance of the thruster and should therefore always be available for the technical staff.
Our service department will provide any technical information required after start up of the
installation.
The manual should be used as guide for ordering spare parts. It is recommended to use only
original spare parts from our spare parts stock. During the guarantee period this is imperative
if the guarantee should be valid.
Note that on the description pages, a figure reference is given on the top right corner. This
reference is according to a reference given on corresponding drawing.
The drawings will be found after the descriptions.
The parts on each drawing are given an item number. Description, article number and
quantity of each part are given in the parts list for each specific drawing.
When ordering spare parts, following information must be given.
1. NAME OF VESSEL AND OWNER'S ADDRESS. IF POSSIBLE, NAME AND

ADDRESS OF THE BUILDING YARD.
- .
2. TYPE OF INSTALLATION, NUMBER AND YEAR OF MANUFACTURE.
3. THE SPARE PART'S ARTICLE NUMBER, DRAWING NUMBER AND

DESCRIPTION OF THE PARTS.
Dep. propulsion .
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INSTRUCTION CONTENTS
INFORMATION Page
Instruction for use of the manual ..................................................................................... 1
Instruction contents .........................................................................................................
2
Drawing contents.............................................................................................................
3
Technical data for thruster type 250 TV-D .....................................................................4
Spare parts and tools .......................................................................................................
5
SERVICE
Maintenance ....................................................................................................................
6
Lubricants for 250 TV-D .414498 .................................................................................
7
DETAILED DESCRIPTION
General information ........................................................................................................8
Tunnel and gearhousing .................................................................................................. 9
Servo system .................................................................................................................
11
Start and stop .................................................................................................................
12
Remote control ..............................................................................................................
13
INSTALLATION
Installation of tunnel into the hull ................................................................................. 14
Installation of the propeller unit .................................................................................... 15
Removal of propeller unit ............................................................................................. 16
Inspection of pinion shaft and dismounting of gear unit ............................................... 17
Adjustment of pinion shaft and gear wheel ................................................................... 18
Hydraulic system ...........................................................................................................
19
The different hydraulic valves ....................................................................................... 20
..
~nstallationof electric motor ..........................:.............................................................. 21
DRAWINGS
Drawings & Partslists ................................................................................................
22+
Dep. propulsion .
6065 ULSTEINVIK
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DRAWING CONTENTS
Dimension drawing ..........................................................................................2 16 141-A

Location of transverse thruster tunnel ...............................................................P20606 F
Transverse thruster ..........................................................................................
106083-G
Propeller shafi seal box ...................................................................................
By rakesh at 5:27 pm, 7/24/07 3 10213-A
Correction of gearwheels ...................................................................................... P4055 1
Piping diagram ................................................................................................
21 5664-C
Hydraulic module .............................................................................................
21 5778-A
Gravity feed tank .................................................................................................
215800
Location of gravity tank ................................................................................ .415865-A
Manoeuvre unit, el . hydr ..................................................................................2 14164-C
Dimension drawing Elmotor ABB ............................................................ M2FA 400LK
Motor data sheet ...............................................................................................
16216 1 17
Drive motor starter drawings .......................................................................... 9584-01-08
I ENCLOSURES I
Instruction for servo pump. Commercial. P3 1A187-BE ...................................990824

Instruction for oil filter. EPE 160LE ................................................................. 990601
Instruction for proportional valve. Danfoss PVG 32 ..........................................86740
Instruction for pressure switch. Danfoss KPS 43 ................................................ 94255
Instruction for level switch. Kiibler BNA DN1SPN .........................................99 1576
Additional Information motor ............................................................................... ABB
Machine Instructions motor .................................................................................
M3000
ROLLS-ROYCE MARTNE AS
6065 ULSTEINVIK 9
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[ RolIs-Royce
lmm
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I TECHNICAL DATA FOR THRUSTER TYPE 250TV I

Transverse Thruster No.: ..........................................................................T8253
Delivered: ................................................................................................................
2003
Owner: ......................................................................................................
PAT Offshore
Yard :..................................................................................................
Aukra Industrier
Yard No.: ....................................................................................................................
110
Vessel name: ....................................................................................................................
Type of vessel: .................................................................................................UT-755L
Classification: .........................................................................................................
DNV
Propeller diameter: ............................................................................................ 1880 rnrn

Number of propeller blades: ............................................................................................ 4
Propeller speed: ................................................................................................... 391 rpm
Reduction ratio: ......................................................................................................3.07:l
Drive motor: ............................................................................................................
ABB
Type:......................................................................................................
M2FA4OOLKA6
Speed: ................................................................................................................
1200 rpm
Rated Voltage Un ......................................................................................... 440V 1 60Hz
Max. Power: ......................................................................................................... 590 kW
Servo Oil Pump: ................................................................... COM. P3 lA187BE**07-30

Max. power: ..........................................................................................................
3 5 kW
Oil capacity: ........................................................................................................
40 llmin
Max. oil pressure: ....................................................................................................
50 bar
Oil pressure on manoeuvring unit: .......................................................................... 20 bar
Oil quantity thruster unit and gravity feed tank:..; .................................approx. 240 litres
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SPARE PARTS AND TOOLS
Following spare parts are delivered with the unit:
Quant. Description Art. no.
2 pcs. Filter element, EPE .........................................................................9906 18

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MAINTENANCE:
Daily before start up:
1. Check oil level in gravity feed tank and fill up if required.
After the first 200-300 and after each 6000 hours of operation:
2. Change oil in the hydraulic system (approx. 240 litres), and oil filter element. Oil
should be tested if seawater is mixed into it. If so, oil to be changed and the reason
must be found.
During each docking:
3. Zink anodes at tunnel ends should be changed if required.
Yearly:
4. Check if seawater is mixed into the oil. If so, oil must be changed and reason found.
Oil filter element should be changed.
l33a3
Rolls-Royce
6065 U L S T E W I K
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LUBRICANTS FOR 250 TV-D - 414498

.'
Ulstein Propeller AS.
Title: Lubricants for Reduction Gears w/cIutch. 1'2

Type:
- - 100,180,220,520,600,1500,2400,2500,3000 AGSC, 4500,6000 AGC
lovers, also reduction gears with servo in propeller hub
2 12 =9
5 TeressoSHP 150 2 12 = 8-9
5 Teresso S H P 220 2 12 =9
M Fina Giran 100 2 12
M Fina Giran 150 1 12
S FrnaGimnP150 2 12
I
S FiaGiran P220 112
Mobil S Mobilgear SHC 150 2 14 =9
S Mobilgear SHC 220 2 14 = 9-10
+
S Mobil SHC 629 (142 cSt) 2 12 = 10
S Mobil SHC 630 (218 cSt) 112 2 10
M Mobilgear 629 (143 cSt) 2 12 =9
M Mobilgear 627 (100 cSt) 2 12 = 8-9
Roy a1Purple' S Synergy 150 2 12
S Synergy 220 2 12
Shell S Paolina 150 112
** S Paolina 220 112
S HyperiaS150 2 12
** S HyperiaSZO 1 12
S - 0mala HD 150 2 13 = 10
** S OmalaHD220 2 13 210
I I I
Statoil S Mereta 150 2 12 = 10
** S Mereta 220 2 12 2 10
Texaco
**
S
S 1 Pinnacle Marine gear 150
Pinnacle Marine gear 220
Page 1 of 2
M = Mineral oil
S = Synthetic (Mainly pol'lphaolefine based oils)
* To be used in Arctic waters only
** This viscosity grade to be preferred, but Ulstein Propeller to approve use in each
case.
*** To be approved by Ulstein Propeller in each case.
PS: Lubricants of toothed coupling, shaft bearings and sterntube g l a d to be in

accordance with each manufacturer's specification.
-Revisions 1 A 17540 1 B 17912 1 C 18134 ( D 18494 ( E 18696 1

1 21.10.96 1 14.03.97 1 28.05.97 1 30.09.97 1 14.1 1.97 )
C h s code: ) Drawing no.: ( Date:
60001 1 414491 E 1 10.09.96
Page 2 of 2
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DETAILED DESCRIPTION
GENERAL INFORMATION
Rolls-Royce Marine transverse thruster, type 250 TV is constructed for vessels where high
degree of manoeuverability is required. Type and size of transeverse thruster dependens of
type and application of the vessel.
Usually one thruster is installed in the bow of the vessel. However, one or more thrusters may
be installed aft and in the bow if required.
The thruster is normally driven by an electric motor running at constant speed, or by a diesel
engine.
The servo oil pump is driven by a seperate electro motor for supply of hydraulic oil.
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TUNNEL AND GEARHOUSING
The thruster unit has a tunnel which is made of steel and welded into the hull. The
gearhousing is made of cast iron and connected to the tunnel with a flange connection. It is
supported by two struts, which are welded to the inside of the tunnel after the gearhousing is
installed in correct position.
On top of the tunnel, the motor frame is installed, on which the electric motor is mounted.
The power from the motor is transmitted via a flexible coupling to the pinion shaft and the
bevel gear to the propeller shaft and propeller.
The pinion shaft is in upper part supported by two axial roller bearings in a common housing.
In lower part it is supported by a roller bearing. This one can be splitted from the outer ring.
This construction is to ease the dismantling of the pinion shaft for service.
The truster unit is designed for anticlockwise rotational direction of propeller seen against
propeller. It can also be delivered for clockwise direction of rotation. However, this means a
new design of propeller blades.
The pinion and shaft is forged in one piece. The gear wheel is connected to the coupling boss
with bolts. The helical teeth on pinion as well as gear wheel are grinded and hardened. The
coupling boss is connected with a key connection to the propeller shaft. The propeller shaft
and the propeller hub is produced in one piece. The boss is locked for axial movement with
the shaft nut, which is secured with socket screw.
The servo cylinder is connected to the coupling boss with common screws as the gearwheel.
The screws should be locked with locking device.
Between propeller hub and gear housing a stem tube seal is installed. The seal is protected by
the rope guard.~hipropeller cap is connected to the propeller hub with hex screws, which is
locked with a locking device.
The propeller has 4 blades with adjustable pitch. To achieve correct tolerance between
propeller blade tips and tunnel, the tunnel is machined inside in the area where the propeller
is running.
The propeller shaft is in the aft end supported by two spherical roller thrust bearings.
In front end the shaft construction is supported by a cylindrical roller bearing.
a3233
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The servo piston is installed in the servo cylinder. It is connected to the piston rod, which is
installed in the hollow bored propeller shaft. The servo piston is locked with the shaft nut.
The piston rod is supported by two liners. One in the fore end and one in the aft end of the
propeller shaft. Additional it is supported in the propeller hub.
At fore end of the piston rod, the oil distribution ring for the servo cylinder is fitted.
When the lever is moved, the movement is transformed via the manoeuvring shaft to the oil
distribution ring.
The axial movement of the piston is transformed via the piston rod to the cross head into
which the sliding block pin is fitted. The sliding shoe is fitted in a groove machined radial in
the blade disk. The propeller blade is connected to the blade disk with blade bolts, which is
locked with locking wire. The axial movement is in this way transformed to pitch setting of
the propeller blades.
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SERVO SYSTEM
The servo system is a closed circulation system, where the servo pump driven by an electric
motor supplies oil through the pipe line and different valves, to the oil distribution ring. The
pump also supplies oil to the servo cylinder in the electro hydraulic control unit for propeller
pitch. As the gravity feed tank should be installed at higher level than the servo pump, the
pump will have a low feed pressure to the suction port.
The oil pressure to the auxiliary servo cylinder is reduced in an adjustable pressure reduction
valve. Return oil from the servo cylinder is evacuated to the gear housing in common pipeline
as oil from the pressure relief valve.
The thrust is controlled by regulating the blade pitch from zero to maximum in both
directions. As the blades are symmetrical, the thrust will be approximate the same in both
directions.
There is a unique arrangement of oil ports in the oil distribution ring and piston rod. This
means that a hydraulic balance at each side of the servo piston is kept independant of the
force on piston rod caused by the propeller pitch.
When the oil distribution ring is moved by means of the control lever, oil flows to the
corresponding side of the servo piston. That means a hydraulic unbalance, and the servo
piston will be moved. The movement is transmitted to the piston rod fitted in the propeller
shaft. The propeller pitch is accordingly altered until the desired pitch is achived. The
hydraulic balance then keeps the piston in this position.
There is a negative overlap between the inlet and exhaust ports in the oil distribution ring and
the piston rod. This ensures a continous flow of oil through the return pipe for lubrication
purpose, while keeping the oil distribution ring in fixed position.
- .
D.
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START AND STOP
Start and stop of the servo pump is carried out from the main panels on bridge and from the
starter box. When the start switch for servo pump is in "ON" position, the servo pump will
start when "START SERVO PUMP" button is pushed. If the manoeuvring levers in the
remote control panels are in "ZERO PITCH" position, the drive motor will start
automatically when "START THRUSTER BUTTON'' is pushed as soon as the minimum
operating servo pressure is obtained.
The thruster must always be started when propeller blades are in "ZERO PITCH
T
POSITION". That means that the levers in the Remote Control Panels should be
synchronized so that they are simultaneously in zero position. If not, the motor will not start.
When the starter for the drive motor automatically is set from star to delta position, the
thruster is ready for operation. That means that pitch can be set to obtain required thrust. This
is indicated with a green light "IN OPERATION" in the remote control panels.
Light in "IN COMMAND" button indicates which panel is in command.
To stop the thruster, press the button for stop drive motor. If the servo pump is stopped first,
the drivemotor will stop automatically as soon as the minimum operating servo pressure is
obtained.
Dep. propulsion - Ulstein Em3
RolIs-Royce
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REMOTE CONTROL.
Remote control of propeller pitch is carried out by a electro hydraulic control system. If
required, several control panels for installation in different positions can be supplied.
For operating the pitch control lever a auxilary servo unit is installed on top of the the thruster
unit. With electrical signals from control panels, the solenoid direction valve is actuated.
This will distribute oil to the hydraulic actuator, which will operate the lever. The oil
distribution ring is then moved in desired direction and position.
The movement of the hydraulic piston is transmitted to the potensiometer. Electrical signal
from the potensiometer is transmitted to the position indicators in the control panels.
For detailed descriptions of the electric part of the remote control, se seperate manual.
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INSTALLATION
INSTALLATION OF TUNNEL INTO THE HULL
The thruster tunnel is manufactured of welded steel plates, normally approved by Det Norske
Veritas. The tunnel is delivered from the factory with machined top flange and welding
grooves in both ends.
The yard has to extend the tunnel to the hull's shell plating by using steel plates of similar
thickness. The diameter of the tunnel extension must correspond with the diameter of the
thruster tunnel. Edges of each end of the tunnel extension
have to be shaped according to drawing P 20606.
When the bow tunnel is installed, a conical entrance shell plating should be arranged aft of
the tunnel. In both ends of the tunnel a grinder should be installed. (See drawing P 20606).
During installation of the tunnel, welding must be carried out in such a way that a
minimum of welding distortions arise in the tunnel.
With exception of what is necessary for lengthening the tunnel, welding must be avoided.
Therefore, grinders floors etc. should not be welded to the tunnel, but only to the tunnel
extensions.
Drawings showing welding of the tunnel and tunnel extension to the hull, as well as grinder
and stantion arrangement, may be sent to Rolls-Royce Marine AS for approval.
For protection against corrosion, three zink anodes should be fitted to each end of the tunnel.
Dep. propulsion - Ulstein lmm
RolIs-Royce
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INSTALLATION OF THE PROPELLER UNIT.
When delivered from factory, the gearbox is complete assembled and ready for installation in
the vessel. The pitch control lever must be dismantled before installing the gear unit in the
tunnel. (See section Removal).
Installation is carried out in the following way:
The complete gear unit with propeller blades in aft position is fitted to a strong base or
similar. The base with the gear unit is pulled into the tunnel. Take care that the gear
unit is inserted from correct side.
Before the bevel struts are mounted, the gearbox may be inserted in the tunnel from
oposite side. However, then with propeller blades in forward position.
Clean the tunnel and the gearbox flanges well and insert the "0"-ring in the groove.
Blank flanges and plugs, if any, as well as stud nuts must be removed.
Strap a solid rope to the coupling flange. Lift the propeller unit into position.
Note! The shaft flange must be secured with a plate and a socket screw.
Connect washers and hexagon nuts to the shortest studs. Check that the clearance
between the tunnel and propeller blade tips is equal in all positions. The nuts should
then be well tightened.
Connect the hexagon screws for the bevel struts and thighten them well. The screws
should be locked with stainless steel wire. When the tunnel and gear unit is delivered
from the factory as one assembled unit, the struts are installed at the factory. If the
tunnel is delivered before the gear unit, the struts have to be adjusted and welded by
the yard. ..
Take care that welding distorsions areminimal.
The pitch control lever, manoeuver unit, motor frame and remaining screws can now
be installed.
NOTE: All oil connections must be protected to prevent water or impurities from
penetrating. Blind flanges and plugs must not be removed until pipes are
connected.
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6. After the installation of the gear unit to the tunnel is completed, the grids at the tunnel
ends should be installed. Before the vessel is launched, oil must be filled into the
gearbox and gravity feed tank, see section "The Hydraulic System".
REMOVAL OF PROPELLER UNIT
When the gearbox with propeller unit should be removed following procedure has to be
carried out:
1. Remove the drive motor from the motor adapter.
2. The oil should be drained from the gear housing.

This can be carried out by running the servo pump, with disconnected pressure pipe
and drain from this.
If the gearbox should be complete emptied, this may be done after removing the
pinion shaft, or by removing the plug when the vessel is in dock.
Remove the manoeuver unit, the oil pipes and the pitch control lever.
3. Disconnect the studs and remove the motor adaptor. Strap a solid rope to the coupling
flange.
Note! The flange must be secured with a stop plate and a socket screw.
Disconnect the screws. Lower the gear box and blind the open holes before the gear
unit is pulled out of the tunnel. This is important to prevent dirt from pentrating into
the gearhousing.
Dep. propulsion - Ulstein mZ3
Rolls- Royce
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INSPECTION OF PINION SHAFT AND DISMOUNTING OF GEAR UNIT
1. Disconnect the screws and lift the complete pinion shaft for inspection. If the roller
bearings should be replaced, adjustment of the bearings's backlash is required. Gear
wheel clearance should also to be checked and adjusted if required. (See separate
instructions below).
2. The gearwheel can now be inspected.
If the propeller shaft and the piston rod are to be dismantled, we recommended to
remove the gear unit from the tunnel.
When removing the servo shaft unit following procedure to be followed:
3. Remove the cone fairing, the circlip, the rope guard and screws.
4. The complete propeller shaft with servo unit can now be dismounted from the
gearbox.
5. When the seal should be removed, the servo cylinder, the servo piston, coupling boss
and the bearings must be removed. If bearings are replaced, adjustment of the
gearwheels have to be checked.
6. Marks on gearwheel should correspond with marks on coupling boss.

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ADJUSTMENT OF PINION SHAFT AND GEAR WHEEL
When the gear unit is initial assembled, and when assembling after changing bearings or
dismantling of gearwheels, adjustment of gear wheels has to be carried out.
The tooth contact patterns are to be verified by using a thin

"Dyken Red Lacquer" applied before the test. The contact patterns should be according to
drawing P4055 1.
Adjustment of gearwheels is carried out as described below:
1. For adjustment of the pinion shaft:

If the distance is too small, adjust the spacer between lower bearing and pinion.
If the distance is too large, machine the flange of bearing housing.
2. For adjustment of the crown wheel:

If distance is too small, machine flange between coupling and crown wheel.
If distance is too large: Weld an extra layer on the distance ring between the forward
bearing and coupling, then machine the distance ring.
The tooth clearance measured at the tooth periphery should be 0,25 - 0,35 nun.
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HYDRAULIC SYSTEM
The hydraulic system consists of an electric driven servo pump, a valve unit and a gravity
feed tank with connecting pipe lines. The gearhousing has the function as oil sump.
A gravity feed tank should be installed acording to calculations in drawing 415865.

This means that oil pressure in the gear housing will be a little higher than surrounding water
pressure. The gravity feed tank also has the function as expansion tank. In the gravity feed
tank a level switch is installed. This should be connected to the ship's alarm circuit.
When connecting pipes to the pump care must be taken that the suction and pressure pipes are
fitted to correct port of the pump and that rotational direction of the pump is correct. The
pipes must be free for burrs, rust, slag or impurities.
The pipes from the gearbox to the gravity feed tank should rise all the way to avoid air in the
pipe system. The easiest way for filling oil into the hydraulic system, is to fill into the gravity
feed tank. During filling oil to the tank, care must be shown so that the tank not is complete
emtied, causing air being mixed into the oil.
The electric driven servo pump supplies oil to the different components in the hydraulic
system, see piping diagram.
The servo system is function tested at the factory. The different hydraulic valves have to be
final adjusted during start up on board the vessel.
With referance to drawing 11935, the different valves in the valve block unit concists of:
Pos.no. Desciption
2: Solenoid valve - 4/3 direction valve

18: Safety relief valve
16: Pressure reducing valve
17: Sequence valve (pressure regulating valve)
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THE DIFFERENT VALVES
1. SOLENOID VALVE: The solenoid valve is controlled by electric signals from the
bridge panels. When the valve is actuated it supplies oil to the different ports of the
pitch control actuator. The movement of the control lever connected to the actuator, is
transmittet to the oil distribution ring which distributes oil to corresponding side of
the servo piston.
SAFETY RELIEF VALVE: The safety relief valve prevents oil from exceeding
permitted pressure. It should be adjusted to approximate 50 bar. This is obtained by
throttling the sequence valve until no oil is flowing through it. The safety relif valve
should then be adjusted until the pressure gauge indicates 50 bar. The sequence valve
is then set back to approx. 25 bar. During normal operation, no oil from hydraulic
pump will flow through the pressure relief valve. If a rope, a net or similar is coming
into the propeller, the servo pressure will increase. To protect blades and servo
mechanism from being damaged, the pressure relief valve will release servo pressure
at 50 bar.
3. PRESSURE REDUCING VALVE: The servo pressure is variable between 20 and

50 bar dependent on pitch during operation. The pressure reducing valve is installed to
secure constant oil pressure to the solenoid valve and the hydraulic actuator on
manoevring unit. The pressure reducing valve should be adjusted to 20 bar.
4. SEQUENCE VALVE: The oil coming from the servo pump will flow in the easiest
direction. When pitch regulating mechanism not is operated, all oil will flow through
the sequence valve. When pitch mechanism is operated, some oil will flow through
the pressure reducing valve for operating the pitch control actuator.
To prevent all oil from flowing through.the

. oil distribution ring without resistance, the
sequence valve is installed. The sequence valve should bed adjusted to 25 bar, and
thereby provide this as minimum system pressure.
ROLLS-ROYCE MAEUNE AS
Dep. propulsion - Ulstein mrm
RolIs-Royce
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OIL PRESSURE GAUGES: Oil pressure gauge is connected after reducing valve. This
gauge shows the control manoeuvring pressure. Main pressure gauge is connected to the
system between pressure relief valve and sequence valve.
PRESSURE SWITCH PANEL: On pressure switch panel, two pressure switches are
installed. The one for "Alarm low servo pressure" has set point 14 bar. The other for "Auto
stop low pressure" has set point 12 bar.
INSTALLATION OF THE ELECTRIC MOTOR
The electric motor should be fitted to the motor adapter with screws. Connection between
motor shaft and pinion shaft is a flexible copling. The dimension drawing of the thruster,
shows details of motorlgear connection.
During installation of motor, care must be taken to prevent damage of the cogwheel rim in the
flexible coupling.
Separate instructions for the electric motor and starter is enclosed.

TYPICAL ARRANGEMENT
OF THRUSTERS
RETTLEDNING FOR INNBYGGING AV TUNNEL I SKROG.

GUIDE FOR LINES DESIGN OF THE THRUSTER TUNNEL I N THE HULL
-----
DETALJ E
ETAIL E
V i rke l en Ol svhenger ov
STMINSSFCRKLEM
l c n y skipssiden og k m
b e s t e m s ek-t bore H c r i s m t a l e r i b b e r 1P.eks. 4 stkl
E D M30aLFa(SW. H c r i z m t o l rib. 10.0. 4 r i b s 1
TI+ ANXE a OEHMS ON

t h e direction of Plow Vertikale r i b - 1 P . k . 4 stkl
Vertical r i b s l e . ~ .4 r i b s 1
a l o n g t h e s h i p ' s side and
con be decided e x a c t l y
I by model t d t e s t m l y .
FOR A WPM BEST U I G EFFEKT. MA

/ T U M E N G 3 A 5 51 KCRT YM Mll G
IJFR.CI 0.3 PLASSERES 5.4
LANGT FORUT SOM MULIG.
-/-- To o b t a i n t h e maximum o f t h r u s t
-7 t h e tunnel s b l d be made os s h o r t
as p o s s i b l e ( r e r . C ) and located
neo-est p o s s i b l y t o the stem.
N-6065 U l s t e i n v i k , NORWAY
Tel.: +47-700-14000
%? CHECK OF
Check t h o t t h e FEEDBACK
avid r o i l is
C o r r e c t mounted o c c o r d l n a t o
t h e reedbock n i p p l e ond shot
t h e reedbock s l i d e s o h .
MllEi
Flonees i n c o n t a c t W i t h seo
woter t o be degreosed ond
t h r e o t e d r t h L o c t l t e 573.
PROPELL
Sw Larlill
lab11 270
Scale 1:2 section A - A

Rev. Vgr.
G T99P 3'
Posnr. Artmr. Betegnelse Antall Enh.
Item Art.no. Description Quantity Unit
O-RING 1 STK
O-RING
O-RING 1 STK
O-RING
LAGERSKJOLD 1 STK
BEARING CAP
TETN.RING 1 STK
SEAL RlNG
DEKSEL SERVOSYLINDER 1 STK
COVER SERVOCYLINDER
TREKKSTANG 1 STK
ACTUATING ROD
EMNEBOLT 0 8 M
ROUND BAR 0
SYL.SKRU 48 STK
SOCKET SCREW
TAPPSKIVE 4 STK
CRANK PIN RlNG
MONEL-SKIVE 0 48 STK
WASHER MONEL 0
BLADTETNINGER 4 STK
SEAL RlNG PROP.BLADE
MEDBRINGERKLOSS 4 STK
SLIDE SHOE
BLADBOLT 24 STK
BLADEBOLT
STYREPINNE SYL. 0 8 STK
DOWEL PIN CYL. 0
LASETRAD 0 2 M
LOCK WIRE
MONT.FLENS 1 STK
MOUNT.FLANGE
LAGERHUS 1 STK
BEARING HOUSING
LAGERHUS 1 STK
BEARING HOUSING
SYLSKRU 8 STK
SOCKET SCREW
LAGER SKF 1 STK
BEARING SKF
STYRERING 1 STK
GUIDE RlNG
02.06.03 ~ 2 : 2 3 : 1 0 Page 1 of 9
Rev. Vgr.
G T99P
32
Posnr. Altnr. Betegnelse Antall Enh.
Item Artmo. Description Quantity Unit
SEEGERRING 1 STK
ClRCLlP
GEARHUS 1 STK
GEAR HOUSING
SLANGE 2 STK
HOSE
HYDR.RBR 3 M
HYDR.PIPE ST
LAGERHUS 1 STK
BEARING HOUSING
EO-KROPP G 2 STK
EO-BODY G
EO-KROPP GE 9 STK
EO-BODY GE
SYLSKRU 10 STK
SOCKET SCREW
SEEGERRING 1 STK
ClRCLlP
O-RING 1 STK
O-RING
EO-KROPP GE 1 STK
EO-BODY GE
PINNESKRU 1 STK
STUD
LASESKIVE LlMT 24 STK
LOCK WASHER CLUED
LAGER SKF 2 STK
BEARING SKF
LAGERHUS 1 STK
BEARING HOUSING
DIST.RING 1 STK
SPACER
AKSELMUTER KMT 1 STK
COLLAR NUT KMT
PAKNING MULElPAPlR 1 STK
GASKET MULElPAPlR
6K.MUlTER 24 STK
HEX.NUT
SYL.SKRU M 4 STK
SOCKET SCREW M
O-RING 1 STK
O-RING
02.06.03 12:23:if Page 2 of 9

Rev. Vgr.
G T99P 33
Posnr. Artnr. Betegnelse Antall Enh.
KlLE 1 ' STK

KEY
SYL.SKRU 8 STK
SOCKET SCREW
O-RING 2 STK
O-RING
KJEDE 1,l M
CHAIN
SENKESKRU 5 STK
CONTERSUNK SCREW
SYLSKRU M 6 STK
SOCKET SCREW M
BRAKETT STYRETR. 1 STK
BRACKET FEEDBACK
SYLSKRU 12 STK
SOCKET SCREW
KJEDESTRAMMER 1 STK
CHAIN STRETCHER
SYL.PASSKRU M 1 STK
CYL.FIT.SCREW M
LASEMUTTER M 1 STK
LOCK NUT M
FEEDBACKARM 1 STK
FEEDBACKARM
BRAKETT FEEDBACKARM 1 STK
BRACKET FEEDBACK
PLUGG 2 STK
PLUG
FORING 2 STK
BUSHING
O-RING 2 STK
O-RING
KAPSEL 1 STK
COVER
SEEGERRING I 2 STK
ClRCLlP
0LJEINNF.RING 1 STK
OIL INLET RING
SYL.SKRU 1 STK
SOCKET SCREW
PLUGG 3 STK
PLUG
02.0503 12:23:if Page 3 of 9

106083 ARR.THRUSTER Rev. Vgr.
62200.106083 ARR.THRUSTER G T99P 34
Posnr. Altnr. Betegnelse Antall Enh.
LAGERHUS 1 STK
BEARING HOUSING
O-RING 3 STK
O-RING
LAGER SKF 1 STK
BEARING SKF
PLUGG 1 STK
PLUG HEX
AKSELFORLENGER 1 STK
SHAFT EXTENSION
SYLSKRU 16 STK
SOCKET SCREW
STEMPELRING 2 STK
PISTON RING
'SE ORDRE 1 STK
'SEE ORDER '
RORKLEMME HYRO 1 STK
TUBE CLAMP HYDRO
LAGER SKF 2 STK
BEARING SKF
DIST.RING 1 STK
SPACER
AKSELMUlTER KMT 1 STK
COLLAR NUT KMT
PINNESKRU 8 STK
STUD BOLT DIN
'SE ORDRE ' 1 STK
'SEE ORDER
SYLSKRU 8 STK
SOCKET SCREW
BESKYrrELSEKAPSEL 1 STK
ROPE GUARD
PLUGG 4 STK
PLUG TAPER
PROPELLAKSEL 1 STK
PROPELLER SHAFT
FORING 0 1 STK
LINER 0
MUTTER 1 STK
NUT
O-RING 1 STK
O-RING
02.06.03 rz.z3:11 Page 4 of 9

Rev. Vgr.
G T99P 35-
Posnr. Art.nr. Betegnelse Antall Enh.
SEEGERRING I STK
ClRCLlP
PLUGG STK
PLUG HEX.
SENKESKRUM STK
CONTERSUNK SCREW
STYRESKIVE STK
GUIDE DISC
SKWEKLOSS STK
CROSS HEAD
KOPL.HYLSE STK
LINER
PROPELLHODE STK
PROPELLER HUB
PAKNING MONT.STEMPEL STK
SEALING MOUNTING PISTON
MONT.STEMPEL STK
MOUNTING PISTON
O-RING STK
O-RING
KULlSSERlNG STK
GUIDE RING
EO-PLUGG VSTl STK
EO-PLUG VSTl
KULISSEKLOSS STK
SLIDE BLOCK
PASSBOLT NON ST. STK
FITTED BOLT
SYL.PASSKRU STK
CYL.FIT.SCREW
LASEMUTER STK
LOCK NUT
STYREPINNE SYL. 0 STK
DOWEL PIN CYL. 0
LEDETRINSE STK
GUIDE WHEEL
SYL.PASSKRU STK
CYL.FIT.SCREW
UNDERLSK ST STK
PLAIN WASHER ST
SYL.SKRU STK
SOCKET SCREW
02.06.03 fz:z3:11 Page 5 of 9

Rev. Vgr.
G T99P 36
Item Artno. Description Quantity Unit
TRUSTRING 1 STK
THRUST RlNG
DIST.RING 1 STK
SPACER
SYL.SKRU M 2 STK
SOCKET SCREW M
LASESKIVE LlMT M 10 STK
LOCK WASHER CLUED M
BRAKElT L&ING AKSELMUTTER 1 STK
BRACKET LOCKING SHAFT NUT
BRAKETT KJEDESKINNE 1 STK
BRACKET GUIDE RAlL
LEDESKINNE KJEDE 1 STK
GUIDE RAlL CHAIN
MONEL-SKIVE 0 24 STK
WASHER MONEL 0
LOCK WASHER CLUED
6K.MUlTER 8 STK
HEX.NUT
FLATSTAL 02 M
FLAT STEEL BAR
SYL.PASSKRU M 5 STK
CYL.FIT.SCREW M
NR.VENTIL RHZ 1 STK
NR.VALVE RHZ
STDTTERING PTFE 4 STK
BACKING RlNG FOR O-RING
GJSTIFT M 3 STK
GRUB SCREW M
LOCK WASHER CLUED
LOCK WASHER CLUED
LASEPLATE 1 STK
LOCKING PLATE
O-RING 1 STK
O-RING
PLUGG 2 STK
PLUG
SYLSKRU 1 STK
SOCKET SCREW
- --
Page 6 of 9
Rev. Vgr.
G T99P %'
Posnr. Artm Betegnelse Antall Enh.
SYL.SKRU M 2 STK
SOCKET SCREW M
SYL.SKRU M 2 STK
SOCKET SCREW M
LASETRAD 0 0,1 M
LOCK WIRE
STOPPER 1 STK
STOPPER
KJEDELAS 2 STK
CHAIN CONN.
PAKNINGSHUS 1 STK
SEAL HOUSING
GLIDERING 1 STK
RUNNER RlNG
O-RING 1 STK
O-RING
TETN.RING 2 STK
SEALING RlNG
EO-KROPP EGE 1 STK
EO-BODY EGE
EO-KROPP EW 2 STK
EO-BODY EW
6K.MUTER 1 STK
HEX.NUT
O-RING 1 STK
O-RING
O-RING 1 STK
O-RING
STANG FEEDB. 1 STK
ROD FEEDB.
NIPPEL FEEDBACK 1 STK
NIPPLE FEEDBACK
FJERVEDERLAG 1 STK
SPRING RETAINER
SEEGERRING A 3 STK
ClRCLlP
R0RSKJ0T 2 STK
PIPE CONNECTOR
INSPEKSJONSLUKE 1 STK
INSPECTION COVER
SYLSKRU M 6 STK
SOCKET SCREW M
02.06.03 iz.23:11 Page 7 of 9

Rev. Vgr.
G T99P 35
O-RING 1 STK
O-RING
EO-KROPP EW 3 STK
EO-BODY EW
EO-KROPP GE 5 STK
EO-BODY GE
EO-KROPP T 1 STK
EO-BODY T
EO-KROPP GE 1 STK
EO-BODY GE
EO-RED RED 1 STK
EO-RED RED
O-RING 4 STK
O-RING
R0RSKJ0T 2 STK
PIPE CONNECTOR
EO-KROPP EW 4 STK
EO-BODY EW
FJAR 1 STK
SPRING
STAG TUNNEL 2 STK
STAY TUNNEL
SYL.SKRU 10 STK
SOCKET SCREW
SUGER0R 1 STK
SUCTION PlPE
FJAR 1 STK
SPRING
GJ.STIFT M 2 STK
GRUB SCREW M
O-RING 1 STK
O-RING
DIST.RING 10 STK
SPACER
HYDR.R0R 1 M
HYDR.PIPE ST
GJ.STIFT 3 STK
GRUB SCREW
GJ.STIFT 3 STK
GRUB SCREW
LOCK WASHER CLUED
02.06.03 12:23:?1 Page 8 of 9

Rev. Vgr.
G T99P
37
Posnr. Art.nr. Befegnelse Antall Enh.
Item Artm. Description Quantity Unit
€0-2 MUTTER FM 22 L 7 STK

EO-2 NUT FM 22 L
SYL.SKRU 8 STK
SOCKET SCREW
EO-2 MUTTER FM 28 L 8 STK
€0-2 NUT FM 28 L
EO-2 NUT FM 15 L
EO-PLUGG VKA 1 STK
EO-PLUG VKA
EO-KROPP GE 2 STK
EO-BODY GE
EO-2 M U T E R FM 06 L 3 STK
EO-2 NUT FM 06 L
HYDR.R0R 1 M
HYDR.PIPE ST
KULEVENTIL 1 STK
BALL VALVE
EO-PLUGG VKA 6 STK
EO-PLUG VKA
KULEVENTIL 1 STK
BALL VALVE
HYDR.R0R 10 M
HYDR.PIPE ST
EO-KROPP EL 6 STK
EO-BODY EL
EO-RED RED 1 STK
EO-RED RED
GJ.STIFT 2 STK
GRUB SCREW
EO-KROPP GE 3 STK
EO-BODY GE
GJSTIFT 1 STK
GRUB SCREW
EO-KROPP EW 1 STK
EO-BODY EW
EO-2 NUT FM 08 L
HYDR.R0R 1 M
HYDR.PIPE ST
02.0603 fz:z3:11 Page 9 of 9

Blohm+Voss draw. no. SAC:3-553-0193-000.2
Wrong contact picture Correction C o r ~ tcontact picture
I ULSTEIN I Correction of oeorwhrels

Fig. C
-
nl. - -,
GRAVITY/EXPANSION TANK
Location oP tank, see calculation
sheet in engineering manual
w
HYDRAULIC MODULE to be placed
Maximum 5 m suction pipe length
Maximum 3 m suction hight PRESSURE SWITCHES AND SENSORS
LPA l, : Alarm low servo oil pressure
4- 2.
Set point 8 bar

1
LPC l : Interlock start/stop drive motor Set point 7 bar
DPA l, : Alarm clog ed filter Setpoint fixed
LLA l : A lorm low Bevel gravity tank Setpoint Pixed
Pipe
vto Pipe
be laid w i t h
inclination Par air
escape lmin. 15' angle)
DETA I L
External piping coded with number, not Ulstein PropeIler supply.

to be comectd to the equipment by the yard.
FjgQnei
~ i b e
tt inos: E M T O "L serie"
-. -
DIN 2391 (steel pipes only, St. 37.4)

Pipes to be laid as short and straight as possible,
with a minim or bends.
Pipe dimensions occording to diagram.
n k 80
1 EGkr sapvai tn-us j toannskt a 80 L 2 215800 -
H y d r a u l i s k rnodul 215778 -
H y d r a u l i c module 1
Return o i I .
Yl.
MTNL
a DESCRIPTION
GJENSTAND
I- .
DRG ART. NO.
TEGN. ART. W.
MATER l AL
MATER l AL
REMARK
ANMERKN I NG
see detai I
Lkain o r t h r u s t e r ,
see datoi I
Boll valve,
i
normall open.
To be cyosed .hen
draining t h r u s t e r .
Ulstein Propeller AS
N-6065 Ulsteinvik, NORWAY
Tel.: +47-700-14000
Telerax: +47-700-14014
I-
STAMPING AREA
A r t . no.
- C e r t .no.
-'i
-Charge no.
- T e s t no.
' PIPE CONNECTIONS

REFER TO P I P ING D I AGRAM
SEPARAT S T Y K K L I S T E 215778
SEPARATE PART LIST 215778
Rev. Vgr. &4
A T99P
Posnr. Artmr. Betegnelse Antall Enh.

KOPL.BOKS 1 STK
JUNCTION BOX
SYL.SKRU M 4 STK
SOCKET SCREW M
LASEMUTTER M 4 STK
LOCK NUT M
EO-KROPP GE 4 STK
EO-BODY GE
TRYKK TEST VENTIL 1 STK
PR.SWITCH VALVE
HYDR.RDR 1 M
HYDR.PIPE ST
EO-KROPP EW 4 STK
EO-BODY EW
EO-RED UTllN BSP RI 1 STK
EO-RED 011 BSP RI
PROP.VENTIL PVG 1 STK
PROP.VALVE PVG
6K.SKRU M 4 STK
HEXSCREW M
UNDERL.SK ST M 4 STK
PLAIN WASHER ST M
HYDR.R@R 4 M
HYDR.PIPE ST
MANOMETER 1 STK
PRESS.GAU
FUNDAMENT 1 STK
FOUNDATION
6K.SKRU 4 STK
HEX.SCREW
FJERSKIVE ELF. 4 STK
SPRING WASHER GALV.
6K.MUTTER 4 STK
HEX.NUT
P.AGG. 1 STK
HYDR.PUMP UNIT
6K.SKRU M 3 STK
HEX.SCREW M
6K.MUTTER M 3 STK
HEX.NUT M
UNDERL.SK ST M 3 STK
PLAIN WASHER ST M
20.06.031o:ss:z3 Page 1 of 2
Rev. Vgr.
A T99P 45
- - ~

Item Artno. Description Quantify Unit
SKlLT "SERVQ PRESSURE" STK

SIGN-SERVO PRESSURE
EO-KROPP GE STK
EO-BODY GE
EO-RED UTllN BSP RI STK
EO-RED 011 BSP RI
EO-KROPP GE STK
EO-BODY GE
NALVENTIL STK
NEEDLE VALVE
EO-KROPP MAV STK
EO-BODY MAV
EO-RED UTIlN BSP RI STK
EO-RED 011 BSP RI
EO-KROPP EGE STK
EO-BODY EGE
EO-KROPP GE STK
EO-BODY GE
FILTER STK
FILTER
HYDR.RDR M
HYDR.PIPE ST
EO-2 MUTTER FM 06 L STK
EO-2 NUT FM 06 L
PRESSOSTAT STK
PRESS.SWITCH
EO-2 NUT FM 22 L
EO-2 NUT FM 28 L
SKILT "ALARM LOW SERVO OIL STK
SIGNALARM LOW SERVO OIL
SKILT "LOCAL CONTROL" STK
SIGN-LOCAL CONTROL
SKlLT "INTERLOCK STK
SlGN INTERLOCK ST.DRIVEMOTOR
SKILT "PRODUKTSKILT" STK
SlGN "PRODUCT SIGN"
ADAPTERDANFOSSVENTIL STK
ADAPTOR DANFOSS VALVE
20.06.03 10:55:23 Page 2 of 2

Pipe conn. ref.
to piping diagram
Pipe conn. ref.

l o piping diagram - ZOTV
Pipe conn. ref.

t o piping diagram - 375TV
Pipe conn. ref.

to piping diagram - 250TV
Connections t o
be marked with
aluminium lables.
Tilknyt ninger merkes

med aluminium merke.
SE SEPARAT STYKKLISTE 215800

SEE SEPERATE PARTS LIST 215800
I I I
Text . -
- -
NivAt ank
G r a v i t y feed tank
80 L
I
Closs code :
Ulstein Propeller AS
N-6065 Ulsteinvlk, NORWAY
Tel.: +47-70-14000
Telefox: +47-70-14011 Rep 1 Dcsd by:
I Thruster installation no.:
of gr-
7
Seawater pressure: a2 (m)~1.025/10: bar Max seawater pressure: a1 (m)*1.025/10: bar
- Underpressure normal"': 0.1 bar + Overpressure normal"': 0.3 bar
= Total tank pressure: bar = Total tank pressure: bar
I => Tank location : d l (m)x0.89/10= bar => Tank location : d2 (m)*0.89/10= bar
=> dl = meters => d2 = meters
( Or: dl=(1,025*a2/0,89) - (0,1*10/0.89)meters ( Or: d2=(1,025*a1/0,89) + (0,3*10/0.89)meters
dl = meters ) d2= meters )
When calculating placing of the leak detection When calculating placing o f the gravity tank,
tank, use case no. 2; minimum immersed vessel. use case no. 1; maximum immersed vessel.
')For shaft gland relative t o outside water pressure.

-)For inside of thruster relative t o outside water pressure.
a,= cl=
NOTE! T h i s d r a w i n g t o be used only a2= c2=
w h e n cl-c2 is less, or equals 8 meters. b= dl=
d2=
r Gravity lank r Gravity tank

Case no. 2 1 r l e a k detection
Min. immersed[vessel / tank
1
I
Line
NOTE! \$/
NORMALLY THRUSTER INSTALLATIONS ONLY HAVE INSTALLED
GRAVITY TANK.
IF LEAK DETECTION TANK I S TO BE INSTALLED, THIS I S
STATED I N THE TECHNICAL SPECIFIATIONS.
Spotwelded to bracket
marked according
t o the thruster
cable p l a n .
11 - Brown
12 - ~ouve
13 - Orange
21 - Pins
22 - L i g h t blue
23 - Grey
31 - Yel l o w
32 - White
33 - Black
FEEDBACK
POTSMETER
214164 FEEDBACK PITCH Rev. Vgr. yo
62500.214164 FEEDBACK PITCH C T99P

Item Artno. Description Quantity Unit
6K.MUlTER 1 STK
HEX.NUT
KULELEDD SAKAC 1 STK
ROD END
SYL.PASSKRU M 1 STK
CYL.FIT.SCREW M
LASEMUTER M 1 STK
LOCK NUT M
UNDERLSK ST M 1 STK
PLAIN WASHER ST M
LENKE 1 STK
FEEDBACK LlNK
6K.MUlTER M 1 STK
HEX.NUT M
LENKEHODE RH SM 1 STK
LlNK HEAD UNIBALL RH SM
SYL.PASSKRU M 1 STK
CYL.FIT.SCREW M
LASEMUTER M 1 STK
LOCK NUT M
UNDERLSK ST M 1 STK
PLAIN WASHER ST M
ARM 1 STK
ARM FOR FEED BACK
BRAKElT FEEDBACK 1 STK
BRACKET FEEDBACK
SYLSKRU M 1 STK
SOCKET SCREW M
FJERSKIVE ELF. M 1 STK
SPRING WASHER GALV. M
LAGER SKF 2 STK
BEARING SKF
AKSELMUTTER KM 1 STK
COLLAR NUT KM
KILESTAL 1,5 CM
KEY STEEL
B R A K E T POT.METER 1 STK
BRACKET FOR POT.METER
EL.KOPL.ACR-M075 1 STK
FL.COUPL.ACR-M075
6K.SKRU M 3 STK
HEXSCREW M
20.06.03 10:58:29 Page 1 of 2

214164 FEEDBACK PITCH Rev. Vgr.
62500.214164 FEEDBACK PITCH C T99P
51
22 90457 6K.MUTER M 3 STK
HEX.NUT M
23 90456 FJERSKIVE ELF. M 3 STK
SPRING WASHER GALV. M
24 412602 POTMETER PK 1 STK
IND. TRANS.
25 412609 AKSEL FEEDB. 1 STK
SHAFT FOR FEED BACK
26 93746 SEEGERRING I 2 STK
ClRCLlP
27 92017 SYL.SKRU 3 STK
SOCKET SCREW
28 90426 FJERSKIVE ELF. 3 STK
SPRING WASHER GALV.
29 90984 SEEGERRING A 1 STK
ClRCLlP
31 80013 KABEL PFSK 4 M
CABLE PFSK
20.06.03 ? o : ~ ~ : z Q Page 2 of 2
Motor Dimension Print I Motor Type:
M2FA 400LK 4... V 1 , 8 5

Document No:
13 M2FA 400LK 1 A
1 A1.1327
Desc"ption:
SQUIRREL CAGE MOTOR
Unit: ABB Motors Oy IMSO Issued by: H.Toivola Replaces:
Dale: 9.3.98 Approved by: Replaced by:

I I
Customer Reference:
ABB Motors AL BR BR
r\BB1B
'ethnical Data Sheet ABB ref. no. 16216117
ustomer: Rolls Royce Marine AS Date: 15.10.2002
53
Handled by: J.A.Hagen
roject name: Aukra lndustrier AS Item Name:
ustomer ref. 41 7222 Case:
47 Type of protection -
- -. --
- 48 Certification No. NA
49 time NA s
3ption Variant Codes I Definition
C thermistors (3xl3ODCtrip, -+ 3xl5O"alarm)

~ .. . .. - -
Remarks:
Jser data 14.02.2000 10:42:03
Sl, LKH80196,w=13
File Name: untitled.xls Page: 1.1
ARB Motors
Load Curves ABB ref. no.
Customer: Rolls Royce Marine AS Date:
Project name: Aukra lndustrier AS Item Name:
Customer ref. 4 17222 Case:
Location: T8253/ T8254/ T8255 Revision:
Product ODP, 3-phase, squirrel cage induction motor

TypdFrame M2FA 400 LKA 6
Product code 3GFA 403 510-BDA
Rated output PN 590 kW
Type of duty s 1(IEC)
I
Voltage (V)
Frequency (Hz)
440
60
Current IN(A)
Speed (rlmin)
941
1193
Power factor at PN
Efficiency (56) at PN
0,86
96,8
File Name: untitled.xls CCW Page: 1
ABB Motors
'tatting Curves ABB ref. no.
~storner: Rolls Royce Marine AS Date:
I
.eject name: Aukra lndustrier AS Item Name:
~stomerref. 4 17222 Case:
cation: T8253/ T8254/ T8255 Revision:
rpe of product ODP, 3-phase, squirrel cage induction motor

@Frame M2FA 400 LKA 6
. d u c t code 3GFA 403 510-BDA
sted output P, 590 kW Rated current ,I 941 A
p e of duty Sl(IEc) Starting from: Hot
mtor (kgm2) 19 voltage (4100% 440 voltage (v) YD 100%

,ad (k9m2) 0,000 Frequency (Hz) 60 Frequency (Hz) 60
a d speed (rlmin) 1193 Starting time (s) Run-up time (s)
(Nm) 4722 Speed (rlmin) Speed (rlmin)
(Nm) Idl~ 7,1 Idl~ Z1
umber of cont. starts
0 200 400 600 800 1000 1200 1400

Speed [r/minl
-
T M o t o r U n 440V
IMotorUn 440V - TMOtOrU2YD 100%
' IMotOrU2YD100%
)ata based on catalogue values 14.02.00
CCW
tile Name: untitled.xls Page: 1.3
ABB Motors
DATE ILo0.W. *BB R m L C T N a S X l (U)
,
,
-
ABB AS Marlne AS. T8253/8254/8255 PO07990 1:lO
El1DOm lO.(XL(U AT CHECKED Dlv. Aut. Tech. Prod. b . l l O . Y/D 590kW WWG NO SINO 1
N mIPllDI DATE SM. WFROKO Oslo, N o m a y Arrangement 9584-01 A 2
Heaters
230V-60Hz
Control Voltage
(dwg.--3)
~31'
Heater
in starter
Supply Mains Service Supply Servo Pump Heater Heater

3 , 5 kW Thruster Option
440V-60Hz 440V-60Hz 7,O A Motor
Rotation:
Anticlockwise
loins: CU I Control current: Texllne HF 1,01 +24V: - IOV: - 1 24V AC: - I Wire rnarkinq: Yes
DATE lamm ABB AS ~TLE *88 PRGECT N- +w (u)
,
, ABB AS A\ I D I b
Rq1111
kpf{E,"$:m Rolls Royce Marine AS. T8253/8254/8255 PO07990 X
CHE(XED Dlv. Aut. Tech. Prod. ern Y,e,nd
Td.phme +,,
7011Qm
Aukra lndustrier b.llO. Y/D 590kW W Y N G NO Hi(N0 2
V C€SmPnCN DATE SM. IPRX)W3
Oslo. Norwoy mm 9584-02.dwg Malns 9584-02 N m 3
- ~p
From T2.
dwg. -2
m
:
3
cP
!2
X2:7-8 Alternative supply t o heaters
Wains: CU 1 Control current: Texllne HF 1,O 1 +24k - IOV: - 1 24V AC: - I Wire morkinq: Yes
DATE i~m.02 W.1sMm ABB AS ~TLE *88 PR~LCTN. S3l.E (U)
ABB AS AA l b l b
Fq1111
~ ~ Rolls$R o y x Marine & ~
AS, T8253/8254/8255 ~ PO07990
~ Z
El *mm 1o.mm AT ME= Dlv. Aut. Tech. Prod. am U-nd
Td.phmc +*, 7011,100 Aukra lndustrier b.llO. Y/D 590kW mwc m, m~ 3
IV O ~ C ~ P ~ M DATE SM. -KO
Oslo, Norway FIEFS 9584-O3.dwg Control Cvrent 9584-03A am 4
X3:6
Pitch
X3:7! X3:9! X3:l
<
0
B
0
Stop E-
l
white Start req. Start req. Pulse Start Servo Pump Motor windings Motor windings
30 sec. 1 set. interlockings alarm overheat
Aains: CU I Control current: Taxline HF 1.01 +24V: - 1 OV: - I 24V AC: - I Wire markinq: Yes
DATE 1xm.02 OJSKWR ABB A S *88 PRaECT No. aUr (N)
PO07990
-
DM, d ABB A= Rolls Royce Marlne AS, T8253/8254/8255 5:
E l m 1e.m.m AT WE= Dlv. Aut. Tech. Prod. mi111 Nand
Aukra lndustrler b.llO. Y/O 590kW DMMG NO si NO 4
V c€scwllQI DAE Sm. m m Oslo. Norway 9584-04A 5
I Pulse
Contocts shown in
positions without
changes.
1.e. in normal operating
condition, X5:21A-21 is NC
and X5:19-20 is NO
loins: CU I Control current: Texllne HF 1,01 +24V: - IOV: - 1 24V AC: - I Wire markinq: Yes
DATE 1aop.m WSWER ABB AS ~TLE bm PROECT NO. sULE W
,
, ABB AS A\ I b I b ~ $ $ ~ a Rolls ~Royce
~ ~ Marine
m AS, T8253/8254/8255 PO07990 X
~l MOW IB.W.(U AT WE- Olv. Aut. Tech. Prod. BWI111 ++,
T,.phonch a n d
70114100 Aukra lndustrler b.110, Y / D 590kW MAW NO % no 5
v awra~nm DATE S(X m m Oslo. Norway FUEFZF 9584-05.dwg Slgnals 9584-05A 6
Thermistors in Thruster Motor
Service supply s u p p ~Heaters 135%
'8
I,,
Heater in Thruster Motor Thermistors in Thnrster Motor

155 O C
Servo Pump Motor
Heater, option Load Signal. 4-20mA
lal Alternative Supply Heaters
Servo Pump Running
Servo Pump not Running
Start/stop Servo Pump
Servo Oil Pressure

w Servo Pump Overload
Thruster Motor Running
Zero Pitch Thruster Motor not Running
In Opsrotion
PMS Interface 3
In Operation
~ o int Operation
Emergency Stop
Stort/stop Thruster
2 & Stort Request to PMS
Overload Indication. NO
Overlood lndicotion. NC
Signal to Mimic Ponel
Pressure Switch Servo Oil
Alarm Servo Oil Pressure
Remote Ammeter (option)
Servo Pump Running
Servo Pump Running
Emergency Stop
= I Rolls Royce Morlne AS. T8253/8254/8255

I lndustrler b.llO. Y/D 590kW
PO07990 X
6
..- . . . . .
...-. .. .. .... MAW6 NO Si NO
Oslo. Norway I 9584-06.dwg Termlnols 9584-06A 7
BOW THRUSTER 1
NOTE T8253
Be sure that all power supplies
are disconnected and securely locked
before performing any maintenance.
SIN - STOP 440 V
7GG-j
The starter cabinet has 3 power supplies:
1. Mains
SERVICE HOURS
590 kW - 941 A
2. X1:l-3 Service supply
3. X2:l-2 Heaters
BOW THRUSTER 2
Tre av hvert innenfor rarnrno
ett av hvert ov de utenfor!
7, SmVlCE NORUAL
3 SERVlCE MODE
STERN THRUSTER
T8255
01
I
THRU- - MOTOR CURRENT
II 440 V
SERVO PUMP
- 3.5 kW - 7.0 A 440 V
590 kW - 941 A
1, ABB AS
Alesund
Prod. no.: P007990#l
I
ABB AS
kesund
'01
Prod. no.: P007990#2

I
T
-
ABB AS
Alesund
Prod. no.: P007990f3
Rolls Royce avd. Ulstein Propeller
SERVICE MANUAL
GKN
GKN UnCardaOOl-1
I
CSMME"' QL'S
:' R E ' P L A C L ~ N TPARTS
Commercial's 'replacement parts are of original
equipment standards. For assured quality of mate-
rial and~'wOrkrnanship, and for compatibility in
. assembly, USE ONLY! GENUINE COMMERCIAL
?.!\*
PARTS.
Plug 7 in position B gives clockwise rotation.

Plug 7 in position A gives counterclockwise ro-
tation.
Check valves in both positions give bi-directional
rotation.
PARTS LIST ,
1. Snap Ring 13. Gasket Seals

2. Spacer or Outboard 14. Gear Housing
Bearing 14A. Dowel Pins (P76 only)
3. Seal Retainer 15. Connecting Shaft.
4. "0" Ring 16. Bearing Carrier
5. Seal 17. Matched Gear Set
6. Shaft End Cover 18. Gear Housing
7. Check Assemblies or 18A. Dowel Pins (P76 only)
Plug 19. Plug
8. Ring Seals 20. Port End Cover
9. Roller Bearings 21. Name Plate
10. Pocket Seals 22. Drive Screws
11. Thrust Plates 23. Washers
12. Integral Drive Shaft 24. Studs or Cap Screws
and Gear Set 25. Nuts
ITEMS SHADED APPLY TO MULTIPLE
ASSEMBLIES ONLY.
GKN UniCardan/P31-2
lubrication and oil
recommendations
All parts, with the exception of the outboard bearing, are lubricated by the hydraulic oil in the
circuit. Particular attention must be paid to keep the oil in the system clean. Whenever there is a
pump or motor failure, and there is reason to feel that metal particles may be i n the system, the
oil must be drained, the entire system flushed clean, and any filter screens thoroughly cleaned
or replaced. New oil should besupplied for the entire system. Oil suitable and recommended for
use in circuits involving Commercial's pumps and motors should meet the following
specifications:
Viscosity: From 7.5 to 2000 cSt

Recommended: 15 to75cSt
Recommended Additives: Foam Depressant

Rust and Oxidation Inhibitors
Other Desirable Characteristics:

Stability of physical and chemical characteristics.
High demulsibility (low emulsibility) for separation of water, air, and contaminants
Resistant to the formation of gums, sludges, acids, tars. and varnishes.
High lubricity and film strength.
General Recommendations:
A good quality hydraulic oil with the characteristics listed above is essential to satisfactory
performance and long life of any hydraulic system.
Oil should be changed on regular schedules in accordance with the manufacturer's

recommendations, and the system periodically flushed.
Oil temperature i n reservoir must not exceed 200" F., (93.3'C.) with a maximum operating
temperature of 180' F. (82.2" C.) recommended. Higher temperatures will result i n rapid oil
deterioration.
Reservoir capacity should equal in gallons the pump output in gpm or the total gpm of all pumps
where there is more than one in the system.
Oil poured into the reservoir should pass through a 100 mesh screen. Pour only clean oil from
clean containers into the reservoir. A 100 mesh screen may beused in thesuctionlineleading to
the pump. A suction filter should be of sufficient size to handle twice the pump capacity. I t must
be cleaned and checked regularly to avoid damage due to contamination and cavitation.
Normal Temperatures:
0°F. (-18°C.) to 100°F. (37.3"C.) Ambient
100°F. (37.8"C.) to 180°F. (82.2"C.) System
Be sure your oil is recommended for the temperatures you expect to encounter
GKN UniCardanIP31-3
tool list
Arbor Press
Awl Xs" DRIII ROD

Bearing Puller (Owatonna Tool Co.
MD-956 or equivalent)
Check valve loo1 is made
from a 4" lenglh of %'
Clean Lintless Cloths drill rod. The drawing gives
delails lor making t h s
Deburring Tool (an old file with handy 1001.
the cutting teeth ground off)
Machinist's Hammer
/
7
Soft Rubber Hammer .12 6 +:$:
Permatex Aviation Form-A-Gasket

No. 3D Sealant or equivalent
Medium Grit Carborundum Stone
Oil and Grease CRad.
Snap Ring Pliers
Center Punch
Sharp Razor Blade

.-- --
The special slsel sleeve is
used l o 111 over Ihe drive
Scale (1132" or 1/64" shaft l o prolect the shaft
graduations) seal during inilaliation.Thls
canbemadelrom barslock.
2 Large ScrewdriversfPry Bars
Torque Wrench
Vise with 6 Minimum

Open Spread
Light Duty Bearing Puller

for Seal Retainer
Special Steel Sleeve

or Cardboard Sleeve
Steel Ball
C F"
A B Radius D Dia. E Dia. Chamfer
P75/76 4%" 5%" %" 1.3795 ;::;

1.259 +
-
.0°2
,000
30°
All External surfaces must be

free of scratches and burrs.
GKN UniCardan/P31-4
Start disassembly here
Place the pump I n a vtse w ~ t hthe Ramovo the 8 cap screws or hex Lilt of1 the porl end cover. II nec- Llft the genr nouslng f m m the
drwe shall polntlng down. Cau- nuts and washers wlth a Bockel c s w r y l o p r y loose. be careful no1 gears. If necessary 10 pry loose,
tlon DO N O T G R I P O N OR NEAR wrench. Iodamngo Ihe machined surlacer. lakecare not todamagernachlned
ANY MACHINED SLRFACES Dowel plns wlll remain i n either surlaccs
DURING ASSEMBLY OR DISAS- porlendcover or goarhouring. D o
SEMBLY I n d e ~mark all scct#ons not remove. If the thrusl plnle rr-
wilh e punch. B e sure l o align mains .n the gear housing. 11 can
those marks when renssembling. bc lsppcd o v t Inter wilh a wooden
barnmer handle. Be caroful not l o
distort Iho lhrusl plate.
Remowtheariwanddrivengears L i l t o r pry OHlhe-beatl* cerrler.

Keep the gears together because
they are B malched sol Exsmlno
Teke care not to d a m s g e l h e me- -
c h ~ n s dsuriaces.
a n d replace il necesmry Sea
below'
R O ~ O Vtho
C drive gcar with shall It Is ocncrally adrlsablc I@replace
and I h r driven gear. Keep lhese Pry the thrust plate from the shnll Examinsall roller bearingslorwear
end ewer. portend cover. or bear- ond dlscoluralion. I1 rcploconwnl ring seals when rebuilding "nil. To
logelher as they are a malchedsel. r~place. rurnovc Ihc drivr gonr
Exam~neand replace il necessury ing carriur w l l l ~H );crew d r i w r or 1s necessary, pull the beerlngs
Slmllar loot. Avoid dislortino the with a bearing puller. Any sign of braring wllh a buar~nyfluller ~ r l d
See below'. remove riny seal from Ihe bottom
Ihrus: plate. Remove and discard wear Or discoloration calls for re-
01 hearing horr Checx 011 rlng u:al
all rubber pochet sealsnnd gnskel placumonl. Rollluvc 110arIn~s with
SOHIS. a boorlng pullar. hnrC6 III unll lor abnorar~alwoar If
w o # nreplac0 lnose scct8ons.
GKN UniCardanlP31-5
Grip theshallend covet In lhevlse Remove the spacer or oulboard
Remove the seal relainer and seal Taptbeseal f r o m theseal relamer
w t h Ihe m o m l m g lace up Re- bearing (pull ttieou~boardbearing a n d discard Clean seal bore with
wtth a llghl duty benrmg puller.
move the snap rlng wlth snap rlng with a benring puller). solvent t o remove old sealanl I f
Remove and dlscsrd "0 m g
pllers bore is scored. smooth wlth flne
gradeemery paper It IS generally
ndvlsable to replncc !he seal re-
talner
, 'tart assembly here
I Stone dl all cast rnachlnad sur-

f a o m with a medlum grit cartto-
rundum stone' 1 b iemove any
wlth Ihe mounlmg lacs down Ex-
amlne the pldp or 2 check vslves.
wh~eheverIS used. l o t-arure they
arellghllyinplnce. AeplawonlyII
II SSEMBLY STEPSS.4.6,IANDB
PPLY TO SHAFT END COVER.
BEARING CARRIERS 4NDPORT
END COVER.
11 frng seals am being replaced.
I f snybearmgshavc beepremoved
from the shaftend cover.pon end
cover or bedrtng carrler. replace
the bearlngs bypresslng lhcm lnto
I beaiinps have been removed:de- the bearmg bore w l h an nrbor

parts are damaged sr rnlssing. Insart lnto bonom o l drwe goar press Take care l o w o l d pruss~ng
burrbearing bores Rlnsc pa* In Check volvoscsn be removed wllh
a solvent Air blast all parts and banrlng born flat s ~ d edown. The on dowel pms
.thA tpeclal tool (see tool list) notch In the. d n g seal MUST BE
I-'
Wlpe wlth a clean, llnlless cloth .'Screw In new valvo wllh Ihc lo41 VISIBLE ThlaIsachecklo becer-
-f?-61afl;g rennsembly untll tight. Peen 'dl0 a 1%' steel tam the notched side ~ s n e x l t o l h e
ball to secure Warin
Cut 6 P O CYcals ~ C Innpralimaloly

Cul 2 pockel seals 1-1/32 long Wllh:hc packslscnls down. Plnce 7 / 7 6 , l o n ~(#am thc P D C seal
~EI
lrom the pocket sanl slrlp. Grease thc thrust plate over the bonrlngs. 11101) Innor! a n o pockst seal l n l ~
these pocket seals and insorl into Tap thrtlrl ~ 1 ~ w10
l h a sol1 trorn. ~ c ~P I l s h1 0~1 ~ i n I t ~ ~ l hplolc.
r~st
the mlaale slols # nthe thrusl plafe. mcr to aboul 1:32' I!om ttle rno- P . m I!~CII ~ O C L C Iscol PII tnc u n y
chlncd 5 ~ i n c o tn SO Itu~1:nu" touch Iho ruller
b,id,ingr. Tnp Iho :I!~vsI plDle
0ou.l !hrmlyiapcltl!bt Iho m;&chnr?d
Vi~llH
3$1<'~l<.11 > 5011 hn>!n01 U P C B
~11,1111l a l u ! blndi! ro t r m rxnoroo
*r10 :)I111(: ;)UC~PI W I Isqilalt! an0
11,:sv W t l " It,,? l ~ b r , l s t r l l d t "
GKN UniCardanlP31-6
I Insert l h e ~ntegrals h a f t and gear
Push down unlll the gear IS t ~ q h l I Gronse the new gnskcl heols ond
m e n them lnlo the orooves ~n I Posllton the beerlng carner with
thrust platcs on the geer housing
that the roller bearings recelve
I
egatnsl the thrust plale. lnsertihc SO
matched driver) gear Ihe lournalso1 thodrwe and driven
nears Make sure that the Index
h o r c s (See Step 1. D~sosscmbly)
are properly al gnoa.Tap1he bear-
Ing carticrllght wllhasoll hammor
FOR MULTIPLE ASSEMBLIES

ONLY.
I slldcmosemnd Wctlon gear houslng

I
I Insert the connechng shalt In the
spltne of the drivegear
loser%the d r l y e m d driven gearsot
lhesecond sectlon I n thetrrespec-
live bearfngs. Push down t ~ g h t l y
aga~nst the thrust plate
overmc seanand tap of tlghtagalnst
rnit~a~tubr~cstlon*hs~pvrnpIsslam.
I Place tho port end cover over the
geer journols a n d t a p l ~ g h l l y
agamsl tho gearhousing Becare-
~ uno;I l o pmch the gasket seal
I
Lmo dp the daalsand tho holes Inthe
LFOR MULTIPLE ASSEMBLIES

J
d 8 testendrs (cap scrcws

~ h r e a the Drop In the spacer or oulboerd
and washers, or studs nnd ntlls! Coat tho OUtsldc of tho 90s1 with bearing The oulboatd beartng
into the shall end covcr and snug- Permotcx Avlst~onForm-A-Gnskel may need lo be llghtly tnppnd Into
~ ~ p a l l e r n n l eor
l y cross-corner. Ro- 3D or equivalent. With the m e l d the benrlng bore
latethedrivoshnll wilh nfiFwrench bldc 01 tho seal down. press il into
l o make surc thereas nu blndnng in lhe soal rotnincr with a 2 % - dlnm-
Ihc pump. elerbarandanarbor ~ r o s sBccarc-
Allor the laslsners arc tiglll ~ n d
you are sure there is no irllernal
b ~ n d l n g . torque Ihc d i a g o n ~ l l y
opposlle lusleners l o 200 11 Ibs
(2400 on. l b )
GKN UniCardanIP31-7
As a guide in answering the question, "How much wear is allowed before
the part should be replaced?", we offer the following suggestions .....
GKN UniCardan/P31-8
recommended
test procedure
Be sure there is an adequate supply of oil for the pump, at least one gallon o f oil foreachgpm o f
pump capacity.
If one section of a tandem pump is being tested, make sure that all other sections not being
tested are adequately supplied with oil. I f any of the other sections run dry, or if plugs are left in
ports. serious and permanent damage will result.
The oil should be a good quality hydraulic oil rated at 150 SSU at 100°F, (37.8"C) withthe oil
temperature held at 120°F (48.goC) plus or minus 5'F (-20.6'C). (Test procedures are de-
scribed i n detail i n SAE handbooks; see Hydraulic Power Pump Test Procedure. SAE J745c.)
The feed line must be of adequate size with n o more than 5" mercury vacuum (.I7 kgs/cmq
adjacent t o the pump inlet. Asa rule, the feed line must provideafeed flowvelocity not inexcess
of 8 feet per second (243.84 cms/sec).
Feeding hot o i l into a cold pump may cause the pump t o seize. J o g the pump by momentarily
starting the driving engine or motor t o gradually equalize pump and oil temperatures.
Run the p u m p a t least t w o minutes at zero pressure and moderatespeed (not over 1500 rpm). If
the pump becomes excessively hot, shut down immediately and locate the problem source.
Gradually increase pump pressure t o the desired test level; this should take approximately 5
minutes.
Delivery should r u n close t o rated catalog performance figures which areaveraged from testing
several pumps. A 5% lower reading may be used as a rated minimum if new or relatively new
parts have been used. When rebuilding with parts f r o m the original pump which may be
satisfactory for re-use, a 10% or 15% lower reading may be used. This depends on the perfor-
mance expected from the equipment; one's own experience will prove the best guide.
Many repairmen measure the output at normal operating speed and atzero pressure, then again
at 1000 psV70 bar (or the operating pressure of the equipment) and allow a volume decrease
approximating the listing below. This is a suggested reference only which makesallowance for
re-used parts.
GPM (I/mn) DELIVERY

at 1800 rpm GPM DROP OFF A T ...
100 psi 1
1000 psi/70 bar 1 1500 psi/l05 bar 12000 psi/l40 bar 1 2500 psi/175 bar
At test speeds other than 1800 rpm, gpm delivery will vary almost proportionately, but the
same (drop-off) figures should be used.
Be sure t o run the pump in the direction for which it was designed and built. Driving pump i n the
wrong direction will build up pressure behind shaft seal, damaging it and necessitating
replacement.
Since it is rarely feasible to test motors o n dynamometers, the practical procedure is to test them
as pumps. running complete testing procedures in each direction.
After completing testing procedures, pump is ready for installation and immediate use on
equipment. Again, remember that to prevent seizure, hot oil must not be fed into a cold pump.
GKN UniCardanlP31-9
p~
Cold Weather Operation

Oils for use in cold weather should have a viscosity not exceeding 7500 SSU at the minimum
start-up temperature. A pour point of at least 20°F ( 6 7 ° C ) below start-up temperature is
recommended. Start-up procedures should allow for a gradual warm-up until the oil reaches a
reasonably fluid state.
The Use of Other Oils

*Automatic Transmission Fluid (ATF): General experience here has been satisfactory; however,
ATF oils are sometimes too expensive for normal use i n hydraulic systems.
*Diesel Fuel or Kerosene (Coal Oil): Sometimes used as dilutants for cold weather operations
but are not recommended as they are not sufficiently refined products.
*Fire Resistant Fluids: Of the several different types, only the inverted emulsion types may be
used without changing to special seal, packing, gasket, hose, etc., compositions. Their use may
materially reduce pump life. Experience indicates that the use of FR fluids can be disastrous
unless certain precautions are followed. DO NOT USE ANY FIRE RESISTANT FLUIDS OR
NON-PETROLEUM OILS WITHOUT CONSULTING OUR TECHNICAL SERVICE DEPART-
MENT.
These suggestions are intended as a guide only. OBTAIN YOUR FINAL OIL RECOM-
MENDATIONS FROM YOUR OIL SUPPLIER.
recommended start-up
procedure for new or rebuilt
pump or motor
Before installing a new or rebuilt pump or motor, back off the main relief valve until the spring
tension on the adjusting screw is relieved. This will avoid the possibility of immediate damage to
the replacement unit in the event that the relief valve setting had been increased beyond the
recommended operating pressure.
Before connecting any lines to the pump or motor, fill all ports with clean oil to provide initial
lubrication. This is particularly important where the unit is located above the oil reservoir.
After connecting the lines and mounting the replacement unit, operate the pump or motor at
least two minutes at zero pressure at lowest possible rpm. During this break-in period, the unit
should run free and not develop an excessive amount of heat. I f the unit operates properly. speed
and pressure can then be increased to normal operating settings.
Reset the main relief valve to its proper setting while the pump is running at maximum operating
engine (motor) speed for the vehicle.
ALWAYS U S E A N A C C U R A T E G A U G E WHEN
A D J U S T I N G T H E RELIEF VALVE PRESSURE SETTING.
GKN UniCardanlP31-10
[p J ~n-~in
Filters
e
74
401160 LE 0020-0045
401160 LEN 0160-0400
Description
EPE In-line filters are designed for operating of 160
bar and are suitable for assembly into pipelines.
The filter consist of filter head with inlet and outlet

on one axis and two drilled fixing holes as well as
the filter bowl screwed in underneath, which is
unscrewed for cleaning and replacing the filter
elements. A quicklock device for the 40 LE and 40
LEN is standard.
These filters have been built and tested in

compliance with the pressure vessel regulations
. .
using high-quality materials.
By using specially tested material, the filters have

the capability option for acceptance by all
certification authorities. Different flange designs
such as ASA, DIN, etc. are available on request.
Depending on the material of the filter element, the

filters are suited for almost fluid media (see data
sheet 63).
Special corrosion protection is possible for

1 40 LE
40 LEN
160 LE
160 LEN
aggressive or aqueous media.

0
b
Quality management according DlNllSO 9001.
Materials
Filter head: Aluminium alloy casting
Filter bowl: pressed carbon steel 40 bar-
-
forged steel C 35 160 bar
release valve
Gaskets: Nitrile (Viton or other on on request
request)
(52>
Equipment
Bypass valve: 40 b a ~ o p e n i n gpressure 3,5 bar
160 ba~openingpressure 7 bar
Maintenance indicator: optical or opticaVelectrical
Dimensions
Connection A B C
Type Slze Ordering code
401160 LE 0020 = 401160 LEN 0160 G 1112 RO 226 120 235
401160 LE 0030 = 401160 LEN 0250 G 1112 I RO 316 120 325
401160 LE 0045 = 401160 LEN 0400 G 1112 RO 466 120 475
[m)
K . & H. EPPENSTEINER GmbH & Co. KG
D-6x775 Krtsch Hardtwaldstrnl3e 4 3 Tclefon 0 62 0 2 1 6 0 3-0 Telefas 0 62 0 2 / 6 0 3 1 99
Orderlng data
Maintenance Indicator* Connection* Haterialr

- -
I
LE In-llnc f l l t a r 0 ~ithout
Wl- I n - l l n e f l l t e r Inlet htlet 0- Stanaara
wl t n standard
A...- Indicator
o~tlcal
-
alement DIN
i n t o Dreaaure
DlPellne8
Order code tor

complete filter: 160
I
LE 0045
T
I 1 T -Tl-
A 00 -
I
0 9 B5,O
I
-RO
I
P 0 0
I
e
T T T T TP T0 T
Order code for
gasket Bet: -0 -
160 --
LE 0045 B
- - R-
O --
Filter grader Gasket*
P- N l r P l l o
v= YltO"
E- E t y l m b
PPOPY~C".
N- Neoprcna
F=7 Element type

I Oa0 Om
m rn
Ez MOP 4810
KEm
A 0 H10
I
Order code for
filter element: 1.
- -
0045 HIOSL - -
A
*other designs on request
are Parts list

Designation 401160 LE 0020 ,401160 LEN 0160
401160 LE 0030 ,401160 LEN 0250
401160 LE 0045 ,401160 LEN 0400
Filter head 1
Filter bowl 1
Filter element 11 2.0020, 11 2.0160
11 2.0030, 11 2.0250
11 2.0045 , 11 2.0400
O-ring Nitrile 70 Sh 11 42 x 2,70
O-ring Nitrile 70 Sh 11 9 4 x 3
Maintenance indicator 11 F...
Overpressure valve (by-pass) 11 M 3 6 x 1 , 5
Locking screw DIN 906
Locking screw DIN 910 11 G 114
Sealing ring DIN 7603 1114xl8x1,5
Maintenance indicator
optical and opticallelectrical
A = F.. A0 00 OOP B= F.. GW 02 OOP
1:. ..
Spare parts
Proportional Valve
PVG 32
HN.57.A2.93 replaces HN.57.Al.93
Vederlagsfri reparation Vi g0r opmaksom pa at den vederlagsfrie reparation som er omtalt i Danfoss
Almindelige Leveringsbetingelser kun udlares hos Danfoss Nordborg eller hos Danloss
autoriserede service shops.
Cost-free repairs We would point out that cost-lree repairs as mentioned in Danfoss General Conditions of Sale.
are carried out only at Danfoss Nordborg or at service shops authorized by Danfoss.
Kostenlose Reparatur Wir machen daraul aufmerksam, dass die in den "Allgemeinen Lieferbedingungen" von Danloss
erwahnte kostenlose Reparatur nur bei Danfoss Nordborg oder bei den von Danloss
autorisierlen Kundendienstwerks~attenausgeluhrl wird.
Reparation gratuite Nous laisons observer que la reparation gratuite mentionnee dans les Conditions generales de
Vente de Danfoss ne devra Btre effectuee que dans les ateliers Danfoss a Nordborg ou dans les
ateliers de depannage agrees par Danfoss.
.. .. ..- -
.. . - -. -. - --
'3 ,'$--
Installation I identification . . .-. .-. .-..
Standard installation: PVP lo the left of PVM
01 3 A 0 0299
Week of manulaclure 2
Year of manulaclure
Day ol the week
(A = Monday, B = Tuesday . . )
Issue number
Series number
C : PVG-number, week and year of

inslallalion
D : PVP-pressure setting
E : PVP-number, week, year and day ol
manufacturing, issue and series No.
PVU
F : PVB-A-port, number, week year and
F
day of manufacturing, issue and
series number.
stallation and plug orientation
PVB 1 2 3 4 5 6 7 8 9 10
Lmm 82 130 178 226 274 322 370 418 466 514
.-
Lm 3.23 5.12 7.01 8.90 10.79 12.68 14.57 16.46 18.35 20.24
Connection, pump side module, PVP
as -~-.
, I I ,
Connection, basic module, PVB
Max. tighening torque T LS. M. LSA. LSB. PVH LX

P A/B
Screwed conneclion BSPF G % G% G S: G ?: G% G U
13 daNm 21 daNm 13 daNm 21 daNm 4 daNm 1,7 daNm
With steel washer (1150 lbf in) (1850 Ibf ln) (350 Ibf in) (150 Ibf in)
(1150 Ibl in) (1850 Ibf in)
3 daNm 5 daNm 3 daNm 5 daNm 2 daNm 1.5 daNm
With copper washer (445 Ibf in) (270 Ibf in) (445 Ibl in) (180 Ibf in) (135 Ibf in)
(270 Ibf in)
. ~

With aluminium washer (970 Ibf in) (620 Ibf ln) (970 Ibl in) (270 Ibf in) (135 Ibf ln)-
(620 Ibf in)
13 daNm 21 daNm 13 daNm 21 daNm 4 daNm 1,7 daNm
With cuttlng edge (1850 Ibf ~ n ) (1150 Ibf in) (1850 Ibf in) (350 Ibf in) (150 Ibf ~ n )
(1150 lbf in)
Screwed connection UNF %,inch-14 18, ~nch-12 inch-14 1%, inch-12 5; ~nch-20 3/, lnch-24
--- - - . ~ - - -
0-r~ng (1060 in4bs) (800 in-lbs) (1060 ~n-lbs) (270 ~n-lbs) (90 in-lbs)
(800 ~n-lbs) . .~
- - . -- -
~ndard,Oil flow direction and setting of max flow. PVP to the left of PVM.
Yectrical connection
Signal voltage. Us, and US2for PVEH, PVEM:
Uoc = Supply voltage

E = Emergency circuit braker
F = Branch circuit for lault indication
~ t i o n ,O i l f l o w d i r e c t i o n a n d s e t t i n g of rnax flow. PVP t o t h e r i g h t of PVM. .- --
Electrical connection
7-
Signal voltage. Usl and UsPfor PVEH, PVEM:

Uoc
11-15 V - - 22-30 V-=
Q
USISP : P + A 0.50 x UDC-t 0.75 x Uoc
USISP : P --f B 0,50 x UDC+ 0,251x Uoc
Uoc = Supply voltage
E = Emergency circuit braker
F = Branch circuit for fault indication
Installation of lever
7 :Screw the lever completely home
=ressure sefting PVF: LS*, LSB

are Parts List --
Survey: Page
Pos . 1 : Pump side module PVP ............................................................................................................... 8 9

Pos . 2 : Basic module PVB ....................................................................................................................... 10 . 11
Pos. 3 : Anti-cavitation valve PVLA ......................... . . ............................................................................10 . 11
Pos . 4 : Shock and anti-cavitation valve PVLP ......................................................................................... 10 . 11
POS. 5 : End plate PVS ............................................................................................................................12 . 13
PoS. 6 : Assemply kit PVAS .................................................................................................................... 12 . 13
Pos. 7 : LS unloading valve PVPX ......................................................................................................... 14 - 15
Pos . 8 : Main soool PVB 14 - 15
P0S. 9 Mechanical activation PVM ................... ..................................................................................... 16 - 17
Pos . 10 Cover for friction detent PVMR or for float position PVMF ............................. .. . ....................16 - 17
Pos . 11 Cover for hydraulic activation PVH .................... . . . . ...............................................................16 - 17
P0S. 12 Cover for mechanical activation PVMD ..................................................................................... 16 - 17
Pos . 13 Electrical activation PVEO ........................................................................................................... 18 - 19
Pos. 14 Electrical activation PVEM .............................. .. ...................................................................... 18 - 19
Pos . 15 Electrical activation PVEH ...................................................................................................... 18 - 19
Set of seals for PVG 32 ..................... . ....
........ ......................................................................20
Sectional drawing .......................................................................................................................21
Service Shops ................... . . . ............................................................................................... 22
PVP (pump side module)
26
17
K e DIN 896-6x7
2.6t0.3 doNm
( 1 8 M 2 5 Ibf in/in-lbs)
PVP ourno side module
8 .
Code NO.
Type G - lhread UNF . thread
PVP = G I5785000
Open centre P-Po" = '/-I4 UNF 15785200
PVP = G3/, 15785100
P-pO'< = 1 %,-I2 UNF p!lot 15785300
Open cenlre
sUI~ly
PVP = G x 15785001
Closed cenlre P-Po*< = '/-14 UNF
PVE -
15785201
PVP = G 34 15785101
Closed centre P-po*< = I Y,,-12 UNF 15785301
PVP =G%
I
Incl, pilot
SUPPV
lor PVE
I I
Open centre P-po*c = 1 '/,,-I2 UNF 15785180
PVP =G)/,
Open centre = I ?&.I
PVP = G )/, and

P-pO'< = 1 '/,,-I2 UNF external 157B5191
Closed centre
PP
PVB (basic module)
PVLA (anti-cavitation valve)
PVLP (shock and anti-cavitation valve)
I
.-a PVB (basic module)
I . I Set ol seals (see page 20) 115786999 1111111 I I I1111111 I I I
PVLA (anti-cavitation valve)

PVLP (shock and anti-cavitation valve)
I Type I Code No. I
PVLP setting pressure 50,63.100,125. 140. 160.175.190.210.
230.240.250,265,280,30 and 320 bar 15781...
-- --
PVLA valve 15781001
PVLA plug 15781002
llcm
18
Descrlptton
PVLP assy --- -..-
Code No - __i_1
19 0 - r ~ n g016.0r 1.5 63381813 1 1 1
20 PVLA assy valve 1
21 PVLA assy. plug 1
PVS (end plate)
PVAS (assembly kit)

/- PVS (end plate)
I I Code No. I
Type G-thread I UNF-Ihread
PVS withoul connecl~ons 15782000 1 15782020
PVS with LX connect~ons 15782020 1 15782021
Item Descriplion Code No.

1 End module. assy. 1 1
2' Name plate (lncl item 3) 155L2150 1 1
3' Drive screw 68121011 1 1
4 Plaslic plug 633x1008 1
only lo be used by change ol specil8cation
PVAS (assembly kit)
llem Description
1 I Nut 8.0
2 1 Washer 8.1 x 15.2 x 1.5
3 1 Slay bolt M8; L = 91
Slay bolt M8: L = 140
Stay bolt M8; L = 189
L Slay boll M8; L = 238
Stay boll M8; L = 287
Slay bolt M8; L = 338
Stay bolt M8: L = 434
Slay bolt M8: L = 576
4' O-ring 05.0 x 2.0
5' O-ring 044.0 x 2.5
6' O-ring 016.0 x 2.5
7' O-ring 010.0 x 2.5
I Sct ol seals (see page 20) 15708999- 1 1 1 1 1 1 1 1 1( 1

PVPX (LS unloading valve)
PVBS (main spool)

PVPX (LS unloading valve)
Code No
Type 12 volt
24 VOII
PVPX normally open 15784232
- -15784234
PVPX normally closed 15784242 15764244 ---
PVPX normally open wilh manuel overdrive 15784252 15764254
P
PVPX plug 15785601

1
Set of seals (see page 20) 15784998

1
PVPC (Plug for external pilot oil supply)
Code No.
Type G%- 1 %-20
I Thread I
UNF-Thread
PVPC External pilot supply 1 15765400 1
I PVPC External pilol supply inc. check valve ( 15765600 ( 15765?00
Item Descript~on Code No.

31 O-ring 0 5 . 0 x 1.O 63381815 1
32 PVPC External pilot supply G % - Thread 1
G % . Thread 1 1
33 PVPC External pilot supply inc. check valve
%-20 UNF - Thread 1
PVBS (main spool)

Type Code No
PVBS normal
PVBS el float posltlon B.pon
PVBS mec float posltlon A-pod
PVBS rnec tloat posltlon 8-pon
PVBS lrtcllon delenl
PVM (mechanical activation)
-
PVMD, PVH, PVMP and PVMF (cover for mechanical activation) --
r---
1.5'0.2 daNm
(133t-18 I b l ;"/in-lbs) \
0 . 4 ? 0 . 1 doNm
(35'9 I b l i n / i n - l b s )
, PVM (mechanical activation)
PVMD, PVH, PVMP and PVMF (cover for mechanical activation)
Type Code NO.
PVM Standard
PVM Standard, wilh base. wilhoul arm and button
-
15763010
15763030 -
PVM Slandard. withoul base, arm and button 15763040
op
PVM Reinlorced verslon (22.5) 15763071 -

PVM Reinlorced verston (37.5-) 15763072
I . I Set of seals (see page 20) 1 15763999 11 11 11 1 11 11
PVMD
(cover for mechanical activation)
Type Code No.
Cover for PVH 15760001
G - thread 15760002
PVH (hydraulic aclivalion)
UNF - thread 15760003
PVMR (Iriclion delenl) 15760004
-
PVMF (mechanical float position) 15760005
Screw MG, L = 30
~ ~-
'
Sct 01 Seals (sec pa($
- 20) --- pp
] 157639~I]Tl-*]
IIN 57 A .
PVEH (electrical activation, proportional high)
PVEM (electrical activation, proportional medium)
PVEO (electrical activation, on-off)
PVEH (electrical activation, proportional high)
PVEM (electrical activation, proportional medium)
PVEO (electrical activation, on-off)
Code No.
Type
12 V 24 V
PVES 0% hysteresis (proportional 15784813 15764825
Standard (proportional) 15784013 15784025 -
PVEH Passive tau11 monitormg (proport~onal) 15784083 15784085
Float position (proponional) 15784313 15784325 -
Standard (proportional) 15784113 15764125
PVEM
Float position (proportional) 15784413 15784425
PVEO Slandard (On - On) 15764213 15764225
Set ot seals (see page 20) 15784997 1 1 1 1 1 1 1

-Set af seals for PVG 32
TYpe Code No.
PVP module 15755999
-
PVB module 15786999
PVMIPVHIPVMDIPVMRIPVMF module 15753999
PVEOIPVEMIPVEH module 15754997'
PVAS lor a PVG with 1 PVB seclion 15758999
0 PVPX
~
15754998
I .PVEOIPVEMIPVEH module belore middle 1993 1 15754999 1
[ .not shown on drawing

'toriserede Service Australia : Danfoss (Australia) Pty. Ltd.. Melbourne
ops: Austria : Hainzl Industriesysteme, Gesellschaft m.b.H. Linz
Authorized service shops: Belgium : N.V. Danfoss S.A., Bruxelles
Kundendienstwerkstatten: Canada : Danfoss Mfg. Co. Ltd., Mississauga
Ateliers de depannage: Denmark : H. Sandergaard N S , MAlm
Finland : OY Danfoss AB, Espoo
France : Danfoss S.a.r.l., Trappes (Paris)
Germany : Danfoss GmbH, OffenbachIMain
Great Britain : Danfoss Limited. Greenford (London)
Iceland : Velsmidjan Hedinn, Reykjavik
India : Dantal Hydraulics, New Delhi
Italy : Sordella & C. Oleodinamica s.r.l., Torino
Japan : Danfoss K.K., Gotemba
Netherlands : ITHO B.V., Schiedam
New Zealand : Danfoss (New Zealand) Limited, Auckland
Norway : Danfoss Norge N S , Skui
Singapore : Danfoss Industries Pte. Ltd., Singapore
Spain : Danfoss S.A.;Madrid
Sweden : Danfoss Hydraulik AB, Molndal, Goteborg
Switzerland : Werner Kuster AG, Frenkendorf
Turkey : HATAT, Makina Sanayi ve Ticaret A.S, Maslak-Istanbul
U.S.A. : Danfoss Fluid Power Div. Racine. Wisconsin
w i c e shops Greece : A. Skoura & Co. E.E.. Athens
Catalogues and leaflets are available for detailed information o n the following hydraulic
.
components:
speed high torque hydraulic motors
Planetary gears
Torque amplifiers
Variable displacement hydraulic pumps
Hydrostatic steering units Pump controls
Steering columns Proportional valves
Remote control units
.Valve blocks
Flow-amplifiers
Prioritv valves
Electronics
Rotary Actuators
Please contact the Danfoss Sales Organization for Hydraulics for further information.
PVG 32
Sectional drawing
1 . Pressure relief valve

2. Pressure reduction valve
for pilot supply.
3. Pressure gauge
connection.
4. Plug. open centre.
5. Orifice, closed centre.
6. Pressure adjustment spool.
7. Plug, closed centre.
8. LS connection.
9. LS signal.
10. Shuttle valve.
11. Main spool limiting.
12. LS pressure relief valve.
13. Shock and suction valve.
PVLP
14. Pressure compensator.
15. LS connection. port A.
16. LS connection, port B.
17. Suction valve, PVLA
18. Load drop check valve.
19. Pilot supply for PVE.
20. Max. oil flow adjustment
screws for port A and B.
# l e vr r c v v r l w m r w
KPS 31, 33, 35, 37, 39, 43, 45, 47 qg
Fig. 4 25
A: Omr&deindstilling
Range spindle
Bereichseinstellung
Ajustage de'plage
Alueen asettelu KPS U 28
HacrpoR~a Awanaaona
B: Differensskala
Differential scale
Dlfferenzskaia
Echeile'ds differentiel
Eroalue .
U l ~ a n apam0c-m
C: Opnaet differens
Differential obtained
Erreichte' Differenz
Differentiel obtenu
Saavutettu ero
AmmyraP ~a3Hm
Flg. 5 KPS 43
I&&! BSP
KPS 45 #:
Fig. 2 KPS 35.37.39
Fig. 6 KPS 45 Flg. 7 KPS 47

' 20, LO m 80 8% 110 I L o lm so m 2a "
Fig. 4 2s
83 L- 81 -I 4
A: OrnrAdeindstilling
Flg. 1 Range spindle
Bereichseinstellung
Ajustage de plage
Alueen asenelu
Hac~poir~ ,qnanasona
a
8: Differensskala
Differential scale
Differenzskala
Echelle de differentiel
Eroalue
U l ~ a n apawornu
C: Opnhet differens
Differential obtained
Erreichte Differenz
Differentiel obtenu
Saavutettu ero
Aomr~yrm pa3HOCTb
Flg. 5 KPS 43
Fig. 2 KPS 35.37.39
Flg. 3
Flg. 6 KPS 45 Flg. 7 KPS 47
Tekniske data Technical data Technische Daten 160
Kontaktbelastning Contact load Kontaktbelastung
Vekselstrorn: Ohrnsk belastning 10 A. 440 V Alternating current: Ohmic load 10 A. 440 V Wechselstrom: Ohrnsche Last 10 A. 440 V
lnduktiv belastning. 6 A. 440 V Inductive load 6 A, 440 V lnduktive Last 6 A. 440 V
Startstram rnax. 50 A Starting current 50 A Anlaufstrorn rnax. 50 A
(blokeret rotor) (locked rotor) (Blockierter Rotor)
Jevnstrarn: 12 W: s p ~ n d i n gi.h.t. fig. 4 Direct current: 12 W: voltage to fig. 4 Gleichstrom: 12 W: Spannung gernass der
Kabelforskruninq: Pq 13.5 (se oasA - under Screwed cable entrv: Pa 13.5 (see also under Kurve in Fio. 4
- rnintagej ' :.i%tingm') Kabelverschraubung: P< 13.5 (Siehe auch
Tzthed: IP 67 i.h.t. IEC 144 og DIN 40050 Enclosure: IP 67 to IEC 144 and DIN 40050 unter -Montage..)
Ornqivelsestern~eratur:4 0 ti1 +7O0C Ambient temperature: - 4 0 to +70°C Schutzart: IP 67 gernass IEC 144 und DIN
~edieternperatur:Max. 100°C Ternuerature of medium: rnax. 100°C 400050
KPS 43-47 rnax. 80°C for vand ~pS.43-47rnax. 80°C for water. Urngebungstemperatur: - 4 0 bis + 70°C
Medientemperatur: max. 100°C
Max. pravetryk: Max. test pressure: KPS 43-47 max. 80°C fur Wasser.
KPS 31: 6 bar KPS 31: 6 bar
KPS 33: 10 bar KPS 33: 10 bar Max. Prufdruck:
KPS 35: 12 bar KPS 35: 12 bar KPS 31: 6 bar
KPS 43; 4 5 4 7 : 180 bar KPS 43.45.47: 180 bar KPS 37: 22 bar
KPS 39: 45 bar
El-tllslutnlng Eledrlcal connectlon KPS 43. 45,47: 180 bar
Se klemmerne p a kontaktsysternet, fig. 2. See terminals on switch, fig. 2.
Elektrischer Anschluss
lndstllllng (se figur 3) Settlng (see fig. 3) Siehe Klemmen des Kontaktsysterns. Fig. 2
LAseskruen mellern indstillingsspindlerne Loosen the locking screw between the set-
lasnes og heretter udfsres indstillingen med ting spindlesand then make thesetting using Elnstellung (siehe Fig. 3)
omradesplndelen(iJ rned aflresning pa skala- the range spindle (iJ while reading the scale Die zwischen den Einstellspindeln befindlb
en Q. Dlfferensindstilllngen (undtagen KPS Q. Differential setting (except onKPS pressu- che Sperrschraube lockern und danach un-
pressostater"med fast .differens) sker ved re controls with fixed differential) is made ter gleichzeitiger Ablesung der Skala Q mit
hjaelp af differensspindelen@med aflaesning with the differential spindle @ while
I reading Hilfe der Bereichspindel (iJ die Einstellung
PA skalaen @. Efter endt indstilling spandes the scale @. After setting, retighten the lock- vornehmen. Die Einstellung der Differenz er-
laseskruen atter. ing screw. folgt (ausgenommen KPS-Pressostate mit fe-
Hvis pressastaten ved lave tryk ikke vil koble If the pressure control on the iow pressure ster Differenz) unter gleichzeitiger Ablesung
ud, underssg da, om det skyldes, at differen- side will not cut out, see if this is because the der Skala @ mit Hilfe der Differenzspindel a.
sen er indstillet ti1 en for stor vaxdi. differential has been set at too high a value. Nach erfolgter Einstellung muss die Sperr-
schraube wieder fest angezogen werden.
1) Eksempel for KPS 31 1) Example. KPS 31 Wenn der Pressostat bei niedrigen Druckwer-
Smereolietrykket i en motor onskes ovewL- Lubricating oil pressure in an engine is to be ten nicht ausschaltet, ist zu priifen, o b die
get med en KPS 31. Min. tryk 0.8 bar. Alarmen monitored by a KPS 31. Min. pressure is 0.8 Differenz auf einen zu hohen Wert eingestellt
udlases via en lampe. Min. tryk indstilles pL bar and the alarm is given via a lamp. Using wurde.
omrldes~indelen= 0.8 bar. Differensen er the range spindle, set the rnin. pressure to 0.8
fast = 0,i bar. dvs. sverste smakpunkt = 0.9 bar. The differential is fixed at 0.1 bar, i.e. the 1) Beisplel f i r KPS 31
bar. Lampen tilsluttes pressostatens klemrner upper snap point = 0.9 bar. Connect the lamp Der Schmieroldruck in einem Motor sol1 mit
1 og 2. to pressure control terminals 1 and 2. einem KPS31 Uberwacht werden. Min. Druck
0.8 bar. Die Warnung erfolgt durch eine Larn-
2) Eksempel for KPS 33-39 2) Example, KPS 33-39 pe. An der Bereichspindel wird der rnin.
Trykket i en hydrofor enskes reguleret med en The pressure in a pressure storage tank is to Druck = 0.8 bar eingestellt. Die Differenz ist
pumpe via KPS 35. Max. tryk 6 bar. min. tryk 5 be regulated by a pump via a KPS 35. Max. fest = 0.1 bar, d.h. der obere Schaltpunkt =
-
bar. Differens 6 5 = 1 bar. pressure is 6 bar, min. pressure 5 bar. The 0.9 bar. Die Lampe wird an die Klernrnen 1
Max. tryk indstilles pa omrLdespindelen = 6 -
differential is 6 5 = 1 bar. Using the range und 2 des Pressostats angeschlossen.
bar. Differensen indstillespL differensspinde- spindle, set the max. pressure to 6 bar. Set the
len = 1 bar. Pumpen tilsluttes pressostatens differential to 1 bar using the differential 2) Belsplel tor KPS 33-39
klemmer 1 og 2. spindle. Connect the pump to pressure con- In einern Hydrophorsoll der Druckijber einen
trol terminals 1 and 2. KPS 35 mit einer Pumpe geregelt werden.
3) Eksempel for KPS 4347 Max. Druck6 bar. Min. Druck5 bar. Dlfferenz 6
Til en startluftbeholder enskes kornpresso- 3) Example, KPS 4347 - 5 = 1 bar. An der Bereichspindel den max.
ren styret rned en KPS 45. Max. t w k 36 bar. The Compressor for a starting air receiver is Druck = 6 barund an der Dlfferenzspindel die
min. t k k 3 0 bar. Differens 36-30 bar = 6 bar. to be controlled with aKP45. Max. pressure is Differenz = 1 bar einstellen. Die Purnpe wird
Max. tryk indstilles pAomrLdespindelen. Ind- 36 bar. min. pressure 30 bar. The differential is an die Klemmen 1 und 2 des Pressostats an-
stlllingen DLdifferensskala a f k s e s DL nomo- -
36 30 = 6 bar. geschlossen.
grammet fig. 6 ti1 knap 2. Set the max. pressure using the range spind-
le. The differential scale setting can be read 3) Belsplel fiir KPS 4347
Montage from the nomogram i n fig. 6, i.e. the setting is An einem Startluttbehalter sol1 der Kornpres-
Ved montage pa dampanlag anbefales det at just under 2. sor mit einem KPS 45 gesteuert werden. Max.
lndskyde en vandfyldt rerslejfe. Ved tilslut- Druck = 36 bar. Min. Druck = 30 bar. Differenz
ning ti1 a n k g , udsat for pulsationer kan en Flttlng -
36 30 = 6 bar. An der Bereichspindel wird
dempeslejfe indskydes. When fitting on asteam plant, the insertion of der max. Druck eingestellt. Die Einstellung
NLr en omleber monteres eller demonteres a water-filled pipe loop is recommended. This auf der Dlfferenzskala wird im Nornogramm
.. .
pa tryktilslutningen, skal der altid sprendes is especially relevant where a system is sub- Fig. 6 rnit Knopf 2 abgelesen.
kontra pL tryktllslutningens nsgleflade. KPS jected to vibration.
pressostaterne er normalt forsynet rned en When fitting or removing a pressure line Montage
Pg 13.5 kabelforskrunlng egnet 111 kabeldi- union. always use counter-torque o n the con- Bei der Montage an Dampfanlagen ernpfiehlt
mensioner fra 5 ti1 14 mm. nector spanner flats. KPS pressure controls es sich, eine wassergeffillte Rohrschleife vor-
are normally equipped with a Pg 13.5 screwed zusehen. 8ei einern Einsatz i n Anlagen, die
cable entry suitable for cables from 5 to 14 Pulsationen ausgesetzt sind, kann e l m
rnm. Darnpfschleife eingebaut werden.
Wenn man am Druckanschluss eine Uber-
wurfmutter montiert oder enlfernt, muss
stets an der Schlirsselfliche des Druckan-
schlusses gegengehalten werden. Die KPS-
Pressostate sind allgemein mlt einer fiir Ka-
beldurchmesservon 5 bis 14 mm geeigneten
Kabelverschraubung Pg 13.5 ausgeriistet.
/m /
Kubler, levcl indicarol- \vlalarm sensor onloff,
BNA-DN 15PN- I6-M500-B60-ES-MNA- I AUM80 Artno. 99 1 33
Operating Principle ;ethnical Advantages

A communicating bypass chamber is flanged to the side of a liquids D Simple, robust, and solid des~gri
vessel, and as the liquid level in the tank rises or falls, a float with a D Pressure- and gas-proof separation of chamber and display
built-in magnetic system inside the chamber rises or falls with it. The D Measuring and indicating of the level of aggressive, combu-
chamber is completely sealed so that the only moving part of the stible, toxlc. hot, agitated, and contaminated liquids
apparatus in contact with the liquid is the float itself (see below). D KSR-Magnetic Roller Displays without external power supply
D Available for applications in all areas of industry through use of
On the 'dry side' of the chamber is the KSR Magnetic Roller Dis- highly corrosion-resistant materials
play, a column of magnetic rollers which are white on one side and D Designs for a pressure range lrom full vacuum to 42 MPa
red (MRA) respectively blue (MRK) on the other. The rollers are ma- D Designs for temperatures from -160°C to +450°C
de from plastic (MRA) or ceramics (MRK) with a distance of 10 mm
between their axes. As the float moves up or down the bunched
field of the permanent magnet mounted in its top section 'pulls' the Epecial designs
rollers through a rotation of 18O0,thus changing their colour. As the
.'-?I rises the rollers are turned from white to red (MRA) or blue B Food industry design
K), and as the float falls, they are changed back to white again. 8 Interlace measurement
,his means that at any given time the amount of liquid in the tank is 8 enamelled
constantly represented by a red or blue column without any external
power supply.
Magnet system
Bypass KSR-Magnetic
Chamber Roller Display
Type MRA-M ....
KSR-Bypass
float
Type Z.SS ....
KSR-Magnetic
switch
Type BGU
KSR-Level
Sensor
Type AVK. .-M....
Options -
As oitions the followinq devices can be attached to a KSR-Bypass Level Indicator to monitor /O %
and control the level o f t h e liquid.
KSR-Level Sensors KSR-Magnetic switches

KSR-Level Sensors are used to measure and transmit the level in KSR-Magnetic switches are used to monitor certain limits of the le-
conjunction with a KSR-controlunit. This control unit converts the vel. The obtained bmav signal can be forwarded to trigger alarms
resistance value of the level sensor to a proporlional analogue or other controls.
signal.
KSR-Level KSR-Magnetic
Sensor switches
or
Type STMl
Type AU
YSR-Bypass Level Indicators PN 16
Type: B. - ../I6 - M.... V60 - MRA rechnical data
Q Type code: Ex0

certified EEx ib IIC T6 for hazardous area
PTB Nr. Ex-8312066
>harnber end top: Welding cap or flat top
Options: (see page 34)
- Vent plug G'h'
- Vent valve
- Vent flange
Zhamber end bottom: Flanged with drain plug G'h'
Options: (see page 34)
- Drain valve
- Drain flange
Process connections: side-side
Flanges PN16 or 150 Ib:
DIN 2633 ; DN10 - DN25
DIN 2527 ; DN32 - DNlOO
- 4'
ANSI B 16.5 : 'I.'
Thread or welding stubs:
GMI... = thread female Isize
GNI... = thread male 1 size
S... = weldina stubs I0
Distance
centre-to-centre M..: rnin.150 mm to max. 6M)O rnm
(Distance between
flange centres) (other dimensions on request)
Float: Type ZSS ...
Length of float depending on S.G.
(see page 9)
Material: Stainless steel 1.4571. 1.4435
or 1.4539 (similar SS 316 Ti,
SS 316 Lor Uranus 86)
Titanium 3.7035
Hastelloy 82 2.4617 '
Hastelloy C4 2.4610
Nominal pressure: rnax. 1.6 MPa
Temperature range: -160°C to +450°C
(according to design)
max. 70°C Ex-0 - desian)
- .
Magnetic Roller Display: Type MRA-M.... - m a . 2W°C
Type MRK-M.... - m a . 450%
M =Distance centre-to-centre Type MNA-M.... (Ex-0 - design)
process connection For technical data and further
designs and options:
U = Length of float - 30 mrn see page 36 and 37
Further options:
Magnetic switches: see page 38.39. 40. and 41
Level sensors: see page 42.43.44. and 45
Electrical trace heating: on request
Chamber insulation: on reauest
Open drip proof motors l o 4- GB 3
lnnengekiihlte Motoren (IP 23) DE 5
FR 9
Motores abiertos ES 11
ad
Motori protetti IT 13
0ppna motorer SE 15
Tippuvesisuojatut moottorit FI 17
ABB Motors
/ @ r
j
Validity The machines must not be used in the presence of
dust of organic origin or other kind of flammable dust
This addendum for ABB Motors Induction motor because such an environment is hazardous.
machine instructions is valid for ABB Motors open
drip-proof machine series M2FA and is to be read WARNING:
together with the general instructions. Additional The machine has a high noise level. Protect the
information may be required for some machines due to ears.
special application and/or design considerations.
Allowed starting time for M2FA motors is half of the
Installation starting time for TEFC-types.
The cooling air intake for the motor is normally at the Electric supply
drive end of the machine and the hot air outlet is at non- MZFA motor series is not designed to be used with
drive end. Ensure free flow of cooling air and control the non-sinusoidal supply.
correct air flow direction. Effective limiting of fault currents with fuses and/or
Lead the hot exhaust air away from coolant intake. Also current limiting circuit-breaker (MCCB-type) is
lead away the hot cooling air of other potential heat recommended.
sources.
The ventilator is designed only to cool the motor itself, Lubrication
not the driven machine. If the machine is fitted with a lubrication information
plate, follow the values given, otherwise use the values
WARNING: as follows. The table is prepared for horizontally
The cooling air temperature at outlet is high. Do mounted machines. The values are based on 80°C
not install cables or other material sensitive to bearing temperature.
heat in the exhaust air flow. -
Fmme Amount 36M) 3000 1800 1500 1OOO 900SM)

WARNING: size grease(g) rlrnin rlrnin rlrnin rlrnin rlmin rlmin
The cooling air carries oil and grease droplets
that are dripping from the bearings. Do not install Ball bearings
any oil-sensitive materials, eg. ribber, in the M2FA Lubrication intervals in dutv hours
coolant flow. 250 .40 800 2000460055M)75008000
WARNING: 280 50 800 20004MX)550075008000
A fault in the machine windings could cause an 315 50 800 2 0 0 0 ~ ~ 7 5 0 0 8 0 0 0
arc and spread molten metal-droplets out of the 355 60 1000 4000 5000 7000 8000
machine. Do not install anything inflammable
Roller bearings
near the machine. Do not remain unnecessarily
close to the machine while it is running. M2FA Lubrication Intervals in duty hours
250 40 3 7 33M)450063006800
Use 280 50 3 3 270038006MX)6500
315 50 ) ) 2700 3800 M)(M 65M)
Operating conditions 355 60 ) ) 2200 3200 5500 6000
Machine series M2FA is designed for use in dry, clean
indoor environments. Installation in locked compressor- *) Use of roller bearings not recommended.
or electric rooms is recommended. If lubrication interval is not given here or stated on the
lubrication information plate, consult ABB Motors.
WARNING:
The velocity of the cooling air is high. Protect For additional information concerning the calculation of
the eyes when remaining near machines whilst the lubrication interval please see the general machine
running. instruction booklet delivered with the machine.
Drip-proof machine M2FA is made to class IP 23 S. NOTE:

Objects having diameter in excess of 12 mm do not Hot cooling air flows around the bearing at
penetrate the openings of the machine. IEC test finger the non-drive end. If the exhaust air temperature
does not reach moving or energized parts inside the exceeds 75°C use shorter lubrication intervals,
machine. Rain falling at angle less than 60 degrees or heat resistant grease.
from vertical will not cause harmful effects when the
machine is standing still. When a new machine is running for the first time,
excess lubricant will be pumped out of the bearing.
WARNING: Roller bearings especially have a strong pumping
Objects having diameter 12 mm or less may effect. The bearing may thus be operating normally
penetrate into the machine and cause damage. even though a certain amount of grease is coming out
during the first start.
M2FA machines are not protected against water whilst
running. Control the mounting designation. WARNING:
The cooling air carries oil- and grease droplets,
The machines have no air intake filter. The machines blowing them out of the machine. Protect the
must not be installed outdoors. The machines are not eyes.
protected against ingress of eg. snow, leaves, metal
chips, oil mist etc.
ABB Motors
Environmental requirements
Noise levels
The sound pressure level of the machines exceeds
70 dB(A).
Frame size Guideline sound pressure level, dB(A) 1rn
The table values refer to 50 Hz sinusoidal supply

conditions.
For 60 Hz sinusoidal supply, add 4 dB(A) to the above
values.
For approximate sound power level, add 13 dB(A) to
above values.
Designs made for 50 Hz may exceed the limits given in
IEC 34-6 when running at 60 Hz.
ABB Motors
Machine Instructions
M3000
Example of the Declaration of Conformity
given by ABB Motors. log
EC Declaration of Conformity
The Manufacturer :- (Name andaddress of the manufacturer)
hereby declares that
The Products :- (Product identification)
are in conformity with provisions of the following Council Directives :
Low Voltage Directive 73/23/EEC (amended by 93/68/EEC),
and, as components, with the essential requirements of the following :
EMC Directive 89/336/EEC (amended by 92/31/EEC and 93/68/EEC), regarding the intrinsic
characteristics to emission and immunity levels,
and are in conformity with :
EN 60 034-1
Additional Information :-
By design, the machines, considered as components, comply with the essential requirements of
Machinery Directive 98/37/EEC provided that the installation be correctly realised by the manufacturer
of the machinery (for example : in compliance with our Installation Instructions and EN 60 204 "Electri-
cal Equipment of Industrial Machines").
Certificate of Incorporation (Directive 98/37/EEC, Art 4.2 and Annex II, Sub B) :
The machines above must not be put into service until the machinery into which they have
been incorporated have been declared i n conformity with the Machinery Directive.
Year of CE marking : CEOO.
Signed b y .......................
.......
...............
Title .........................................................
Date ..........................................................
Translations into other languages are available from

ABB Motors.
LV MotorsIMachine Instructions 00-10

Machine lnstructions Insulation resistance check I oCP
Measure insulation resistance before commissioning and
NOTE! when winding dampness is suspected.
These instructions must be followed to ensure safe and Resistance, measured at 25"C, shall exceed the
proper installation, operation and maintenance of the reference value, i.e. 10 M ohm (measured with 500V dc
motor.They should be brought to the attention of
anyone who installs, operates or maintains this Megger)
equipment. Ignoring the instruction may invalidate the
warranty. WARNING
Declaration of Conformity I Windings should be discharged immediately after

measurement to avoid nsk of electric shock.
Insulation resistance reference value is halved for each

Declarations of Conformity with respect to the Low 20°C rise in ambient temperature.
voltage Directive 73/23/EEC amended by Directive 93/68
EEC are issued separately with individual machines. If the reference resistance value is not attained, the
winding is too damp and must be oven dried.
The Declaration of Conformity also satisfies the Oven temperature should be 90°C for 12-16 hours
requirements of a Declaration of lncor~oration with followed by 105°C for 6-8 hours.
respect to the Machinery Directive 9 8 1 3 7 1 ~ ~ ~ .
Drain hole plugs, if fitted, must be removed during
Validity heating.
The instructions are valid for the following ABB electrical Windings drenched in seawater normally need to be
machine types, in both motor and generator operation. rewound.
series MT*, MBT*, MXMA, Direct-on-line or starkfelta starting

series M2A*/M3A', M2B*/M3B*, M2C'/M3C', M2F*/ The terminal box on standard single speed machines
M3F*, M2L*/M3L*, M2M'/M3M*, M2R*/M3R*, normally contains 6 winding terminals and at least one
earth terminal.
in frame sizes 63 - 400.
Earthing must be carried out according to local
(Additional information may be required for some regulations before the machine is connected to the
machine types due to special application and/or design
supply voltage.
considerations.)
The voltage and connection are stamped on the rating
Putting into service (starting) plate.
Direct-on-linestarting (DOL):
Reception check
Y or A winding connections may be used.
Immediately upon receipt check the machine for external
eg 660 VY, 380 VA indicates y-connection for 660 V and
damage and if found, inform the forwarding agent without A-connection for 380 V.
delay.
StarIDelta starting (YIA) :
Check all rating plate data, especially voltage and The supply voltage must be equal to the rated voltage of
winding connection (star or delta).The type of bearing is the machine in A-connection.
specified on the rating plate from size 112 and larger. Remove all connection links from the terminal block.
Remove transport locking if employed.Turn shaft by
hand to check free rotation. For two-speed, single phase and special machines,
supply connection must follow the instructions inside the
Motors equipped with roller bearings: Running the terminal box.
motor with no radial force applied to the shaft may
damage the roller bearing. Terminals and direction of rotation
Direction of rotation is clockwise when viewina the shaft
Motors equipped with angular contact bearing: face at the machine drive end, when the line ihase
Running the motorwith no axial force applied in the right sequence L1, L2, L3 is connected to the terminals as
direction to the shaft may damage the angular contact shown in the figure 1.
bearing.
Toalter the direction of rotation, interchange the
Motors equipped with regreasingdevices: connection of any two line cables.
When starting the motor for the first time, apply at least
the specified quantity of grease until new grease is If the machine has a uni-directional fan, ensure that the
forced out of the grease outlet. direction of rotation is according to the arrow marked on
For details see section "Machines with relubrication the machine.
system" on page 6.
LV MotorsIMachine lnstructions 00-10

needed the position of the eyebolt must be adjusted with
Use suitable washers.
Ensure that proper lifting equipment is used and that the
Operating conditions sizes of the hooks are suitable for the lifting lugs.
The machines are intended for use in industrial drive Care must be taken not to damage auxiliary equipment
applications. and cables attached to the motor.
Normal ambient temperature limits are -25" to +4OoC.
Maximum altitude 1000 m above sea level. Machine weights
Total machine weight can vary within the same frame
Safetv considerations size (center height) depending on different output,
The machine is intended for installation and use by mounting arrangements and added features.
qualified personnel, familiarwith relevant safety
requirements. The following table shows estimated maximum weights
for machines in their basic versions as a function of
Safety equipment necessary for the prevention of frame material.
accidents at the installation and operating site must be
provided in accordance with the local regulations. On machines weighing more than 25 kg, the actual
weight is stated on the rating plate.
/ WARNING
Small motors with supply current directly
switched by thermally sensitive switches can Frame
Aluminium
Weight Add.
Cast iron
Weight Weight
start automatically. size kg or brake kg
Points to observe 63 6
1. Do not use the machine to step on 71 8
2. The temperature of the outer casing of the 80 12
machine may be hot to the touch during normal 90 17
operation. 100 25
3. Some special machine applications require 112 36
special instructions (e.g. using frequency 132 63
converter supplies) 160 110
4. Lifting lugs must only be used for lifting the motor. 180 160
They must not be used to lift the motor when it is 200 220
attached to other equipment. 225 295
250 370
Handling 280
315
Storage 355
The machine should always be stored indoors, in dry, 400
vibration free and dust free conditions.
Installation
Unprotected machined surfaces (shaft-ends and flanges)
should protected with anti-corrosive paint.
Normal ambient temperaturesshould not exceed 40°C
It is recommended that shafts be rotated periodically by (marine standard 50°C) if standard ~erforrnanceis to be
hand to prevent grease migration. achieved. Check that the motor has sufficient airflow.
Ensure that no nearby equipment or surfaces radiate
Anti condensation heaters, if fitted, should preferably be additional heat to the motor. For more information about
energised. higher ambient temperatures and cooling, see "the Motor
Guide" or contact ABB Sales Office.
The characteristics of electrolytic capacitors, if fitted to
single-phase motors, will require "reforming" following Foundation
periods of storage exceeding 1-2years. The purchaser bears full responsibility for preparation of
Contact ABB Sales Office for details. the foundation.
Transportation Metal foundations should be painted to avoid corrosion.

Machines fitted with cylindrical-roller and/or angular
contact bearings must be fitted with locking devices Foundations must be even, and sufficiently rigid to
during transport. withstand possible short circuit forces.They shall be
dimensioned as to avoid the occurrence of vibration due
Lifting to resonance.
Lift the motor using the lifting lugs only.
Foundation studs
The center of gravity of motors with the same frame
Bolt the foundation studs to the feet of the motor and
may vary due to different outputs, mounting arrange- place a 1-to-2 mm shim between the stud and the feet.
ments and auxiliary equipment.
Check that eyebolts or the lifting lugs integrated with the Align the motor directly using appropriate means.
motor frame are undamaged before lifting. Damaged
lifting lugs must not be used. Grout the studs with concrete, check alignment and drill
Lifting eyebolts must be tightened before lifting. If holes for locating pins.

) I i
Drain holes
Always check that open drain holes face downward. This arrangement has no electrical safety function; the
Machines with closable plastic drain plugs are delivered purpose is to equalise the potentials. When the motor
with these open. and the gearbox are mounted on acommon steel funda-
In extremely dusty environments, all drain holes should ment, no potential equalisation is required.
be closed.
Potential equalisation
Alignment
Correct alignment is essential to avoid bearing failures,
P/ate/srrip
vibrations and possible fractured shaft extensions.
Slide rails and belt drives

Fasten the machine to the slide rails as shown in
figure 2.
min 50 rnm
Place the slide rails horizontally on the same level.
Check that the machine shaft is parallel with driven, or
driving, shaft. To comply with EMC-requirements, use only cables and
Any belt must be tensioned according to the supplier's connectors approved for this purpose. (See instruction for
instructions. frequency converters.)
WARN1 Assembly and dismantling

Excess,ive belt tension w ~ ldamage
l beanngs and
Ise_ shaft
can cac- _ _ .-breakaoe
_ - -,-. I
General
Dismantling and assembly of machines must be carried
Do not exceed the maximum belt forces (i.e. radial out by qualified personnel using only suitable tools and
bearing loading) stated in the relevant product working methods.
catalogues.
Bearings
Connection Special care should be taken with the bearings.
These must be removed using pullers and fitted by
Normal machine design has the terminal box on top and heating or using special tools for the purpose. How
cable entry possible from both sides. to replace bearings is described in detail in a separate
instruction leaflet available from ABB Sales Office.
As a special option, some machines are available with
top mounted terminal boxes rotatable 4 x 90°, and some Fitting coupling halves and pulleys
with side mounted terminal boxes. Coupling halves and pulleys must be fitted using suitable
equipment and tools that do not damage the bearings.
Availability of these solutions is described in the product
catalogues. Never fit a coupling half or pulley by hammering into
place or remove it using a lever pressed against the
Unused cable entries must be closed. body of the machine.
As well as main winding and earthing terminals, the Mounting accuracy of coupling half :
terminal box can also contain connections for check that the clearance b is less than 0,05 mm and
thermistors, standstill heating elements, bimetallic, that the difference a1 to a2 is also less than 0,05 mm.
switches, or PT 100 resistance elements. See figure 3.
/ WARNING
Voltaqe may be connected at standstill ins~dethe
terminal box for heating elements or direct
I Balancing
The rotor of the machine is dynamically balanced.
winding heating.
As standard, balancing has been carried out using half
Connection diagrams for auxiliary elements are found key, and the shaft is marked with a RED tape, with the
inside the terminal box cover. text "Balanced with half key".
To avoid vibration the coupling-half or pulley must be
balanced with half key after the keyway has been
The capacitor in single-phase motors can retain machined.
a charge that appears across the motor
terminals, even when the motor has reached In the event of balancing with full key the shaft is
standstill. marked with aYELLOW tape, with the text "Balanced
with full key".
In frequency converter applications motor frame To avoid vibration the coupling-half or pulley must be
external earthing must be used for equalising the poten- balanced without a key after the keyway has been
tial between the motor frame and the driven machine, machined.
unless the two machines are mounted on the same
metallic base. For motor frame sizes above IEC 280, In case balancing without key, the shaft is marked with
use 0.75 x 70 mm flat conductor or at least two 50 mm2 a BLUE tape, with the text "Balanced without key".
round conductors.The distance of the round conductors
must be at least 150 mm from each other.
LV Motors/Machine Instructions 00-10
Maintenance and lubrication 11 2 ABB Motors policy is to have reliability as a vital issue
in bearing lubrication intervals.That is why we follow the
General inspection L1-principle (meaning that 99 OL, of the motors are sure
- Inspect the machine at regular intervals. to make the interval time). According to L1 policy the
- Keep the machine clean and ensure free lubrication intervals are as follows:
ventilation airflow.
- Check the condition of shaft seals (eg V-ring) and Frame Amount 3600 30M) 1800 1500 1000 500-900
replace if necessary. size ofgreaserimin rimin rimin r/min rimin rimin
- Check the condition of connections and mounting dbearino
and assembly bolts.
- Ball bearings
Check the bearing condition by listening for
Lubrication intervals in duty hours
unusual noise, vibration measurement, bearing
10 10000 13000 18000 21000
temperature, inspection of spent grease or SPM
15 9000 11000 17000 19000
bearing monitoring.
25 7000 9500 14000 17000
When changes of condition occur,
30 6000 8000 13500 16000
dismantle the machine, check the parts
and replace if necessary. 40 4000 6000 11000 13000
50 3000 5000 10000 12500
60 2500 4000 9000 11500
Lubrication
70 2000 3500 8000 10500
90 2000 3500 6500 8500
Machines with permanentlv greased bearings
120 1200 2000 4200 6000
Machines up to frame size 180 are normally fitted with
120 1200 2000 4200 6000
permanently greased bearings of either Z or 22 types.
Bearing types are specified in the respective product Roller bearings
catalogues and on the rating plate of each motor from Lubrication intervals in duty hours
size 112 and larger. 25 3500 4500 7000 8500
30 3000 4000 7000 8000
As a guide, adequate lubrication can be achieved for the 40 2000 3000 5500 6500
following duration, according to L1 at ambient 50 1500 2500 5000 6000
temperature of 25" C. 60 1300 2000 4500 5700
32 000 - 45 000 duty hours for 4 pole machines.') 70 1000 1700 4000 5300
16 000 - 26 000 duty hours for 2 and 214 pole 90 1000 1700 3300 4300
machines.') 120 400 1000 2000 3000
120 400 1000 2000 3000
The shorter times apply to larger frame sizes.
Lubrication intervals for vertical machines are half of the
Depending on application and load conditions, see above values.
applicable product catalogue.
Hours of operation for vertical motors are half of the The amount of grease stated in the table should be
above values. doubled if an automatic regreasing system is used.
Machines with relubrication svstem The table values are based on the motor running at rated
output in an ambienttemperature of about + 25" (approx.
WARNING 80°C bearing temperature).The values should be halved
Beware of all rotating parts! for 15°C increase in bearing temperature and may be
doubled for 15°C decrease in ambient temperature.
Relubrication procedure:
- Remove grease outlet plug if fitted. WARNING
- Press fresh grease into the bearing until all old grease
-
has been forced out
Let the motor run 1-2 hours to ensure that all excess
I The maximum operating temperature of the
grease and bearings must not be exceeded. 1
grease is forced out of the bearing. Close the grease Higher speed operation, eg in frequency converter
outlet plug if fitted. applications, or lower speed with heavy load will require
shorter lubrication intervals. Consult ABB Sales Office in
Regrease motors while running. If this is not possible, such cases.
lubrication can be carried out while the machine is at a
standstill. In this case, use only half the quantity of Typically a doubling of speed will require a reduction of
grease, then run the motor for a few minutes at full lubrication intervals to approx. 40 %of values tabulated
speed. When the motor hasstopped, the remaining above.
quantity of grease can be forced in until the old grease
has been replaced. Suitability of bearings for high speed operation must be
After 1-2 running hours close the grease outlet plug (if checked.
fitted).
The grease outlet plug must be removed permanently
with automatic lubrication.
If the machine is fitted with a lubrication information
plate, follow the given values, otherwise use the values
in table below.
LV MotorsIMachine Instructions 00.10

Lubricants ! I3 Environmental requirements
When regreasing, use only special ball bearing grease
with the following properties: Noise levels
- good quality grease with lithium complex soap and with Smaller machines have a sound pressure level not
mineral- or PAO-oil exceeding 70 dB(A).
- base oil viscosity 100-150 cST at 40°C
- consistency NLGl grade 2 or 3 The following table shows catalogue values of sound
- temperature range -30°C - +120°C, continuously. pressure levels at 1 m from the machines surface.
Grease with the correct properties is available from all Frame Guideline sound pressure level, dB(A)
the major lubricant manufacturers. size 2 pole 4pole 6 pole 8 pole
The following (or similar) high performance grease can
be used
EssoUnirex N2 or N3
Shell Albida EMS 2
SKF LGHQ 3
Mobil Mobilith SHC 100
Kliiber Kluberplex BEM 41-132
BP Energrease LC2
NOTE! ~ ~ ~ -
Always use high speed grease for high speed machines 400 83 80
and some other models, e.g. M21M3- 355 and 400 2- Values for specific machines can be found in the
pole machines, where the speed factor is higher than relevant product catalogues.Tolerance * 3 dB(A).
400 000 (calculated as Dm x n where Dm = average
bearing diameter, mm ; n = rotational speed, rpm).The The table values refer to 50 Hz sinusoidal supply
following, or similar, types of grease can be used: conditions.
Kluber Asonic GHY 72 For 60 Hz sinusoidal supply, add 4 dB(A) to the above
Kluber Asonic HQ 72-102 values.
Shell Albida EMS 2
Esso LT2 For sound pressure levels with non-sinusoidal supplies,
Mobil Mobilith SHC 100 contact ABB Sales Office.
The following normal type of grease can be used if the Sound pressure levels for all machines in the above
regreasing interval is halved (these types of grease frame sizes having separate cooling systems and for
should not be used when bearing temperature is above series M2F'/M3F*, M2L*/M3L*, and M2R*/M3R*, are
100°C) indicated in separate Machine Instructions.
Esso Beacon 2 or 3
Shell Alvania RL2 or RL3 Rewinding
SKF LGMT 2 or 3
Mobil Mobilux 2 Rewinding should always be carried out by qualified
Kluber Centoplex 2 repair shops.
BP Energrease LS2
Smoke venting and other special motors should not be
If the make of grease is changed and compatibility is rewound without first contacting ABB Motors.
uncertain, consult ABB Sales Office.
Highly loaded and/or slowly rotating bearings require EP-
grease.
If the ambient temperature is below -25°C or above
+55"C, or bearing temperature is above 11O0C,consult
ABB Sales Office regarding suitable grease.
WARNING
Grease can cause skin irritation and eye
inflammation.
Follow all safety precautions specified by the
manufacturer.
Spare parts
When ordering spare parts, the full type designation and
product code, as stated on the rating plate, must be
specified.
If the machine is stamped with a serial manufacturing
number, this should also be given.

These instructions do not cover all details or variations in equipment nor provide for every possible condition to be
met in connection with installation, operation or maintenance. Should additional information required, please contact
the nearest ABB Sales Office. I 14
Motor trouble shooting chart
Your motor service and any trouble shooting must be handled by qualified persons with proper tools and equipment.
CAUSE WHATTO DO
dotor fails to start Blown fuses Rewlace fuses with wrower tvwe and ratina
Overload triws Check and reset overload in starter.
lmproper power supply Sheck to see that power supplied agrees with mot0
ratina olate and load factor.
lmproper line connections Check connections with diagram supplied with
notor.
Open circuit in winding or control lndicated by humming sound when switch is
switch zlosed. Check for loose wiring connections. Also,
snsure that all control contacts are closed.
Mechanical failure Check to see if motor and drive turn freely. Check
bearings and lubrication.
Short circuited stator Indicated by blown fuses. Motor must be rewound.
Poor stator coil connection Remove end bells, locate with test lamp.
Rotor defective Look for broken bars or end rinas.
Motor mav be overloaded Reduce load.
Motor stalls One whase mav be oDen Check lines for oDen ~ h a s e .
Wrong application Change type or size. Consult manufacturer.
Overload Reduce load.
Low voltage Ensure the rating plate voltage
- is maintained.
Check c~nnecti~n..
Open circuit Fuses blown, check overload relay, stator and push
buttons.
Motor runs and then Power failure Check for loose connections to line, fuses and
3ies down control.
Motor does not come Not applied properly Consult s u ~ ~ l ifor
e rDroDer Woe.
up to speed Voltage too low at motor terminals Use higher voltage or transformerterminals or
because of line drop reduce load. Check connections. Checkconductors
for DroDer size.
Starting load too high Check load motor is supposes to carry at start.
Broken rotor bars or loose rotor Look for cracks near the rings. A new rotor may be
required, as repairs are usually temporary.
Open primary circuit Locate fault with testing device and repair.
Motor takes too long to Excessive load Reduce load.
accelerate and/or draws Low voltaae durina start Check for hiah resistance. Adeauate wire size.
high amp Defective sauirrel caae rotor Re~lace with new rotor.
Applied voltage too low Get power company to increase power tap.
Wrong rotation Wrong sequence of phases Reverse connections at motor or at switchboard.
Motor overheats while Overload Reduce load.
running underloaded Frame or bracket vents may be Open vent holes and check for a continuous stream
clogged with dirt and prevent proper of air from the motor.
ventilation of motor
Motor may have one phase open Check to make sure that all leads are well
connected.
Grounded coil Locate and rewair,
Unbalanced terminal voltage Check for faulty leads, connections and
transformers.

'ROUBLE CAUSE WHATTO DO
lotor vibrates Motor misaligned Realign.
]weak support /strengthen base.
Coupling out of balance Balance coupling.
Driven equipment unbalanced Rebalance driven equipment.
Defective bearings Replace bearings.
Bearings not in line Line up properly.
Balancina weiahts shifted Rebalance motor.
Contradiction between balancing of Rebalance coupling or motor
rotor and coupling
(half key - full key)
Polyphase motor running single phase Check for open circuit.
Excessive end play Adjust bearing or add shim.
icraping noise Fan rubbing fan cover Remove interference.
Fan striking insulation Clear fan.
Motor loose on bedplate Tighten holding bolts.
loisy operation Airgap not uniform Check and correct bracket fits or bearing.
Rotor unbalance Rebalance.
lot bearings general Bent or sprung shaft Straighten or replace shaft.
Excessive belt pull Decrease belt tension.
Pulleys too far away Move pulley closer to motor bearing.
Pulley diameter too small Use larger pulleys.
Misalignment Correct by realignment of drive.
lot bearings ball lnsuff icient grease Maintain proper quality of grease in bearing.
Deterioration of grease or lubricant Remove old grease, wash bearings thoroughly in
contaminated kerosene and replace with new grease.
Excess lubricant Reduce quantity of grease, bearing should not be
more than 112 filled.
Overloaded bearing I ~ h e c alignment,
k side and end thrust.
Broken ball or rough races l ~ e ~ l a bearing,
ce first clean housing thoroughly.

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Service manual and part list for

Teleph: 47 700 14000

BOW AND STERN TUNNEL

IN ORDER TO PROTECT THE TUNNEL

I ROLLS-ROYCE MARINE AS - SERVICE MANUAL I

When ordering spare parts, following information must be given.

1. NAME OF VESSEL AND OWNER'S ADDRESS. IF POSSIBLE, NAME AND

2. TYPE OF INSTALLATION, NUMBER AND YEAR OF MANUFACTURE.

3. THE SPARE PART'S ARTICLE NUMBER, DRAWING NUMBER AND

Teleph: 47 700 14000

Telefax: 47 700 14011 PAGE: 3 of 22

Teleph: 47 700 14000

Dimension drawing ..........................................................................................2 16 141-A

Instruction for servo pump. Commercial. P3 1A187-BE ...................................990824

Tcleph: 47 700 14000

I TECHNICAL DATA FOR THRUSTER TYPE 250TV I

Propeller diameter: ............................................................................................ 1880 rnrn

Servo Oil Pump: ................................................................... COM. P3 lA187BE**07-30

Telefax: 47 700 14011 PAGE: 6 of 22

SPARE PARTS AND TOOLS

Following spare parts are delivered with the unit:

Quant. Description Art. no.

2 pcs. Filter element, EPE .........................................................................9906 18

Telefax: 47 700 1401 1 PAGE: 7 of 22

Daily before start up:

1. Check oil level in gravity feed tank and fill up if required.

During each docking:

3. Zink anodes at tunnel ends should be changed if required.

LUBRICANTS FOR 250 TV-D - 414498

Ulstein Propeller AS.

Title: Lubricants for Reduction Gears w/cIutch. 1'2

PS: Lubricants of toothed coupling, shaft bearings and sterntube g l a d to be in

-Revisions 1 A 17540 1 B 17912 1 C 18134 ( D 18494 ( E 18696 1

TUNNEL AND GEARHOUSING

Telefax: 47 700 1401 1 /8 PAGE: 13 of 22

START AND STOP

INSTALLATION OF TUNNEL INTO THE HULL

INSTALLATION OF THE PROPELLER UNIT.

Installation is carried out in the following way:

Teleph: 47 700 14000 d Z

REMOVAL OF PROPELLER UNIT

1. Remove the drive motor from the motor adapter.

2. The oil should be drained from the gear housing.

INSPECTION OF PINION SHAFT AND DISMOUNTING OF GEAR UNIT

2. The gearwheel can now be inspected.

When removing the servo shaft unit following procedure to be followed:

6. Marks on gearwheel should correspond with marks on coupling boss.

ADJUSTMENT OF PINION SHAFT AND GEAR WHEEL

The tooth contact patterns are to be verified by using a thin

Adjustment of gearwheels is carried out as described below:

1. For adjustment of the pinion shaft:

2. For adjustment of the crown wheel:

A gravity feed tank should be installed acording to calculations in drawing 415865.

2: Solenoid valve - 4/3 direction valve

Teleph: 47 700 14000

THE DIFFERENT VALVES

3. PRESSURE REDUCING VALVE: The servo pressure is variable between 20 and

To prevent all oil from flowing through.the

INSTALLATION OF THE ELECTRIC MOTOR

Separate instructions for the electric motor and starter is enclosed.

RETTLEDNING FOR INNBYGGING AV TUNNEL I SKROG.