Manual TT FP 13350

Instruction manual
For
ZF Marine Systems
ZF Tunnel Thruster Fixed Pitch
ZF ORDER 13350 (bow)
SK 120 Heavy Cargo Vessel

Shipkits
ZF Marine Krimpen B.V.

Zaag 27
P.O. Box 2020
2930 AA Krimpen aan de Lek
Holland
Tel.no +31 (0)180-331000
Telefax no. +31 (0)180-331099
INDEX
REVISION:
1. GENERAL DESCRIPTION ZF TUNNEL THRUSTER
1.1 Technical specification
1.2 Introduction
1.3 Ordering spare parts
2. THRUST PERFORMANCE AND BUILD-IN INSTRUCTIONS OF TUNNELTHRUSTERS
2.1 Installation of lubrication
2.2 Connecting electrical wiring
2.3 Check points
2.4 Operation instructions
2.5 Thrust Performance of tunnel thrusters (P0125)
2.6 Paint instructions (P0181)
3. SAFETY AND TRANSPORT
3.1 Safety and transport (P0168)
3.2 Hoisting (P0502)
4. MAINTENANCE INSTRUCTIONS
4.1 Maintenance schedule (P0163)
4.2 Lubricants list (P0166)
4.3 Maintenance instructions of tunnel thrusters (P0303)
4.4 Propeller installation (P0110)
4.5 Propeller change procedure (P0118)
4.6 Leakages test of propeller fitting system (P0113)
4.7 Storage (P0211)
5. ZF TUNNELTHRUSTER UNIT
5.1 General Arrangement ZF thruster unit
5.2 ZF lower gearbox assembly
5.3 Drain plug
6. ZF TUNNELTHRUSTER OIL SYSTEM (OPTIONAL)
6.1 Arrangement lubricating oil tank
7. MAIN DRIVE (OPTIONAL)
7.1 Motor
8. TECHNICAL DESCRIPTION TRANSMISSION (OPTIONAL)
8.1 Flexible coupling
8.2 Cardan shaft
8.3 Shaftline (optional)
9. PROCEDURE SHEETS
9.1 Torque list (P0072)
9.2 Anodes (P0210)
10. ELECTRICAL SYSTEM (OPTIONAL)
10.1 Operation manual ZF control system
10.2 Connection diagram Tunnel Thruster
Revision:
Date: Revision: Change:

1. GENERAL DESCRIPTION ZF TUNNEL THRUSTER
1.2 Introduction

TECHNICAL SPECIFICATION TS00 13350 & 13351
25 April 2012
ZF® FIXED PITCH TUNNEL THRUSTER

TYPE ZF TT 3001 FP
ELECTRIC DRIVEN
GENERAL:
Customer : Shipkits
Ship yard : not yet known

Yard reference : SK-120 (optional SK-121)
Owner/end-user : not yet known
Vessel type : Heavy Cargo Ship
No. units per ship : 2 (1 bow thruster & 1 stern thruster)

No. of ship sets : 1+1 optional
CLASSIFICATION:
Classification : BV, including certificates
Class notation : I ?HULL ?MACH AUT-UMS
Ice class : none
OPERATING CONDITIONS:
Ambient temp. on deck : min. -20°C to max 45°C
Enclosed spaces : max. 45°C
Relative air humidity : max 95% at 45°C
Quality standards : according to ISO 9001
Vibrations : according Class requirements
MAIN PARTICULARS:
BOW THRUSTER 13350 STERN THRUSTER 13351
Type : ZF 3000, L-Drive unit ZF 3000, L-Drive unit
Type code : ZF TT 3001 FP ZF TT 3001 FP
Rating : 300 kW 300 kW
Input speed : 1500 rpm 1500 rpm
Application : bow thruster stern thruster
Duty cycle : auxiliary use auxiliary use
Reduction ratio : 2.462:1 2.462:1
Propeller diameter : Ø1050 mm Ø1050 mm
Tunnel : Ø1110 x 15 x 4000 mm Ø1110 x 15 x 2300 mm
Estimated thrust at propeller : 39 kN 39 kN
Mentioned quantities, data and descriptions in this technical specification are per unit, unless
specifically mentioned otherwise.
TS00 13350_51 Apr25-12 1 of 4

25 April 2012
SCOPE OF SUPPLY:
A FIXED PITCH TUNNEL THRUSTER, L-DRIVE
A.1 FIXED PITCH PROPELLER

A.2 TUNNEL
A.3 UNDERWATER-GEARBOX WITH RIGHT-ANGLE DRIVE
A.4 LUBRICATION OIL SYSTEM
A.5 FLEXIBLE COUPLING
B GENERAL
B.1 DRAWINGS, INSTRUCTION MANUALS & NAME PLATES

B.2 PAINTING AND PRESERVATION
B.3 ANODES
B.4 SPECIAL TOOLS
B.5 SPARE PARTS
B.6 WORKSHOP TESTING/FACTORY ACCEPTANCE TEST
C EXCLUDED ITEMS
TS00 13350_51 Apr25-12 2 of 4

25 April 2012
A FIXED PITCH TUNNEL THRUSTER, L-DRIVE

Each thruster consists of:
A.1 FIXED PITCH PROPELLER
A 4-bladed kaplan propeller, material Ni-AL Bronze, ISO-class II. Propeller is key-fitted.
A.2 TUNNEL
Tunnel out of Grade-A steel, with machined foundation for electric drive-motor, provided with both
transverse and longitudinal stiffeners. Number and position of the stiffeners as per ZF Marine
Krimpen standard.
A stainless steel wear-ring is welded inside the tunnel on propeller location.
The tunnel thickness, as mentioned on the first page, is to be at least as thick as the hull plating (to
be checked by customer).
Changes in the tunnel thickness and/or length, as well as changes in the standard number and
position of the transverse and longitudinal stiffeners, can be optionally quoted.
A.3 UNDERWATER-GEARBOX WITH RIGHT-ANGLE DRIVE
Underwater-gearbox made of cast iron in streamlined shape, with heavy duty spiral bevel gears
and a propeller shaft. A bronze propeller lock plate with stainless steel bolts.
A.4 LUBRICATION OIL SYSTEM
The lubrication oil system is based on a full oil bath principle. A lubrication oil header tank is loose
delivered. The tank needs to be placed by the shipyard above the loaded water line of the vessel,
height will be advised by ZF Marine Krimpen on the GA-drawing. The tank is complete with; self-
closing type level glass, filler cap/breather, level alarm switch and drain-plug.
A.5 FLEXIBLE COUPLING
Flexible coupling on the drive shaft, suitable to be connected to the main electric drive motor.
TS00 13350_51 Apr25-12 3 of 4

25 April 2012
B GENERAL
B.1 DRAWINGS, INSTRUCTION MANUALS & NAME PLATES
• Set of drawings and schedules in PDF format comprising:

- general lay-out drawing of tunnel thruster and loose delivered items
- electric schedules and wiring diagrams
• Manuals and parts lists in PDF format on CD-rom
• Printed copy of above mentioned documents in 3-fold (one set per shipset)
All drawings, manuals, parts list and name plate(s) in English language
B.2 PAINTING AND PRESERVATION
Gearbox structure : 2-component, multi layer coating, suitable for operation

in fresh or salt water, as per ZF Marine Krimpen
standard specification
Tunnel construction : single layer of Hempadur weld primer
Preservation : the components are standard supplied, suitable for
indoors storage of 6 months
B.3 ANODES
The units are equipped with sacrificing aluminum anodes (zinc anodes can be supplied on your
request, to be specified at order), against electrolytic corrosion as per ZF Marine Krimpen
standard. The tunnel is not equipped with anodes. As the anodes on the thruster are part of the
complete cathodic protection design of the vessel, lifetime of the anodes can not be predicted by
ZF Marine Krimpen.
B.4 SPECIAL TOOLS
No special tools required.
B.5 SPARE PARTS
There are no class requirements for the spare parts, therefore spare parts are excluded. If
requested, we can issue an end-user specific advisory spare part list, that best ensures a high
availability rate.
B.6 WORKSHOP TESTING/FACTORY ACCEPTANCE TEST
As per ZF Marine Krimpen standard procedure.
C EXCLUDED ITEMS
• Electric drive motor with control system

• Steering and speed control system (Electronic Control Unit (ECU))
• Remote control panel(s)
• Protective grids for tunnel
• Shaft brake (if required)
• Oil and grease
• Piping, couplings, electric cables, cable glands (for control boxes etc.) and other components
needed to connect the thruster and the loose supplied components
• Anything not specifically mentioned in this specification
--------------------
TS00 13350_51 Apr25-12 4 of 4

1.2 Introduction
This manual contains / maintenance instructions and parts lists for your ZF Tunnel propulsion units.
Read this instructions very carefully !
For a long and trouble free life time of your unit it is essential that the instructions given in this manual
are followed up and the maintenance instructions take care of.
Use when replacing and repair only genuine ZF parts, because parts that have been supplied by
another manufacturer can not be relied upon for correct material, dimensions or finish.
For owners wishing to carry out their own maintenance and service it is very important to follow up
instructions as given in this manual.
If any doubt, ask ZF manufacturer.
Use only genuine parts for repair on your ZF propulsion unit.
When ordering spare parts one must specify the following to us :
1. Serial number and type : Find at the typeplate
2. .Description of the part.: Position no. and drawing no. on which the part is shown.
Quantity of the required spare part.
Ordering address ZF manufacturer.
ZF Marine Krimpen BV
Zaag 27, P.O. Box 2020
2930 AA, Krimpen aan de Lek
The Netherlands
Telefax. +31 (0)180 331000

Tel. no. +31 (0)180 331099
KRM-service@zf.com
2. Thrust Performance and build-in instructions of Tunnelthrusters
2.3 Check points
2.5 Trust performance of tunnel thrusters (P0125)
2.6 Paint Instructions (P0181)

Before the ship is launched the ZF must be filled with lubrication oil to prevent water penetrating the
gearbox.
1. Filling the thrusters with oil:
Minimum of 24 hours before the launching of the vessel (out of dry dock), fill the thruster unit with
lubr.oil Æ see attached “recommended and allowed lubricants”P0166 in chapter 4 and look at system
for the type and dimension code. Do not fill the thruster a long time before, without the connection of
the headertank, it will create excessive pressure on the propeller shaft seal. When thruster is kept for
a long time in stock please fill the thruster together with the headertank, rotate the propeller monthly,
refill the thruster with new oil before installation.
Filling from thruster may be done through the filling line. See chapter 5. Filling may take some time
because the lub. oil runs through relatively narrow openings in the thruster.
Place the lubrication tank when the tank is part of supply at minimal 20% of the underwater height
above the highest water line, this for pressure compensation of the underwater seals. Fill tank
between minimum and maximum. Press the self closing valve on the lubrication tank for oil level
indication.
Connect the electrical wiring according to cable wiring diagram from thruster junction box up the
Electronic Control Unit / box which will be installed in the thruster control room by yard. See for
electrical installation chapter 8.
2.3 Check points
a. Check levels of: cooling water system, lub. oil in thruster, lub. oil in engine and hydraulic system.
b. (when mounted hydraulic system) Open the ball valve in the suction line of the hydraulic system. Fill up
hydraulic pump through leakage line with specified oil, this to ensure the hydraulic pump is not running
dry during starting up.
c. (when mounted hydraulic system) Switch on the electrical power by means of the main circuit breaker in
the engine room and with the keys in the wheelhouse panel.
d. Check all electrical functions (as far as possible) without running the engine.
e. Double-check bolts, nuts and electric components.
f. Make sure the control lever for speed control is in idle and clutch is in disengaged position .
Attention
- Use clean oils and proper filters when filling the systems, dirt in the oil can cause serious damage to all
moving parts.
- Do never start the engine when there is no oil in the hydraulic system or gearbox, this to avoid damage to
the engine driven hydraulic pump and bearings.
UNIT IS NOW READY TO BE STARTED UP!

All functions of the propulsion unit are controllable from the wheel-house.
Some important points to follow-up by master and technical personal.
1. Never start the engine from wheel-house during maintenance or repair.
2. Check oil levels, etc. daily before putting units into operation.
3. Do not engage or disengage clutch when engine is running more than 900 rpm.
4. Check when putting into service and after any maintenance or repair work the correct position and sense of
rotation.
Follow-up instructions of diesel engine supplier too.( when diesel engine is in scope of delivering)
2.5 Thrust Performance of tunnel thrusters (P0125)
Procedure Sheet
Edition March 2011
Thrust performance of tunnel thruster
Installation
P 0125
Thrust performance of Tunnel thruster
The performance of a tunnel thruster propeller is subject to several factors. As an advice to a shipyard
placing a tunnel thruster into a ship, ZF Marine has listed down the following in order to increase the
effective thrust at the output side of a tunnel thruster.
1. Radius tunnel edges

In many cases a radius is made here, but a conical form
may be a satisfactory too. This solution is simple to
produce and therefore inexpensive. On the inlet side,
favourable inflow conditions are created. On the outlet side
a make and break point for the water flow is provided
which is necessary for reducing losses in the outlet stream.
Outlet indentations behind the tunnel do have a significant
effect.
2. Minimum length of the pipe

In order for the water to calm down somewhat after its
turbulent inflow, the distance between the propeller and
the inlet/outlet edge should be at least L/2=1*D (D=
propeller diameter). Longer tunnel length like L/2=1.5*D up
to 2*D will give a higher performance.
For tunnel length above L=6*D, loss due to friction in the

pipe will increase significantly.
3. The cut at the pipe end

Installation between two-paralleled hull sides is optimal. Any
inclination of the hull sides will increase the loss of thrust.
Therefore, one should try to locate the tunnel thruster in an
area where the angles between the outer hull and the water
line are small.
Hence the location in bulbous bows is suitable.
4. Minimum distance form the ship’s bottom

If the distance between the lower edge of the pipe and the
lowest edge of the keel is too small, circular currents below
the ships bottom will result in thrust losses, especially when
the pipe is short.
K = greater than or equal to 0.25*D, for long pipe where L >

3D.
K = greater than or equal to 0.5*D, for short pipes where L
< 3D.
5. The correct protective grid

For different reasons, protective grids are fitted to reduce the ship drag resistance because of the
transfer pipes. Travel in ice also requires protective grids. Not too many grid bars shall be used.
As a standard, for installations up to a tunnel diameter of 1,5 m, 4 vertical bars, for larger diameters
5 up to 7 vertical bars which are connected with 3 or 4 horizontal bars. In case of ice class additional
requirements may have to be taken into account.
Amendments Applicable dept. Drawn PV 06-10-10

AE,WS,PS Checked JWvS 11-03-18
Page1 of 3
Procedure Sheet
Edition March 2011
Thrust performance of tunnel thruster
Installation
P 0125
Five grid bars will reduce the thrust of the installation by approx. 9%, seven bars by approx. 10%. At
the same time the installation requires more power. The protective grid shall have no large “cover”.
Cover in these terms signifies the ratio between the area of the bars and the tunnel opening.
Grid area must be less than 15% of tunnel area, preferably less than 10 %.
Elliptical bars have the most favourable profile, but protective grids made from flat iron bars are
simpler and cheaper to produce. For flat bars it is important to make sharp edges to reduce the
resistance. The “cover” is the same with elliptical bars.
Please find attached a proposal drawing “Grid construction”.
6. Correct installation of the protective grid

The protective grid should be mounted behind the inlet/outlet cone and not in front of it.
7. The correct inclination of grid bars

Flat iron bars are closer to the favourable elliptical profile. The bars should be laid out in a way that
places them at right angles to the direction of the water flow passes the bow. If results from model
tests are available, the vertical bars should be perpendicular to the direction of the current. If no
model tests are available, the vertical bars should be mounted at approximately 15º from the
vertical. The angle between the vertical and horizontal bars must be 90 deg.
8. Minimum submersion of the tunnel thruster

If the inlet opening is too close to the surface, the risk of air suction arises. Therefore the upper edge
of the transverse pipe must be at least 0.4*D below the waterline.
9. The propeller on centerline

The propeller of the tunnel thruster should always be installed on ships centerline, especially in
short pipes. The longer the pipe, the smaller the influence is if the propeller is not installed at the
centerline. The consequence of a location off centerline is uneven delivered thrust for both
directions and additional noise and vibration.
10. Pressure compensation channel

When the ship travels slowly, the effect of the tunnel thruster is sharply reduced because of suction
area created on the hull behind the area.
The installation of a pressure compensation pipe decreases these suction areas and allows
effective use of the bow thruster up to 4 to 6 knots forward speed.

Page2 of 3
Procedure Sheet
Thrust performance of tunnel thruster Edition March 2011
Installation
P 0125
OK
Ensure that the flat
bars (in horizontal and
vertical direction)
are aligned with
the tunnel centerline
NOT OK
Sharpen both ends of the

bars as much as possible
Note:
In case of ice class additional requirements may apply.

Page3 of 3
2.6 Paint instructions (P0181)
Edition Dec 2011
Standard coating schedules
Work instruction
P 0181
PREPARATIONS
Preparations according to P0185
BLACK BELOW WATERLINE

(total dry film thickness 300 micron)
Spreading
DFT Mixing Pot life
Ridder nr. Product Colour Colour nr. rate Hardener
[µ] ratio (@ 20°C)
[m2/l]
*1400000351 HEMPADUR 45148 Light grey 12170 75 8 97430 3:1 1h
1400000351 HEMPADUR 45148 Light grey 12170 75 8 97430 3:1 1h
1400000400 HEMPADUR 45148 Black 19990 75 8 97430 3:1 1h
1400000400 HEMPADUR 45148 Black 19990 75 8 97430 3:1 1h
Recoating intervals:
30°C 20°C 10°C 0°C -10°C
Product Recoated with
min. max. min. max. min. max. min. max. min. max.
HEMPADUR 45148 HEMPADUR 45148 100 min - 2h - 4h - 10 h - 20 h -
* This layer may be omitted if at least 75 micron primer is present
BLACK ABOVE WATERLINE

Spreading
DFT Mixing Pot life
[µ] ratio (@ 20°C)
[m2/l]
1400000400 HEMPADUR 45148 Black 19990 50 12 97430 3:1 1h
1400000400 HEMPADUR 45148 Black 19990 50 12 97430 3:1 1h
30°C 20°C 10°C 0°C -10°C
HEMPADUR 45148 HEMPADUR 45148 65 min - 85 min - 3h - 6h - 13 h -
BLUE
Spreading
DFT Mixing Pot life
[µ] ratio (@ 20°C)
[m2/l]
HEMPATHANE
1400000194 Blue 35120 40 12,5 95370 7:1 4h
TOPCOAT 55219
30°C 20°C 10°C 0°C -10°C
HEMPATHANE 13 27
HEMPADUR 45148 65 min 54 h 85 min 72 h 3h 6 days 6h 13 h
TOPCOAT 55219 days days
Amendments Applicable dept. Drawn DR 07-06-07

Checked JWvS 11-12-23
Pagina 1 / 2
Edition Dec 2011
Standard coating schedules
Work instruction
P 0181
WHITE
Spreading
DFT Mixing Pot life
[µ] ratio (@ 20°C)
[m2/l]
1400000833 HEMPADUR 45148 Wit 10000 50 12 97430 3:1 1h
1400000833 HEMPADUR 45148 Wit 10000 50 12 97430 3:1 1h
30°C 20°C 10°C 0°C -10°C
TUNNELS / NOZZLES
Spreading
DFT Mixing Pot life
[µ] ratio (@ 20°C)
[m2/l]
1400000835 HEMPADUR 15579 Red 50630 50 11 95570 3:1 2h
THRUSTER PARTS IN CONTACT WITH OIL

Spreading
DFT Pot life
Ridder nr. Product Colour Colour nr. rate Hardener Mixing ratio
[µ] (@ 20°C)
[m2/l]
Base : Hardener
HEMPADUR
1400001015 85671 Light grey 12170 50 11 97371 3 uur
8.8 : 1.2 by volume
(Base 85675)
13.8 : 1.0 by weight
Amendments Applicable dept. Drawn DR 07-06-07

Checked JWvS 11-12-23
Pagina 2 / 2
3. SAFETY AND TRANSPORT

Procedure sheet
Edition February 2007
Safety and transport
P 0168
1. Important Safety Information

Many accidents involving product operation, maintenance and repair, are caused by failure to observe basic
safety rules or precautions. Accidents can often be avoided by recognizing hazardous situations. Personnel must
be alert to potential hazards. They must also have the necessary training, skills and tools to perform the job.
Improper operation or maintenance of this product can be dangerous and could result in injury or death.
Do not operate or perform maintenance or repair on this product, until you have read and understand the
operation, maintenance and repair information.
Safety precautions and warnings are given in this manual. If they are not heeded, bodily injury or death
could occur to you or other persons.
The hazards are identified by the ‘Safety Alert Symbol’ and followed by a ‘Signal word’ such as ‘WARNING’
WARNING
The meaning of this safety alert symbol is as follows:
Attention! Become alert! Your safety is involved.
The message that appears under the warning, explaining the hazard, can be written or pictorially presented.
Danger of: Danger of: High noise level : Caution:

Electrical shock Electrical shock Wear ear protection Heavy loads
ZF Marine Krimpen bv cannot anticipate every possible circumstance that may involve a potential hazard.
The warnings in this document are therefore not all inclusive. If a tool, procedure, work method or
operating technique not specifically recommended by ZF Marine is used, you must satisfy yourself that it
is safe for you and others. You should also ensure that the product will not be damaged or made unsafe
by operation, maintenance or repair procedures you choose.
These safety regulations are to be used as a guideline in addition to applicable law.
Oils, detergents, preservatives and acids must be collected and disposed in a non polluting manner and
in compliance with the relevant laws governing water pollution control.
2. Transport
Caution when moving or lifting.

When lifting or lowering an ZF unit keep the following in mind:
1. Use only certified hoisting materials and lifting gear
2. Do not stand or work under an ZF unit hanging in a crane.
3. When lifting the unit in the horizontal plane use the lifting lugs provided on the inner well together with
lifting straps wrapped around the stem of the lower gear box.

AE,WS,PS Checked WL 06-10-10
Page 1 of 3
Procedure sheet
P 0168
4. Do not lift the ZF unit by the propeller nozzle.
5. While lifting ensure that smaller delicate components (gauges, thermometers, filters etc.) do not get
entangled in the lifting wires and consequently damaged.
6. Do not use lifting straps in the vicinity of the steering seal or any other sealing surface for that matter.
7. When the ZF thruster is lifted with the oil still in the housing, make sure that no oil can leak through vent
pipes or open mounting holes
8. All possible safety precautions must be taken to ensure that oil cannot pollute the environment.
3. Storage:
The ZF unit has been delivered with preservation treatment sufficient for transport and 6-month storage.
During spin testing of the unit in our workshop conservation oil is used that is 100% compatible with other oils.
This conservation oil leaves a film of oil on the internal parts and prevents corrosion, for a period no longer than 6
months in a dry climate.
All external metal parts have been treated with an anti corrosion grease.
When the ZF unit is put out of operation for a period of time it must always be filled completely with oil. In case of
prolonged storage of the ZF unit it may be necessary to close the vent valve.
In environments with large temperature fluctuations drain a few liters of oil from the unit and keep the vent pipe
open to allow for expansion of the oil.
The electrical components of your ZF unit installation must always be stored in a clean and dry environment.
4. Personnel safety precautions

Working in the vicinity of a ZF Marine Krimpen bv installation requires personal protection such as:
Eye protection Ear protection Gloves Safety boots

Other items that are compulsory in workshops or engine rooms spaces.
Protective clothing
All rotating parts must be well protected by covers to prevent personal injuries
Covers that protect rubber elements and couplings must be made of a rigid frame covered with tough metal mesh
to allow for sufficient airflow to the element or coupling.
DO NOT TOUCH ROTATING PARTS SUCH AS SHAFTS ETC.

Please Note:
Cardan shafts should have ample sized strong protection covers. This cover should be strong enough to
withstand the forces and restrain the cardan shaft should it break or shear.
Warning
Keep the engine room and Thruster compartments closed for non-technical personnel, to avoid damage or
accidents caused by actions due to insufficient knowledge of the equipment.
5. Maintenance
Please Note:
During maintenance works the thruster installation must be put out of operation and no remote control may be
possible.
Always use proper tools so that no damage is done to bolts and nuts.
Electrical tools must be well isolated for personnel protection.
The maintenance should take place under the best possible conditions.

Page 2 of 3
Procedure sheet
P 0168
Dismantling of parts is to be done by qualified personnel. Reassembly should be done by the same persons.
Please Note:
Always mark the mounting position of the parts and write down all necessary notes important for reassembling.
Always wear eye protection when cleaning parts by means of compressed air.
If an accident happens always consult a doctor.
Maintenance and repair of the electrical system may only be done when the power supply is switched off and
locked in this position.
Warning
Do not touch or remove hot parts during or quickly after operation, do not tighten or slacken pipes and hoses
under pressure.
Never short circuit a battery, an explosion may occur. The fluid level of batteries must be checked weekly. No
smoking or fire near batteries. Batteries must be well ventilated at all times.
The fixing screws must be well tightened with the right torque and secured against self-loosening.
6. Repair
In case of malfunctioning of the ZF the cause must be established immediately.
If the source cannot be discovered or repaired, Please seek advice from specialized personnel.
Spare parts and fittings not supplied by ZF Marine Krimpen bv or its agency should not be used on ZF Marine
units.
These parts are not approved by us and may have a negative influence on the reliability of our product.
The use of non-original spare parts voids the guarantee of the ZF Marine Krimpen bv installation.
7. Maneuvering
The ZF unit is a sophisticated piece of equipment.
The thruster can be rotated over 360° under full thrust conditions and thus gives the vessel great maneuverability.
In cases of emergency the ZF Marine Krimpen bv can be rotated over 180° at all times to reduce the ship's speed.
With two units installed the units can be turned under full speed as follows:
- Starboard unit counter clockwise
- Portside unit clock wise
Warning
Extremely difficult maneuvers can easily be done with the ZF unit. Always reduce the revolutions of the propellers
so that maneuvering takes place at a safe speed.
Warning
Navigating with ZF units should only be done by qualified personnel.
Mistakes in navigation due to lack of knowledge of this system is the responsibility of the operator and not the
manufacturer of the propulsion system.

Page 3 of 3
Edition Nov 2008
Hoisting
Safety instruction
P0502
WHEN IN DOUBT ASK YOUR MANAGER!
(Lifting activities usually are subject to local laws and regulations)
Risks
Getting crushed by a moving or falling load, getting pinched when attaching load
Attaching load
Inspect lifting accessories (shackles, slings, chains, hooks, eyebolts, etc.) before use. Use
only lifting accessories suitable for your specific job. Make sure that lifting accessories cannot
be damaged by sharp edges. Store lifting accessories in a dry place when not in use. Do not
use lifting accessories not bearing the CE mark. Make sure that the safe working load SWL
of both lifting equipment and lifting accessories is observed.
Pay attention to the weight and the center of gravity of a load.
Where possible, remove packaging material in order to prevent sliding of the load.
Slings, chains and shackles must be able to move freely in their hook. No pinching is
allowed. The tip of a hook is not to be under any load.
No one is allowed to be on or under a lifted load.
Make sure no limbs are pinched when

attaching the load.
Eyebolts must be screwed in completely. The forces in the cables, when hoisting
1000 kg with the cables under various
No loading of eyebolts perpendicular to angles
bolt is allowed. 30°= 52% of the load = 520 kg
45° = 55% of the load = 550 kg
60° = 58% of the load = 580 kg
Dunnage must be thick enough to easily 90° = 70% of the load = 700 kg
120° = 100% of the load = 1000 kg
remove slings etc. 150° = 194% of the load = 1940 kg
After use, the hook must be positioned

high enough in order to prevent people
from hurting their head.
Diagram of forces
(Figure refers)
The tensile forces in slings or chains

depend on the angle under which they are
being used.
The picture shows tensile forces in (kgf),
that occur when lifting a 1000 kg weight.
Department Issued DR
WS, WH Gecontr. GZ
Page 1 of 1
4. MAINTENANCE INSTRUCTIONS
4.7 Storage (P0211)

Procedure Sheet
Maintenance schedule
Tunnel thruster
Checklist
P 0163
Maintenance schedule for ZF Marine tunnel thrusters
1000 hours or
daily monthly docking
once a year**
Lubrication oil level - check 
Hydraulic oil level - check* 
Flexible coupling element* - check 
Lubrication oil condition – analysis of 

sample***; change oil if necessary
Hydraulic oil condition* - analysis of 
sample***; change if necessary
Hydraulic filter* - check; replace if necessary 
Oil connections – check for leakage 
Propeller condition - check 
 
Bolts & nuts - check tightening
inboard outboard
Electrical system - visual inspection 
Anodes - check 
(* if applicable)
(**whichever comes first)
(***oil manufacturers offer analysis services at very reasonable pricing e.g. Shell E-quip)
Amendments Applicable dept. Drawn WL 06-06-23

All Checked DR 07-01-18
Page1 of 1
Procedure Sheet
Lubricant equivalents list Edition August 2012
P 0166 Rev04
Power
Power pack
pack (based on Planetary
Synthetic lubricant (based on mineral gearboxes*)
Lubrication polyalphaolefin (POA) based Biological oil mineral oil) valid for
Mineral oil gearbox
Oil gearbox oil) Only for ambient
Before use oil must be Deck temperature
checked is possible! Placed in Units of +5ºC /
machinery operating +40ºC
room in ice cold
conditions
Z-
L-drive
Viscosity at L-drive Z-drive L-drive Z-drive drive VG 46 VG 46
VG VG 100/150
40°C VG 100 VG 150 VG 100 VG 150 VG HLP HVLP
100
150
Basia 100/ Blasia 150/
Blasia SX Blasia
AGIP/ENI Blasia FMP Blasia FMP - - Oso 46 Arnica 46
100 100/150
100 150
Degol BG Degol BG Degol Pas Aral Vitam Aral Vitam Degol BG

ARAL - -
100 Plus 150 Plus 150 GF 46 HF 46 100/150
Avia Fluid
Gear RSX Gear RSX Syntogear Syntogear RSL 46/ Avia Fluid
AVIA - Avia Fluid -
100 150 PE100 PE150 HVI 46
ZAD 46
Energol
Energol GR Energol GR Bartran HV GR XP
BP See Castrol - HLP-HM
XP 100 XP 150 46 100/150
46
Alpha SP Alpha SP Alphasyn Alphasyn Biostat Biostat Hyspin Hyspin Alpha SP
Castrol
100 150 HG 100 HG 150 100 150 AWS 46 AWH 46 100/150
Meropa Meropa Non leaded

100/ Gear 150/ Gear Hydraulic Mechanism Gear
Chevron - -
compound compound oil AW 46 LPS 46 compound
100 150 100/150
Reductelf
ELF See Total - - See Total See Total
SP 100/150
Giran
FINA See Total - - See Total See Total
100/150
Renolin
Gearmaster Gearmaster Gearmaster Gearmaster Renolin Gearmaster
Fuchs - MR15
CLP 100 CLP 150 SYN 100 SYN 150 MR 46 MC CLP 150
VG46
Klüberoil Klüberoil Klübersynth Klübersynth
LAMORA Gem 1-100/
Klüber GEM 1- GEM 1- GEM 4- GEM 4- - -
HLP 46 1-150
100N 150N 100N 150N
MobilGear MobilGear
Mobilgear Mobilgear Mobil DTE Mobil DTE Mobilgear
Mobil, Esso 600 XP 100 600 XP 150
SHC Gear SHC Gear - 10 Excel 10 Excel XMP
(ExxonMobil) / MobilGear / MobilGear
100 150 46 46 100/150
XMP 100 XMP 150
Lubrax Lubrax
Petrobras - - - - -
Gear 100 Gear 150
Goya 100 Goya 150 Q8
Goya EI Goya EI Q8 Haydn Goya
Q8 Goya NT Goya NT - Hoffmeister
Greco 100 Greco 150 46 100/150
100 150 HVLP-D-46
Telex Tauro
Repsol-YPF Tauro 100 Tauro 150 - - Telex E 46
HVLP 46 100/150
Omala HD Omala
Shell Omala 100 Omala 150 - - Tellus 46 Tellus T 46
150 100/150
Meropa Meropa Pinnacle Rando HD Rando MEROPA
Texaco - -
WM 100 WM 150 EP 150 46 HDZ 46 100/150

AE, WS, PS Checked JWvS 14-08-12
Page1 of 3
Procedure Sheet
P 0166 Rev04
Power
Power pack
pack (based on Planetary
Synthetic lubricant (based on mineral gearboxes*)
Lubrication polyalphaolefin (POA) based Biological oil mineral oil) valid for
Mineral oil gearbox
Oil gearbox oil) Only for ambient
Before use oil must be Deck temperature
checked is possible! Placed in Units of +5ºC /
machinery operating +40ºC
room in ice cold
conditions
Epona Z Epona Z
100 150 / Giran Carter Carter Total Total
Carter EP
Total / Giran 100 150 / - Bio Bio Azolla ZS Equivis ZS
100/150
/ Carter EP Carter EP 100 150 46 46
100 150
Tribol 1100/100 1100/150 - - Tribol 772 - -
Greases Cardan shaft and Water tight gland Steering pipe

Tooth couplings Bearing / Shaft line
guiding rods greasing points sealing
Castrol Spheerol AP3 Spheerol SX2 Spheerol SX2 Grippa 355
Total Multis EP 3 Ceran WR2 Ceran WR2 Ceran AD Plus

Kluberplex
Shell Alvania R3 Rhodina EP 2 Rhodina EP 2 Malleus GL 205 BEM 41-132
Molub Alloy 936SF

Tribol 3030/100-2 Molub Alloy 968 SF Molub Alloy 968 SF
Heavy

Page2 of 3
Procedure Sheet
P 0166 Rev04
Planetary gear Planetary gear

Upper (Half Full)
Lower box oil cap. boxes oil cap. SD LG-
Stem section Stem section Gearbox Slew
Oil Gearbox For 1 unit For 1 unit part oil
Oil capacity Oil capacity Oil capacity bearing
volumes Oil capacity cap.
Z-drive L-drive Oil level house SD
System Full Shallow Draft Azimuth (litres)
(litres)** (litres)** glass/full thrusters
(litres) thrusters thrusters
(litres) (litres)
(litres) (litres)
1000 7 - - - - - - -
0.01748*CTC 0.01657*CTC
2000 20 9.1/14.4 SD52: 1.4 - 21 30
-14.7 -9.7
0.01761*CTC 0.01579*CTC
3000 44.5 14.5/22.5 SD73: 1.4 - 29 59
-18.6 -11.6
0.03715*CTC
400C 43 - 52.5
-32.4
4000FP/ 0.03003*CTC 0.03001*CTC
72/52 39/68 SD98: 1.4 - 81 167
CPP -38.3 -26.4
5000FP/
172/125/ 0.06439*CTC 0.06445*CTC
CRP/ 75/126 SD126: 4.2 3.3 76 269
178 -94.6 +26.8
CPP
6000 LS 0.08466*CTC 0.08466*CTC
(720- 268 152/341 - 3.3 - -
1000rpm)
-5.1 +35.7
6000 MS 0.08466*CTC 0.08466*CTC -
(1200- 268 152/341 - 3.3 -
-5.1 +35.7
1500rpm)
6000 HS 0.08466*CTC 0.08466*CTC
(1600- 268 25/93 SD153: 4.2 3.3 92 525
1800rpm)
-5.1 +35.7
7000 LS 0.09937*CTC 0.09949*CTC -
(750- 441 152/341 - 3.3 -
1000rpm)
+0.8 +45.9
7000 HS 0.09937*CTC 0.09949*CTC
(1600- 441 35/118 SD7000: 3.3 3.3 440L***) -
1800rpm)
+0.8 +45.9
8000 LS 0.10963*CTC 0.11049*CTC
(720- 730 162/513 - 3.3 - -
1000rpm)
+91.2 +160.5
8000 HS 0.10963*CTC 0.11049*CTC
(1600- 730 152/341 - 3.3 - -
1800rpm)
+91.2 +160.5
*) When not connected to the main lubrication oil system, use oil as indicated in table.
**) For CTC (center to center) value see general arrangement drawing manual.
***) Content is valid for complete SD thruster because it consist only one compartment.
Overall remarks:
The capacity of the header tank and the filling of piping system must be taken into account. For the header tanks up to
60 litre around 50% and for a header tank of 130 litre around 30% must be filled in cold condition.
For continuous operation we recommend lubrication oil with EP additives.

Page3 of 3
Procedure Sheet
Edition August 2012
MAINTENANCE INSTRUCTIONS
TUNNELTHRUSTERS
P 0303 Rev01
Service
1. Introduction
For a long lifetime of your ZF Marine propulsion unit, keep the following instructions in mind:
Follow instructions as given in the manuals.
Keep the equipment clean, so that oil leakage or other faults can be discovered quickly.
Use correct oils and clean funnels when filling.
Check oil condition and level every day.
Grease all blank parts to prevent corrosion.
Use genuine parts for repair.
Specific systems and parts may have their own manuals or chapters in the manual.
Important
Suddenly vibrations in the thruster drive together with loss of thrust may be the result of a damaged
propeller, gears, shafts, bearings, couplings etc. STOP the thruster must be done immediately and repair
should be carried out.
2. Main procedures
In this chapter some procedures are mentioned to get quickly some basic knowledge and find some
important procedures about the thruster system.
2.1 Hoisting P0502

In this procedure you can find some basics about hoisting.
2.2 Storage P0211

In this procedure you can find all the information about storage of the unit or loose gearboxes.
2.3 Lubricant equivalents list P0166

In this procedure you can find all the different type of oils and greases that are approved to use in the
thruster system.
2.4 Lubrication oil fill/change P0205

Some points out of P0205 are mentioned below. For a detailed description see P0205.
IMPORTANT NOTES:
Oils, detergents, preservatives and acids must be collected and disposed of in a non-
polluting manner and in compliance with the relevant laws governing water pollution control.
After changing of the oil make sure that the waste oil is disposed of in a non-polluting
manner and the used oilcans and the oil itself is not spilled, we as manufacturers cannot be
held responsible for environmental claims what so ever;
Always refill the thruster unit immediately after the oil is taken out. This to prevent the
gearboxes from condense water or from seawater penetrating the drives through seals.
The filling can be done through the header tank when a header tank is applied, otherwise
through the cover plate of the upper gearbox.
In this procedures is mentioned how to change the oil while the vessel is still in the water or in dry-dock.
Attention lubrication oil change:

If the oil has a white/yellowish colour, water has entered the thruster. This could be caused by a
worn propeller shaft seal or damaged o-rings in the flange connections. After repair, the system
must be flushed with oil or kerosene in order to remove all water from the system.
It is advisable to use a new bonded seal when fitting the plug.
For a header tank up to 40 liters of oil content fill the header tank up to 1/2 of the level glass.

Page1 of 2
Procedure Sheet
Edition August 2012
MAINTENANCE INSTRUCTIONS
TUNNELTHRUSTERS
P 0303 Rev01
Service
For a header tank from 60 liters of oil content and more, fill the header tank up to 1/3 of the level
glass.
When no header tank is applied fill the upper gearbox up to the level glass (only in case of Z-drive
tunnel thrusters). Z-drive system de-aeration itself.
For tunnel thrusters with header tank open the venting/de-aeration screw in the bearing cap of the
lower gearbox.
Tunnel thruster version
venting/de-aeration screw
After first filling check the next day if the oil level has dropped, fill if necessary and check for
leakages.
2.5 Maintenance schedule P0163

In this procedure you can find information about the maintenance schedule.
2.6 Propeller installation (P0110) (not for controllable pitch tunnel thrusters)
In this procedure you can find all the information about propeller mounting and dismounting.
2.7 Leakages test of propeller fitting system (P0113) (not for controllable pitch tunnel thrusters)
In this procedure you can find all the information about leakage test of propeller fitting system.
2.8 Propeller shaft seal (re)placement (P0118)

In this procedure you can find all the information about propeller shaft seal change.

Page2 of 2
Procedure Sheet
Edition August 2012
Propeller installation
Fixed pitch
Installation and maintenance

P 0110 Rev02
Scope
This procedure describes the workflow for installing or changing a fixed pitch propeller. This procedure is
valid for all kind of propellers, open, nozzle, tunnel and contra rotating propellers.
IMPORTANT NOTES:
- Before dismounting or mounting a propeller take care about the safety instructions
mentioned in P0168.
- WARNING
- HEAVY LOADS, CAUTION WHEN MOVING OR LIFTING
Use related procedures:

- P0072 Mounting Torque
- P0111 Propeller installation (hydraulic fit)
- P0113 Leakage test of propeller fitting system
- P0118 Propeller shaft seal (re)placement
- P0168 Safety and transport
- P0182 Propeller cone check

AE,WS,Q, PS Checked JWvS 12-08-14
Page1 of 5
Procedure Sheet
Edition August 2012
Fixed pitch

P 0110 Rev02
1 Workflow for dismounting propeller (open, nozzle, tunnel and CR

propellers)
Position numbers given in this chapter refer to cross section drawing of a lower gearbox.
Step Picture Description

1 Before starting be sure that the propeller is secured by suited
hoisting equipment!
Remark:
For removing the front propeller of an CR unit use the locking
plate of the aft propeller.
2 Remove the washer with a grinding tool.
3 Loosen the bolts (Pos. 34).
4 Remove the locking plate (Pos. 33) with o-ring. When the
locking plate is difficult to remove use the disassembly holes.

Page2 of 5
Procedure Sheet
Edition August 2012
Fixed pitch

P 0110 Rev02
5 Remove the plug (Pos. 214) if applicable from the 4000 up to

the 8000.
6 Use the locking plate (Pos. 33) as a pulling plate for propeller
dismounting by using its opposite side as mounted originally.
Fit the bolts (Pos. 34) through the locking plate as far as
possible in the thread holes of the propeller boss and fasten
the bolts tightly. For the maximum tightening moment see
P0072 table 3. By the pulling force on the bolts the propeller
starts loosen from the cone. Sometimes the bolts can be too
long then use a washer under the bolt head.
Propeller can be removed from the propeller shaft. Do this very

Pulling force on bolts acts only carefully to avoid damaging the propeller shaft.
on contact surface between
locking plate and propeller shaft.
During dismounting the propeller it can happen that the
propeller don’t want to move, than the following can be done:
• Using not the stainless steel bolts but normal steel
bolts with 10.9 class. These bolts can have a higher
tightening moment, see P0072 table 1.
• Use a plastic hammer to hit the propeller cone, locking
plates, propeller blades (only near the cone).
• If the propeller still doesn’t want to move, then heating
up of the propeller cone is allowed up to maximum
100°C.
Do not over tightening the bolts in any case this can result in
damaging the bolt and thread.
IMPORTANT:
For dismounting it is not allowed to use chains, hydraulic jacks
etc. between propeller and housing or between propeller and
nozzle.

Page3 of 5
Procedure Sheet
Edition August 2012
Fixed pitch

P 0110 Rev02
2 Workflow for mounting existing or new propeller
Often when a propeller will be dismounted the propeller shaft seals will be replaced. For propeller shaft seal
(re)placement see P0118. For leakages test of propeller fitting system see P0113.
1. Make sure that the propeller shaft cone, cone propeller and locking plate are clean and have no
burrs, scratches or sharp edges!
2. Ensure that ‘Propeller’ and ‘Propeller shaft’ have the same temperature when they will be fitted.
Check with Thermometer.
3. Before mounting propeller do a propeller cone check according P0182. If the contact area is not
sufficient the propeller cone must be repaired.
4. Check free running of ‘Propeller’ constantly during fitting!
5. Place the propeller on the propeller shaft. Place the locking plate with bolts and tightening the bolts
on 50% of the tightening torque mentioned in table 1 below, see also P0072 table 3.
Table 1 Mounting Torque

Mounting Mounting
Thruster type Bolts Size Class
moment (100%) moment (50%)
2000 M12 A4-70 50 25
1000 / 3000 M16 A4-70 121 60
4000 M20 A4-70 244 122
5000 M24 A4-70 418 209
6000 M30 A4-70 823 411
7000 / 8000 M36 A4-70 1434 717
6. Measure the gap “x” between propeller cone and seal cover, the distance should be minimum
2.5mm. When distance “x” is not enough machine the propeller to ensure that “x” is minimum
2.5mm.
7. Check the distance “y” between the propeller shaft and the collar on the locking plate. The distance
must have a minimum value of 2mm.
Distance “x” Distance “y”
8. When the distance “x” and “y” are OK place the locking plate with o-ring and bolts on the propeller
shaft. Mount the o-ring with acid free vaseline.

Page4 of 5
Procedure Sheet
Edition August 2012
Fixed pitch

P 0110 Rev02
9. Place a measurement gauge on a fixed point on the housing for measuring the gap between
propeller and seal cover. Start pushing up the propeller according the values mentioned in the table
2. This pushing up can be done by the propeller locking bolts.
Fixing point the

Table 2 Push up distance propeller housing
Mounting
Type Type Type Type Type Type Type Type
Temperature Measurement
1000 2000 3000 4000 5000 6000 7000 8000
in ºC gauge
0 0.32 0.49 0.60 0.75 0.81 1.06 1.21 1.31
5 0.30 0.47 0.57 0.72 0.77 1.02 1.15 1.24
10 0.29 0.46 0.55 0.69 0.73 0.97 1.09 1.18
15 0.28 0.44 0.53 0.66 0.69 0.93 1.03 1.11
18 0.27 0.43 0.51 0.64 0.66 0.90 0.99 1.07
20 0.27 0.42 0.50 0.62 0.65 0.88 0.97 1.05
25 0.26 0.40 0.48 0.59 0.61 0.84 0.91 0.98
30 0.25 0.39 0.46 0.56 0.57 0.79 0.85 0.92
35 0.23 0.37 0.43 0.52 0.53 0.74 0.79 0.85
10. It is advisable to use standard steel bolts class 8.8 or 10.9 for
pushing up the propeller. These bolts can have higher
mounting torques than the stainless steel bolts. In all cases do not over tightening the bolts.
11. When the push up is finished replace the steel bolts by the stainless steel bolts.
12. If the locking plate is fitted with a plug perform a leakage test according P0113.
13. Lock ‘Bolts’ by welding ‘Stainless-steel-wire’ or ‘Stainless-steel-disk’ to bolt heads (Pos.189). Make
sure that ground connection for welding is at one of the bolt heads (preferred) or at a propeller
blade.
Plug
Stainless-steel-wire / disc

Page5 of 5
Procedure Sheet
Edition August 2012
Propeller shaft seal (re)placement
Workshop / Service
P 0118 Rev05
Scope
This procedure describes the workflow of the (re)placement of propeller shaft seals.
IMPORTANT NOTES:
- Oils, detergents, preservatives and acids must be collected and disposed of in a non
polluting manner and in compliance with the relevant laws governing water pollution control.
After changing of the oil make sure that the waste oil is disposed of in a non-polluting
manner and the used oilcans and the oil itself is not spilled, we as manufacturers cannot be
held responsible for environmental claims whatsoever;
- Always refill the thruster immediately after propeller shaft seal replacement. This to prevent
the gearboxes from condense water or from seawater penetrating the inside of the thruster;
- When the ‘Seal cover plate’ is loosen after running of the ‘Lips seals’, the ‘Lip seals’ are not
allowed to use again. Replace the ‘Lip seals’!
Use related procedures:

- P0205 Lubrication oil change
- P0110 Propeller installation (with keyway)
- P0111 Propeller installation (hydraulic fit)
- P0113 Leakage test of propeller fitting system
Amendments Scope description changed Applicable dept. Drawn SH 270412

AE, PS, WS Checked JWvS 140812
Page1 of 4
Procedure Sheet
Edition August 2012
Workshop / Service
P 0118 Rev05
Workflow
Pos. numbers are related to ‘Lower gearbox’ drawing number. Shown drawings may differ from reality.
1. Drain the lubrication oil as prescribed in the procedure: ‘P0205, Lubrication oil change’;
2. Remove the ‘Propeller’ with keyway as prescribed in the procedure: ‘P0110, Propeller installation’ or
without keyway as prescribed in procedure: ‘P0111, Propeller installation , hydraulic fit’;
3. Remove all the seals from the ‘Liner’ (Pos.37);
4. If applicable, release the ‘Set screws’ (Pos.36) in ‘Liner’;
5. If necessary, heat the ‘Liner’ and remove it. When the ‘Liner’ is heated up above 150°C, the ‘Liner’
cannot reused anymore;
6. Remove the ‘Bolts’ (Pos.26) and the ‘Seal cover plate’ (Pos.25, 150);
7. Remove the ‘Lip seals’ (Pos.24) and the ‘Spacer’ (Pos.38);
8. CLEAN AND DEGREASE ALL COMPONENTS;
9. Use a little bit grease, Shell Rodina EP3 or equivalent, on the lip and inside of the seal as shown in
sketch below according to line 02;
Do NOT grease the outside of the seal as shown in sketch according to line 01;
Do NOT grease the inside of the ‘Seal cover’ as shown in sketch below according to line 03;
Seal cover
01
02
03
- Propeller shaft -

Page2 of 4
Procedure Sheet
Edition August 2012
Workshop / Service
P 0118 Rev05
10. Replace the new ‘Lipseals’ and ‘Spacer(s)’ in correct position in the ‘Seal cover’ as shown below;
ZF 400 Classic,
ZF 1000 – ZF 3000
ZF 4000 – ZF 8000
Seal cover Seal cover

~ WATER SIDE ~ ~ WATER SIDE ~
1 Spacer 2 Spacers
3 Lip seal 3 Lip seal
~ OIL SIDE ~ ~ OIL SIDE ~
Propeller shaft Propeller shaft
11. Replace the ‘Seal cover plate’ with the ‘Bolts’. In the first step, pre-tension the ‘Lip seals’ to tighten the
‘Bolts’, so that the remaining space between the ‘Lip seals’ is removed. To achieve a proper
clamping force on the ‘Lip seals’ with a cotton inlay, the length ‘X’ as shown below, between the
‘Seal cover plate’ and the ‘Seal cover’, must be taken according the distance in table below.
ZF 400 Classic,
ZF 1000 – ZF 3000
ZF 4000 – ZF 8000
Seal cover Seal cover

~ WATER SIDE ~ ~ WATER SIDE ~
1 Spacer 2 Spacers
3 Lip seal 3 Lip seal
X X
Bolts Bolts
~ OIL SIDE ~ ~ OIL SIDE ~

Seal cover plate Seal cover plate
Propeller shaft Propeller shaft
Distance X [mm] Distance X [mm]

ZF 1000: 0.6 – 1.0mm ZF 400 Classic: 0.9 – 1.7mm
ZF 2000 – ZF 3000: 0.9 – 1.5mm ZF 4000 – ZF 7000: 1.2 – 2.0mm
ZF 8000: 1.5 – 2.5mm
The compression is absolute necessary to prevent that the seals shrink. Sealing around the outer
diameter of the seals is also achieved in this way. Before pressing the ‘Lip seals’, use liquid sealant
between ‘Seal cover plate’ and ‘Seal cover’. Use Loctite 2701 to secure the ‘Bolts’;
WHEN THE ‘SEAL COVER PLATE’ IS LOOSEN AFTER RUNNING OF THE ‘LIP SEALS’, THE
‘LIP SEALS’ ARE NOT ALLOWED TO USE AGAIN. REPLACE THE ‘LIP SEALS’!
12. Grease the ‘O-ring(s)’ (Pos.27) with acid free Vaseline and place them in the ‘Liner’ (ZF 1000: not
applicable);
13. Oil the outside of the ‘Liner’ with Shell Omala 150 or equivalent;
14. Slide the ‘Liner’ carefully on the ‘Propeller shaft’. Prevent damage of the ‘Lip seals’ by pushing the
‘Liner’ through the ’Lip seals’;

Page3 of 4
Procedure Sheet
Edition August 2012
Workshop / Service
P 0118 Rev05
15. ZF 1000: Glue this ‘Liner’ with Loctite 603 against the inner ring of the ‘Taper roller bearing’
ZF 2000 and bigger types: Fix the ‘Liner’ on the correct distance ‘Y’ (as shown below) with ‘Set
screws’ (Pos.36). Drill center points in the ‘Propeller shaft’ before mounting ‘Set screws’.
Use Loctite 243.
Distance Y [mm] ±0.5

ZF 2000: 9mm
~ WATER SIDE ~
ZF 3000: 9mm
ZF 400 Classic: 10.5mm
Y
ZF 4000: 10.5mm
ZF 5000: 12mm
End face seal
ZF 6000: 12mm ~ OIL SIDE ~
ZF 7000: 20mm
ZF 8000: 20mm
Set screw
- Propeller shaft -
O-ring
Liner
16. Replace the ‘End face seal’ on the ‘Liner’ with the lip against the ‘Seal cover plate’;
17. Place ‘Propeller’ on ‘Propeller shaft’ as prescribed in the procedure: ‘P0110, Propeller installation
(with keyway)’ or ‘P0111, Propeller installation (hydraulic fit)’
18. CHECK IF THE ‘PROPELLER FITTING SYSTEM’ IS WATERTIGHT, ACCORDING P0113

Page4 of 4
Procedure Sheet
Edition December 2010
Leakages test of propeller fitting system
Installation, Maintenance, Service
P 0113
Scope
This procedure describes the workflow of the leakage test of the propeller ’.
IMPORTANT NOTES:
- If applicable, the ‘Liner’ (Pos.37) of ZF 2000 until ZF 6000 needs to be modified.

Remove excess material by turning until shoulder according sketch below. Replace ‘Liner’
on ‘Propeller shaft’ in the correct position according P0118;
Remove
until shoulder
- If applicable, drill a hole with BSP-thread in the ‘Locking plate’ (Pos. 33, 122, 148) according
to the latest drawing of the ‘Locking plate’;
Hole (BSP-thread)
Locking plate
Propeller
- Check free running of ‘Propeller’ constantly during fitting of ‘Propeller.’ Fitting of ‘Propeller’
must be done according to P0110 for ‘Key fit propeller’ and P111 for ‘Hydraulic fit propeller’;
- Check blue fit between ‘Propeller’ and ‘Propeller shaft’ according P0110/P111. Blue fit must
be at least 90% of the contact area between ‘Propeller’ and ‘Propeller shaft’;
Amendments Applicable dept. Drawn SH 201210

AE, PS, WS Checked
Page1 of 3
Procedure Sheet
P 0113
Workflow
Pos. numbers are related to ‘Lower gearbox’ drawing number. Shown drawings may differ from reality.
Some steps are double with other procedures.
HRP 400 Classic,
HRP 1000 HRP 2000 - HRP 3000 HRP 4000 - HRP 6000
Propeller (hub) Propeller (hub) Propeller (hub)
~ WATER ~ ~ WATER ~ ~ WATER ~
Prop. seal (o-ring) (Pos.94) Liner (Pos.37) Prop. seal (silicone) (Pos.231) Liner (Pos.37) Prop. seal (silicone) (Pos.231) Liner (Pos.37)
Prop. seal (silicone) (Pos. 230) Prop. seal (silicone) (Pos. 230)
- Propeller shaft -
- Propeller shaft - - Propeller shaft -
HRP 7000 HRP 8000
Propeller (hub) Propeller (hub)
~ WATER ~ ~ WATER ~
Prop. seal (o-ring) (Pos.72) Prop. seal (silicone) (Pos.231) Liner (Pos.37) Prop. seal (o-ring) (Pos.72) Liner (Pos.37)
Prop. seal (silicone) (Pos. 230)
- Propeller shaft - - Propeller shaft -
1. ZF 1000: Place ‘O-ring’ (Pos.94) against the ‘Liner’;

ZF 2000 till ZF 6000: Place the silicone ‘Prop. seals’ (Pos.230 and 231) on the ‘Prop. shaft’ against
the ‘Liner’;
ZF 7000: Place the silicone ‘Prop. seals’ (Pos.230 and 231) on the ‘Liner’ against the shoulder;
ZF 8000: Not applicable;
The number of the seals depends on the position of ‘Propeller’ on ‘Propeller shaft’. The
silicone seals must be sufficiently compressed to get a good watertight 'Propeller fitting
system', but not too much silicone seals to prevent that the ‘Propeller’ is fitted insufficiently
on ‘Propeller shaft’. The total height of the silicone seals should be approximately 130% of
the distance (X) between the ‘Propeller (hub)’ and the shoulder of the ‘Liner’
Distance 'X'
Liner
Silicone seals
Propeller shaft
Locking plate
Propeller (hub)

AE, PS, WS Checked
Page2 of 3
Procedure Sheet
P 0113
2. ZF 7000: Place ‘O-ring’ (Pos.72) in ‘Propeller’ with acid free Vaseline (petroleum jelly);
ZF 8000: Place ‘O-ring’ (Pos.72) on ‘Liner’ with acid free Vaseline;
3. Place the ‘Propeller’ on the ‘Propeller shaft’ against / over the seal;
4. Place the ‘O-ring’ (Pos.32) with acid free Vaseline on the ‘Locking plate’ (Pos. 33, 122, 148);
5. Mount the ‘Locking plate’ with ‘O-ring’ against the ‘Propeller with the stainless steel ‘Bolts’ (Pos. 05,
32). Use a little bit ‘Copper paste’ on the thread. Mounting torque on bolts: acc. to P0072;
Be assured that the ‘Propeller’ is sufficiently pressed on the ‘Propeller shaft’ If the ‘Bolts’ are
removed from the ‘Locking plate’, the ‘Propeller’ remains clamped/fixed on the ‘Propeller
shaft’.
6. Connect a ‘Pressure gauge’ and a ‘Valve’ at the ‘Locking plate’ according to the sketch below;
Pressure gauge
Air pressure
Valve
Locking plate
Propeller
7. Press air through the valve on the system. Pressure on system between 0.3 - 0,5 bar;
8. Close the valve and disconnect the ‘Air pressure’;
9. Wait at least 15 minutes. The pressure must remain absolutely constant!;
10. If the pressure has dropped: find the cause and fix the leakage. Test again!
- Leakage between ‘Bolts’ and ‘Locking plate’: Grind the contact surfaces;
- Leakage between ‘Locking plate’ and ‘Propeller hub’: Check the o-ring;
- Leakage between ‘Propeller hub’ and ‘Seal cover’: Place an additional thin silicone seal (Pos.231);
If the pressure has not dropped. Mount ‘Plug’ (Pos.214) into hole. Use Loctite 577
11. Lock ‘Bolts’ by welding ‘Stainless-steel-wire’ or ‘Stainless-steel-disk’ to bolt heads (Pos.189). Make
sure that Ground connection for welding is at one of the bolt heads (preferred) or at a propeller
blade.
Plug
Stainless-steel-wire / disc

AE, PS, WS Checked
Page3 of 3
4.7 Storage (P0211)
Procedure Sheet
Edition March 2012
Storage
Work instruction
P0211 Rev01
Scope
This document describes the procedure for storage of complete ZF Marine units and gearboxes, which are
out of operation for a period longer than 6 months.
Storage of ZF Marine thruster unit

The ZF Marine thruster unit has been delivered with preservation treatment sufficient for transport and 6-
month storage.
During spin testing of the unit in the ZF Marine Krimpen B.V. workshop conservation oil is used that is 100%
compatible with other oils. This conservation oil leaves a film of oil on the internal parts and prevents
corrosion, for a period no longer than 6 months in a dry climate.
All external metal parts have been treated with anti-corrosion grease.
When the ZF Marine thruster unit is put out of operation or stored for a period longer than 6 months, the unit
must be stored according to following conditions:
• ZF Marine unit must be placed in a clean and dry climate without temperature difference more than
20°C.
• ZF Marine unit must be placed in a vertical position.
• ZF Marine tunnel thruster must be placed in a horizontal position, when possible.
• ZF Marine unit must be filled completely with lub. Oil (P.166), a half filled header tank must be
placed above the unit for expansion of the oil.
• Propeller- and/or input shaft must be turned monthly.
Amendments Applicable dept. Drawn JV 11-10-10

ALL Checked JWvS 12-03-12
Page1 of 3
Procedure Sheet
Edition March 2012
Storage
Work instruction
P0211 Rev01
Storage of ZF Marine gearbox.
When the ZF Marine gearbox is put out of operation or stored for a period longer than 6 months, the unit
must be stored according to following conditions:
• Input shaft of the ZF Marine lower gearbox needs to be protected, with a watertight cover.
• ZF Marine lower gearbox needs to be completely filled vertically, with header tank half filled, and
thereafter be placed in horizontal position. (fig. 1)
• Propeller shaft of the ZF Marine lower gearbox needs to be greased and protected.
• Propeller shaft of the ZF Marine lower gearbox needs to be turned monthly.
• Connection flange of the ZF Marine upper gearbox needs to be closed with a water tight cover.
• ZF Marine upper gearbox needs to be completely filled vertically, with header tank half filled.(fig. 2)
• Input shaft of the ZF Marine upper gearbox needs to be turned monthly.
Figure 1 Figure 2

Page2 of 3
Procedure Sheet
Edition March 2012
Storage
Work instruction
P0211 Rev01
Storage of ZF Marine CPP gearbox.
When the ZF Marine CPP lower gearbox is put out of operation or stored the unit must be treated according
to following conditions:
• Input shaft of the ZF Marine lower gearbox needs to be protected with a watertight cover.
• ZF Marine lower gearbox needs to be completely filled vertically, with header tank half filled, and
thereafter be placed in horizontal position. (fig. 1)
• Hydraulic pipe lines need to be filled.
• The air needs to be vented from the CPP-hydraulic propeller head according to P161. (fig. 3)
• Propeller shaft of the ZF Marine lower gearbox needs to be turned monthly.
• Blade carriers need to be rotated monthly, by applying pressure to the 2 hydraulic connection pipes
on top of the gearbox, clockwise and counterclockwise.
Socket head bolt

(Lock with Loctite 243)
Sealing ring
Threaded de-aeration hole
Figure 3
Note; when CPP gearbox has been stored without oil the rotor seal needs to be disassembled and let it turn
on a lathe!

Page3 of 3
5. ZF Tunnelthruster unit
5.1 General Arrangement ZF Thruster unit
5.2 ZF Lower Gearbox assembly
5.3 Drain Plug

5.1 General Arrangement ZF thruster unit
Part List
For external use
Partlist number 160113350
Drawing No. 16011335004
Description General Arrangement ZF TT 3001 FP
Last revision date 27-8-2012
MEMO
Pos Qty Part code Part description Weight

001 1 285113350 Tunnel Construction ZF TT 3001 FP 2.136,59
002 1 080313350 Lower Gearbox 347,01
003 1 38018087 Propeller 112,00
004 24 3000000062 Hexagon head bolt 2,95
007 1 400111803 Flex.coupling Centa 34,00
009 1 54310000 Lubrication tank 7,40
011 8 3500000012 Washer 0,14
012 8 3500000011 Washer 0,12
013 8 3000000208 Hexagon nut 0,51
015 2 9900000064 Lubrication hose assembly 0,00
020 2 9500000512 Str. m. st. fit L/st 0,37
Total Weight 2.643,323 kg
Page 1 of 1
5.2 ZF lower gearbox assembly
Part List
For external use
Drawing No. 0803X30005
Description Lower Gearbox ZF TT 3001 FP
MEMO

001 1 0901X300 Gear house 153,20
002 1 0902X300 Pinion 23,00
004 1 4000000063 Taper roller bearing 8,80
005 4 3000000113 Socket head cap screw 0,01
007 1 0907X300 Cap 28,20
008 1 2000000462 O-ring 0,00
013 1 0913X300 Spacer 0,44
015 1 0915X300 Bearing flange 25,10
016 1 0916X300 Crown wheel 33,84
018 1 2000000046 O-ring 0,00
019 1 0919X300 Cover 6,20
020 1 4400X000 Drain Plug 0,00
022 1 2000000039 O-ring 0,00
024 3 2000000217 Lip seal 0,00
025 1 0925X300 Seal cover plate 0,60
026 6 3000000049 Hexagon head screw 0,07
027 2 2000000148 O-ring 0,00
032 1 2000000153 O-ring 0,00
033 1 0933X300 Locking plate 3,20
036 3 3000000096 Socket set screw 0,01
037 1 0937X300 Liner 1,10
038 1 0938X300 Spacer 0,18
Page 1 of 2
Part List
For external use
Description Lower Gearbox ZF TT 3001 FP
MEMO

043 1 4000000114 Lock nut 0,75
044 1 0944X234 Plug 0,12
046 1 2000000025 O-ring 0,00
047 1 2000000069 O-ring 0,00
048 1 2000000094 O-ring 0,00
049 1 2000000417 O-ring 0,00
051 1 0951X300 Spacer 0,00
052 1 0952X300 Bearing cover BT 3,47
053 1 2000000197 Lip seal 0,00
054 1 2000000180 Lip seal 0,00
055 1 2000000228 End face seal 0,00
056 1 2000000301 O-ring 0,00
173 1 09173X300 Propeller shaft 33,20
175 1 09175X300 Parallel key 0,30
182 1 09182X300 Seal cover 9,58
183 1 09183X300 Spacer 0,13
188 1 2000000766 End face seal 0,00
189 1 3500000032 Washer 0,13
190 2 1200000027 Anode 1,60
214 1 3000000896 G 1/4" 0,02
230 1 09230X300 Seal 0,01
231 1 09231X300 Seal 0,02
Total Weight 347,014 kg
Page 2 of 2
5.3 Drain plug
Part List
For external use
Partlist number 4400X000
Description Drain plug ZF LG
MEMO

001 1 09202X000 Plate 0,03
002 1 3900000072 Retaining ring 0,01
003 1 1200000299 Spring 0,00
004 1 09201X000 Plug 0,20
005 1 09200X000 Plug 1,00
006 4 3000000670 Socket set screw 0,01
007 1 2000000558 O-ring 0,00
008 1 2000000696 Bonded seal 0,01
009 1 3000000193 Hexagon head screw plug 0,20
010 1 8000001096 Magnet 0,03
Page 1 of 1
6. ZF Tunnelthruster Oil System (optional)
6.1 Arrangement lubricating oil tank

Part List
For external use
Drawing No. 5431000002
Description Lub oil tank 14 ltr.

001 1 54300000 Lub. tank consruction 6,50
002 1 9000000549 Level switch lub. oil tank 0,00
003 1 9000000017 Filler breather filter 0,00
004 1 9000000018 Level gauge upper part 0,00
005 1 9000000019 Level gauge self closing part 0,00
006 1 9000000020 Level glass dia 0,00
007 2 9500000512 Str. m. st. fit L/st 0,37
008 1 9000000021 Plug square head 0,00
010 4 3000000213 Hexagon nut 0,02
011 4 3500000428 Washer 0,01
Page 1 of 1
7. Main Drive (optional)
7.1 Motor
8. TECHNICAL DESCRIPTION TRANSMISSION (OPTIONAL)
8.1 Flexible coupling (optional)
8.2 Cardan Shaft (optional)

8.1 Flexible coupling
8.2 Cardan shaft
9. Procedure Sheets
9.1 Torque List (P0072)
9.2 Anodes (P0210)

9.1 Torque list (P0072)
Procedure Sheet
Edition July 2010
Mounting Torque
Work Instruction
P 0072
Scope
This procedure describes the maximum mounting torques for several bolted connections in different
conditions. Connections must be carried out with method of controlled applied torque (e.g. torque
wrench).
Treated surfaces of bolts

Roughness of the threaded surface of the bolt has been taken into account for determining the
maximum mounting torques. The friction coefficients are:
0,10 Bolt surface heavy oiled or with Loctite 243;
0,12 Bolt surface light oiled or with Loctite 2701 (270 old version).
Type of connections
The table below gives a summary
Type of connection Mounting torque

according table
Direct and Indirect power and torque transmitting connections Table 1
like:
-Steering pipe connections;
-Slew bearing connections;
-Nozzle connections;
-Bearing flange connections;
-Steering pipe lower gearbox connections;
-Lower gearbox steering cover connections;
-Steering motor connections;
-Slew bearing housing retractable thrusters;
-Support flange retractable thrusters
-etc.
CPP blade bolt connections: Table 2
Propeller locking bolts: Table 3
Shaft line connections: Table 4
-Cardan shaft/Clutch connections;
-Cardan shaft/Counter flange connections;
-Counter flange/Counter flange connections.
Non power/torque transmitting connections: Table 5
-top flange connections;
-seal package connections with stainless steel bolts;
-cover connections;
-inner and outer well connections (Note: when the rubber gasket is starting
to deform (i.e. coming from underneath of out the flanges) the
tightening of the bolts should be considered as sufficient.)
Stainless steel bolts direct and indirect power and torque Table 6
transmitting like:
-CCP head connections
Amendments Applicable dept. Drawn JWvS 29-07-2010

RD, AE, PS, WS, QA Checked GJK
Page 1 of 5
Procedure Sheet
Edition July 2010
Mounting Torque
Work Instruction
P 0072
Table 1:
Normal maximum mounting torque for bolt(s) (Nm)
Hexagon head bolts / Socket bolts (according VDI 2230 with ZF
experience 1986 table 1) 90% of yield strength
friction coefficient friction coefficient

Bolts Size Class 0.10 0.12 Bolts Size Class 0.10 0.12
M4 8.8 2.5 2.8 M20 8.8 350 390
10.9 3.7 4.1 10.9 490 560
12.9 4.3 4.8 12.9 580 650
M6 8.8 8.5 9.5 M22 8.8 470 530
10.9 12.5 14 10.9 670 750
12.9 14.5 16.5 12.9 780 880
M8 8.8 20.5 23 M24 8.8 600 670
10.9 30 34 10.9 850 960
12.9 35 40 12.9 1000 1120
M10 8.8 41 46 M27 8.8 880 1000
10.9 60 68 10.9 1250 1400
12.9 71 79 12.9 1450 1650
M12 8.8 71 79 M30 8.8 1190 1350
10.9 104 117 10.9 1700 1900
12.9 121 135 12.9 2000 2250
M14 8.8 113 125 M33 8.8 1600 1850
10.9 165 185 10.9 2300 2600
12.9 195 215 12.9 2700 3000
M16 8.8 170 195 M36 8.8 2100 2350
10.9 250 280 10.9 3000 3300
12.9 300 330 12.9 3500 3900
M18 8.8 245 280 M39 8.8 2700 3000
10.9 350 390 10.9 3800 4300
12.9 410 460 12.9 4500 5100

Page 2 of 5
Procedure Sheet
Edition July 2010
Mounting Torque
Work Instruction
P 0072
Table 2:
CPP blade bolt connections (Nm) oiled/greased
Material number
1.4542 comparable
Bolts Size with 8.8 class bolts Mounting moment
M16 / 4000CPP 8.8 175
M20 / 5000CPP 8.8 351
M24 / 4000CPP 8.8 600
M27 / 5000CPP 8.8 950
Table 3:
Propeller locking bolts (Nm) oiled/greased
Bolts Size Class Mounting moment

M8 A4-70 14.5
M12 A4-70 50
M16 A4-70 121
M20 A4-70 244
M24 A4-70 418
M30 A4-70 823
M36 A4-70 1434
Table 4:
Shaft line connections (Nm) (according Gewes documentation)
Bolts DIN 931 ISO 4014 10.9;
Hexagon nut DIN 980V-10 ISO 7042-V-10, self locking nut.
Bolts Size Class Mounting moment

M8 10.9 35
M10 10.9 70
M12 10.9 120
M14 10.9 200
M16 10.9 300
M18 10.9 410
M20 10.9 600
M22 10.9 800
M24 10.9 1000
M27 10.9 1500

Page 3 of 5
Procedure Sheet
Edition July 2010
Mounting Torque
Work Instruction
P 0072
Table 5:
Non power/torque transmitting connections (Nm)
Hexagon head bolts / Socket bolts 70% of yield strength
friction coefficient
Bolts Size Class 0.10 0.12
M4 8.8 2 2
A4-70 1 1
A4-80 2 2
M6 8.8 6 7
A4-70 4 5
A4-80 6 6
M8 8.8 14 16
A4-70 10 11
A4-80 14 15
M10 8.8 29 32
A4-70 21 23
A4-80 28 31
M12 8.8 50 55
A4-70 35 39
A4-80 47 52
M14 8.8 79 88
A4-70 55 62
A4-80 74 83
M16 8.8 119 137
A4-70 85 95
A4-80 113 127
M18 8.8 172 196
A4-70 122 137
A4-80 162 183
M20 8.8 245 273
A4-70 171 192
A4-80 228 256
M22 8.8 329 371
A4-70 127 144
A4-80 306 346
M24 8.8 420 469
A4-70 164 185
A4-80 393 444
M27 8.8 616 700
A4-70 230 260
M30 8.8 833 945
A4-70 312 352

Page 4 of 5
Procedure Sheet
Edition July 2010
Mounting Torque
Work Instruction
P 0072
Table 6:
Stainless steel bolts (A4-70 and A4-80 class) power/torque transmitting
connections (Nm)
Hexagon head bolts / Socket bolts 90% of yield strength
friction coefficient
Bolts Size Class 0.10 0.12
M6 A4-70 6 6
A4-80 8 9
M8 A4-70 14.5 16
A4-80 19 22
M10 A4-70 30 33
A4-80 39 44
M12 A4-70 50 56
A4-80 67 74
M14 A4-70 79 89
A4-80 106 119
M16 A4-70 121 136
A4-80 161 181
M18 A4-70 174 196
A4-80 232 261
M20 A4-70 244 274
A4-80 325 366

Page 5 of 5
9.2 Anodes (P0210)
Procedure Sheet
Edition October 2011
Anodes
Listing
P 0210
Scope
This listing gives inside into the number of anodes, the type of anode and on which thruster (lower gearbox)
they should be used. The listing is given in table 1.
Table 1
Thruster type Qty Anode type

ZF 1000 2 MME 02 A
ZF 2000 2 MME 02 A
ZF 3000 2 MME 08 A
ZF 400 C 2 MME 08 A
ZF 4000 2 MME 08 A
ZF 5000 2 MME 08 A
ZF 6000 2 MME 15 AB
ZF 7000 4 MME 125 A
ZF 8000 4 MME 125 A
ZF 9000 4 MME 125 A

R&D,AE,P&S,WS,PM Checked
Page1 of 1
10. Electrical system (optional)


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Instruction manual

SK 120 Heavy Cargo Vessel

ZF Marine Krimpen B.V.

Date: Revision: Change:

1.1 Technical specification

1.3 Ordering spare parts

ZF® FIXED PITCH TUNNEL THRUSTER

Ship yard : not yet known

Owner/end-user : not yet known

Vessel type : Heavy Cargo Ship

No. units per ship : 2 (1 bow thruster & 1 stern thruster)

TS00 13350_51 Apr25-12 1 of 4

A FIXED PITCH TUNNEL THRUSTER, L-DRIVE

A.1 FIXED PITCH PROPELLER

B.1 DRAWINGS, INSTRUCTION MANUALS & NAME PLATES

TS00 13350_51 Apr25-12 2 of 4

A FIXED PITCH TUNNEL THRUSTER, L-DRIVE

A.1 FIXED PITCH PROPELLER

A.3 UNDERWATER-GEARBOX WITH RIGHT-ANGLE DRIVE

A.4 LUBRICATION OIL SYSTEM

A.5 FLEXIBLE COUPLING

TS00 13350_51 Apr25-12 3 of 4

B.1 DRAWINGS, INSTRUCTION MANUALS & NAME PLATES

• Set of drawings and schedules in PDF format comprising:

B.2 PAINTING AND PRESERVATION

Gearbox structure : 2-component, multi layer coating, suitable for operation

B.4 SPECIAL TOOLS

No special tools required.

B.5 SPARE PARTS

B.6 WORKSHOP TESTING/FACTORY ACCEPTANCE TEST

As per ZF Marine Krimpen standard procedure.

• Electric drive motor with control system

TS00 13350_51 Apr25-12 4 of 4

Read this instructions very carefully !

If any doubt, ask ZF manufacturer.

1.3 Ordering spare parts

Use only genuine parts for repair on your ZF propulsion unit.

When ordering spare parts one must specify the following to us :

1. Serial number and type : Find at the typeplate

Ordering address ZF manufacturer.

Telefax. +31 (0)180 331000

2.1 Installation of lubrication

2.2 Connecting electrical wiring

2.3 Check points

2.4 Operation instructions

2.5 Trust performance of tunnel thrusters (P0125)

2.6 Paint Instructions (P0181)

1. Filling the thrusters with oil:

2.2 Connecting electrical wiring

2.3 Check points

e. Double-check bolts, nuts and electric components.

UNIT IS NOW READY TO BE STARTED UP!

1. Never start the engine from wheel-house during maintenance or repair.

Thrust performance of Tunnel thruster

1. Radius tunnel edges

2. Minimum length of the pipe

For tunnel length above L=6*D, loss due to friction in the

3. The cut at the pipe end

4. Minimum distance form the ship’s bottom

K = greater than or equal to 0.25*D, for long pipe where L >

5. The correct protective grid

Amendments Applicable dept. Drawn PV 06-10-10

Please find attached a proposal drawing “Grid construction”.

6. Correct installation of the protective grid