Voith Manualspare Part List

Voith Turbo
Voith Schneider® Propeller

VSP BOSPORUS 18R5 EC/150-1
Operation Manual
Shipset 1822056851000
Keep for future use!

Voith Turbo Marine | Operation Manual | VSP BOSPORUS 18R5 EC/150-1 Revision Sheet
Revision Sheet
Date of amendment Modified pages Person responsible Signature
Revision: 000-v6r4
Created: 2007-6-1
Author: VTMH amsk TLd
Editor: VTMH amsk TLd
SSNr.: 1822056851000
VGNr.: 000
A-1
A-2
Revision Sheet
Voith Turbo Marine | Operation Manual | VSP BOSPORUS 18R5 EC/150-1
SSNr.: 1822056851000 Author: VTMH amsk TLd Created: 2007-6-1

VGNr.: 000 Editor: VTMH amsk TLd Revision: 000-v6r4
Voith Turbo Marine | Operation Manual | VSP BOSPORUS 18R5 EC/150-1 Preface
Preface
This Operation Manual is intended for the operating, maintenance and supervisory
personnel.
This Operation Manual also describes components, equipment and ancillary units
which are not or only partially included in the scope of supply.
The scope of supply always refers to the delivery specification according to Chapter
3, Technical Specifications.
The operating personnel must have read, understood and must comply with this Ope-
ration Manual. We wish to emphasize that we do not accept any liability for damage
and/or downtime due to non-compliance with the Operation Manual.
We reserve the right to make any technical changes to representations and data given
in this Operation Manual that may become necessary to improve the unit.
Copyright
Copyright by Voith Turbo Schneider Propulsion GmbH & Co. KG. All rights reserved.
The reproduction, distribution and utilization of this document as well as the commu-
nication of its contents to others without explicid authorization is prohibited. Offenders
will be held liable for the payment of damages. All rights reserved in the event of the
grant of a patent, utility model or design.
System Supplier
Voith Turbo Schneider Propulsion GmbH & Co. KG
Alexanderstraße 18
Revision: 000-v6r4
89522 Heidenheim
Created: 2007-6-1
Germany
Tel. +49 (0) 7321 37-6595

Fax +49 (0) 7321 37-7105
E-Mail: vspmarine@voith.com
Internet: www.voith.com
SSNr.: 1822056851000
VGNr.: 000
B-1
Preface Voith Turbo Marine | Operation Manual | VSP BOSPORUS 18R5 EC/150-1
Status Quo
This Operation Manual complies with the technical status quo of the unit on
2007-6-1
Any changes made on the unit after this date are not included.
Created: ________________________
Reviewed:________________________
Approved:_____________________
Revision: 000-v6r4
Created: 2007-6-1
SSNr.: 1822056851000
VGNr.: 000
B-2
Voith Turbo Marine | Operation Manual | Template
Chapter C Preliminary remarks 1–1
3.1 Storage system and structure 1–1

3.1.1 Storage system 1–1
3.1.2 Structure of the operation manual 1–2
3.2 Safety instructions 1–3
3.3 Symbols and accentuation elements 1–5

3.3.1 Symbols and accentuation elements in the text 1–5
3.3.2 Symbols in graphics 1–5
3.3.2.1 Lines 1–5
3.3.2.2 Surfaces 1–6
3.3.2.3 Arrows 1–6
Chapter C Safety 2–1
3.1 Fundamental safety instructions 2–1

3.1.1 Basic principles for the safety of personnel and machine 2–1
3.1.2 Organizational measures 2–1
3.1.3 Personnel 2–2
3.2 Safety instructions on specified operating stages 2–3

3.2.1 Start-up 2–3
3.2.2 Normal operation 2–3
3.2.3 Safety instructions in dock 2–3
3.3 Notes on specific types of hazard 2–4

3.3.1 Electrical energy 2–4
3.3.2 Heat-generating works 2–4
3.3.3 Hydraulics, pneumatics 2–4
3.3.4 Noise 2–4
3.3.5 Oils, greases and other chemical substances 2–4
Created: 2007-6-1
3.4 Safety instructions on the propeller 2–5

3.4.1 Fundamental information 2–5
Revision:
3.4.2 Response in the case of fire 2–5

3.4.3 General hazards 2–5
3.4.4 Hazards due to electrical equipment 2–6
3.4.5 Use for the intended purpose 2–6
3.4.6 Authorized operators 2–6
3.4.7 Workplaces for the operating personnel 2–8
Author:
Editor:
3.4.8 Personal protective equipment 2–8

3.4.9 Safety measures taken by the user 2–8
3.4.10 Safety measures taken by the operator 2–9
3.4.11 Safety measures during operation 2–9
VGNr.:
SSNr.:
C-1
Template Voith Turbo Marine | Operation Manual |
3.4.12 Work on the running unit 2–10

3.4.13 Protecting against unexpected start-up 2–10
3.4.14 Safety equipment 2–11
Chapter C Technical specifications 3–1
3.1 Vessel data 3–1

3.1.1 Administrative information and order data 3–1
3.2 Voith Schneider propeller 3–2
3.3 Propeller 3–3

3.3.1 Project data 3–3
3.3.1.1 Design 3–3
3.3.1.2 Dimensions and weight 3–4
3.3.1.3 Performance data 3–4
3.3.2 Blade actuating mechanism 3–5
3.3.2.1 Blades and blade bearings 3–6
3.3.2.2 Blade actuating gear 3–7
3.3.2.3 Control rod 3–8
3.3.2.4 Servomotors 3–9
3.3.2.5 Indicator plate 3–9
3.3.3 Rotor 3–10
3.3.3.1 Rotor casing 3–10
3.3.3.2 Main bearing and main seal 3–11
3.3.3.3 Main gear 3–12
3.3.4 Stator 3–13
3.3.4.1 Propeller housing 3–13
3.3.4.2 Control rod support 3–13
3.3.4.3 Housing cover 3–14
3.3.4.4 Propeller housing components 3–14
3.3.5 Oil supply 3–15
3.3.5.1 Oil pumps 3–17
3.3.5.2 Filter 3–18
3.3.5.3 Valves 3–19
Created: 2007-6-1
3.3.5.4 Pipes 3–19

Revision:
3.3.5.5 Oil cooler 3–19

3.3.5.6 Elevated oil tank 3–20
3.3.5.7 Measuring and monitoring equipment 3–21
3.4 Drive unit 3–23

3.4.1 Shaft line 3–23
3.4.1.1 Coupling, propeller-sided 3–23
Author:
Editor:
3.4.1.2 Intermediate gear 3–24

3.4.1.3 Coupling, engine-sided 3–24
3.5 Control system 3–25

VGNr.:
SSNr.:
C-2
3.5.1 Control stand unit 3–26
3.6 Accessories 3–27

3.6.1 Tools 3–27
3.6.2 Spare parts 3–27
3.6.3 Coating 3–27
Chapter C Description 4–1
3.1 Design assemblies of the unit 4–1
3.2 Propeller 4–2

3.2.1 Function 4–3
3.2.1.1 Propeller thrust 4–3
3.2.1.2 Pitch 4–5
3.2.1.3 Eccentricity 4–5
3.2.1.4 Inflow conditions 4–6
3.2.2 Blade actuating mechanism 4–7
3.2.2.1 Blades and blade bearings 4–10
3.2.2.2 Blade actuating gear 4–12
3.2.2.3 Control rod 4–13
3.2.2.4 Servomotors 4–15
3.2.2.5 Indicator plate 4–18
3.2.3 Rotor 4–20
3.2.3.1 Rotor casing 4–21
3.2.3.2 Main bearing 4–24
3.2.3.3 Main seal 4–25
3.2.3.4 Elevated oil seal 4–32
3.2.3.5 Main gear 4–33
3.2.3.6 Input shaft bearing 4–35
3.2.4 Stator 4–36
3.2.4.1 Propeller housing 4–37
3.2.4.2 Control rod support 4–38
3.2.4.3 Housing cover 4–39
3.2.4.4 Parts of propeller housing, housing cover and control rod support 4–40
Created: 2007-6-1

Revision:
3.2.5.1 Pressure generation 4–44

3.2.5.2 Oil consumers 4–46
3.2.5.3 Measuring and monitoring equipment 4–49

Author:
Editor:

3.4.1 Control stand unit 4–53
3.5 Accessories 4–55

VGNr.:
SSNr.:
C-3
3.5.1 Tools 4–55

3.5.2 Spare parts 4–55
3.5.3 Coating 4–55
Chapter C Installation 5–1
3.1 General safety instructions concerning installation 5–1
Chapter C Operation 6–1
3.1 Start-up 6–1

3.1.1 Prior to start-up 6–1
3.1.2 Starting the unit 6–2
3.1.2.1 Power supply 6–2
3.1.2.2 Initializing the control system 6–2
3.1.2.3 Starting the drive unit 6–2
3.1.2.4 Couplings and readiness for operation 6–3
3.1.2.5 Checking control system functions 6–4
3.1.2.6 Speed setting 6–5
3.1.3 Starting from rest 6–6
3.1.4 Running 6–6
3.1.4.1 Longitudinal and transverse pitch 6–7
3.1.4.2 Running with one propeller / running in emergency situations 6–8
3.1.4.3 Having vessel towed 6–8
3.1.5 Alarm 6–9
3.1.5.1 Propeller 6–9
3.1.5.2 Control system 6–10
3.1.6 Examples for maneuvering 6–11
3.1.6.1 Moving straight ahead 6–11
3.1.6.2 Moving astern 6–11
3.1.6.3 Turning to starboard while moving ahead 6–12
3.1.6.4 Turning to starboard while moving astern 6–12
3.1.6.5 Turning to port while moving ahead 6–13
3.1.6.6 Turning to port while moving astern 6–13
Created: 2007-6-1
3.1.6.7 Traversing to starboard 6–14

3.1.6.8 Traversing to port 6–14
Revision:
3.1.7 Stopping 6–15

3.1.7.1 Normal stopping 6–15
3.1.7.2 Emergency stopping 6–15
3.2 Decommissioning of the propeller 6–16

3.2.1 Berthing vessel and shutting down propeller 6–16
Author:
Editor:
3.2.2 Measures after propeller shutdown 6–16

3.2.2.1 After propeller shutdown 6–16
3.2.2.2 When the propeller is switched off for prolonged periods 6–16
VGNr.:
SSNr.:
C-4
3.3 Faults 6–17

3.3.1 Leakages 6–18
3.3.2 Propeller and drive unit 6–21
3.3.3 Control system 6–24
Chapter C Maintenance 7–1
3.1 General safety instructions concerning maintenance 7–1
3.2 Maintenance and inspection 7–2

3.2.1 Maintenance and inspection intervals 7–2
3.2.1.1 With the vessel afloat 7–2
3.2.1.2 During prolonged lay periods in the water 7–3
3.2.1.3 During routine docking 7–3
3.2.1.4 Following irregularities 7–3
3.2.2 Inspection protocols 7–4
3.2.3 Repair works 7–4
3.2.4 Major overhaul 7–5
3.2.5 Drawings and illustrations 7–6
3.2.6 Maintenance and inspection plan 7–6
3.2.6.1 Specially trained crew members 7–6
3.2.6.2 Specially trained personnel of the customer 7–8
3.2.6.3 Specially trained shipyard personnel 7–11
3.2.7 Seals and gaskets – General 7–14
3.2.8 Corrosion damage – General 7–14
3.2.9 Screw joints – General 7–15
3.2.9.1 Tightening screw joints 7–15
3.2.9.2 Checking screw joints 7–16
3.2.10 Oil chamber covers 7–16
3.2.11 Propeller removal and installation 7–17
3.2.11.1 Removal in dry dock 7–17
3.2.11.2 Setting down the propeller 7–18
3.2.11.3 Installation in dry dock 7–19
3.2.12 Turning the propeller without propulsion engine 7–20
3.2.12.1 Turning with the vessel afloat 7–20
Created: 2007-6-1
Revision:
3.3 Blade actuating mechanism 7–22

3.3.1 Checking the blade actuating mechanism 7–22
3.3.1.1 Measuring torsional clearance 7–22
3.3.1.2 Determining zero position of the blades 7–23
3.4 Blades and blade bearings 7–25

3.4.1 Checking for leaks 7–25
Author:
Editor:
3.4.2 Checking blade condition 7–26

3.4.3 Checking blade end play 7–27
3.5 Rotor casing 7–28

VGNr.:
SSNr.:
C-5
3.5.1 Checking rotor casing 7–28

3.5.1.1 Checking reactive anodes 7–28
3.5.1.2 Renew reactive anodes 7–28
3.5.1.3 Checking for corrosion and leaks 7–29
3.6 Main bearing with main seal 7–30

3.6.1 Checking for leaks 7–30
3.6.1.1 Lower shaft seal 7–30
3.6.1.2 Center and upper shaft seal 7–32
3.7 Main gear 7–34

3.7.1 Maintenance 7–34
3.7.2 Inspection 7–35
3.7.2.1 Noise and oil temperature 7–35
3.7.2.2 Checking toothing 7–36
3.8 Input shaft bearing 7–40

3.8.1 Checking for noise 7–40
3.8.2 Checking input shaft seals for leaks 7–40
3.9 Propeller housing 7–41

3.9.1 Checking propeller housing 7–41
3.10 Parts of propeller housing, housing cover and control rod support 7–42
3.10.1 Checking mounting cover for leaks 7–42
3.10.2 Checking permanent magnet filter rods 7–44
3.10.3 Checking aeration filter 7–45
3.10.4 Checking rotor space ventilation for function 7–46
3.10.4.1 Checking non-return valve with propeller running 7–47
3.10.4.2 Checking non-return valve at standstill 7–48
3.10.4.3 Checking shut-off valve 7–49
3.11 Lubricant and oil supply 7–50

3.11.1 Limitation of warranty 7–50
3.11.2 Maintenance contract 7–50
3.11.3 Lubricants 7–50
Created: 2007-6-1
3.11.3.1 Lube oils 7–50

Revision:
3.11.3.2 Grease 7–51

3.11.4 Oil quality 7–52
3.11.4.1 Checking oil quality 7–52
3.11.5 Hydraulic fluid 7–54
3.11.5.1 Requirements 7–54
3.11.5.2 Safety instructions 7–54
3.11.5.3 Purpose 7–54
Author:
Editor:
3.11.5.4 Properties 7–54

3.11.5.5 Choice and maintenance 7–54
3.11.5.6 Viscosity 7–54
3.11.5.7 Choice of oil type 7–55
VGNr.:
SSNr.:
C-6
3.11.6 Oil temperature 7–56

3.11.6.1 Checking control and lube oil temperature 7–56
3.11.6.2 Checking oil cooler thermostat 7–57
3.11.7 Oil level 7–58
3.11.7.1 Checking oil level 7–58
3.11.8 Oil filters 7–60
3.11.8.1 Checking and replacing lube oil filter 7–61
3.11.8.2 Checking and replacing control oil filter 7–64
3.11.9 Oil pressure 7–67
3.11.9.1 Checking oil pressure 7–67
3.11.9.2 Setting oil pressure 7–69
3.11.9.3 Checking oil level 7–72
3.11.9.4 Hose lines 7–73
3.11.10 Checking and setting sight feed oilers to main seal 7–76
3.11.11 Oil change 7–78
3.11.12 Checking oil pumps 7–79
3.11.13 Checking and cleaning oil cooler 7–79
3.11.14 Measuring and monitoring equipment 7–80
3.11.14.1 Checking measuring and monitoring equipment 7–80

3.12.1.1 Checking shaft line alignment 7–81
3.12.2 Couplings 7–81
3.12.2.1 Checking couplings 7–81

3.13.1 Checking control system 7–82
3.14 Tools 7–83

3.14.1 Checking tools 7–83
3.15 Spare parts 7–84

3.15.1 Renewing corrosion protection 7–84
3.15.2 Spare parts ordering 7–85
3.15.3 Storing propeller 7–86
Created: 2007-6-1
3.15.3.1 Storage area 7–86

Revision:
3.15.3.2 Measures for storing 7–86

3.15.4 Storing rubber parts 7–86
3.15.4.1 Storage area 7–86
3.16 Coating 7–88

3.16.1 Checking coating 7–88
Author:
Editor:
Chapter C Drawings and schematics 8–1
3.1 Overview 8–1

VGNr.:
SSNr.:
C-7
3.1.1 Propeller 8–1

3.1.2 Blade actuation 8–1
3.1.3 Rotor 8–1
3.1.4 Stator 8–1
3.1.6 Drive unit 8–2
Chapter C Annex 9–1
3.1 Components supplier documentation 9–1

3.1.1 Stator 9–1
3.1.2 Ölversorgung 9–1
3.2 Standards 9–4
Chapter C Standard lists 10–1
3.1 Overview 10–1
3.2 Parts list 10–2
Created: 2007-6-1
Revision:
Author:
Editor:
VGNr.:
SSNr.:
C-8
Voith Turbo Schneider Propulsion | Operation Manual | VSP BOSPORUS 18R5 EC/150-1 Preliminary remarks
1 Preliminary remarks
To ensure that you find information quickly and reliably in the operation manual,
this chapter familiarizes you with its structure.
Symbols and special characters are used in this manual that make it easier for
you to find information. Please read the explanations of the symbols given in the
section below.
Ensure that you read all the safety instructions in this operation manual very ca-
refully. You will find safety instructions in Chapter 2, in the foreword to the chap-
ters and before any working instructions.
1.1 Storage system and structure
1.1.1 Storage system
Hardcover books are used as storage systems. Information on spine, front and back
side allows easy access and facilitates orientation within the documentation of an en-
tire unit.
Spine, front and back side provide information on:
• Spine
– Code name
– Design
– Language
– Folder number
• Front side
– Code name
– Document type
• Back side
– Manufacturer
– Contact
Revision: 000-v6r4
Created: 2007-6-1
SSNr.: 1822056851000
VGNr.: 000
1-1
Preliminary remarks Voith Turbo Schneider Propulsion | Operation Manual | VSP BOSPORUS 18R5 EC/150-1
1.1.2 Structure of the operation manual
Chapter Contents
– Title page
Revision sheet
Preface
Table of Contents
1 Preliminary remarks
Overall structure of the documentation and the product classification
Structure of the operation manual
Explanation of the chapter structure
Explanation of the signs and symbols used
2 Safety
Warning of general dangers when using the unit
Notes on the safe operation of the unit
3 Technical Specifications
Summary of unit characteristics
4 Description
Description of the unit, its components and functional groups
5 Installation
Information on installing the unit
6 Operation
Information for the operating personnel on how to operate the unit
7 Maintenance
Description of servicing and inspection work carried out when the vessel
is in the water.
8 Drawings and schematics

List of all supplied drawings and schematics
9 Annex
A list of all documents provided and all cited standards and Voith works
Revision: 000-v6r4
Created: 2007-6-1
standards
10 Standard lists
A list of all supplied standard lists for the unit
11 Index
Catalog containing important key words on the unit

Tab. 1-1 Structure of the operation manual
SSNr.: 1822056851000
VGNr.: 000
1-2
1.2 Safety instructions

Safety instructions are used to warn against injury and material damage. The safety
instructions in this operation manual are designed according to the American standard
ANSI Z535. Safety instructions always contain the following elements:
1 2 3
4
Danger!
5
Floating load hazard!
6
Mortal danger and risk of injury caused by suspended loads!
Monitor danger area.

Wear a safety helmet.
Use only suitable load lifting devices and slinging material.
000001021
Fig. 1-1 Safety instruction according to ANSI Z535
1 Hazard pictogram 4 Type and source of danger

2 Symbol 5 Consequences
3 Signal word 6 Action
Hazard pictogram
Hazard pictograms according to ANSI Z535.
Signal word
The signal word explicitly indicates the level of hazard seriousness:
Signal word Symbol Level of hazard se- Possible risks in case of

riousness non-observance
DANGER Highest hazard Fatal or serious injury

seriousness level
Revision: 000-v6r4
Created: 2007-6-1
WARNING Medium hazard Risk of fatal or serious injury

seriousness level
CAUTION Low hazard serious- Minor injuries

ness level
CAUTION – Lowest hazard Material damage

seriousness level
SSNr.: 1822056851000
Tab. 1-1 Signal word

VGNr.: 000
1-3
Type and source of danger

Type and source of danger are specified by means of an accurate signal word or a
short and memorable sentence.
Consequences
The consequences of interaction with the hazard are specified.
Action
The actions required to avoid the hazard are specified.
Revision: 000-v6r4
Created: 2007-6-1
SSNr.: 1822056851000
VGNr.: 000
1-4
1.3 Symbols and accentuation elements

Symbols and accentuation elements are used in this operation manual to provide fast
access to information.
1.3.1 Symbols and accentuation elements in the text
Symbol Use Explanation
Ö Action instruction Action has to be taken here
1. Action instruction, Action instructions have to be carried out in the

2. multi-step stated sequence
Any deviations from the given order may result

in damage to the unit and accidents
• List, two-stage No activities are linked with lists

–
Î Cross-reference References to figures, tables, other chapters or

other instructions
Tab. 1-1 Symbols and accentuation elements in the text
1.3.2 Symbols in graphics
Drawing elements are used in the graphics of this operation manual to illustrate defi-
ned information and situations.
1.3.2.1 Lines
Parameter Usage Definition
Concealed outlines of empha- Weight: 1 pt

sized/addressed components style: continuous
color: 100% black
Edges of objects, dimension lines Weight: 0.5 pt

style: continuous
Revision: 000-v6r4
Created: 2007-6-1
color: 100% black
Center line Weight: 0.25 pt

style: dashed
color: 100% black
Partial section edges Weight: 0.25 pt

style: continuous
color: 100% black
Tab. 1-1 Lines
SSNr.: 1822056851000
VGNr.: 000
1-5
1.3.2.2 Surfaces
Components or modules to be explained are displayed in gray scales in graphics:
1 2
4 3
G21200100
Fig. 1-2 Surfaces
1.3.2.3 Arrows
Parameter Usage Definition
Pointing towards details not drawn 5 Simple arrow,

filled, white background
Weight: 0.5 pt
color: 100% black
Revision: 000-v6r4
Created: 2007-6-1
Representing linear movements Outline arrow, medium
Arrows at dimensioning lines Simple arrow, long, thin

weight: 0.25 pt
color: 100% black
Representing radial circular move- Outline arrow, radius

ment medium
SSNr.: 1822056851000
Tab. 1-1 Arrows

VGNr.: 000
1-6
Voith Turbo Schneider Propulsion | Operation Manual | VSP BOSPORUS 18R5 EC/150-1 Safety
2 Safety
The chapter „Safety“ warns the operator of potential hazards emanating from the
unit.
2.1 Fundamental safety instructions

Please observe the explanation of the pictograms for warnings, symbols and accen-
tuation elements (Î Page 1-5, Chapter 1.3 „Symbols and accentuation elements”).
2.1.1 Basic principles for the safety of personnel and machine
The unit has been constructed using the latest technology and in accordance with the
recognized safety guidelines.
Nevertheless, the use of the unit may still represent a risk of injury or death to the ope-
rator or third parties, or damage to the machine and other material assets.
The unit may only be used for its intended purpose when it is in perfect working order.
The operator must follow the instructions in the operation manual and be fully aware
of the safety requirements and hazards posed by the unit.
In particular, any faults that may compromise the safety of the unit should be rectified
immediately.
2.1.2 Organizational measures
The operation manual should be kept in a place where it is always accessible to the
operators.
In addition to the operation manual, observe and instruct all users in all other generally
applicable legal and other mandatory regulations relevant to accident prevention and
environmental protection.
Observe all safety instructions and warnings on the unit!
Ensure that all safety instructions and warnings attached to the are always complete
Revision: 000-v6r4
Created: 2007-6-1
and perfectly legible.
Never make any modifications additions or conversions to the unit that might compro-
mise safety without the supplier's permission.
Spare parts must comply with the technical requirements specified by the manufactu-
rer. Only use genuine spare parts.
The personnel must be familiar with the location and operation of fire extinguishers.
SSNr.: 1822056851000
Provide regular training to ensure the safety during operation.

VGNr.: 000
2-1
Safety Voith Turbo Schneider Propulsion | Operation Manual | VSP BOSPORUS 18R5 EC/150-1
2.1.3 Personnel
Personnel selection and qualification

Operators must be familiar with the operation manual and be trained accordingly.
Any work on the unit may only be carried out by personnel trained for this purpose.
This applies to servicing and inspection work on board during operation and also for
maintenance work in dock.
Observe the minimum legal age!
Define staff responsibilities!
Works on electrical components and equipment may only be carried out by operators
qualified through professional training in the field of electrical engineering.
Works on the hydraulic equipment may only be carried out by personnel with special
knowledge and experience in hydraulics.
Basic duties
Do not carry out any procedure that may compromise the safety of personnel or unit.
Do not make any modifications on the unit without permission.
Before starting up the drive unit, ensure that no persons are endangered by the unit
starting up.
Check the unit for visible external damage and defects at least once per day. Also lis-
ten for unusual sounds.
The mounting covers on the housing plate must not be released when the vessel is in
the water.
When working on a running propeller, use extreme caution and have a second person
standing by who can activate the emergency stop switch in an emergency.
Revision: 000-v6r4
Created: 2007-6-1
Before servicing the oil supplies, depressurize the control and lube oil systems.
Servicing work may only be carried out when the unit is shut down and locked to pre-
vent accidental start-up and self-acting rotating movements.
The unit must not be started in dock.
Only use suitable lifting gear that works properly and lifting devices with sufficient lif-
ting capacity.
SSNr.: 1822056851000
Do not work under suspended loads.

VGNr.: 000
2-2
2.2 Safety instructions on specified operating stages

Observe the basic safety instructions for the safety of personnel and machine.
(Î Page 2-1, Chapter 2.1 „Fundamental safety instructions”)
2.2.1 Start-up
Before switching on/starting the unit, ensure that no persons are endangered by the
unit starting up.
2.2.2 Normal operation
Do not put out to sea if safety is compromised.
Monitor unit and control instruments during operation.
Only operate the unit if all safety devices and safety-related equipment are fitted and
functioning correctly.
Check the unit for visible external damage and defects at least once per day. Imme-
diately report any changes (including changes in operational behavior) to the wheels-
man and stop the unit if necessary.
Immediately have faults rectified!
2.2.3 Safety instructions in dock
Observe all setting, maintenance and inspection activities and intervals, including in-
structions for replacing parts/secondary devices, as described in the operation manu-
al.
For all work relating to operation, refitting or setting work on the unit and its safety de-
vices, as well as to inspection, servicing and repairs, observe the start-up and
shut-down procedures specified in the operation manual and the notes on mainte-
nance work!
Safeguarding the unit against accidental activation:

Revision: 000-v6r4
• Disconnect the unit from the power supply.

Created: 2007-6-1
• Secure the unit with a mechanical locking device.

• Keep all accessible areas around the drive unit clean and free.
• Retighten loose screw connections after finishing servicing and maintenance work.
• When maintenance and inspection work is completed, immediately refit any removed
safety devices and ensure correct functioning of the unit.

• Dispose of operating and auxiliary materials and replacement parts in a safe and en-
vironmentally friendly manner.
SSNr.: 1822056851000
VGNr.: 000
2-3
2.3 Notes on specific types of hazard
2.3.1 Electrical energy
Only use original fuses with the specified amperage.
Components and devices that are being inspected, serviced or repaired must be dis-
connected from the power supply if specified. First check that the isolated parts are
free of voltage, then earth and short-circuit them and insulate adjacent parts still car-
rying current.
Components and devices should be inspected and checked on a regular basis. Cor-
rect any faults immediately!
Should it be necessary to work on live parts, have a second person standing by who
can activate the emergency stop switch or a main switch with shunt tripping in case of
an emergency. Only use insulated tools.
2.3.2 Heat-generating works
Danger of inflammation and explosion! Do not carry out any welding, firing or grinding
works on the unit as long as the propeller is filled with oil.
2.3.3 Hydraulics, pneumatics
Works on the hydraulic equipment may only be carried out by personnel with special
knowledge and experience in hydraulics.
Regularly check all pipes, hoses and threaded joints for leaks and visible external da-
mage! Rectify any damage immediately! Escaping oil may result in injuries and fires.
Any system sections and pressurized pipes to be opened should be depressurized in

accordance with the module descriptions before starting repair work.
Lay and assemble compressed air ductwork correctly. Fittings, length and quality of
tubing must comply with the specifications.
Revision: 000-v6r4
Created: 2007-6-1
2.3.4 Noise
Wear any mandatory personal ear protection.
2.3.5 Oils, greases and other chemical substances

Observe the safety regulations applicable to the product when using oils, greases and
other chemical substances.
Take care when using hot operating and auxiliary materials (risk of fire and scalding).
SSNr.: 1822056851000
VGNr.: 000
2-4
2.4 Safety instructions on the propeller

Dangerous situations on the propeller may be caused by:
• Operating errors
• Lack of experience
• Carelessness, especially during rough sea
• Missing or inappropriate protective equipment in the area of the drive unit and the
shafting
• Inappropriate clothing
2.4.1 Fundamental information
Responsibilities with regard to the operation of the unit and during maintenance and
repair work must be clearly defined and observed in order to prevent any confusion of
tasks in relation to safety.
Do not carry out any procedure that may compromise safety on the unit.

2.4.2 Response in the case of fire
The unit will be at risk of serious damage in the event of a fire in its vicinity. Fight the
fire as quickly as possible using a suitable fire extinguisher!
The operating personnel must be informed and trained in the procedure to be used in
raising a fire alarm and on escape routes.
Once the fire has been extinguished, remove all fire debris from the vicinity of the unit!
Fire extinguishing equipment should be subjected to functional testing at regular inter-

vals!
2.4.3 General hazards

Revision: 000-v6r4
Any work that results in a danger from rotating parts must not be carried out while the
Created: 2007-6-1
unit is in operation; alternatively, personnel must be secured using special safety de-
vices.
A shut-down propeller may break away and turn when the vessel is in operation. In
this case the drive motor might turn as well. In the event of repair or maintenance work
carried out on the drive unit, turning must be prevented by means of a securing me-
chanism.
Danger areas on the unit itself are marked accordingly:

• Large moving bodies (blades)
SSNr.: 1822056851000
• Drive unit, rotor, shafting

• Slowly proceeding movements (adjustment of the servo motors)
VGNr.: 000
2-5
• All bearing points between rotating axles and stationary parts

• Never reach into the propeller when the unit is running
• Stay away from the drive unit and the shafting
Frequent causes of accidents:

• Ignorance of the operator
• Rushing and time pressure
• Slippery surfaces
• Acidic and alkaline cleaning agents
• Inadequate personal protective equipment being worn
• Clambering over walkways and safety guards
• Tampering with components using tools during operation
• Work on pressurized lines, tubes and showers
• Tripping over machine parts, tools and auxiliary materials left lying around
2.4.4 Hazards due to electrical equipment
Due to the permanent dampness, electrically-operated machine parts represent a po-

tential source of danger.
Comply with all regulations on electrical equipment in damp areas!
2.4.5 Use for the intended purpose
The Voith Schneider® propeller unit is exclusively designed as a marine propulsion

unit.
Any use of the Voith Schneider® propeller unit exceeding this regulation or its use in
a different type of ship is not in accordance with regulations. In this case the operator
bears the risk of potential damage.
2.4.6 Authorized operators
Care for the life and limb and good health of the employees is a legal obligation of the
employer, which derives from the Occupational Safety and Accident Prevention Rules
and Regulations.
Revision: 000-v6r4
Created: 2007-6-1
Besides the employer, the superiors are obliged to ensure the safety of the employees
entrusted to them.
Operators must be qualified through professional training and have experience in the
operation of the machine. They should be up to the physical and mental demands
placed on them.
Operators should be aware of the relevant health and safety and accident prevention
regulations in order to be able to recognize and avert the risks.
SSNr.: 1822056851000
Before carrying out start-up operations, maintenance or repair work for the first time,
operating personnel must have read the operation manuals –.in particular the chapter
VGNr.: 000
2-6
on safety.
Voith Turbo Schneider Propulsion | Operation Manual | VSP BOSPORUS 18R5 EC/150-1
2-7
Safety
2.4.7 Workplaces for the operating personnel
The workplaces are located on the control stand room and the machine control room.
2.4.8 Personal protective equipment
The personnel must be instructed in the correct use of safety equipment.
To prevent accidents, wear protective equipment if required during all work on the unit!
This applies in particular to checks carried out at sea when the unit is running.
Activity Protective equipment
Operation • No loose-fitting clothing

• Ear protection
• Non-slip safety shoes
In all work in which there is a danger of • Safety helmet

knocking the head
Cleaning • Eye protection

• Hand protection
• Protective suit
Checks/Repairs • Safety helmet

Tab. 2-1 Protective equipment (minimum requirements)
Observe the relevant data sheets when using dangerous substances.
When personnel are required to wear protective clothing or other equipment due to
danger in the workplace, these persons must be trained in the correct use of this
equipment.
Consider ergonomics and comfort when choosing personal safety clothing!
2.4.9 Safety measures taken by the user

Revision: 000-v6r4
Created: 2007-6-1
An efficient safety program is the responsibility of the executive personnel.
The safety program should at least cover:

• Recognition and elimination of potential danger areas
• Personnel safety training for safety-conscious behavior
• Checking the safety in all working processes

• Instruction of the personnel concerning the safety rules and regulations of the Voith
Schneider ® Propeller as well as its characteristics
SSNr.: 1822056851000
VGNr.: 000
2-8
2.4.10 Safety measures taken by the operator
Only operate the propeller if the required safety devices are available and effective!
Re-attach any safety devices removed for maintenance work.
Aisles and transport routes must be free from obstacles.
Remove any slippery and uneven places! Remove escaped oil and water! Clear away
tools and materials that are no longer required!
Before starting up the propeller, ensure that the personnel are outside the danger zo-
ne! Check danger areas!
Prior to and during start-up of the unit, ensure that no persons put at risk!
2.4.11 Safety measures during operation
Observe the colors coding for danger areas!
Observe all instructions on warning signs!
Do not remove any protection devices, do not dismantle barriers, do not remove war-
ning signs!
Thoroughfares, walkways and passageways should be kept clean and free from
obstacles! Clear away tools and materials that are no longer required!
In the machine area only walk on those steps, platforms and walkways intended for
the purpose.
Never reach in-between or climb between protection devices and rotating parts of the
machine!
Ensure that all safety guards are installed at all times!
Take care in the area of the drive unit and the shafting.Do not remove any protective
Revision: 000-v6r4
Created: 2007-6-1
devices!
SSNr.: 1822056851000
VGNr.: 000
2-9
2.4.12 Work on the running unit
Work may only be carried out on running parts of the unit if it is unavoidable and does
not endanger people!
Do not wear loose-fitting clothing! Loose clothing can become caught up in moving
machine parts.
Use protective equipment!
Do not tamper with moving parts!
Do not bend over into danger areas!
Do not climb on railings or protective devices!
Mounting covers facing the seaward side

Never unscrew bolts at the mounting openings with the vessel afloat!
If the mounting covers on the casing bottom facing the seaward side are not comple-
tely closed or not closed at all, there is a risk of water entering the vessel's interior.
This situation could also occur if the bolts are overtightened i.e. not tightened profes-
sionally.
2.4.13 Protecting against unexpected start-up

Source of energy Recommended ways to isolate energy sources
Electrical current with vol- Close main switch

tage U < 1 kV
Electrical current with vol- Turn off power switch with isolator, circuit breaker or
tage U > 1 kV breaker with interlock against connecting in cur-
Revision: 000-v6r4
Created: 2007-6-1
rent-bearing condition
Hydraulic system Close shut-off valve
Pneumatic system Close the shutoff devices

Tab. 2-1 Ways to isolate energy sources

SSNr.: 1822056851000
VGNr.: 000
2-10
2.4.14 Safety equipment
Safety equipment must not be switched off due to changes on the unit.
Safety equipment may not be tampered with or removed!
Carry out functional tests on all safety devices at regular intervals to ensure reliable
functioning!
Required testing on safety equipment:

• Secure fastening
• Prescribed position
• Prescribed function
• Prescribed condition
Have all shortcomings on safety devices corrected immediately!

Revision: 000-v6r4
Created: 2007-6-1
SSNr.: 1822056851000
VGNr.: 000
2-11
2-12
Safety

Voith Turbo Schneider Propulsion | Operation Manual | VSP BOSPORUS 18R5 EC/150-1 Technical specifications
3 Technical specifications
The „Technical Specification“ chapter provides a summary of all technical speci-
fications of the unit.
3.1 Vessel data
3.1.1 Administrative information and order data
Designation Value
Codename VSP BOSPORUS
Vessel type Voith double-ended ferry
Propeller type 18 R5/150-1
Shipset 1822056581000
Ship owner IDO,

Istanbul, Turkey
Shipyard Ceksan Gemi Insa,

Istanbul, Turkey
Yard No. NB. 41, 42, 43, 44
Classification Society Turkish Lloyd

Tab. 3-1 Administrative information and order data
Revision: 000-v6r4
Created: 2007-6-1
SSNr.: 1822056851000
VGNr.: 000
3-1
Technical specifications Voith Turbo Schneider Propulsion | Operation Manual | VSP BOSPORUS 18R5 EC/150-1
3.2 Voith Schneider propeller

The Voith Schneider® propeller consists of the following design assemblies: propeller,
drive unit, control system and accessories.
Components
R00000000
Fig. 3-1 Voith Schneider® Propeller

Revision: 000-v6r4
Created: 2007-6-1
1 Control system 3 Propeller

2 Drive unit
Item Component Description
1 Control system Î Page 3-25, Chapter 3.5 „Control system”

2 Drive unit Î Page 3-23, Chapter 3.4 „Drive unit”
3 Propeller Î Page 3-3, Chapter 3.3 „Propeller”

Tab. 3-1 Voith Schneider® propeller
SSNr.: 1822056851000
VGNr.: 000
3-2
3.3 Propeller
3.3.1 Project data
Components
1 2 3 4
R01000100
Fig. 3-2 Propeller
1 Oil supply 3 Rotor

2 Stator 4 Blade actuating mechanism
3.3.1.1 Design
Designation Value
Propeller size 18
Propeller type R5/150-1

Revision: 000-v6r4
Created: 2007-6-1
Year of propeller manufacture 2007/2008
Propeller number (anticlockwise rotation) 3873 to 3880
Propeller position inside the vessel midships

Tab. 3-1 Design

SSNr.: 1822056851000
VGNr.: 000
3-3
3.3.1.2 Dimensions and weight
Designation Value Unit
Maximum outer diameter 2405 mm
Propeller height including blades 2992
Blade circle diameter 1800
Total propeller weight without oil 9500 kg

Tab. 3-1 Dimensions and weight
For further information regarding the propeller dimensions Î Page 8-1, Chapter 8
i „Drawings and schematics” under „Propeller“, „Main dimensions“ drawing.
3.3.1.3 Performance data
Reference value Symbol Value Unit
Propeller input power Pe 780.000 kW
Propeller input speed ne 579.000 min-1
Rotor output speed na 117.200
Overall ratio ig 4.938 –

Tab. 3-1 Performance data
Revision: 000-v6r4
Created: 2007-6-1
SSNr.: 1822056851000
VGNr.: 000
3-4
3.3.2 Blade actuating mechanism
Components
1 2
R01100100
Fig. 3-3 Blade actuating mechanism
1 Control rod 3 Blades and blade bearings

2 Servomotors 4 Blade actuating gear
Propeller pitch λ0 0.8 –
Control time, ahead - astern – 8 s
Control time, starboard - portside 6.8
Torsional clearance 7 mm
Divergence V ±6
Revision: 000-v6r4
Created: 2007-6-1
Test torque Md 250 Nm

Tab. 3-1 Blade actuating mechanism
SSNr.: 1822056851000
VGNr.: 000
3-5
3.3.2.1 Blades and blade bearings
Reference value Symbol* Value Unit
Design
Number of blades – 5 –
Blade leaf length 1500 mm
Blade weight 1372 kg
Type of blade bearing top Plain bearing –
bottom Roller bearing
Gland ring diameter D3min 204.885 mm
D3max 205.000
Blade bearings - design bearing clearance
Blade bearing clearance, top Lmin 0.190 mm
Lmax 0.250
Blade bearing clearance, bot- Mmin 0.120

tom
Mmax 0.180
Blade bearings - max. permissible bearing clearance
Blade bearing clearance, top L 0.330 mm
Blade bearing clearance, bot- M 0.260

tom
Tab. 3-1 Blades and blade bearings
* D3, L and M Î Page 8-1, Chapter 8 „Drawings and schematics” under „Blade actu-
i ation“, „Blade bearings“ drawing.

Revision: 000-v6r4
Created: 2007-6-1
SSNr.: 1822056851000
VGNr.: 000
3-6
3.3.2.2 Blade actuating gear
Design
Kinematic No. – 17 (2.70-150) –
Design bearing clearance
Coupler sleeve Dmin 0.270 mm
Coupler sleeve, outer Emin 0.250
Rocking arm bolt Hmin 0.100
Coupler bolt Jmin 0.100
Rocking arm Kmin 0.100
Max. permissible bearing clearance
Coupler sleeve D 0.480 mm
Coupler sleeve, outer E 0.500
Rocking arm bolt H 0.300
Coupler bolt J 0.270
Rocking arm K 0.300

Tab. 3-1 Blade actuating gear
* D, E, H, J and K Î Page 8-1, Chapter 8 „Drawings and schematics” under „Blade

actuation“, „Blade bearings“ drawing.
i
Revision: 000-v6r4
Created: 2007-6-1
SSNr.: 1822056851000
VGNr.: 000
3-7
3.3.2.3 Control rod
Bores
Fixing buttstrap D1 20.000 mm
Control rod D2 30.000
Control rod, top Amin 0.072 mm
Control rod, center Bmin 0.005
Control rod, bottom Cmin 0.005
Max. permissible bearing clearance
Control rod, top A 0.220 mm
Control rod, center B 0.200
Control rod, bottom C 0.200

Tab. 3-1 Control rod
* A, B, C, D1 and D2 Î Page 8-1, Chapter 8 „Drawings and schematics” under „Pro-
i peller“, „Longitudinal section“ drawing.
Revision: 000-v6r4
Created: 2007-6-1
SSNr.: 1822056851000
VGNr.: 000
3-8
3.3.2.4 Servomotors
Pressure specifications
Control oil pressure, mecha- p1 100 -5/+15 bar

nically driven pump
Control oil pressure, electri- 90±5

cally driven pump
Drive servomotor, longitudinal setting
Stroke, adjusted – 78.25 mm
Stroke, max. 100
Propeller pitch 0.8 λ0
Control time, ahead - astern 8 s
Rudder servomotor, transverse setting
Stroke, adjusted – 66.5 mm
Stroke, max. 100
Control time, starboard - 6.8 s

portside
Tab. 3-1 Servomotors
For further information regarding the servomotors Î Page 9-1, Chapter 9.1 „Compo-
nents supplier documentation”under Control system, documents regarding „VBR-D
control“. i
3.3.2.5 Indicator plate
Reference value Value Unit
Factory-set diagram type 3 –

Revision: 000-v6r4
Created: 2007-6-1
Tab. 3-1 Indicator plate

SSNr.: 1822056851000
VGNr.: 000
3-9
3.3.3 Rotor
1 2
4 3
R01200100
Fig. 3-4 Rotor
1 Input gear 3 Rotor casing

2 Main gear 4 Main bearing, main seal
3.3.3.1 Rotor casing
Design
Type Standard 18R5 –
Material Sheet steel
Weight, empty 1420 kg

Revision: 000-v6r4
Created: 2007-6-1
Reactive anode
Manufacturer Grillo-Werke –
Type 20-Z
Material Zinc
Tab. 3-1 Rotor casing
SSNr.: 1822056851000
VGNr.: 000
3-10
3.3.3.2 Main bearing and main seal
Gland ring diameter D5min 694.800 mm
Design bearing clearance - tolerances
Main thrust bearing, end play Fmin 0.030 mm
Fperm. 0.100
Cylinder roller bearing, radial Gperm. 0.480

play
Leak rate
Oil – 1.0 l/h
Water 5.5
Tab. 3-1 Main bearing and main seal
* D5, F and G Î Page 8-1, Chapter 8 „Drawings and schematics” under „Propeller“,
„Longitudinal section“ drawing.
i
Revision: 000-v6r4
Created: 2007-6-1
SSNr.: 1822056851000
VGNr.: 000
3-11
3.3.3.3 Main gear
Type of toothing – Cyclo-palloid –
Ratio i 4.938
Speed
Bevel pinion shaft – 579.000 min-1
Bevel gear 117.200
Permissible backlash
cold min 0.550 mm
max 0.700
warm min 0.450
max 0.600
Design bearing clearance - tolerances
Rotary palm D4min 299.870 mm

Tab. 3-1 Main gear
* D4 Î Page 8-1, Chapter 8 „Drawings and schematics”under „Propeller“, „Longitudi-
i nal section“ drawing.
Revision: 000-v6r4
Created: 2007-6-1
SSNr.: 1822056851000
VGNr.: 000
3-12
3.3.4 Stator
Components
1 2 3
R01300100
Fig. 3-5 Stator
1 Propeller housing 3 Control rod support

2 Housing cover
3.3.4.1 Propeller housing
Design Single-piece with cast support ring –

Tab. 3-1 Propeller housing
Revision: 000-v6r4
Created: 2007-6-1
3.3.4.2 Control rod support
Design 2-part –

Tab. 3-1 Control rod support
SSNr.: 1822056851000
VGNr.: 000
3-13
3.3.4.3 Housing cover
Design Cast aluminum –
Weight, empty 82 kg
Tab. 3-1 Housing cover
3.3.4.4 Propeller housing components
Type plate location Housing cover –
Rotor space ventilation Yes

Tab. 3-1 Propeller housing components
For further information regarding the rotor space ventilation Î Page 8-1, Chapter 8
i „Drawings and schematics” under „Stator“, „Rotor space ventilation“ drawing.
Revision: 000-v6r4
Created: 2007-6-1
SSNr.: 1822056851000
VGNr.: 000
3-14
3.3.5 Oil supply
Components
P M P
1 2 3
4
5 6 7 8 9
10
A B
G21401020
Fig. 3-6 Oil supply
1 Pressurization p1 6 Oil pressure indicators

2 Standby pump 7 Oil consumers p1
3 Pressurization p2 8 Oil consumers p2
4 Control block (lube oil) 9 Oil consumers p3
Revision: 000-v6r4
Created: 2007-6-1
5 Control block (control oil) 10 Propeller housing
A Control oil circuit

B Lube and rotor oil circuit
SSNr.: 1822056851000
VGNr.: 000
3-15
Control oil
Control oil pressure, mecha- p1 100 -5/+15 bar

nically driven pump
Control oil pressure, electro- 90 ±5

nically driven pump
Control oil quantity – 110 l
Oil viscosity ISO VG46 –
Lube oil
Lube oil pressure p2 2 +1/-0.5 bar
Propeller oil capacity – 900 l
Rotor oil capacity 360
Oil viscosity ISO VG150 –
Rotor oil
Rotor oil pressure p3 1 ±0.5 bar

Tab. 3-1 Control, lube and rotor oil circuit
Revision: 000-v6r4
Created: 2007-6-1
SSNr.: 1822056851000
VGNr.: 000
3-16
3.3.5.1 Oil pumps
3.3.5.1.1 Control and lube oil pumps
Reference value Value
Control oil
Manufacturer Bosch Rexroth
Design Axial piston pump
Type A10VSO45
Control oil (Standby pump)
Design Axial piston pump
Type A10VSO18
Lube oil
Manufacturer Rickmeier
Design Gear pump
Type R45/80 FL-Z-SO

Tab. 3-2 Oil pumps (control and lube oil)
For further information on the oil pump Î Page 9-1, Chapter 9.1 „Components sup-
plier documentation”under Oil supply.
i
Revision: 000-v6r4
Created: 2007-6-1
SSNr.: 1822056851000
VGNr.: 000
3-17
3.3.5.2 Filter
3.3.5.2.1 Aeration filter
Manufacturer Hydac –
Design Tank aeration filter with filling strainer
Type ELF P7 F10W1.0
Filter material Paper mat
Filter transmittance 10 μm
Tab. 3-2 Aeration filter
For further information regarding the aeration filter Î Page 9-1, Chapter 9.1 „Compo-
i nents supplier documentation” under „Stator“, „Aeration filter“ supplier documentation.
3.3.5.2.3 Oil filters
Schmieröl
Design Double filter
Type RFLD BN/HC 501
Filter material Betamicron® (BN/HC)
Filter element 0500 R 020 BN/HC
Steueröl
Revision: 000-v6r4
Created: 2007-6-1
Design Double filter
Type R 240 BN/HC 10

Filter material Betamicron® (BN/HC)
Filter element 240 R 010 BN/HC
Tab. 3-4 Ölfilter
SSNr.: 1822056851000
VGNr.: 000
3-18
For further information regarding the oil filter Î Page 9-1, Chapter 9.1 „Components
supplier documentation” under „Oil supply“.
i
3.3.5.3 Valves
Lube oil
Manufacturer Kracht
Type SPV pressure valve
Control oil
Type ABVSK-AGEV1-37364/002F809A
Tab. 3-1 Valve assembly
For further information regarding the oil filter Î Page 9-1, Chapter 9.1 „Components
supplier documentation” under „Oil supply“.
i
3.3.5.4 Pipes
Design – Standard –
Test pressure pp1 51 bar

Tab. 3-1 Pipes
For further information regarding the pipes Î Page 8-1, Chapter 8 „Drawings and
schematics” under „Oil supply“, „Pipes“ drawing.
i
3.3.5.5 Oil cooler
Revision: 000-v6r4
Created: 2007-6-1
Lube oil
Manufacturer HS Cooler –
Cooler type KS12-BTC-421
Power 15.000 kW
Quantity flow, oil 4.200 m3/h

SSNr.: 1822056851000
Quantity flow, water 4.000

VGNr.: 000
3-19
Control oil
Manufacturer Bosch-Rexroth –
Cooler type RD50111
Power 4.000 kW
Quantity flow, oil 1.800 m3/h
Tab. 3-1 Oil cooler
For further information regarding the oil cooler Î Page 9-1, Chapter 9.1 „Compon-
i ents supplier documentation” under „Oil supply“, „Oil cooler“ supplier documentation.
3.3.5.6 Elevated oil tank
Design Standard –
Capacity 40 l
Oil level indicator Yes –
Level switch
Tab. 3-1 Elevated oil tank
For further information regarding the elevated oil tank Î Page 8-1, Chapter 8 „Dra-
i wings and schematics” under „Oil supply“, „Elevated oil tank“ drawing.
Revision: 000-v6r4
Created: 2007-6-1
SSNr.: 1822056851000
VGNr.: 000
3-20
3.3.5.7 Measuring and monitoring equipment
3.3.5.7.1 Control oil
Pressure
Manufacturer – Hydac –
Design Pressure measuring switch
Type EDS 347-4-250-SO1
Control oil pressure p1 100 -5/+15 bar
Temperature
Manufacturer – SIKA –
Design Thermometer
Type K422104102110
Manufacturer – Danfoss –
Design Temperature sensor
Type MBT5250
Oil level
Manufacturer – KSR Kuebler –
Design Float switch
Type ARV-1,5-VU-L300/12-V44A-VER
ST.
Tab. 3-2 Control oil
For further information regarding the measuring and monitoring equipment

Î Page 9-1, Chapter 9.1 „Components supplier documentation” under „Oil supply“.
i
Revision: 000-v6r4
Created: 2007-6-1
3.3.5.7.3 Lube oil

Pressure
Manufacturer – Hydac –
Design Pressure measuring switch

SSNr.: 1822056851000
Type EDS 347-4-016-SO1

VGNr.: 000
3-21
Lube oil pressure p2 2 +1/-0.5 bar
Temperature
Manufacturer – Danfoss –
Design Temperature sensor
Type MBT5250
Oil tperm. 65 °C
Alarm tmax 75
Oil level
Manufacturer – KSR Kuebler –
Design Float switch
Type ARV-1,5-VU-L300/12-V44A-VER
ST.
Tab. 3-4 Lube oil
i Î Page 9-1, Chapter 9.1 „Components supplier documentation” under „Oil supply“.
3.3.5.7.5 Lube oil
Speed
Manufacturer Noris
Design Speed sensor
Type FA1J-4E-70
Revision: 000-v6r4
Created: 2007-6-1
Pressure
Manufacturer Danfoss
Design Pressure transducer

Type MBS 5100-3411-1CB04-0

Tab. 3-6 Lube oil
i Î Page 9-1, Chapter 9.1 „Components supplier documentation” under „Oil supply“.
SSNr.: 1822056851000
VGNr.: 000
3-22
3.4 Drive unit
3.4.1 Shaft line
Components
1 2 3 4 5 6
R00000020
Fig. 3-7 Shaft line
1 Propeller 4 Intermediate gear (Kumera)

2 Control system (Bosch-Rexroth) 5 Coupling, engine-sided (Centa)
3 Kupplung, propeller-sided (Renk) 6 E-Engine (Siemens)
3.4.1.1 Coupling, propeller-sided
Manufacturer Renk AG –
Type SBG 125 SPEZ

Revision: 000-v6r4
Created: 2007-6-1
Design Coupling with intermediate shaft
Oil capacity per coupling half 0.340 l
Weight 300.000 kg
Tab. 3-1 Coupling, propeller-sided

For further information regarding the gear coupling Î Page 9-1, Chapter 9.1 „Com-
ponents supplier documentation” under „Shaft line“.
i
SSNr.: 1822056851000
VGNr.: 000
3-23
3.4.1.2 Intermediate gear
Manufacturer Kumera –
Type FVE355
Speed, input 1500.000 min-1
Speed, output 579.000
Power, output 580.000 kW

Tab. 3-1 Intermediate gear
For further information regarding the intermediate gear Î Page 9-1, Chapter 9.1
i „Components supplier documentation” under „Shaft line“.
3.4.1.3 Coupling, engine-sided
Manufacturer Centa –
Type CM 7000 SCEW466
Weight 123.300 kg
Tab. 3-1 Coupling, engine-sided
For further information regarding the coupling Î Page 9-1, Chapter 9.1 „Components
i supplier documentation” under „Shaft line“.
Revision: 000-v6r4
Created: 2007-6-1
SSNr.: 1822056851000
VGNr.: 000
3-24
3.5 Control system
Components
R05700060
Fig. 3-8 Control system
1 Control stand unit 3 Propeller

2 Control cabinet
Factory-set diagram type 3 –

Revision: 000-v6r4
Created: 2007-6-1
Control time, ahead - astern 8 s
Control time, starboard - portside 6.8

Tab. 3-1 Control system
SSNr.: 1822056851000
VGNr.: 000
3-25
3.5.1 Control stand unit
Design
Design VBR-D control
Manufacturer Bosch Rexroth AG
Type Marex OS VBR-D control
Number of control stands in control room 4
Overload regulation Yes
Speed transmitter
Autopilot connection
Interfaces, output
Alarm system Yes
Zero-position indicator
Pump control
Interfaces, input
Level feedback Yes
Speed feedback
Coupling feedback
Tab. 3-1 Control stand unit
For further information regarding control Î Page 9-1, Chapter 9.1 „Components sup-
i plier documentation” under „Control system“, document on „VBR-D control“.

Revision: 000-v6r4
Created: 2007-6-1
SSNr.: 1822056851000
VGNr.: 000
3-26
3.6 Accessories
The accessories include tools, spare parts and paint specifications.
3.6.1 Tools
Standard tools Î Page 10-2, Chapter 10.2 „Parts list” under

List of part Nos.
Tab. 3-1 Tools
3.6.2 Spare parts
Installation spare parts Î Page 10-2, Chapter 10.2 „Parts list” under
List of part Nos.
Tab. 3-1 Spare parts
3.6.3 Coating
Voith Turbo Marine Coatings Î Page 10-2, Chapter 10.2 „Parts list” under
VN1619 Part 1, Sheet 1
Tab. 3-1 Coating
Revision: 000-v6r4
Created: 2007-6-1
SSNr.: 1822056851000
VGNr.: 000
3-27
Revision: 000-v6r4
Created: 2007-6-1
SSNr.: 1822056851000
VGNr.: 000
3-28
Voith Turbo Schneider Propulsion | Operation Manual | VSP BOSPORUS 18R5 EC/150-1 Description
4 Description
The „Description“ chapter describes purpose, design and function of the unit and
its main components as far as required for operation and maintenance.
4.1 Design assemblies of the unit

The unit consists of the following design assemblies: control system, propeller and dri-
ve unit.
Components
˚3
0520.15
˚3
3˚
51.0250
3˚
2 3
00000000010
Fig. 4-1 Design assemblies of the unit (DEF)
1 Control system 3 Drive unit

2 Propeller
1 Control system Î Page 4-52, Chapter 4.4 „Control system”
2 Propeller Î Page 4-2, Chapter 4.2 „Propeller”

Revision: 000-v6r4
Created: 2007-6-1
3 Drive unit Î Page 4-51, Chapter 4.3 „Drive unit”
– Accessories Î Page 4-55, Chapter 4.5 „Accessories”

Tab. 4-1 Design assemblies of the unit
SSNr.: 1822056851000
VGNr.: 000
4-1
Description Voith Turbo Schneider Propulsion | Operation Manual | VSP BOSPORUS 18R5 EC/150-1
4.2 Propeller
Task
The VSP is the ideal propulsion system for all watercraft that must maneuver in con-
fined areas or be held on an exact position.
Components
1 2 3 4
R01000100
Fig. 4-2 Propeller
1 Oil supply 3 Rotor

2 Stator 4 Blade actuating mechanism
1 Oil supply Î Page 4-44, Chapter 4.2.5 „Oil supply”
2 Stator Î Page 4-36, Chapter 4.2.4 „Stator”

Revision: 000-v6r4
Created: 2007-6-1
3 Rotor Î Page 4-20, Chapter 4.2.3 „Rotor”
4 Blade actuating Î Page 4-7, Chapter 4.2.2 „Blade actuating

mechanism mechanism”
Tab. 4-1 Propeller
SSNr.: 1822056851000
VGNr.: 000
4-2
4.2.1 Function
4.2.1.1 Propeller thrust
The generation of thrust by the VSP differs significantly from that of a screw propeller:
On the VSP, the blades projecting from the rotor rotate around a vertical axis.
Thrust is generated only if the blades are set at a certain angle to the orbital. The lar-
ger the blade angle, the higher the resulting thrust.
Performance characteristics
• Thrust and power can be changed with the help of the variable blade angle. This al-
lows perfect adaptation to any operating status.
• Thrust and performance are the same in any direction; the thrust diagram therefore
is a circle.
• Magnitude and direction of thrust are continuously variable; pitch setting is by x- and
y-coordinates.
4.2.1.1.1 Propeller operation without thrust
The blades circle tangentially around propeller center of rotation O if the blade setting
is not changed (control point S = propeller center of rotation O). No thrust is generated.
S=O
Revision: 000-v6r4
Created: 2007-6-1
001001030
Fig. 4-3 Propeller operation without thrust

1 Blade with blade actuating gear 2 Propeller center of rotation O

SSNr.: 1822056851000
VGNr.: 000
4-3
4.2.1.1.2 Propeller operation with thrust generation
The blade pitch is altered by moving control point S. Control point S is located outside
propeller center of rotation O (control point S ≠ propeller center of rotation O). Thrust
is generated.
1
T
S
O
2
B
001001040
Fig. 4-4 Propeller operation with thrust generation
1 Blade with blade actuating gear 2 Control rod
Item Symbol Designation
1 – Blade with blade actuating gear
2 Control rod
– T Direction of thrust
B Direction of water jet

Revision: 000-v6r4
Created: 2007-6-1
S Control point
O Propeller center of rotation

Tab. 4-3 Propeller operation with thrust generation
SSNr.: 1822056851000
VGNr.: 000
4-4
4.2.1.2 Pitch
Control point shift from O to S is referred to as pitch with a magnitude of 0 – 100%.
This shift results in the following:

• pitch direction determines the direction of thrust
• pitch magnitude determines the magnitude of thrust
4.2.1.3 Eccentricity
The control point shift from O to S is referred to as eccentricity.

• Eccentricity eN
Eccentricity eN is the maximum OS value during normal operation.
• Eccentricity eAu
Eccentricity eAu is the OS value where the control rod contacts the stop ring of the
blade actuating gear.
• Eccentricity eD
Eccentricity eD is the OS value where the blade actuating gear still moves freely in
the rotor casing and does not hit the stop.
Check dimension
Eccentricity eD is the check dimension for sufficient clearance of the blade actuating
gear components in the rotor casing.
For further information regarding the eccentricity Î Page 3-7, Chapter 3.3.2.2 „Blade
actuating gear”.
i
Revision: 000-v6r4
Created: 2007-6-1
SSNr.: 1822056851000
VGNr.: 000
4-5
4.2.1.4 Inflow conditions
Plotting the absolute path of one blade provides an overview over the blade inflow
conditions. While for screw propellers each point of the screw surface moves along a
cylindrical screw path, the VSP blades describe a cycloidal path.
This movement results from a rotary motion being superimposed on a straight-line

motion at a right angle to the axis of rotation. The cycloide running radius is λ x D/2.
The cycloide is generated by the propeller rolling on an imaginary radius λ x D/2. Du-
ring one revolution the propeller turns by λ x D x π in the direction of motion.
To generate thrust, the blade profiles must be angled to the blade path described abo-
ve.
λ•D•π
180°
225° 135°
D
270° 90°
λ•D
45° 315°
0° 360°
001001020
Fig. 4-5 Absolute path of one blade
Symbol Designation
Revision: 000-v6r4
Created: 2007-6-1
λ Degree of progress
D Diameter
π 3.1415
Tab. 4-1 Absolute path of one blade

SSNr.: 1822056851000
VGNr.: 000
4-6
4.2.2 Blade actuating mechanism
The blade actuating mechanism comprises those assemblies within the propeller that
change the blade setting in the rotor.
The force required to actuate the blades is generated hydraulically by to servomotors

that are supplied with control oil pressure p1 by the oil supply system.
Components
1 1
4 3
001102000
Fig. 4-6 Blade actuating mechanism

Revision: 000-v6r4
Created: 2007-6-1
1 Servomotors Î Page 4-15, Chapter 4.2.2.4 „Servomotors”
2 Control rod Î Page 4-13, Chapter 4.2.2.3 „Control rod”

3 Blade actuating gear Î Page 4-12, Chapter 4.2.2.2 „Blade actuating

gear”
4 Blades and blade bea- Î Page 4-10, Chapter 4.2.2.1 „Blades and
rings blade bearings”
SSNr.: 1822056851000
Tab. 4-1 Blade actuating mechanism

VGNr.: 000
4-7
Function
The below explanation of the blade actuating mechanism is based on the following
propeller operating status:
• propeller is operating
• rotor turns at rated speed
• longitudinal and transverse pitch set to zero on control stand; propeller does not ge-
nerate any thrust (S = O)
Components
2
3
R01101100
Fig. 4-7 Blade actuating mechanism and control
1 Control stand unit 4 Rotor

Revision: 000-v6r4

Created: 2007-6-1
1 Control stand unit Î Page 4-52, Chapter 4.4 „Control system”

2 Control rod Î Page 4-13, Chapter 4.2.2.3 „Control rod”
3 Servomotors Î Page 4-15, Chapter 4.2.2.4 „Servomotors”
4 Rotor Î Page 4-20, Chapter 4.2.3 „Rotor”
5 Blades and blade bea- Î Page 4-10, Chapter 4.2.2.1 „Blades and
SSNr.: 1822056851000
rings blade bearings”

VGNr.: 000
4-8
6 Blade actuating gear Î Page 4-12, Chapter 4.2.2.2 „Blade actuating

gear”
Tab. 4-2 Blade actuating mechanism and control
Every control command from control stand (1) results in a change of the blade actua-
ting mechanism setting:
• Servomotors (3) move from their rest position to the selected control point S.
• Blade actuating gear (6) is supported on the bottom ball of control rod (2) and rotates
around the set control point S (Î Page 4-4, Fig. 4-4). Every linkage is swiveled to
the outside and inside once per rotor revolution (4).
• All blades (5) are connected to the blade actuating gear and follow this movement.
As a result of the blade angle alteration the blades generate thrust.
Revision: 000-v6r4
Created: 2007-6-1
SSNr.: 1822056851000
VGNr.: 000
4-9
4.2.2.1 Blades and blade bearings
Task
Thrust is generated by the VSP blades.
Components
1
2
6
5 4
R01110300
Fig. 4-8 Longitudinal section of propeller with blades and blade bearings
1 Blade bearing cap 4 Shaft seals

2 Upper blade bearing 5 Junk excluder
3 Lower blade bearing 6 Actuating lever
Revision: 000-v6r4
Created: 2007-6-1
SSNr.: 1822056851000
VGNr.: 000
4-10
Function
The VSP blades are supported vertically in the rotor. The section of the blade outside
the rotor casing creates the thrust and is referred to as blade leaf. The blade section
inside the rotor casing is referred to as blade shaft. Blade shaft and blade leaf are
made in one piece from sea water-resistant material.
• Bearing points
Each blade shaft is supported axially and radially at two bearing points.
– axially
at the top by blade bearing cap (1) and at the bottom by the mating face of actu-
ating lever (6)
– radially
at the top in a plain bearing and at the bottom in a roller bearing
• Sealing
– Shaft seal
Two shaft seals (4) prevent oil leaking from the rotor casing as well as sea water
ingress into the rotor casing.
– Junk excluder
Junk excluder (5) in front of the sealing rings protects the seals from coarse dirt.
It also acts as a vibration damper against pressure peaks.
• Connection to the blade actuating linkage
Actuating lever (6) is connected to the blade shaft and linked to the blade actuating
gear of the blade actuating mechanism (Î Page 4-12, Chapter 4.2.2.2 „Blade actu-
ating gear”).
Revision: 000-v6r4
Created: 2007-6-1
SSNr.: 1822056851000
VGNr.: 000
4-11
4.2.2.2 Blade actuating gear
Task
If the propeller control setting is changed, each linkage moves around joint control
point S thereby moving the blades.
Components
1 2 3
R01130100
Fig. 4-9 Blade actuating gear
1 Rotor casing 3 Blade actuating gear

2 Lower bearing
Function
Blade actuating gear (3) is supported in the propeller rotor casing and rotates with it
around the propeller axis.
It consists of a kinematic linkage assembly which is linked to lower bearing (2) of the
control rod.
Revision: 000-v6r4
Created: 2007-6-1
This design is very robust in terms of resisting pressure peaks or foreign objects in the
blades.
The bearing points at the blade actuating gear are friction bearings. They are lubrica-
ted by rotor oil p3.

For further information regarding the blade bearings Î Page 8-1, Chapter 8 „Dra-
i wings and schematics”, „Longitudinal section“ drawing

SSNr.: 1822056851000
VGNr.: 000
4-12
4.2.2.3 Control rod
Task
The control rod is located on the longitudinal axis of the propeller. It transmits the set-
tings of the two servomotor hydraulic cylinders to the blade actuating gear in the rotor.
Components
1 2 3 4
R01140100
Fig. 4-10 Control rod
1 Pointer 4 Center bearing

2 Indicator plate 5 Lower bearing
3 Upper bearing
Revision: 000-v6r4
Created: 2007-6-1
SSNr.: 1822056851000
VGNr.: 000
4-13
Function
The control rod has several functions:
• Bearing points
The control rod bearing points are designed as spherical bearings. They allow control
rod movement in all directions:
– Upper bearing (3) is connected to the servomotors (only one shown)
– Center bearing (4) supports the control rod in the stator
– Lower bearing (5) controls the blade actuating gear
• Pitch indicator
Pointer (1) is located at the upper end of the control rod. It is visible from the outside
through indicator plate (2).
The pointer provides information on the pitch and allows checking of the control sys-
tem.
• Rotor oil supply
The control rod has a bore along its longitudinal axis. In exceptional circumstances
this bore allows rotor oil to be removed or added with the vessel afloat.
Revision: 000-v6r4
Created: 2007-6-1
SSNr.: 1822056851000
VGNr.: 000
4-14
4.2.2.4 Servomotors
Task
The servomotors generate the force required to move the blade actuating gear
(Î Page 4-12, Chapter 4.2.2.2 „Blade actuating gear”) and keep it in the set position.
Function
The forces and settings of the servomotors on the control rod are shown here using a
propeller that rotates anti-clockwise as an example.
Components
S'
B
R
90°
T O
S D
001151000
Fig. 4-11 Servomotors on the control rod
Symbol Designation
B Direction of water jet
D Indicator plate
Revision: 000-v6r4
Created: 2007-6-1
R Direction of rotation (anti-clockwise)
S Lower control point on control rod
S’ Upper control point on control rod

T Direction of thrust
Tab. 4-1 Components of the control rod adjusting mechanism
SSNr.: 1822056851000
VGNr.: 000
4-15
Position of the control point and the servomotors on the propeller

• Control points
– Position of the control point
The position of control point S’ determines the magnitude and direction of the wa-
ter jet. During operation, jet direction B, starting from upper control point S', is al-
ways at a 90° angle (anti-clockwise) to propeller direction of rotation R.
– Control point indication
The servomotors are set to zero (S' = O) when both servomotors are set so that
the pointer below the indicator plate also points to zero. In this case the control
rod is exactly in the center of the propeller.
• Servomotors
– Longitudinal and transverse adjustment
The servomotor for longitudinal adjustment is positioned at a 90° angle to the ves-
sel's direction of movement. The servomotor for transverse adjustment is located
in the vessel's direction of movement at a 90° angle to the one for longitudinal ad-
justment.
When the transverse and longitudinal components are set on the control stand,
any point on the diagram can be selected.
Revision: 000-v6r4
Created: 2007-6-1
SSNr.: 1822056851000
VGNr.: 000
4-16
4.2.2.4.2 Servomotor adjustment
The servomotors are part of the scope of supply of the control system. For a descrip-
tion of the design and function see chapter „Annex“ (Î Page 9-1, Chapter 9.1 „Com-
ponents supplier documentation” under „Control system“). i
Components
R01150100
Fig. 4-12 Servomotor adjustment
1 Control point S' at control rod, top 2 Control point S at control rod, bottom
Longitudinal and transverse adjustment

• Longitudinal adjustment
The servomotor for longitudinal adjustment moves upper control point S' in the lon-
gitudinal direction of thrust.
• Transverse adjustment
Revision: 000-v6r4
Created: 2007-6-1
The servomotor for transverse adjustment moves upper control point S' in the trans-
verse direction of thrust.
Lower control point S (2) follows this adjustment exactly but in the opposite direction.
SSNr.: 1822056851000
VGNr.: 000
4-17
4.2.2.5 Indicator plate
Task
Reduction of the longitudinal component depends on vessel type, vessel application
and open-water speed. Based on experience with similar vessels, it is stated as a limit
line on the indictor plate.
The indicator plate is transparent and installed in the housing cover. The pointer is vi-
sible from the outside through the indicator plate.
On fast vessels the longitudinal component is reduced drastically if the transverse

component is increased.
On slow vessels such as river ferries or floating cranes the longitudinal component is
reduced to a lesser extent. For these applications the magnitude of the transverse
component can almost reach that of the longitudinal component.
Components
1 2 3
Revision: 000-v6r4
Created: 2007-6-1
7 6 5 4
001163010
Fig. 4-13 Indicator plate
1 Diagram shape 5 Direction of motion of the vessel

2 Limit line 6 Circles
SSNr.: 1822056851000
3 Limit line 7 Graduation

4 Zero-position of control rod
VGNr.: 000
4-18
Item Designation
1 Diagram shape (curve) at open-water speed
2 Limit line just before control rod stop
3 Limit line for 100% pitch
4 Zero-position of control rod

(indicator plate center)
5 Direction of motion of the vessel

(ahead, astern, starboard, port)
6 Circles in percent of max. pitch
7 Graduation for pitch direction

Tab. 4-1 Indicator plate
Function
The maximum permissible speed reduction is printed on the indicator plate. The re-
sulting diagram shape (1) is marked in black.
For severe speed reduction the diagram shape is narrow, for small reduction almost
circular.
Even for longitudinal components of less than 100% the longitudinal component is re-
duced if a transverse component is set.
The control rod can be set to any position within the diagram shape.
Markings
• The limit line (3) marks a pitch setting of 100%.
• The limit line (2) marks the stop eccentricity eAo at which the control rod contacts the
sleeve in the control rod support.
For further information regarding the set diagram shape Î Page 3-9, Chapter 3.3.2.5
„Indicator plate”.
i
Revision: 000-v6r4
Created: 2007-6-1
SSNr.: 1822056851000
VGNr.: 000
4-19
4.2.3 Rotor
Task
The rotor is the propeller component that is driven by the engine and turns. The blades
and the blade actuating gear are supported in the rotor.
Components
3 2
R01200110
Fig. 4-14 Rotor
1 Input gear 3 Rotor casing

2 Main gear 4 Main bearing with main seal
1 Main gear Î Page 4-33, Chapter 4.2.3.5 „Main gear”
2 Rotor casing Î Page 4-21, Chapter 4.2.3.1 „Rotor casing”

Revision: 000-v6r4
Created: 2007-6-1
3 Main bearing with Î Page 4-24, Chapter 4.2.3.2 „Main bearing”

main seal
Tab. 4-1 Rotor
SSNr.: 1822056851000
VGNr.: 000
4-20
4.2.3.1 Rotor casing
Task
The rotor casing absorbs the thrust forces and torques of each blade and transmits
them to the main bearing.
Components
1
R51212000
Fig. 4-15 Rotor casing
1 Rotor casing 2 Blade support openings
Function
Rotor casing (1) is in the water and is flush with the vessel hull. The rotor casing inte-
rior is filled with oil. This chamber is closed off from the remainder of the propeller
space by an elevated oil seal and is pressurized with rotor oil p3.
Support openings (2) for blades and blade bearings are located on the blade circle di-
ameter.
Revision: 000-v6r4
Created: 2007-6-1
SSNr.: 1822056851000
VGNr.: 000
4-21
4.2.3.1.1 Oil drain device
Task
An oil drain valve is integrated into the rotor casing bottom. This valve is used to drain
the oil when the vessel is docked in.
Components
R01210300
Fig. 4-16 Oil drain device
1 Rotor casing 2 Oil drain device

Revision: 000-v6r4
Created: 2007-6-1
SSNr.: 1822056851000
VGNr.: 000
4-22
4.2.3.1.2 Corrosion protection
Task
To prevent corrosion damage, the VSP is equipped with highly efficient reactive ano-
des.
The reactive anodes are welded to the rotor casing bottom and are evenly spaced
near the blades.
Components
001213000
Fig. 4-17 Reactive anodes, single-row
Revision: 000-v6r4
Created: 2007-6-1
SSNr.: 1822056851000
VGNr.: 000
4-23
4.2.3.2 Main bearing
Task
The rotor casing and its internal assemblies are supported by the main bearing.
At the smallest diameter of the main bearing, seals prevent ingress of sea water as
well as oil leaks from the propeller.
Components
1 2
7 6
R03220300
Fig. 4-18 Main bearing with main seal
1 Upper plain bearing, axial 5 Shaft seal, preventing oil leakage

2 Thrust plate 6 Shaft seal, preventing water ingress
Revision: 000-v6r4
Created: 2007-6-1
3 Driving sleeve 7 Lower plain bearing, axial

4 Cylinder roller bearing, radial
Function
Axial forces from the drive system and the blades are transmitted to the friction bea-
rings, radial forces to the cylinder roller bearings and from these bearings to the pro-
peller housing.
SSNr.: 1822056851000
VGNr.: 000
4-24
4.2.3.3 Main seal
The main seal prevents oil leakage from and water ingress into the propeller.
The three shaft seals of the main bearing are rigidly mounted in the bearing flange.
Their sealing lips contact the rotor gland ring.
4.2.3.3.1 Lower shaft seal
Task
The lower shaft seal prevents water ingress into the propeller. This seal must keep dirt
and sea impacts away from the center seal.
Components
3
4
5
G23220310
Fig. 4-19 Lower shaft seal
1 Sight feed oiler supply line 4 Lower shaft seal

Revision: 000-v6r4
Created: 2007-6-1
2 Center shaft seal 5 Protective ring in front of lower shaft seal to

3 Ring channel protect against sea impact
Function
Two pipes are routed from the outside to ring channel (3) between the lower (4) and
center (2) shaft seal into the propeller housing: Sight feed oiler line (1) to the lower
shaft seal and the ventilation and control line.

SSNr.: 1822056851000
VGNr.: 000
4-25
Sight feed oiler line to lower shaft seal
Components
1
3
G23220360
Fig. 4-20 Sight feed oiler for lower shaft seal
1 Bleeding valve 3 Line to lower shaft seal

2 Sight feed oiler 4 Lower shaft seal, sealing lip
Function
The oil released by sight feed oiler (2) is routed through line (3) directly to the sealing
lip of lower shaft seal (4).
Revision: 000-v6r4
Created: 2007-6-1
SSNr.: 1822056851000
VGNr.: 000
4-26
Ventilation and control line
Components
G23220100
Fig. 4-21 Ventilation and control line
1 Control valve 3 Line to lower shaft seal

2 Overflow valve 4 Lower shaft seal, sealing lip
Function
The ventilation and control line ends at overflow valve (2) and control valve (1) in the
bilge or in a collecting basin. This line ventilates the chamber between the lower and
center shaft seal and drains off any leakage.
To prevent constant leakage to the outside, the elevated overflow valve must be kept
open and the control valve closed. Leakage accumulates in the entire line (3) until the
control valve is opened during routine checking.
Only close the overflow valve in the event of a complete failure of lower shaft seal (4).
Revision: 000-v6r4
Created: 2007-6-1
In this case the center shaft seal takes over sealing against water ingress into the pro-
peller chamber.
Vessel operation can continue for the time being. Schedule docking for damage re-
pair.
i
SSNr.: 1822056851000
VGNr.: 000
4-27
4.2.3.3.2 Center shaft seal
Task
The center shaft seal is the main seal against water ingress into the propeller.
Components
2 3
G23220390
Fig. 4-22 Center shaft seal
1 Sight feed oiler for center shaft seal 3 Leakage drain

2 Center shaft seal
Function
Two pipes are routed from the outside to the ring channel in the propeller housing bet-
ween the center and upper shaft seal: Sight feed oiler line (1) and leakage drain line
(3).
Revision: 000-v6r4
Created: 2007-6-1
SSNr.: 1822056851000
VGNr.: 000
4-28
Sight feed oiler line to center and upper shaft seal
Components
4 3
G23220370
Fig. 4-23 Sight feed oiler for center and upper shaft seal
1 Sight feed oiler 3 Center shaft seal

2 Upper shaft seal 4 Line
Function
The oil released by sight feel oiler (1) is routed through line (4) directly to the sealing
lips of center and upper shaft seals (3 and 2).
Revision: 000-v6r4
Created: 2007-6-1
SSNr.: 1822056851000
VGNr.: 000
4-29
Leakage drain
Components
1 2
G23220380
Fig. 4-24 Leakage drain
1 Ring channel 2 Leakage drain pipe
Function
The leakage drain consists of ring channel (1) and leakage drain pipe (2) outside the
propeller housing. The non-pressurized leakage (oil or water) from the center and up-
per shaft seal can drain off through this line.
Revision: 000-v6r4
Created: 2007-6-1
SSNr.: 1822056851000
VGNr.: 000
4-30
4.2.3.3.3 Upper shaft seal
Task
The upper shaft seal prevents oil leakage from the propeller. Leaking oil is routed to
the bilge via the drain channel.
Components
G23220330
Fig. 4-25 Upper shaft seal
1 Cylinder roller bearing, radial 2 Upper shaft seal

Revision: 000-v6r4
Created: 2007-6-1
SSNr.: 1822056851000
VGNr.: 000
4-31
4.2.3.4 Elevated oil seal
Task
The elevated oil seal separates the rotor casing oil chamber from the propeller hou-
sing. It allows the rotor casing to be pressurized with oil against the water pressure on
the outside when the propeller is at standstill.
The shaft seal is located in the rotor and turns with it around the propeller axis.
Components
3 4
R03220340
Fig. 4-26 Elevated oil seal
1 Propeller housing 3 Gland ring

Revision: 000-v6r4
Created: 2007-6-1
2 Rotor casing 4 Shaft seal (elevated oil seal)

SSNr.: 1822056851000
VGNr.: 000
4-32
4.2.3.5 Main gear
Task
The main gear is designed as a bevel gear unit and transmits the drive power to the
rotor casing of the propeller.
Components
2 3 4
R03240100
Fig. 4-27 Main gear
1 Drive axis 4 Propeller axis

2 Input shaft bearing 5 Rotor casing
3 Main gear
Function
The main gear
• drives the rotor casing
• changes from the horizontal drive axis to the vertical rotor casing axis
Revision: 000-v6r4
Created: 2007-6-1
For further information regarding ratio and number of gear teeth

Î Page 3-12, Chapter 3.3.3.3 „Main gear”.
i
SSNr.: 1822056851000
VGNr.: 000
4-33
Lubrication
The bevel gear unit is lubricated and cooled by:
• the stationary oil in the propeller
• the additional splash lubrication at the bevel pinion
The pinion is supplied with filtered lube oil via the spray tube. The oil lubricates the
main gear and returns to the propeller housing via the bevel gear rim. This cools and
lubricates the teeth.
For further information regarding the lube oil supply Î Page 3-15, Chapter 3.3.5 „Oil
i supply”.
Revision: 000-v6r4
Created: 2007-6-1
SSNr.: 1822056851000
VGNr.: 000
4-34
4.2.3.6 Input shaft bearing
Task
The input shaft bearing supports the drive shaft.
Components
1 2 3
R03253000
Fig. 4-28 Input gear
1 Axial piston pump (control oil) 3 Gear pump (lube oil)

2 Input shaft
Function
The control and lube oil pumps (1 and 3) are flanged onto the input shaft bearing and
are driven directly by the engine via the drive shaft and a gear reducer unit.
Revision: 000-v6r4
Created: 2007-6-1
SSNr.: 1822056851000
VGNr.: 000
4-35
4.2.4 Stator
Task
The stator consists of several welded assemblies that are bolted together. This design
provides the stator strength and stiffness required to transmit the forces and torques
to the hull.
Components
1 2 3
R01300110
Fig. 4-29 Stator
1 Propeller housing 3 Housing cover

2 Control rod support 4 Propeller pit
1 Propeller housing Î Page 4-37, Chapter 4.2.4.1 „Propeller housing”
2 Control rod support Î Page 4-38, Chapter 4.2.4.2 „Control rod support”
Revision: 000-v6r4
Created: 2007-6-1
3 Housing cover Î Page 4-39, Chapter 4.2.4.3 „Housing cover”
4 Propeller pit –
Tab. 4-1 Stators
SSNr.: 1822056851000
VGNr.: 000
4-36
4.2.4.1 Propeller housing
Task
The three propeller housing feet are arranged in a star pattern and allow statically se-
cure positioning of the propeller on the propeller pit in the hull.
Components
R01310110
Fig. 4-30 Propeller housing
1 Propeller housing 2 Support ring
Function
A torsion-resistant support ring (2) is welded into the center of propeller housing (1).
On it, the main bearing and the main seal are bolted together.
Two of the three feet of the tightly welded propeller housing contain the tanks for the
Revision: 000-v6r4
Created: 2007-6-1
entire oil supply system. The servomotors as well as the input shaft bearing are rigidly
mounted on the propeller housing.
SSNr.: 1822056851000
VGNr.: 000
4-37
4.2.4.2 Control rod support
Task
The two-part control rod support is bolted into the propeller housing. Its conical shape
provides high torsion resistance, thereby increasing the overall stiffness of the stator
considerably.
Bearing carrier (1) supports the main gear bevel pinion.
Control rod support (2) supports the control rod on the center ball.
Components
1 2
R01330100
Fig. 4-31 Control rod support
1 Bearing carrier 2 Control rod support

Revision: 000-v6r4
Created: 2007-6-1
Bearing carrier and control rod support are manufactured together with the propeller
i housing and separated afterwards. These two components can therefore not be re-
placed!
SSNr.: 1822056851000
VGNr.: 000
4-38
4.2.4.3 Housing cover
Task
The housing cover closes the top of the propeller housing.
Components
1 2
R01360100
Fig. 4-32 Housing cover
1 Indicator plate 2 Housing cover

Revision: 000-v6r4
Created: 2007-6-1
SSNr.: 1822056851000
VGNr.: 000
4-39
4.2.4.4 Parts of propeller housing, housing cover and control rod support
This section covers fasteners such as screws, covers and small parts. They are used
to bolt the stator assemblies together and provide sealing.
4.2.4.4.1 Mounting cover
The mounting covers provide sealing against sea water ingress into the propeller
space. These covers are bolted and sealed against the propeller housing bottom.
They are secured with splint pins on four bolts to prevent accidental opening. When
the ship is in dock, the covers can be removed to gain access to the rotor and the bla-
de bearings.
1 001373000
Fig. 4-33 Splint pin (1) on large mounting cover
Revision: 000-v6r4
Created: 2007-6-1
1
001373010
Fig. 4-34 Splint pin (1)
SSNr.: 1822056851000
VGNr.: 000
4-40
4.2.4.4.2 Type plate
A type plate with the following manufacturing data is located on the housing cover of
each propeller:
• Product name
• Propeller type
• Propeller size
• Propeller number
• Year of manufacture
4.2.4.4.3 Magnet filter in housing base (Lube oil)
Task
Several magnet rods are located in the oil chamber cover of the suction foot. The per-
manent magnet rod force retains the steel wear and dirt particles.
Components
1
Revision: 000-v6r4
Created: 2007-6-1
G21373020
Fig. 4-35 Magnet filter
1 Magnet rod
For further information regarding cleaning of the magnet rods

Î Page 7-44, Chapter 7.10.2 „Checking permanent magnet filter rods”.
i
SSNr.: 1822056851000
VGNr.: 000
4-41
4.2.4.4.4 Aeration filter
Task
The filter unit is located in the housing cover and is used as an aeration filter for the
propeller oil chamber.
Components
G21373030
Fig. 4-36 Aeration filter
1 Filter element
For further information regarding the aeration filter Î Page 3-18, Chapter 3.3.5.2.1
i „Aeration filter”.
Revision: 000-v6r4
Created: 2007-6-1
SSNr.: 1822056851000
VGNr.: 000
4-42
4.2.4.4.5 Rotor space ventilation
Task
The rotor space ventilation vents the space between propeller well and rotor.
When the propeller (rotor) is started, a centrifugal force is created in the rotor space,
that acts on the water. Negative pressure is created. The rotor space ventilation redu-
ces the formation of this negative pressure by allowing air to flow in.
Components
3 2
R01371000
Fig. 4-37 Rotor space ventilation
1 Non-return valve 3 Rotor space

2 Flanged valve
Function
A pipe is connected to the flanged valve on the bottom of the propeller housing. It is
Revision: 000-v6r4
Created: 2007-6-1
routed inside the vessel to a height of 2000 mm above the waterline. A non-return val-
ve is located at the end of the pipe, which allows air to flow into the rotor space.
When the unit is switched off, water tries to flow back into the rotor space. This is pre-
vented by a non-return valve. The air is trapped in the rotor space until the unit is star-
ted again (unless leaks occur).
This prevents dirt and foreign objects from the outside from reaching the main seal.
SSNr.: 1822056851000
VGNr.: 000
4-43
4.2.5 Oil supply
On electronically controlled VSP units, the oil supply is subdivided into the control oil
circuit and the lube oil and rotor casing circuit. These oil circuits are separate from
each other and are equipped with their own pressure generating equipment, oil con-
sumers, measuring and monitoring devices.
The oil supply of the control oil circuit is part of the scope of supply of the control sys-
i tem. For a description of the design and function see chapter „Annex“
(Î Page 9-1, Chapter 9.1 „Components supplier documentation” under „Control sys-
tem“).
4.2.5.1 Pressure generation
The following form part of the pressure generating system:

• Oil tank
• Oil pumps and standby pump
• Oil filter with contamination indicator
4.2.5.1.1 Oil tank
• Control oil circuit

The entire oil quantity of the control oil circuit is contained in a tank, the pipes and
servomotors.
• Lube oil and rotor casing circuit
One third of the total VSP oil quantity is contained in the propeller housing, the rest
in the rotor as well as in the oil circuit components.
4.2.5.1.2 Oil pumps
• Control and lube oil pumps

Each oil circuit is equipped with a separate oil pump.
The control and lube oil pumps are flanged onto the input shaft bearing and are dri-
ven directly by the engine via the drive shaft and a gear reducer unit. The oil pumps
generate the pressure required in the oil circuit. The oil quantity delivered by the
pumps depends on the propeller speed.
• Standby pump
An additional standby pump is integrated into the control oil circuit. In the event of
Revision: 000-v6r4
Created: 2007-6-1
excessive pressure drops, this pump prevents control system failure.
4.2.5.1.3 Oil filter with contamination indicator
The control and the lubricating oil is cleaned respectively in a double filter before it is
returned to the oil circuit. The oil filter has two separate filter elements: one active filter
element and one standby element. Contamination of the active filter element can be
read directly from the contamination indicator (PIN) or from a display in the machine
control room. In the event of increased contamination the duplex filter must be swit-
ched to the standby element.
SSNr.: 1822056851000
VGNr.: 000
4-44
4.2.5.1.4 Control block
The control block consists of three pressure limiting valves. These valves are used to
set the pressure required for oil supply pressure circuits p1, p2 and p3.
Downstream of the control block, excessive oil from the oil pumps is routed back to
the propeller housing.
Revision: 000-v6r4
Created: 2007-6-1
SSNr.: 1822056851000
VGNr.: 000
4-45
4.2.5.2 Oil consumers
The oil supply system is subdivided into the three pressure ranges control oil pressure
p1, lube oil pressure p2 and rotor oil pressure p3.
Components
P M P
1 2 3
4
5 6 7 8 9
10
A B
G21401020
Fig. 4-38 Oil consumers
1 Pressurization p1 6 Oil pressure indicators

Revision: 000-v6r4
Created: 2007-6-1
2 Standby pump 7 Oil consumers p1

3 Pressurization p2 8 Oil consumers p2
4 Control block (lube oil) 9 Oil consumers p3
5 Control block (control oil) 10 Propeller housing
A Control oil circuit
B Lube and rotor casing oil circuit
SSNr.: 1822056851000
VGNr.: 000
4-46
4.2.5.2.1 Control oil p1
Control oil circuit p1 supplies control oil to the servomotors for longitudinal and trans-
verse pitch adjustment.
The oil supply of the control oil circuit is part of the scope of supply of the control sys-
tem. For a description of the design and function see chapter „Annex“
(Î Page 9-1, Chapter 9.1 „Components supplier documentation” under „Control sys-
tem“).
i
4.2.5.2.2 Lube oil pressure p2
Control oil circuit p2 supplies the gears, bearings and main seals with lube oil.
• Gears
– Gear reducer unit (bevel gear unit)
The control and lube oil pumps are flanged onto the input shaft bearing and are
driven directly by the engine via the drive shaft and a gear reducer unit.
– Main gear
The main gear is supplied with lube and cooling oil via a lube oil line and splash
lubrication.
Pinion bearing
The pinion bearing is supplied with lube and cooling oil via a lube oil line.
Splash lubrication
The pinion toothing is lubricated and cooled via a splash tube. The oil quantity
supplied is regulated with the help of a throttle.
• Bearings
The plain bearing (step bearing) is supplied with lube and cooling oil via a lube oil
line. The oil quantity supplied is regulated with the help of a throttle.
The oil returns via the pinion through the upper and lower bearing gap in the thrust
plate plain bearing as well as through return bores in the thrust plate.
• Main seal
The main seals are supplied with lube and cooling oil via the sight feed oilers. The oil
quantity supplied is regulated with the help of a throttle. The unused oil from the sight
feed oilers returns to the propeller housing via the return line.
– Sight feed oiler for center shaft seal of the main seal
The oil dripping into the center sealing chamber is distributed evenly around the
Revision: 000-v6r4
Created: 2007-6-1
circumference of the center shaft seal. Excess oil can drain off into the drainage
channel and collects in a container.
– Sight feed oiler for lower shaft seal of the main seal
The oil dripping into the lower sealing chamber is distributed evenly around the
circumference of the lower shaft seal. The sealing chamber is vented through an
open overflow valve. With the help of a control valve the sealing chamber can be
checked for the presence of oil or water.
• Oil cooler
The lube oil circuit contains an oil cooler with a thermostat. At oil temperatures of
44 °C or higher, the oil flows through the oil cooler to ensure a steady operating tem-
SSNr.: 1822056851000
perature.
VGNr.: 000
4-47
4.2.5.2.3 Rotor oil pressure p3
Oil pressure circuit p3 supplies the rotor casing with oil for propeller oil cooling.
The oil quantity available to cool the rotor casing is determined and reduced by the
following factors:
• Current oil pump capacity
• Oil consumption of all lubrication points (pressure circuit p2)
• Oil temperature in the propeller
• Height of the elevated oil tank above the water line (CWL)
4.2.5.2.4 Elevated oil tank
The elevated oil tank maintains the pressure required inside the rotor to provide a ba-
lance against the water pressure after propeller shutdown. A non-return valve in the
rotor supply line prevents emptying of the elevated oil tank.
The elevated oil tank consists of:

• Oil level indicator
The oil level indicator shows the oil level inside the tank.
• Float switch
The float switch closes an electrical contact when the oil level in the elevated oil tank
has sunk and the tank needs to be refilled with the hand pump.
• Ventilation
A ventilation line is routed from the elevated oil tank cover to the propeller. This line
vents the elevated oil tank chamber.
Revision: 000-v6r4
Created: 2007-6-1
SSNr.: 1822056851000
VGNr.: 000
4-48
4.2.5.3 Measuring and monitoring equipment
All important operating parameters such as temperature, oil pressure, oil level and
speed are monitored and triggered with the help of measuring and monitoring equip-
ment.

Î Page 8-1, Chapter 8 „Drawings and schematics” under „Oil supply“.
For further information regarding the measuring and monitoring equipment of the con-
i
trol system Î Page 9-1, Chapter 9.1 „Components supplier documentation” under
„Oil supply“.
4.2.5.3.1 Temperature
• Control oil tank

The control oil temperature is monitored by a temperature sensor. An alarm is dis-
played if the upper limit is exceeded.
• Lube oil tank

The lube oil temperature is monitored by a temperature sensor. An alarm is displayed
if the upper limit is exceeded.
4.2.5.3.2 Oil pressure
• Control block
The pressures prevailing in the three pressure circuits p1, p2 and p3 are controlled
by the control block.
If the upper or lower control or lube oil limit is exceeded, an alarm is triggered.
4.2.5.3.3 Oil level
• Elevated oil tank

The elevated oil tank is equipped with a float switch to monitor the oil level. An alarm
is triggered if the oil level remains below the lower limit for a prolonged period of time.
• Housing
A float switch and an oil dipstick are located in the lowest housing base.
Revision: 000-v6r4
Created: 2007-6-1
– Float switch
The float switch monitors the oil level. An alarm is triggered if the oil level remains
below the lower limit for a prolonged period of time.
– Oil dipstick
The min. and max. oil level is marked on the oil dipstick. At propeller standstill the
oil level must be between these two marks.
4.2.5.3.4 Filter contamination
• Oil filter
SSNr.: 1822056851000
The oil filter is equipped with contamination indicators to monitor filter contamination.
If the permissible filter contamination is exceeded, an alarm is displayed.
VGNr.: 000
4-49
Note
When the oil is cold (< 40°C) no alarm is displayed!
• Filling and aeration filter
The degree of contamination is checked visually. No alarm is displayed!
4.2.5.3.5 Speed
• Input shaft gear

The input shaft gear is equipped with a proximity switch to monitor speed. An alarm
is displayed if the upper or lower limit is exceeded.
4.2.5.3.6 Operation
• Start interlock
The pitch reduction linkage control shafts are monitored by zero-position switches.
Starting is possible only if both switches are in zero-position.
Note
In emergencies starting is possible via the additional „Emergency start button“.
Revision: 000-v6r4
Created: 2007-6-1
SSNr.: 1822056851000
VGNr.: 000
4-50
4.3 Drive unit
4.3.1 Shaft line
Task
All assemblies between engine and propeller that are used to transmit drive power are
part of the shaft line. It consists of:
• Coupling, propeller-sided (Renk)
• Intermediate gear (Kumra)
• Coupling, engine-sided (Centa)
Components
1 2 3 4 5
R05700080
Fig. 4-39 Shaft line
1 Propeller 4 Coupling, engine-sided (Centa)

2 Coupling, propeller-sided (Renk) 5 E-Engine (Siemens)
3 Intermediate gear (Kumera)
For details regarding the shaft line Î Page 8-1, Chapter 8 „Drawings and sche-
matics” „Shaft line“ drawing.
i
Revision: 000-v6r4
Created: 2007-6-1
SSNr.: 1822056851000
VGNr.: 000
4-51
4.4 Control system
Task
The electronic control system is used to hydraulically move the control rods of two
VSP propulsion systems.
Components
R05700030
Fig. 4-40 Control system
1 Control stand 3 Propeller

2 Control cabinet
Function
Revision: 000-v6r4
Created: 2007-6-1
The target values for transverse and longitudinal pitch of the VSP propulsion systems
are set at a control console using joysticks. In addition the speed of the propulsion en-
gines can be altered.
The remote control system is separate for each VSP propulsion system and has a re-
dundant design. In the event of a VSP main system failure, operation automatically
switches to a redundant system.
Separate control of both propellers is required for certain maneuvers such as traver-
sing (Î Page 6-11, Chapter 6.1.6 „Examples for maneuvering”).
SSNr.: 1822056851000
VGNr.: 000
4-52
For a description of the design and function of the electronic control system see chap-
ter „Annex“Î Page 9-1, Chapter 9.1 „Components supplier documentation” under
„Control system“). i
4.4.1 Control stand unit
Components
1 2
3
7 6 5
005770020
Fig. 4-41 Control stand unit
1 „Extended controls“ area 5 Joystick

2 „Standard controls“ area 6 Control console 2
3 „Transverse pitch“ indication 7 Control console 1
4 „Longitudinal pitch“ indication 8 „Propulsion“ control area
Pos. Designation
1 „Extended controls“ area

This control area allows important subfunctions to be activated and dis-
played. These functions include autopilot, standby pump, main and redun-
dant control system.
2 „Standard controls“ area

This control area allows the main basic functions to be activated and dis-
played. These functions include the display of alarms and readiness for
operation as well as activating control stand switching.
Revision: 000-v6r4
Created: 2007-6-1
3 „Transverse pitch“ indication

This indication provides information on the transverse component thrust
setting.
4 „Longitudinal pitch“ indication

This indication provides information on the longitudinal component thrust

setting.
5 Joystick
The joystick is used to control direction of motion as well as magnitude of
thrust.
SSNr.: 1822056851000
6 Control console 2
VGNr.: 000
4-53
Pos. Designation
7 Control console 1
8 „Propulsion“ control area

This area provides information on the current propulsion plant status.
Tab. 4-1 Components
For further information regarding the control stand components
i Î Page 9-1, Chapter 9.1 „Components supplier documentation” under „Control sys-
tem“.
Revision: 000-v6r4
Created: 2007-6-1
SSNr.: 1822056851000
VGNr.: 000
4-54
4.5 Accessories
4.5.1 Tools
The standard tools for the VSP are stored in a lockable metal toolbox.
Large special tools may be supplied in a separate transport box.
A list of all tools supplied is located on the inside of the tool box cover.
4.5.2 Spare parts
Spare and wear parts for the unit are in stock at Voith Turbo Marine, so that very short
delivery times can usually be guaranteed.
For further information regarding spare parts Î Page 7-84, Chapter 7.15 „Spare
parts”
i
4.5.3 Coating
Due to the operation of the VSP in seawater, optimum corrosion protection of the pro-
peller components is of the utmost importance.
Special paint coatings are therefore applied to the different areas exposed to corrosi-
on.
The coating should be checked regularly and repaired or renewed according to the
specification.
For further information regarding coating renewal Î Page 9-4, Chapter 9.2 „Stan-
dards” „VN1619 - Voith Turbo Marine Coatings“ standard.l
i
Revision: 000-v6r4
Created: 2007-6-1
SSNr.: 1822056851000
VGNr.: 000
4-55
4-56
Description

Voith Turbo Schneider Propulsion | Operation Manual | VSP BOSPORUS 18R5 EC/150-1 Installation
5 Installation
The chapter „Installation“ contains information on the installation of the unit.
5.1 General safety instructions concerning installation

Observe all safety instructions and protective measures described in chapter 2 as well
as all applicable legal requirements!
Installation work may only be carried out by trained and qualified personnel.
i
Revision: 000-v6r4
Created: 2007-6-1
SSNr.: 1822056851000
VGNr.: 000
5-1
5-2
Installation

Voith Turbo Schneider Propulsion | Operation Manual | VSP BOSPORUS 18R5 EC/150-1 Operation
6 Operation
The chapter „Operation“ describes all actions required for normal operation of
the unit.
6.1 Start-up
Initial start-up of the unit is carried out by technical personnel of the Voith Turbo
Schneider Propulsion GmbH & Co. KG and is based on a schedule contained in the
"Instructions for installation and start-up".
This procedure must be repeated following major overhaul of the propeller.
Danger
Danger to personnel and machinery!
Before carrying out start-up operations, maintenance or re-

pair work for the first time, operating personnel must have
read the operation manuals.
1. Read the Voith operation manual, in particular the chap-

ter on safety.
2. Read the operation manuals provided by the suppliers.
3. Arrange for specialists to provide training and instruc-
tion
6.1.1 Prior to start-up
• Checking the oil level in the propeller

Check the oil level in the propeller housing prior to starting.
Note
Whenever possible, carry out check at the same trim, transverse inclination, elevated
oil tank level and oil temperature to facilitate timely detection of any changes.
• Taking oil samples
Take an oil sample following prolonged out-of-service periods to detect ageing and
Revision: 000-v6r4
Created: 2007-6-1
water content (Î Page 7-52, Chapter 7.11.4.1 „Checking oil quality”).

• Checking the main seal for leaks
Check seepage in the line to the bilge (Î Page 7-30, Chapter 7.6 „Main bearing with
main seal”).
• Checking control system functions

Following prolonged out-of-service periods or adjustments during repair work, the

control system must be checked for correct functioning.
– Checking control system functions
Î Page 6-4, Chapter 6.1.2.5 „Checking control system functions”
– Fault display
SSNr.: 1822056851000
Î Page 9-1, Chapter 9.1 „Components supplier documentation” under "Control

system"
VGNr.: 000
6-1
Operation Voith Turbo Schneider Propulsion | Operation Manual | VSP BOSPORUS 18R5 EC/150-1
6.1.2 Starting the unit
6.1.2.1 Power supply
Action
Ö Switch on power supply systems (24 V and 230 V).
6.1.2.2 Initializing the control system
Precondition
1. "System selection" switch is set to position "1" (main system and redundant system
are active).
Action
2. Switch on operating voltage.
3. Position joystick in Neutral.
Result
The control system outputs a slow signal sequence via the command transfer button
lamp and the buzzer.
4. Press command transfer button 1×.
Result
If joystick is in Neutral, a fast signal sequence is output. If not, the output signal se-
quence is slow.
5. Press command transfer button 1× within 10 seconds. After this time, step 3 is initi-
ated.
Result
Control system initializing is complete, the command transfer button lights up conti-
nuously, the buzzer does not sound.
6.1.2.3 Starting the drive unit
Precondition
The Control system has been initialized (Î Page 6-2, Chapter 6.1.2.2 „Initializing the
control system”).
Ö Switch on drive unit.

Revision: 000-v6r4
Created: 2007-6-1
Result
The drive unit is ready for operation.
SSNr.: 1822056851000
VGNr.: 000
6-2
6.1.2.4 Couplings and readiness for operation
Precondition
Drive unit has been started.
Action
1. Position joystick at Neutral.
Result
If the VSP drive is at Neutral and no coupling is activated, the "Engine 1 Coupling"
and "Engine 2 Coupling" lamps are flashing. Otherwise the lamps are off and the
"Ready for operation" lamp flashes.
2. Press the "Engine 1 Coupling" and/or "Engine 2 Coupling" button.
Result
An active coupling is indicated by continuous illumination of the "Engine 1 Coupling"
and/or "Engine 2 Coupling" lamp(s).
Note
If only one coupling is activated, the second lamp is switched off.
If one coupling is already active, the second can be activated during operation.
Result
If the control system and the VSP drive are ready for operation, the "Ready for opera-
tion" lamp is illuminated continuously. The propeller now generates thrust.
Revision: 000-v6r4
Created: 2007-6-1
SSNr.: 1822056851000
VGNr.: 000
6-3
6.1.2.5 Checking control system functions
Danger
Malfunctions in the control system result in the inability to

maneuver the vessel. Correct functioning of the control sys-
tem must be guaranteed.
Ö Before each start-up, check the control system for cor-

rect functioning and initiate troubleshooting as applica-
ble.
Precondition
• Drive unit has been started
• Main system is active
Action
1. Move the joystick from Neutral to Straight ahead and, when observing thrust gene-
ration, back to Neutral.
Note
If no thrust is generated, locate the error and fix it. The vessel is neither maneuverab-
le nor ready for operation in this condition!
2. Repeat step 1 for Astern, Starbord and Port.
3. Switch to the redundant system.
4. Repeat steps 1 and 2.
5. Switch to the main system.
Revision: 000-v6r4
Created: 2007-6-1
SSNr.: 1822056851000
VGNr.: 000
6-4
6.1.2.6 Speed setting
Caution!
Machine damage resulting from insufficient oil pressure!
The oil pump capacity is speed-dependent.
1. Ensure idle speed of at least 40% of the rated speed.

2. Avoid operation at propeller speeds of less than 60% of the rated speed.
Caution!
Control system malfunction!
During operation at insufficient oil temperatures, control time delays can occur which
may lead to the control system reaction being severely impaired, thereby putting the
vessel at risk.
Ö Operate propeller at "Zero" pitch (neutral position) until the required minimum tem-
perature of +10 °C has been reached.
Action
1. Set propeller idle speed to 40% of the rated speed.
2. When idle speed is reached, check control oil pressure p1 and lube oil pressure p2
followed by the oil temperature.
Result
The following operating values must be obtained:
• Control oil pressure p1: 100 -5/+15 bar
• Lube oil pressure p2: 2 +1/-0.5 bar
• Oil temperature: > +60 °C
3. Check main seals.

Revision: 000-v6r4
Created: 2007-6-1
Result
The unit is ready for operation.
SSNr.: 1822056851000
VGNr.: 000
6-5
6.1.3 Starting from rest
Caution!
Machine damage resulting from engine overload!
1. Avoid excessive output power and overload.

2. Carry out control processes slowly.
Action
1. Set idle speed to at least 60% of the rated speed.
2. Slowly increase longitudinal and/or transverse pitch as desired.
3. For course alterations while going straight ahead move handwheel slowly and with
small changes. This prevents vibrations and course deviations.
6.1.4 Running
Danger
Uncontrolled vessel movement!
The vessel must only be maneuvered by specially trained

operators that are familiar with the propulsion system.
In particular the propeller function and its connection with
the vessel as well as the control system must be fully un-
derstood.
1. Ensure that the function of the propeller as well as its ef-

fects on the ship are understood.
2. Ensure that several days of training have been given for
VSP vessels.
3. Practise running in emergency mode (running with one
drive unit).
Revision: 000-v6r4
Created: 2007-6-1
For further information
i See leaflet "Operation instructions for Voith Water Tractor No. 3021".
SSNr.: 1822056851000
VGNr.: 000
6-6
6.1.4.1 Longitudinal and transverse pitch
When towing, maximum propeller thrust is already reached when the pitch is set to
80% of the rated speed.
6.1.4.1.1 Extreme longitudinal pitch
Caution!
Machine damage resulting from engine overload!
Extreme changes in longitudinal pitch result in a severe strain on the drive unit.
Ö Avoid extreme changes in longitudinal pitch!
Voith Turbo Schneider Propulsion GmbH & Co. KG does not accept any liability for
damage resulting from extreme pitch settings.
i
6.1.4.1.2 Extreme transverse pitch
Danger
Risk of capsizing!
Extreme changes in transverse pitch at full longitudinal

pitch result in heeling.
Ö Avoid extreme changes in transverse pitch!
Extreme increases in transverse pitch automatically result in a reduction of longitudi-

nal pitch without the levers being actuated.
At maximum transverse pitch longitudinal thrust is not possible.

i
Revision: 000-v6r4
Created: 2007-6-1
SSNr.: 1822056851000
VGNr.: 000
6-7
6.1.4.2 Running with one propeller / running in emergency situations
Switch off the diesel engine in the event of damage to the engine, shaft line or propel-
ler unit. Run the vessel using the other propeller.
This results in reduced vessel performance. Maneuverability and speed are signifi-
cantly reduced.
If vessel operation continues with both propellers, there is a risk of consequential da-
mage and complete failure of the damaged component. Only the vessel operator can
take this decision based on the situation.
6.1.4.3 Having vessel towed
Action
Caution!
Propeller damage!
The rotor can move by the backlash and damage the gear tooth flanks.
Ö Only have vessel towed in calm sea and over short distances.
1. Mechanically block propeller against turning.

2. Set propeller pitch to zero.
Revision: 000-v6r4
Created: 2007-6-1
SSNr.: 1822056851000
VGNr.: 000
6-8
6.1.5 Alarm
6.1.5.1 Propeller
Precondition
All supplied electrical sensors are connected to the visual or acoustic alarms on the
bridge or in the machine control room. Alarms are part of the scope of supply of the
shipyard.
i
6.1.5.1.1 Oil pressure and oil filter
System Component Specification Limit value Action
Oil pressure Control oil Main pump < 70 bar Increase

pressure p1 100 -5/+15 speed
(sensor D11) Standby pump
> 120 bar Reduce speed
90 ±5
Lube oil pres- 2 +1/-0.5 bar < 0.5 bar Increase

sure p2 speed
(sensor D21)
Oil filters Duplex filter Contamina- Contamina- Change filter

control oil tion < 100% tion 100%
(sensor D41)
Duplex filter
lube oil
(sensors D51
and D52)
Tab. 6-2 Oil pressure and oil filter
6.1.5.1.3 Levels
Oil level Elevated oil > lower < lower Add oil
tank measuring measuring
Revision: 000-v6r4
Created: 2007-6-1
(sensor L21) level level
Control oil
tank
(sensor L11)
Lube oil tank

(sensor L22)
Tab. 6-4 Levels
SSNr.: 1822056851000
VGNr.: 000
6-9
6.1.5.1.5 Guard circuits
Propeller Longitudinal = Zero position – Set longitudinal

start and transverse (prior to star- and transverse
enable pitch ting the pro- pitch to zero
(sensor K13) peller)
Overload Propeller No Overload Reduce longitu-

protection overload dinal or trans-
verse pitch
Tab. 6-6 Guard circuit
6.1.5.1.7 Temperature
Oil tempera- Control oil < 75 °C > 75 °C Reduce

ture (sensor T11) speed
Lube oil
(sensor T21)
Tab. 6-8 Temperature
6.1.5.2 Control system
Central fault evaluation for the control system is integrated in the system processor of
the Bosch-Rexroth VBR-D control system. Alarms are indicated on a display.
For further information regarding the VBR-D alarms Î Page 9-1, Chapter 9.1 „Com-
i ponents supplier documentation” under "Control system".
Revision: 000-v6r4
Created: 2007-6-1
SSNr.: 1822056851000
VGNr.: 000
6-10
6.1.6 Examples for maneuvering
The following examples for maneuvering apply to a double-ended ferry with two pro-
pellers installed at the bow and stern.
Each propeller is controlled via a control console (A). The magnitude of thrust and the
direction (B) of the respective propeller are set via the corresponding joystick.
6.1.6.1 Moving straight ahead
A B C
015701000
Fig. 6-1 Moving straight ahead
With the joystick in the indicated position (A), the vessel moves straight ahead (C).
The direction of thrust (B) is in direction of motion straight ahead.
6.1.6.2 Moving astern
A B C
1
Revision: 000-v6r4
Created: 2007-6-1
2
015701010
Fig. 6-2 Moving astern
With the joystick in the indicated position (A), the vessel moves astern (C). The direc-
tion of thrust (B) is in direction of motion astern.
SSNr.: 1822056851000
VGNr.: 000
6-11
6.1.6.3 Turning to starboard while moving ahead
A B C
015701020
Fig. 6-3 Turning to starboard while moving ahead
With the joystick in the indicated position (A), the vessel turns to starboard while mo-
ving ahead (C). The direction of thrust (B) is in direction of motion port ahead.
6.1.6.4 Turning to starboard while moving astern
A B C
2
3
015701030
Fig. 6-4 Turning to starboard while moving astern
Revision: 000-v6r4
Created: 2007-6-1
With the joystick in the indicated position (A), the vessel turns to starboard while mo-
ving astern (C). The direction of thrust (B) is in direction of motion port astern.
SSNr.: 1822056851000
VGNr.: 000
6-12
6.1.6.5 Turning to port while moving ahead
A B C
015701040
Fig. 6-5 Turning to port while moving ahead
With the joystick in the indicated position (A), the vessel turns to port while moving
ahead (C). The direction of thrust (B) is in direction of motion starboard ahead.
6.1.6.6 Turning to port while moving astern
A B C
2
3
015701050
Fig. 6-6 Turning to port while moving astern
Revision: 000-v6r4
Created: 2007-6-1
With the joystick in the indicated position (A), the vessel turns to port while moving as-
tern (C). The direction of thrust (B) is in direction of motion starboard astern.
SSNr.: 1822056851000
VGNr.: 000
6-13
6.1.6.7 Traversing to starboard
A B C
1 2
015701060
Fig. 6-7 Traversing to starboard
With the joystick in the indicated position (A), the vessel traverses to starboard C). The
direction of thrust (B) of both propellers is to starboard.
6.1.6.8 Traversing to port
A B C
2 1
015701070
Fig. 6-8 Traversing to port
Revision: 000-v6r4
Created: 2007-6-1
With the joystick in the indicated position (A), the vessel traverses to port C). The di-
rection of thrust (B) of both propellers is to port.
SSNr.: 1822056851000
VGNr.: 000
6-14
6.1.7 Stopping
6.1.7.1 Normal stopping
Action
1. Set pitch to 40% astern.
2. At mean speed reduce pitch to 60% astern.
6.1.7.2 Emergency stopping
Action
Caution!
Propeller damage!
Immediate pitch reduction by 80% or more does not result in shorter stopping times
but causes extreme drive unit overload.
This setting is not permissible!
Non-compliance results in significant wear which can lead to propeller failure. No lia-
bility is accepted for damage caused by such extreme pitch alterations!
Ö Extreme pitch alterations must be avoided!
1. Immediately reduce pitch to 60% astern.

2. At mean speed reduce pitch to 80% astern.
Revision: 000-v6r4
Created: 2007-6-1
SSNr.: 1822056851000
VGNr.: 000
6-15
6.2 Decommissioning of the propeller
6.2.1 Berthing vessel and shutting down propeller
Action
1. Bring vessel to the berth and moor.
2. Position joystick in neutral position.
3. Switch off drive unit.
4. Switch off operating voltage.
6.2.2 Measures after propeller shutdown
6.2.2.1 After propeller shutdown
Action
Ö No special checks or maintenance work required
6.2.2.2 When the propeller is switched off for prolonged periods
Action
1. Check main seals for leaks immediately after switching off the propeller
(Î Page 7-30, Chapter 7.6 „Main bearing with main seal”)
2. Carry out regular checks as stated in the table below:
Interval Check
Daily Oil level in elevated oil tank

(Î Page 7-72, Chapter 7.11.9.3 „Checking oil level”)
Weekly Mounting covers for leaks

Î Page 7-42, Chapter 7.10.1 „Checking mounting cover for
leaks”
Main seals for leaks

Î Page 7-30, Chapter 7.6 „Main bearing with main seal”
Oil level in propeller housing

Î Page 7-58, Chapter 7.11.7 „Oil level”
Revision: 000-v6r4
Created: 2007-6-1
Checking oil quality

Î Page 7-52, Chapter 7.11.4 „Oil quality”
Tab. 6-1 Intervals for checking
SSNr.: 1822056851000
VGNr.: 000
6-16
6.3 Faults
The monitoring system provides the operator with information on important control
points. The data is collected with the help of electric sensors and transmitted to the
machine control room or the onboard monitoring system.
The following design assemblies are monitored:

• Leakages
Î Page 6-18, Chapter 6.3.1 „Leakages”
• Propeller and drive unit
Î Page 6-21, Chapter 6.3.2 „Propeller and drive unit”
• Control system
Î Page 6-24, Chapter 6.3.3 „Control system”
The "Monitoring system" drawing (Î Page 8-1, Chapter 8 „Drawings and sche-
matics”) shows the control elements that are factory-fitted with electrical transmitters.
i
Revision: 000-v6r4
Created: 2007-6-1
SSNr.: 1822056851000
VGNr.: 000
6-17
6.3.1 Leakages
Fault Possible cause Immediate action Remedial action
Loss of lube oil in propel- Oil leakage outboard Emergency operation! Dock in vessel
ler housing (measured at a sealing point or Immediately switch off
with oil dipstick) as a result of rotor or propeller and continue Determine cause and rec-
Check useful only at nor- propeller housing operation with the tify leak
mal trim and standstill! leak second propeller
Check-tighten all screw
Screw joint loose Caution! joints
Maneuverability signifi-
cantly reduced Caution!
If these instructions are not
followed, oil can continue to
leak into the water
Danger!
Loose screw joints can lead
to rotor loss
Loss of control oil in hou- Oil leakage towards Emergency operation! Determine cause and rec-
sing foot (measured with the inside of the pro- Immediately switch off tify leak
oil stick or level switch) peller housing as a propeller and continue
Check useful only at nor- result of pipe or operation with the Check-tighten all screw
mal trim and standstill! hydraulic hose leak. second propeller joints
Caution! Caution!
Maneuverability signifi- Lube oil will be impurified
cantly reduced by control oil
Danger!
If these instructions are not
followed, the control can be
failed!
Revision: 000-v6r4
Created: 2007-6-1
SSNr.: 1822056851000
VGNr.: 000
6-18
Significant amount of Leak at a sealing Emergency operation! Dock in vessel

water in the propeller oil. point Switch off propeller and Determine cause and rec-
continue operation with tify leak
Indication: Leak on rotor, propel- the second propeller
Oil level in propeller hou- ler housing or loose
sing rises. screw joint allowing Tightly close all ope-
the oil level in the nings to the propeller oil
propeller housing to chamber to prevent water
rise significantly from entering the vessel
interior
Danger!
Noncompliance with
these instructions puts
the vessel and crew at
risk!
Small amount of water in Minor leakage at a No limitations Dock in vessel

the propeller oil sealing point
Leave water to evaporate Determine cause and rec-
Indication: Leak on rotor, propel- by removing the propeller tify leak
Indicator plate shows con- ler housing or oil coo- covers
densation ler Separate oil.
Amount of water at the Lower shaft seal of Close control valve and Schedule docking
lower control valve or the the main seal leaking overflow valve
upper overflow valve of
the main seal exceeds The center shaft seal
specification still seals against
water ingress
Amount of water at drai- Lower and center Immediately dock in ves- Repair lower and center
nage channel exceeds shaft seal of the main sel shaft seal of the main seal
specification seal leaking
Revision: 000-v6r4
Created: 2007-6-1
SSNr.: 1822056851000
VGNr.: 000
6-19
Amount of oil at the cont- Sight feed oiler for – Reset sight feed oiler for
rol cock of the main seal lower shaft seal gives lower shaft seal
(bottom) exceeds specifi- off too much oil
cation
Amount of oil at drainage Sight feed oiler for Reset sight feed oiler for
channel exceeds specifi- center shaft seal center shaft seal.
cation gives off too much oil
Upper shaft seal to Collect oil at drainage

main seal leaking channel and return to pro-
peller housing if free of con-
taminants.
Dock in vessel at the next

opportunity and renew
main seal.
Traces of oil in the water Oil leak at a sealing Emergency operation! Dock in vessel
outboard point Reduce propeller speed
Leak at rotor, propel- Determine cause and rec-
ler housing or at a Switch off unit and conti- tify leak
loose screw joint nue operation with the
second propeller
Caution!
cantly reduced
Traces of oil in the water Rotor space ventila- Open flanged valve for Flanged valve must always
outboard tion closed rotor space ventilation remain open during opera-
tion
Repeat oil loss in elevated Oil loss in propeller Add missing oil quantity Determine cause and rec-
oil tank following shut- caused by leaking to elevated oil tank using tify
down of the unit elevated oil seal, the hand pump
Revision: 000-v6r4
Created: 2007-6-1
control rod or
non-return valve
Tab. 6-1 Propeller

SSNr.: 1822056851000
VGNr.: 000
6-20
6.3.2 Propeller and drive unit
Propeller noise or vibra- Rough running of the Emergency operation! Repair engine as per
tion drive engine Reduce speed until pro- manufacturer's instructions
peller runs evenly
Misfiring
Caution!
Valve damage Maneuverability signifi-
cantly reduced
Governor damage
Propeller damage Emergency operation! Localize noise

Reduce speed, switch off
propeller and continue Determine cause
operation with the
second propeller Switch off propeller and
rectify damage.
Caution!
cantly reduced
Control rod turns with pro- Blade bearing blo- Emergency operation! Dock in vessel
peller cked Switch off propeller and
continue operation with
the second propeller
Caution!
cantly reduced.
Control rod turns with pro- Blade blocked by a Emergency operation! Switch off propeller
peller hawser Switch off propeller and
continue operation with Have foreign object remo-
the second propeller ved by a diver
Blade actuating Have blade zero position

Revision: 000-v6r4
Created: 2007-6-1
Caution!
mechanism seized or checked by a diver
deformed
cantly reduced
Dock in vessel and repair
blade actuating mechanism
SSNr.: 1822056851000
VGNr.: 000
6-21
Temperature in propeller Sea water tempera- Reduce propeller output Adapt oil type to climate
too high ture too high zone
Coolant flow through – Clean oil cooler

oil cooler restricted
Cooler contaminated
Oil level in propeller Add oil Determine cause of oil loss

too low and repair leak
Oil supply to bearing Emergency operation! Determine cause and clear

points insufficient Switch off propeller and oil line
continue operation with
Line blocked. the second propeller
Caution!
cantly reduced
Rotor oil supply p3 Increase propeller speed Check rotor oil supply at
(internal cooling) too operating speed and rec-
low tify fault
Operating pressures – Reset operating pressures

p1 and p2 set too at operating speed
high
Temperature of control oil Thermostat to switch – Adjust Thermostat

too high oil or air cooler set
too high
Oil cooler of control Reduce propeller speed Check cabling and connec-
oil is not connected tion
Oil level in oil tank of Add oil Determine cause of oil loss
Revision: 000-v6r4
Created: 2007-6-1
control oil too low and rectify leakage
Oil pressure too high Pressure limiting Reduce propeller speed Reset operating pressure
valve in control block and observe operating p1 or p2 on control block
set too high or defec- pressures.
tive Replace valve if defective
Oil flow to a consu- Reduce propeller speed Check oil flow to consu-
mer restricted and actuate control. mers and rectify fault.
Observe operating pres-
Oil supply line blo- sures.
SSNr.: 1822056851000
cked
VGNr.: 000
6-22
Oil pressure too low Frequent control Increase propeller speed –

actuation at low pro- and observe oil pressu-
peller speeds res.
Pressure limiting Emergency operation! Remove pressure limiting

valve in control block Switch off propeller and valve p1 or p2 from control
defective continue operation with block and repair.
the second propeller
Caution!
cantly reduced
Pump capacity redu- Set pressure limiting Switch off propeller and
ced at operating valve p1 or p2 to a higher replace pump
speed value
Caution!
Propeller operation with
insufficient oil pressure
p1 can result in diver-
gences from the desired
thrust and control delays
Differential pressure in Duplex filter contami- Switch duplex filter to Immediately replace conta-
duplex filter too high nated second filter unit minated filters
Tab. 6-1 Drive unit

Revision: 000-v6r4
Created: 2007-6-1
SSNr.: 1822056851000
VGNr.: 000
6-23
6.3.3 Control system
For information regarding malfunctions of the control system
i Î Page 9-3, Chapter 9.1.4 „Control system” under "Control system".
Revision: 000-v6r4
Created: 2007-6-1
SSNr.: 1822056851000
VGNr.: 000
6-24
Voith Turbo Schneider Propulsion | Operation Manual | VSP BOSPORUS 18R5 EC/150-1 Maintenance
7 Maintenance
Chapter 7, „Maintenance“, summarizes all maintenance and inspection works
that can be carried out by personnel specially trained to work on the unit. It con-
tains information on how to prolong the service life of the unit.
7.1 General safety instructions concerning maintenance

Observe all safety instructions and protective measures described in chapter 2 as well
as all applicable legal requirements!
Inspection and maintenance work must only be carried out by specially trained per-
sonnel.
Personnel requirements
• On-board maintenance and inspection
Crew members trained to work on the unit
• Inspection in dock
Shipyard personnel specially trained to work on the unit or crew members
• Repair
Voith personnel or personnel of customer specially trained to work on the unit
• Major overhaul
Specially trained Voith personnel
Questions regarding maintenance

Should you have any questions regarding maintenance, please do not hesitate to con-
tact our customer service or, out of office hours, the emergency service. i
Customer service
Phone: +49 (0) 73 21 - 37 65 54
Emergency service
Phone: +49 (0) 1 73 - 3 29 01 95
Revision: 000-v6r4
Created: 2007-6-1
SSNr.: 1822056851000
VGNr.: 000
7-1
Maintenance Voith Turbo Schneider Propulsion | Operation Manual | VSP BOSPORUS 18R5 EC/150-1
7.2 Maintenance and inspection

With the help of maintenance work and inspections, the unit is kept in a safe and ope-
rational condition.
Maintenance work
Maintenance work comprises: lubricating, cleaning, checking, adjusting, setting,
measuring, recording, evaluating and decision-taking.
Inspections
Inspections are checks to determine the current status.
Inspections can be carried out under the following operating conditions without the
need to disassemble the unit:
• from the inside with the vessel afloat
• from the outside during docking
Following each inspection, the current status must be compared with:

• those of earlier inspections to determine divergences
• the target status to facilitate decisions regarding necessary repair work
If the findings show that the wear or corrosion limits have been exceeded, the unit
i must be disassembled and repaired as required.
7.2.1 Maintenance and inspection intervals
The intervals for all maintenance work and inspections described both here and in the
detailed descriptions are guidelines only. Variations may be possible depending on
application and environmental conditions.
7.2.1.1 With the vessel afloat
Inspection work can be carried out either with the propeller running or at standstill. The
maintenance and inspection intervals are stated in the maintenance and inspection
schedule (Î Page 7-6, Chapter 7.2.6 „Maintenance and inspection plan”).
Revision: 000-v6r4
Created: 2007-6-1
Standstill is a short out-of-service period of the unit during daily operation.
i
SSNr.: 1822056851000
VGNr.: 000
7-2
7.2.1.2 During prolonged lay periods in the water
Caution!
Machine damage during prolonged lay periods in the water!
During prolonged lay periods in the water without propeller operation, there is a risk
of the main bearing setting due to oil gumming.
Contamination can lead to increased corrosion and marine fouling. Under these cir-
cumstances, starting-up the propellers may require an increased break-away force.
Ö Operate propeller once every two weeks for approx. 15 minutes.
7.2.1.3 During routine docking
The intervals between routine dockings are determined by the operator of the unit and
the vessel classification societies and are dependent on the vessel operating conditi-
ons.
During routine docking all inspections must be carried out that are impossible with the
vessel afloat.
To remove the propeller blades in dock, the minimum vessel docking height must be
such as to allow a clearance equal to the blade shaft length!
i
7.2.1.4 Following irregularities
After specific events such as ground contact, the unit must be checked carefully be-
fore operation is resumed. The check must include all inspection and maintenance
work that can be carried out under the current operating conditions. The propeller
must be turned (Î Page 7-20, Chapter 7.2.12 „Turning the propeller without propul-
sion engine”) prior to putting the unit back into operation.
Revision: 000-v6r4
Created: 2007-6-1
SSNr.: 1822056851000
VGNr.: 000
7-3
7.2.2 Inspection protocols
Regular documentation of the inspection results provides valuable information for
i maintenance and inspection work on the unit!
The recorded values facilitate the evaluation of the current unit status and provide a
helpful overview in the event of irregularities or faults.
Regularly record the following measured values:

• Blade end play
• Control divergence
• Control oil and lube oil losses
• Backlash and contact pattern of the main gear teeth
• Torsional blade clearance and zero-position at the blade actuating mechanism
• Time of filter change
7.2.3 Repair works
Repair work must be carried out by specially trained shipyard or Voith personnel. Prior
to commencing this type of work, the oil must be drained or extracted from the propel-
ler housing and rotor casing.
Danger
Prior to commencing any work, make sure that the propel-

ler cannot be started.
1. Tow vessel into quiet waters protected from outside in-

fluences.
2. Secure vessel against seaway and currents.
3. Ensure that the propeller cannot be switched on acci-
dentally (locking device).
Danger
Revision: 000-v6r4
Created: 2007-6-1
The lifting eyes and lifting threads of the various compon-

ents are dimensioned as per international standards and

strength classifications. They must only be used for the

component itself.
Ö Use suitable and sufficient lifting equipment.

SSNr.: 1822056851000
VGNr.: 000
7-4
7.2.4 Major overhaul
Major overhaul of the VSP must be carried out every 30,000 – 50,000 hrs by specially
trained Voith personnel. This value is a guideline only and is based on experience.
The timing of the major overhaul mainly depends on the operating conditions. The in-
terval can be longer or shorter.
To prevent damage with more severe consequences, the VSP condition must be eva-
luated based on a condition protocol.
During major overhaul the unit is disassembled and checked. Any defective or worn
parts are replaced.
The condition protocol can be requested from the Voith Turbo Schneider Propulsion
GmbH & Co. KG service department.
i
Revision: 000-v6r4
Created: 2007-6-1
SSNr.: 1822056851000
VGNr.: 000
7-5
7.2.5 Drawings and illustrations
The illustrations and photos of work steps integrated into the text have been simplified.
Binding illustrations Î Page 8-1, Chapter 8 „Drawings and schematics”.
i
7.2.6 Maintenance and inspection plan
The maintenance and inspection schedule is subdivided into three groups in line with
the personnel requirements:
• Specially trained crew members
Î Page 7-6, Chapter 7.2.6.1 „Specially trained crew members”
• Specially trained personnel of the customer
Î Page 7-8, Chapter 7.2.6.2 „Specially trained personnel of the customer”
• Specially trained shipyard personnel
Î Page 7-11, Chapter 7.2.6.3 „Specially trained shipyard personnel”
The relevant maintenance and inspection tasks must only be carried out by the per-
i sonnel stated for the relevant group!
7.2.6.1 Specially trained crew members
Daily Weekly Monthly Every 6

months
Main seal • • • •
Check for leaks
(Î Page 7-30, Chapter 7.6.1 „Checking for
leaks”)
Mounting cover • • •
Check for leaks
(Î Page 7-42, Chapter 7.10.1 „Checking
mounting cover for leaks”)
Oil temperature ∗ ∗ ∗ ∗
Revision: 000-v6r4
Created: 2007-6-1
Check temperature
(Î Page 7-56, Chapter 7.11.6 „Oil tempera-
ture”)
Oil level • • •
Check oil levels

(Î Page 7-58, Chapter 7.11.7.1 „Checking
oil level”)
Oil filter ∗• • • •
Check filters
SSNr.: 1822056851000
(Î Page 7-60, Chapter 7.11.8 „Oil filters”)

VGNr.: 000
7-6
Daily Weekly Monthly Every 6

months
Oil pressure ∗ ∗ ∗ ∗
Check pressures p1, p2 and p3
oil pressure”)
Elevated oil tank • • • •

Check oil level
oil level”)
Sight feed oiler ∗ ∗ ∗

Check sight feed oilers
and setting sight feed oilers to main seal”)
Oil quality • •
Check quality
oil quality”)
Input shaft bearing • • • •

Check input gear
(Î Page 7-40, Chapter 7.8 „Input shaft bea-
ring”)
Tab. 7-1 Maintenance and inspection schedule for specially trained crew members
• Maintenance and inspection with propeller at standstill

* Maintenance and inspection with propeller running
Revision: 000-v6r4
Created: 2007-6-1
SSNr.: 1822056851000
VGNr.: 000
7-7
7.2.6.2 Specially trained personnel of the customer
After After During rou- During pro-

approx. approx. tine docking longed lay
5000 hrs 10000 hrs periods in
the water
Screw joints • • •
Check
(Î Page 7-15, Chapter 7.2.9 „Screw joints –
General”)
Blade bearing •
Check for leaks
leaks”)
Blades •
Check condition
blade condition”)
Blades •
Check end play
blade end play”)
Rotor casing •
Check coating as well as anodes and check
for leaks
(Î Page 7-28, Chapter 7.5.1 „Checking rotor
casing”)
Main seal • • • •
Check for leaks
(Î Page 7-30, Chapter 7.6 „Main bearing
with main seal”)
Main gear • • •
Revision: 000-v6r4
Created: 2007-6-1
Check toothing
toothing”)

Check input shaft bearing

ring”)
SSNr.: 1822056851000
VGNr.: 000
7-8

the water
Mounting cover • • • •
Check for leaks
Permanent magnet filter rods • • •

Check
permanent magnet filter rods”)
Aeration filter ∗• ∗• •
Check filter
aeration filter”)
Rotor space ventilation ∗• ∗• • •

Check function
rotor space ventilation for function”)
Oil temperature ∗ ∗ ∗
Check temperature
ture”)
Oil level • • • •
Check oil level
(Î Page 7-58, Chapter 7.11.7 „Oil level”)
Oil filter ∗• ∗• ∗•
Check filters
Oil pressure ∗ ∗ ∗
Revision: 000-v6r4
Created: 2007-6-1

oil pressure”)
Elevated oil tank • • • •

Check oil level

oil level”)
SSNr.: 1822056851000
VGNr.: 000
7-9

the water
Sight feed oiler ∗ ∗ ∗

Oil quality • • • •
Check quality
oil quality”)
Main pump ∗ ∗ ∗
Check
(Î Page 7-79, Chapter 7.11.12 „Checking oil
pumps”)
Tools ∗
Check tool kit for completeness
tools”)
Spare parts ∗
Renew corrosion protection
(Î Page 7-84, Chapter 7.15.1 „Renewing
corrosion protection”)
Coating ∗
Check
coating”)
Tab. 7-1 Maintenance and inspection schedule for specially trained personnel of customer

∗ Maintenance and inspection with propeller running
Revision: 000-v6r4
Created: 2007-6-1
SSNr.: 1822056851000
VGNr.: 000
7-10
7.2.6.3 Specially trained shipyard personnel
Prior to eve- After every During run- Major

ry undo- undocking ning-in af- overhaul af-
cking ter 100 hrs ter 30,000 to
and 500 hrs 50,000 hrs
by Voith
Screw joints • • •
Check
(Î Page 7-15, Chapter 7.2.9 „Screw joints –
General”)
Blade actuating mechanism • •

Check
(Î Page 7-22, Chapter 7.3.1 „Checking the
blade actuating mechanism”)
Blade bearing • •
Check for leaks
leaks”)
Blades • •
Check condition
blade condition”)
Blades • •
Check end play
blade end play”)
Rotor casing • •
Check coating as well as anodes and check
for leaks
(Î Page 7-28, Chapter 7.5.1 „Checking rotor
casing”)
Revision: 000-v6r4
Created: 2007-6-1
Main seal • • •
Check for leaks
(Î Page 7-30, Chapter 7.6 „Main bearing
with main seal”)
Main gear •
Check toothing
(Î Page 7-34, Chapter 7.7 „Main gear”)
SSNr.: 1822056851000
VGNr.: 000
7-11

by Voith

Check input shaft bearing
ring”)
Mounting cover • • •
Check for leaks
Permanent magnet filter rods •

Check
permanent magnet filter rods”)
Aeration filter •
Check filter
aeration filter”)
Rotor space ventilation • •

Check function
rotor space ventilation for function”)
Oil temperature ∗
Check temperature
ture”)
Oil level • • •
Check oil levels
Revision: 000-v6r4
Created: 2007-6-1
(Î Page 7-58, Chapter 7.11.7 „Oil level”)
Duplex filter •
Check filters
Oil pressure ∗
oil pressure”)
SSNr.: 1822056851000
VGNr.: 000
7-12

by Voith
Elevated oil tank • • •

Check oil level
oil level”)
Sight feed oiler ∗

Oil quality • • •
Check quality
oil quality”)
Main pump •
Check
(Î Page 7-79, Chapter 7.11.12 „Checking oil
pumps”)
Tools •
Check tool kit for completeness
tools”)
Spare parts •
Renew corrosion protection
(Î Page 7-84, Chapter 7.15.1 „Renewing
corrosion protection”)
Coating ∗ ∗
Check
Revision: 000-v6r4
Created: 2007-6-1

coating”)
Tab. 7-1 Maintenance and inspection schedule for specially trained personnel of customer

∗ Maintenance and inspection with propeller running
SSNr.: 1822056851000
VGNr.: 000
7-13
7.2.7 Seals and gaskets – General
Caution!
Risk of machine damage as a result of old or worn seals and gaskets!
1. Replace toroidal sealing rings prior to each reassembly.

2. Only use new, oil and seawater resistant toroidal sealing rings.
3. Use oil and grease to install shaft seals.
4. Do not damage sealing lips during installation.
5. The tolerance for the toroidal sealing ring diameter is ±0.3 mm.
6. Only use recommended lubricants.
7.2.8 Corrosion damage – General
Caution!
Insufficient corrosion protection results in reduced service life of the unit.
1. Regularly remove corrosion damage, especially during docking.

2. Only use coatings of the same type and quality.
For further information regarding the coating Î Page 9-4, Chapter 9.2 „Standards”,
i under "VN1619 – Voith Turbo Marine Coatings".
Revision: 000-v6r4
Created: 2007-6-1
SSNr.: 1822056851000
VGNr.: 000
7-14
7.2.9 Screw joints – General
All screws and nuts that are secured using cotter pins, locking rings or thread locking
compound must be secured again during reassembly.
7.2.9.1 Tightening screw joints
Caution!
Plant failure!
If the screw joints are not tightened correctly and as per specification, they may sla-
cken thus causing plant failure.
Ö Always tighten screw joints correctly as per specified tightening torque.
Screw joints for which drawings indicate a tightening torque (MSP) must be tightened
using a calibrated torque wrench.
Exception
If no suitable torque wrench is available, the screws can be tightened as follows:
• Applying a definite tightening torque:

– Using a smaller torque wrench, tighten the screw to torque value MSP-A stated
in the table.
– Position screw heads on supports and, using a normal spanner, turn by the further
angle of rotation (ϕ SP-A) stated in the table.
• Further rotate by tightening angle (ϕ SP) using a normal spanner.
To reach the stated tightening torques, the screw threads and mating faces must al-
ways be coated with oil.
i
Screws for which no tightening torque is stated must be tightened in line with proven
experience.
Revision: 000-v6r4
Created: 2007-6-1
SSNr.: 1822056851000
VGNr.: 000
7-15
7.2.9.2 Checking screw joints
Interval
• During running-in after approx. 500 hrs
• Yearly
• Following average, during major overhaul or routine docking:
– with propeller at standstill
– in dock
– with the propeller disassembled
Action
Danger
Risk of pinching!
Very severe injuries caused by rotating and moving parts.
Ö Mechanically block the drive to prevent rotation.
Ö Check all screw joints for which a tightening torque (MSP) is indicated in the dra-
wings and which can be accessed at the time of checking (without docking).
For further information regarding tightening torques Î Page 8-1, Chapter 8 „Dra-
i wings and schematics”, drawing "Longitudinal Section".
For further information regarding safety "Safety" Î Page 2-1, Chapter 2 „Safety”.
7.2.10 Oil chamber covers
Caution!
Oil accumulation in the bilge in the event of leaking propeller housing covers!
1. The oil chamber covers must never be opened during propeller operation.
2. Tighten screws or replace seals in the event of leaks.
Revision: 000-v6r4
Created: 2007-6-1
SSNr.: 1822056851000
VGNr.: 000
7-16
7.2.11 Propeller removal and installation
Danger
The lifting eyes and lifting threads of the various compon-

ents are dimensioned as per international standards and
strength classifications. They must only be used for the
component itself.
Ö Use suitable and sufficient lifting equipment.
Danger
Prior to commencing any work, make sure that the propel-

ler cannot be started.
1. Tow vessel into quiet waters protected from outside in-

fluences.
2. Secure vessel against seaway and currents.
3. Ensure that the propeller cannot be switched on acci-
dentally (locking device).
7.2.11.1 Removal in dry dock
Based on experience, the complete propeller has to be removed only if repair work
must be carried out on the propeller housing or propeller foundation.
Removal is possible only in the direction of the vessel interior. This requires sufficient
clearance above the propeller or an opening in the deck above the propeller. If this is
not possible, the propeller must be disassembled.
Revision: 000-v6r4
Created: 2007-6-1
Action
1. Lock propeller main drive against accidental starting.
2. Disconnect power supply to propeller.
3. Drain off or extract oil from propeller and rotor casing.
4. Remove all pipes leading to the propeller.
5. Decouple drive unit (shaft line).

6. Separate control units and corresponding lines for transverse and longitudinal pitch
setting.
7. Remove screws and conical pins between propeller and foundation flange.
SSNr.: 1822056851000
VGNr.: 000
7-17
8. Suspend propeller using the lifting eyes provided.

Note
For larger propellers, the blades or the complete rotor casing should be removed pri-
or to detaching the propeller from the foundation flange on the hull.
9. Press propeller off flange.
Note
Prior to lifting the propeller with a crane, the propeller must be pressed off the flange.
Install forcing-off screws in the threads provided in the foundation flange and tighten
until the propeller flange comes off the well flange.
10.Lift the propeller.
Note
For oblique setups the propeller must be maintained in the correct position with ad-
ditional lifting gear.
The lifting point (crane hook) must be as directly above the center of gravity as pos-
sible.
7.2.11.2 Setting down the propeller
7.2.11.2.1 Setting down propeller with blades installed
Having been lifted out of the hull, the propeller can be set down on the blades. To
ensure safe and even weight distribution, wooden blocks must be placed under all bla-
des.
7.2.11.2.2 Setting down propeller with blades removed
If the blades have already been removed, the propeller can be set down directly on
the rotor casing. To prevent permanent deformation, wooden blocks must be placed
under at least three blade bearing openings of the rotor casing. Avoid supporting the
propeller on small areas such as between the blade bearing openings.
Revision: 000-v6r4
Created: 2007-6-1
SSNr.: 1822056851000
VGNr.: 000
7-18
7.2.11.3 Installation in dry dock
Action
1. Attach propeller to crane.
2. Coat gasket elements with liquid sealant (Permatex) and position and align them on
the foundation flange.
Note
Obliquely installed propellers can be guided with the help of several assembly studs
in the foundation flange. This allows easier propeller alignment on the well flange.
3. Insert conical pins in the existing propeller flange bores and tap in lightly.
Note
This aligns the propeller in the original position (prior to removal).
4. Coat the underside of the propeller flange with liquid sealant (Permatex) in the area
of the gaskets prior to positioning the propeller on the foundation flange.
5. Check the alignment of the shaft line.
6. Bolt on the propeller.
Revision: 000-v6r4
Created: 2007-6-1
SSNr.: 1822056851000
VGNr.: 000
7-19
7.2.12 Turning the propeller without propulsion engine
Danger
Risk of pinching!
Prior to turning the entire drive unit must be out of operati-

on.
Ö Decommission the entire drive unit!
Turn propeller on the drive shaft coupling if:

• a specific propeller position is required for maintenance and inspection work
• a functional check must be carried out without starting the main engine
7.2.12.1 Turning with the vessel afloat
7.2.12.1.1 At the input shaft / coupling
If a turning device with bores is provided at the coupling, the propeller can be turned
without drive engine using a bolt.
Revision: 000-v6r4
Created: 2007-6-1
003513000
Fig. 7-1 Turning on the coupling
1 Turning bores on the coupling 2 Pin
7.2.12.1.2 Using a clamping hub
If a clamping hub with bores is provided on the shaft line, the propeller can be turned
SSNr.: 1822056851000
without drive engine using a bolt.

VGNr.: 000
7-20
1 2
003501010
Fig. 7-2 Turning on the clamping hub
1 Clamping hub 2 Pin

Revision: 000-v6r4
Created: 2007-6-1
SSNr.: 1822056851000
VGNr.: 000
7-21
7.3 Blade actuating mechanism
7.3.1 Checking the blade actuating mechanism
Measuring torsional clearance and theoretical zero position of every blade provides
information on the condition of the blade actuating gear.
Interval
• During routine docking
7.3.1.1 Measuring torsional clearance
Measuring torsional clearance and theoretical zero position of every blade provides
information on the condition of the blade actuating gear.
Components
1 2
Md1 Md
a1
+ Md1 = Md
a1+a
a1 a
001001050
Fig. 7-3 Measuring torsional clearance
1 Torque wrench 2 Rotary arm
Action
Revision: 000-v6r4
Created: 2007-6-1
Precondition
During measurement, the pointer must remain below the indicator plate in the center.
1. Remove growth around blade trailing edge to ensure that the rotor casing bottom is
visible.
2. Attach rotary arm to one blade.
3. Apply test torque Md head outwards and head inwards.
Note
To ensure the same conditions apply to all blades, the blades must be brought to the
SSNr.: 1822056851000
stop position with approx. the same test torque Md (Î Page 3-5, Chapter 3.3.2 „Bla-
de actuating mechanism”).
VGNr.: 000
7-22
An additional torque wrench on the rotary arm allows exact test torque setting. (The
test torque Md1 must be calculated using the above equation and set on the torque
wrench.)
4. Mark stop positions on the bottom of the rotor casing.
5. Measure distance between the stop positions.
Result
The distance between the stop positions is referred to as setting play.
7.3.1.2 Determining zero position of the blades
Components
R
S
+
001001060
Fig. 7-4 Determining zero position of the blades
R Dimension R
S Torsional clearance
N Theoretical zero position of blade
D Outer diameter of rotor casing bottom
Revision: 000-v6r4
Action
Created: 2007-6-1
1. Halve torsional clearance (S) measured at the blade tail end. This position corres-
ponds to the theoretical zero position of the blade (N).
2. Measure the shortest distance (R) between the theoretical zero position of the blade
and the outer diameter of the rotor casing bottom (D).
Result
Dimension R must be the same for all blades. If one blade deviates from the others by
more than the permissible value V, fault diagnosis is required.
SSNr.: 1822056851000
VGNr.: 000
7-23
For further information regarding torsional clearance, divergence V and test torque Md
i Î Page 3-5, Chapter 3.3.2 „Blade actuating mechanism”.
For further information regarding the blade actuating mechanism

Î Page 8-1, Chapter 8 „Drawings and schematics”, "Blade bearings" and "Blade
angle setting" drawings.
Revision: 000-v6r4
Created: 2007-6-1
SSNr.: 1822056851000
VGNr.: 000
7-24
7.4 Blades and blade bearings
7.4.1 Checking for leaks
When checking the shaft seals, the strain on the shaft seals is simulated. In the event
of leakage, the shaft seals have become worn and inflexible.
Interval
Components
1/3
1
2/3
R01110010
Fig. 7-5 Checking for leaks
1 Possible oil leak 2 Lifting device
Action
1. Remove dirt from rotor casing bottom in the blade area.
2. Position a rope around the blades in the upper third of the blade leaf area and tighten
with force Z (weight of one blade x 10 N) using a lifting device.
3. Maintain for 2 hrs and subsequently check area between blade leaf and rotor casing
Revision: 000-v6r4
Created: 2007-6-1
bottom for leaks.
Findings and measures

• No leaks
The shaft seals are in good condition. They can remain installed until the next do-
cking unless contrasting experience regarding the shaft seal lifetime has been made.
• Leaks
Leakage indicates that shaft seals are no longer tight or that a blade bearing is da-
maged. Damaged components must be replaced.
SSNr.: 1822056851000
VGNr.: 000
7-25
7.4.2 Checking blade condition
Interval
During each docking the blades must be checked for damage such as cracks or cor-
rosion. Surface crack-testing must be carried out if damage is evident or in the event
of suspected leaks. The damaged areas found must be marked and documented in a
protocol together with a photo. This protocol must be sent to the service department
of Voith Turbo Schneider Propulsion GmbH & Co. KG to clarify further proceedings.
Revision: 000-v6r4
Created: 2007-6-1
SSNr.: 1822056851000
VGNr.: 000
7-26
7.4.3 Checking blade end play
Interval
Components
1 3
2 4
R01110010
Fig. 7-6 Positioning of the measuring gauge on the blade
1 Measuring point on axis of rotation rotation

2 Lifting point on axis of rotation 4 Lifting device
3 Measuring gauge at the height of the axis of
Action
1. Attach measuring gauge (1/100 mm)(3) to bottom of rotor casing.
2. Lift blade using lifting device (mechanic or hydraulic) (4) until the bearing end play
has been overcome.
3. Read off end play and record.

• Excessive end play
The position of the blade shaft in relation to the actuating lever has changed. The be-
aring carrier is worn or the axle support is distorted. The defective components must
be replaced.
Revision: 000-v6r4
Created: 2007-6-1
• Insufficient end play

– The blade securing device is distorted. The axle support must be replaced.
– Foreign objects or marine fouling prevent axial movement of the blade. The fo-
reign objects / marine fouling must be removed.
For further information regarding end play Î Page 3-6, Chapter 3.3.2.1 „Blades and
blade bearings”.
For further information regarding blade bearings Î Page 8-1, Chapter 8 „Drawings
i
and schematics”, "Blade bearings" drawing.
SSNr.: 1822056851000
VGNr.: 000
7-27
7.5 Rotor casing
7.5.1 Checking rotor casing
Interval
7.5.1.1 Checking reactive anodes
Action
Ö Check reactive anodes and replace if required.

• The decision whether a reactive anode must be replaced mainly depends on the area
of operation and the docking interval of the vessel.
• Ensure that at least 1/3 of the anode capacity remains until the next scheduled do-
cking of the vessel.
Note
If no wear is found on the reactive anodes, the anode type must be checked.
7.5.1.2 Renew reactive anodes
Action
1. Remove consumed anodes with grinding tool.
2. Weld anodes.
Note
Don’t screw reactive anodes!
3. Coating the welding seams and the weld-on clamps.
Note
Don’t coat the anodes!
For further information regarding the reactive anode type
i Î Page 3-10, Chapter 3.3.3.1 „Rotor casing”

Revision: 000-v6r4
Created: 2007-6-1
SSNr.: 1822056851000
VGNr.: 000
7-28
7.5.1.3 Checking for corrosion and leaks
Corrosion warranty
Corrosion on the rotor casing is influenced by a variety of factors, such as water qua-
lity, marine fouling, sand particles in the water, range of operating conditions, stray
currents and the water current at the berth. Together their effects are so complex that
i
no corrosion warranty can be given.
In order to minimize corrosion sufficient inspections, especially during the first few ye-
ars of operation as well as continuous maintenance of the coating and the reactive an-
odes are required.
Action
1. Check rotor casing epoxy coating at the bottom for leaks and corrosion.
Note
Marine fouling must be removed if required.
2. Working through the assembly opening of the propeller housing, check rotor casing
for leaks and corrosion. This requires turning the rotor casing in various steps.
Result
Finding Action
Corrosion depth
≤ 30% of sheet thickness Action

1. Shot-blast the area with fine shot.
2. Apply new coating to the area.
> 30% of sheet thickness Schedule rotor casing repair.
Suspected cracks Action

1. Carry out surface crack testing.
2. Record findings.
3. Inform Voith Turbo Schneider Propulsion GmbH
& Co. KG customer service to clarify further pro-
ceedings.
Tab. 7-1 Checking for corrosion and leaks
Revision: 000-v6r4
Created: 2007-6-1
For further information regarding the coating Î Page 9-3, Chapter 9.2 „Standards”,
under "VN1619 - Voith Turbo Marine Coatings".
i
SSNr.: 1822056851000
VGNr.: 000
7-29
7.6 Main bearing with main seal
7.6.1 Checking for leaks
7.6.1.1 Lower shaft seal
Caution!
Excessive water leakage!
If the water leakage on the overflow valve exceeds the permissible limit, the lower
shaft seal is no longer functional.
1. Close the sight feed oiler as well as the control and overflow valve to the lower
shaft seal.
2. Have damaged shaft seal replaced during next stay in dock.
Interval
• Daily at standstill
• Following each undocking at standstill
Components
1
Revision: 000-v6r4
Created: 2007-6-1
G23220100
Fig. 7-7 Lower shaft seal
1 Overflow valve 2 Control valve

SSNr.: 1822056851000
VGNr.: 000
7-30
Action
Precondition
To allow venting of the sealing chamber between the lower and the center shaft seal,
overflow valve (1) must be kept open and control valve (2) closed.
1. Open control valve for at least five minutes and allow fluid to drain into a pan.
2. Determine leak rate and take recommended measures if required.
(Leak rate Î Page 3-11, Chapter 3.3.3.2 „Main bearing and main seal”)
3. Close control valve (overflow valve remains open).
Result
Findings Remedial action recommended
No oil or water accumulation None
Very small oil or water accu-

mulation
Small water accumulation Close rotor space ventilation for two minutes during
starting
Oil accumulation exceeding Reduce oil feed on sight feed oiler

the permissible leak rate
Water accumulation excee- • Lower shaft seal damaged

ding the permissible leak rate • Close sight feed oiler, control and overflow valve
• Have damaged shaft seal replaced during next
stay in dock!
Tab. 7-1 Leak rate at lower shaft seal
For further information regarding the sight feed oilers Î Page 7-76, Chapter 7.11.10
„Checking and setting sight feed oilers to main seal”.
i
Revision: 000-v6r4
Created: 2007-6-1
SSNr.: 1822056851000
VGNr.: 000
7-31
7.6.1.2 Center and upper shaft seal
Interval
• Daily at standstill
• Following each undocking at standstill
Danger
Excessive water leakage!
If the water accumulation on the leakage channel exceeds

the permissible leak rate, this puts the crew and vessel at
risk.
1. Close the sight feed oiler as well as the control and

overflow valve to the lower and center shaft seal.
2. Stop the propeller if possible.
3. Have the damaged shaft seal replaced immediately.
Components
3 4 5 6
Revision: 000-v6r4
Created: 2007-6-1
G23220110
Fig. 7-8 Center and upper shaft seal
1 Propeller oil 4 Leaking oil

2 Leakage drain 5 Leaking water
3 Sea water 6 Connection to bilge
Action
1. Check leakage drain for leakage.
2. Determine leak rate and take recommended measures if required.
(Leak rate Î Page 3-11, Chapter 3.3.3.2 „Main bearing and main seal”)
SSNr.: 1822056851000
VGNr.: 000
7-32
Result
Findings Remedial action recommended
Oil accumulation Reduce oil feed on sight feed oiler.
Oil accumulation exceeding Collect oil and return to housing unless contamina-
the permissible leak rate ted.
Water accumulation excee- • Lower shaft seal severely damaged

ding the permissible leak rate • Close sight feed oiler, control and overflow valve
• Have the damaged shaft seal replaced immedia-
tely!
Tab. 7-1 Leak rate at lower shaft seal
For further information regarding the sight feed oilers Î Page 7-76, Chapter 7.11.10
„Checking and setting sight feed oilers to main seal”.
For further information regarding the main bearing and main seal
i
Î Page 3-11, Chapter 3.3.3.2 „Main bearing and main seal” and
Î Page 8-1, Chapter 8 „Drawings and schematics”, "Longitudinal section" drawing.
Revision: 000-v6r4
Created: 2007-6-1
SSNr.: 1822056851000
VGNr.: 000
7-33
7.7 Main gear
Components
1 2
R03240110
Fig. 7-9 Main gear
1 Bevel pinion 2 Bevel gear
7.7.1 Maintenance
The main gear is maintenance-free.
Revision: 000-v6r4
Created: 2007-6-1
SSNr.: 1822056851000
VGNr.: 000
7-34
7.7.2 Inspection
Consider the following when inspecting the main gear:

• Noise
• Oil temperature
• Toothing
7.7.2.1 Noise and oil temperature
Interval
• daily, during operation
Action
1. Check main gear for unusual noise.
2. Check oil temperature in the propeller housing.
Result
Findings Action
No unusual noise None
Unusual noise Check toothing.
Oil temperature = 0 °C Check thermometer for correct functioning

and replace if required.
Oil temperature < 75 °C None
Oil temperature > 75 °C Check toothing.

Tab. 7-1 Noise and oil temperatures
Revision: 000-v6r4
Created: 2007-6-1
SSNr.: 1822056851000
VGNr.: 000
7-35
7.7.2.2 Checking toothing
The Klingelnberg toothing can be checked visually by means of openings in the hou-
sing cover.
Consider the following checkpoints when inspecting the toothing:

• Visual check
• Check toothing
7.7.2.2.1 Visual check
Danger
Risk of pinching!
Ö Mechanically block the drive to prevent it from rotating.
Interval
• Every 5000 hrs at standstill
• If the gear noise level increases
• Following contact with hard ground or foreign objects
Components
A B C
Revision: 000-v6r4
Created: 2007-6-1
001250000
Fig. 7-10 Contact pattern
A Contact pattern (target status)

B Incorrect contact pattern (offset too big in tooth tip direction)
C Incorrect contact pattern (offset too big in tooth base direction)
SSNr.: 1822056851000
VGNr.: 000
7-36
Action
1. Open the opening in the housing cover above the bevel pinion.
2. Mark the bevel gear position.
3. Slowly turn rotor by hand through at least one full turn (Î Page 7-20, Chapter 7.2.12
„Turning the propeller without propulsion engine”) and check the toothing on bevel
pinion and gear for damage and wear.
Result
Findings Measuring point Action
Contact pattern 4 times on circumference Schedule gear repair for next

docking.
Pitting On every tooth (Leading and Arrange for immediate repair

trailing flank) by Voith Turbo Marine.
Tooth chipping
Tab. 7-2 Checking toothing

Revision: 000-v6r4
Created: 2007-6-1
SSNr.: 1822056851000
VGNr.: 000
7-37
7.7.2.2.3 Measuring backlash
Danger
Risk of pinching!
Ö Mechanically block the drive to prevent it from rotating.
Components
G21243000
Fig. 7-11 Positioning of the measuring gauge on the bevel pinion
Precondition
Temperature ranges for backlash measurement on the main gear
Revision: 000-v6r4
Created: 2007-6-1
• Operating temperature: ~ 40 – 60 °C
• Cold: ~ 20 °C
Tools
• Measuring gauge with an accuracy of 1/100 mm (not part of the scope of supply of
Voith Turbo Marine).

SSNr.: 1822056851000
VGNr.: 000
7-38
Action
Caution!
Gearbox damage!
Operating the propeller without backlash results in gearbox failure.
Ö Do not start propeller if the backlash is insufficient.
1. Remove cover over main gear.

2. Attach magnetic measuring gauge base with measuring gauge to control rod sup-
port. Position measuring bolt tangentially in the gear center.
3. Mark measuring point.
4. Turn pinion in one direction until the pinion teeth contact the gear. Zero measuring
gauge.
5. Carefully turn pinion in the opposite direction until the pinion tooth on the rear tooth
flank contacts the gear. The bevel gear must not move.
6. Read off measuring gauge while keeping the pinion in this position. Record measu-
red backlash and compare to Technical Data (Î Page 3-12, Chapter 3.3.3.3 „Main
gear”).
7. Repeat measurement on at least three more points.
8. Remove magnetic measuring gauge base with measuring gauge.
For further information regarding backlash specifications

Î Page 3-12, Chapter 3.3.3.3 „Main gear”.
i
Revision: 000-v6r4
Created: 2007-6-1
SSNr.: 1822056851000
VGNr.: 000
7-39
7.8 Input shaft bearing
7.8.1 Checking for noise
Interval
• Weekly, during operation
Action
Ö Regularly check unit for unusual noise.
7.8.2 Checking input shaft seals for leaks
Interval
• Weekly, during operation
Action
Ö Check input shaft for increased traces of oil in the area of the input shaft bearing.
For further information regarding the input shaft seal Î Page 8-1, Chapter 8 „Dra-
i wings and schematics”, "Longitudinal Section" drawing.
Revision: 000-v6r4
Created: 2007-6-1
SSNr.: 1822056851000
VGNr.: 000
7-40
7.9 Propeller housing
7.9.1 Checking propeller housing
Interval
Corrosion warranty
Corrosion on the rotor casing is influenced by a variety of factors, such as water qua-
lity, marine fouling, sand particles in the water, range of operating conditions, stray
currents and the water current at the berth. Together their effects are so complex that
i
no corrosion warranty can be given.
In order to minimize corrosion sufficient inspections, especially during the first few ye-
ars of operation as well as continuous maintenance of the coating and the reactive an-
odes are required.
Action
Ö Working through the assembly openings, check bottom of propeller housing (sea wa-
ter area) for leaks and corrosion.
Result
Finding Action
Corrosion depth
≤ 30% of sheet thick- Action

ness 1. Shot-blast the area with fine shot.
2. Apply new coating to the area.
> 30% of sheet thick- Re-weld corrosion pits using filler of the same type.
ness Note
Provisional repair of the propeller housing bottom is pos-
sible during docking if the propeller is installed and the
rotor lowered.
Ideally the stator should be removed and repair welding be
carried out in a better position.
Suspected cracks Action

Revision: 000-v6r4
Created: 2007-6-1
1. Carry out surface crack testing.

2. Record findings.
3. Inform Voith Turbo Schneider Propulsion GmbH & Co.
KG customer service to clarify further proceedings.
Tab. 7-1 Checking for corrosion and leaks
For further information regarding the coating Î Page 9-4, Chapter 9.2 „Standards”
under "VN1619 - Voith Turbo Marine Coatings".
i
SSNr.: 1822056851000
VGNr.: 000
7-41
7.10 Parts of propeller housing, housing cover and control rod

support
Danger
Danger for vessel and personnel!
Ö Never slacken screws and splint pins on the assembly

openings with the vessel afloat
If the sea-water side mounting covers on the housing bot-

tom are open or insufficiently closed, water can enter the
vessel interior.
This situation can also arise if the screws are over-tighte-

ned (not tightened correctly).
7.10.1 Checking mounting cover for leaks
Interval
• In dock prior to undocking
• Weekly at standstill
Components
Revision: 000-v6r4
Created: 2007-6-1
1 001373000
Fig. 7-12 Screw lockings (1) on one of the three mounting covers on the housing bottom
1 Splint pins
SSNr.: 1822056851000
VGNr.: 000
7-42
1
001373010
Fig. 7-13 Detail of screw locking (1)
1 Splint pin
Action
1. Professionally retighten screws in the event of leakage.
Note
The gasket must not be deformed as a result of the contact pressure!
If leak-tightness cannot be achieved, immediately dock in and repair damage.
2. Visually check mounting covers (screw joints, splint pins, leaks).
Revision: 000-v6r4
Created: 2007-6-1
SSNr.: 1822056851000
VGNr.: 000
7-43
7.10.2 Checking permanent magnet filter rods
Interval
Components
G21373020
Fig. 7-14 Permanent magnet filter rods
1 Permanent magnet filter rod
Action
1. Remove screws from cover.
2. Remove cover with filter rods from oil sump.
3. Strip filter rods over a suitable container and clean.
Revision: 000-v6r4
Created: 2007-6-1
4. Check composition of contamination.
The material and shape of the foreign objects allows timely detection of abnormal
i wear.
For further information regarding the permanent magnet filter rods

Î Page 8-1, Chapter 8 „Drawings and schematics”, "Longitudinal section" drawing.

SSNr.: 1822056851000
VGNr.: 000
7-44
7.10.3 Checking aeration filter
Interval
Components
G21373030
Fig. 7-15 Filter element
1 Filter element
Action
1. Turn filter cover anticlockwise to open.
2. Remove filter element and clean filter housing.
3. Install new filter element.
4. Reinstall filter cover.
For further information regarding the aeration filter Î Page 9-1, Chapter 9.1 „Compo-
nents supplier documentation”, "Propeller - Stator".
i
Revision: 000-v6r4
Created: 2007-6-1
SSNr.: 1822056851000
VGNr.: 000
7-45
7.10.4 Checking rotor space ventilation for function
Caution!
Shut-off valve (2) must be open during operation.
Ö Close shut-off valve only in cases of emergency such as pipe fracture.
Interval
• Every 5000 hrs with propeller running and at standstill
3 2
R01371000
Fig. 7-16 Rotor space ventilation in propeller area
1 Non-return valve 3 Rotor space

2 Shut-off valve
Revision: 000-v6r4
Created: 2007-6-1
Action
There are two different function checks:
• Check non-return valve (1) with propeller running
(Î Page 7-47, Chapter 7.10.4.1 „Checking non-return valve with propeller running”)
• Checking non-return valve at standstill
– Check non-return valve

(Î Page 7-48, Chapter 7.10.4.2 „Checking non-return valve at standstill”)
– Check shut-off valve (2)
SSNr.: 1822056851000
VGNr.: 000
7-46
7.10.4.1 Checking non-return valve with propeller running
Components
G21371000
Fig. 7-17 Checking non-return valve with propeller running
Action
Ö Seal non-return valve with your hand.
Especially during acceleration and speed increase air is sucked into the rotor space.
i
Revision: 000-v6r4
Created: 2007-6-1
SSNr.: 1822056851000
VGNr.: 000
7-47
7.10.4.2 Checking non-return valve at standstill
Components
G21371010
Fig. 7-18 Checking non-return valve at standstill
Action
Ö Lift valve head of non-return valve from below using a finger several hours after pro-
peller shutdown.
Result
• If air flows out, the valve is OK. The air volume in the rotor space is maintained for
some time.
• If no air flows out, the non-return valve is defective. Replace non-return valve.
For further information regarding the non-return valve Î Page 9-1, Chapter 9.1
i „Components supplier documentation”, under "Propeller - Stator".

Revision: 000-v6r4
Created: 2007-6-1
SSNr.: 1822056851000
VGNr.: 000
7-48
7.10.4.3 Checking shut-off valve
Caution!
The shut-off valve must be open during operation.
Ö Close shut-off valve only in cases of emergency such as pipe fracture.
Components
001373040
Fig. 7-19 Shut-off valve
1 Opening shut-off valve 2 Closing shut-off valve
Action
Ö Check shut-off valve for ease of movement by briefly closing and opening it.
Revision: 000-v6r4
Created: 2007-6-1
SSNr.: 1822056851000
VGNr.: 000
7-49
7.11 Lubricant and oil supply
7.11.1 Limitation of warranty
The specified lubricant requirements are based on operational experience. Adherence
i to these specifications does not warrant any specific functionality of the lubricant.
Should a lubricant prove to be ineffective, no claims whatsoever can be derived

against Voith.
When selecting a lubricant type and brand, the relevant lubricant grade/classification
must be adhered to.
7.11.2 Maintenance contract
Voith recommends a maintenance contract with the lubricant manufacturer or supplier

in order to detect any reduction in lubricant performance in good time.
The maintenance contract must include regular oil sample checks to prove further
usability.
7.11.3 Lubricants
To ensure operational safety over an extended period of time, the lubricant must con-
form to the characteristics laid down in the DIN and ISO standards.
Lubricant manufacturers / suppliers that can provide references regarding stability

and maintenance should be preferred.
Consult the lubricant manufacturer or supplier regarding the choice of lubricant.
7.11.3.1 Lube oils
7.11.3.1.1 Requirements
Mineral oils must meet the following requirements:

• Mineral oils with additives to increase load-carrying capacity (FZG test A/8, 3/90 da-
Revision: 000-v6r4
Created: 2007-6-1
mage force stage > 12) and to increase corrosion protection

• Mineral oils with good air and water separation, minimum foaming and compatibility
with NBR and FPM seals as well as bronze and babbitt metal bearings.
7.11.3.1.2 Oils used

The oils used (CLP oils) must conform to DIN 51517, part 3, as these have the re-
quired properties.
SSNr.: 1822056851000
VGNr.: 000
7-50
7.11.3.1.3 Oil viscosity
To determine the suitable viscosity, the specific application and operating conditions
must be taken into account.
Viscosity grades as per DIN Viscosity limits at Oil temperature

51519 or ISO 3448 40 °C in mm2/s (VI
80)
ISO VG 100 90 – 110 Check oil temperature in

propeller, see Mainte-
ISO VG 150 135 – 165
nance and Inspection
chapter
Tab. 7-4 Oil viscosity
The viscosity grades are guidelines only. For units equipped with oil coolers the next
lower viscosity grade may be used.
Discuss the choice of oil viscosity and the use of synthetic oils with Voith. i
For further information regarding oil supply
Î Page 3-15, Chapter 3.3.5 „Oil supply” and
Î Page 9-4, Chapter 9.2 „Standards” under "VN103" and "VN105".
7.11.3.2 Grease
7.11.3.2.1 Requirements
Greases must meet the following requirements:

• Salt water/sea water resistant
• Compatible with NBR and FPM seals
• Resistant against ageing
7.11.3.2.2 Oils used
Use only K2K grease conforming to DIN 51825 or XM2 conforming to ISO 3498 for the
installation of shaft seals and other components during assembly as well as to lubri-
cate bearings.
Revision: 000-v6r4
Created: 2007-6-1
SSNr.: 1822056851000
VGNr.: 000
7-51
7.11.4 Oil quality
7.11.4.1 Checking oil quality
Caution!
Insufficient oil quality results in machine damage!
The quality of severely aged and contaminated oil cannot be improved by adding new
oil.
Ö Do not mix oils of different brands.
At temperatures above 65 °C, every temperature increase by 10 °C doubles the age-
i ing rate of the oil.
Interval
• At oil temperatures > 60 °C weekly at standstill
7.11.4.1.1 Condition
Ageing and contamination of oils depends on various operating conditions such as

temperature, operating pressure, filtering, foreign particle ingress from the environ-
ment via ventilation equipment and moving seals or humidity.
7.11.4.1.2 Evaluation criteria for oil quality
To evaluate the oil quality, compare the used oil to new oil. To do this, remove an oil
sample from the propeller immediately after stopping the unit.
Test result Effects on Recommended measures

oil quality
Light mineral oil No conse- –

Revision: 000-v6r4
Created: 2007-6-1
quences
Severely darke- Deterioration up Take 2 to 3 samples and have the oil analy-
ned mineral oil to no longer zed in a laboratory.
usable (oil has
aged) Replace the oil if insufficient oil quality as a
result of ageing is determined (see specifica-

tions of manufacturer/supplier).
Cloudy mineral No deterioration Determine cause (possibly leaking oil cooler

oil with a water or blade shaft seal).
SSNr.: 1822056851000
content of up to
2%* Rectify leak.
VGNr.: 000
7-52
Test result Effects on Recommended measures

oil quality
Water content Marked deterio- Rectify leak.

between 2 and ration
5%* Run propeller at operating temperature until
all water has evaporated.
Water content No longer Rectify leak.

above 5%* usable
Drain oil from propeller and separate or
replace.*
Particles Deterioration up Take 2 to 3 samples and have the oil analy-

to no longer zed in a laboratory.
usable
Request information on permissible particle
content and necessary measures from
manufacturer/supplier.
Analyze oil filter deposits to determine the

cause.
Foamy or milky Marked deterio- Rectify cause for excessive foaming or have
mineral oil ration oil quality checked by manufacturer/supplier.
Tab. 7-3 Evaluation criteria for oil quality
* The high water content is indicated by severe condensate formation on the indicator
plate.
For further information regarding oil quality Î Page 9-4, Chapter 9.2 „Standards” un-
der "VN103" and "VN105".
i
Revision: 000-v6r4
Created: 2007-6-1
SSNr.: 1822056851000
VGNr.: 000
7-53
7.11.5 Hydraulic fluid
7.11.5.1 Requirements
Hydraulic fluids must meet the following requirements:

• Hydraulic fluid on mineral oil basis
• Minimum requirements as per DIN 51524, part 2
7.11.5.2 Safety instructions
Hydraulic fluid on mineral oil basis

• contaminates water
• is combustible (note flame point!)
• must only be used if the safety data sheet of the hydraulic fluid is available and all
measures described are taken
7.11.5.3 Purpose
• Transmission of the hydraulic energy from the pump to the hydraulic cylinder and/or
hydraulic motor
• Lubrication of sliding parts
• Corrosion protection
• Removal of contaminants
• Heat dissipation
7.11.5.4 Properties
The hydraulic fluid properties are reduced as a result of ageing (chemical transforma-
tion). Hydraulic fluid ageing is accelerated by:
• High temperatures
(Above 70 °C the ageing process doubles in speed with every increase by 10 °C)
• Air
(oxygen)
• Water
• Metallic catalysts and dirt
7.11.5.5 Choice and maintenance

Revision: 000-v6r4
Created: 2007-6-1
Hydraulic fluid choice and maintenance depend on

• Operational safety
• Lifetime
• Operating economy
7.11.5.6 Viscosity
At a hydraulic fluid temperature of 0–80 °C, the operating conditions of the hydraulic
system require viscosity grade HLP 46 (ISO-VG 46).
SSNr.: 1822056851000
VGNr.: 000
7-54
7.11.5.7 Choice of oil type
• HLP (DIN 51524, part 2)

Hydraulic fluid based on mineral oils with additives to increase corrosion protection,
reduce ageing and increase wear protection.
• HV (multigrade hydraulic fluid)
Hydraulic fluids with particularly low temperature-dependency of the viscosity.
Revision: 000-v6r4
Created: 2007-6-1
SSNr.: 1822056851000
VGNr.: 000
7-55
7.11.6 Oil temperature
7.11.6.1 Checking control and lube oil temperature
Interval
• Daily with propeller running
Components
G21403000
Fig. 7-20 Thermometer in propeller housing base
1 Electric temperature sensor 2 Temperature display
Action
Ö Read control and lube oil temperatures off the relevant temperature display (2).
Viscosity grade** as Viscosity limits at 40 Oil tempera- Operating

per ISO 3448 or DIN °C in mm2/s ture time
51519 (VI 80)
Revision: 000-v6r4
Created: 2007-6-1
ISO VG 100 90-110 65 °C at least 5 hrs

under full load
ISO VG 150 135-165 70 °C
Tab. 7-1 Lube oil, viscosity class
**Note viscosity grade of the oil type as well as max. permissible temperature!
Max. oil temperature

If the oil temperature is exceeded, troubleshooting must be carried out. If the fault can-
not be repaired immediately, run propeller with reduced load.
SSNr.: 1822056851000
VGNr.: 000
7-56
Min. oil temperature

At low temperatures (< +10 °C), the propeller must be run at zero pitch until the control
oil temperature reaches at least +10 °C.
7.11.6.2 Checking oil cooler thermostat
Based on the operating temperature, the thermostat controls whether the oil flow is
routed through the oil cooler or directly to the consumers.
• Cold oil of up to +44 °C:

No oil flow through oil cooler (closed position)
• Medium-temperature oil +44 – 55 °C:
Opening range, intermediate position
• Hot oil above 55 °C:
Oil flow through cooler only
Action
Ö Manually check cooler temperature.
At oil temperatures below +44 °C the cooler must not get warm!
Note
Remove thermostat assembly if the switching points do not correspond to the speci-
fied temperatures.
The viscosity grades are guidelines only. For units equipped with oil coolers the next
lower viscosity grade may be used.
Discuss the choice of oil viscosity and the use of synthetic oils with Voith. i
For further information regarding the oil cooler with thermostat
Î Page 8-1, Chapter 8 „Drawings and schematics”, "Oil cooler" drawing.
For further information regarding the thermostat

Î Page 9-1, Chapter 9.1 „Components supplier documentation”, under "Thermos-
tat".
For further information regarding oil supply

Î Page 9-4, Chapter 9.2 „Standards”, under "VN103" and "VN105".
Revision: 000-v6r4
Created: 2007-6-1
SSNr.: 1822056851000
VGNr.: 000
7-57
7.11.7 Oil level
7.11.7.1 Checking oil level
Caution!
Insufficient oil can lead to consequential propeller damage.
Oil leaks outboard constitute an environmental hazard!
Ö Troubleshoot oil leak and rectify!
Interval
• Weekly with propeller at standstill
Components
Revision: 000-v6r4
Created: 2007-6-1
G21483000
Fig. 7-21 Oil dipstick
1 Max. oil level 2 Min. oil level

Action
1. Unscrew oil dipstick from corresponding housing base.
2. Wipe dipstick.
3. Immerse dipstick for checking; do not screw onto opening.
SSNr.: 1822056851000
4. Pull out dipstick and read off oil level.

5. Screw on dipstick tightly.
VGNr.: 000
7-58
Always check the oil level under the same conditions (temperature, heeling, elevated
oil tank filling).
If oil loss is found, carry out troubleshooting. Check for traces of oil outboard. Note
i
quantity lost and intervals.
Add the missing oil quantity through the opening on the housing base.
Filter the oil while pouring it in. Mesh size max. 10 μm.
Do not mix oils of different manufacturers or different viscosities!

Revision: 000-v6r4
Created: 2007-6-1
SSNr.: 1822056851000
VGNr.: 000
7-59
7.11.8 Oil filters
Revision: 000-v6r4
Created: 2007-6-1
SSNr.: 1822056851000
VGNr.: 000
7-60
7.11.8.1 Checking and replacing lube oil filter
7.11.8.1.1 Duplex filter
The duplex filter consists of two exchangeable filter units.
Components
1 2
R51423000
Fig. 7-22 Duplex filter on propeller
1 Ventilation screw for pressure release 3 Contamination indicator

2 Switch lever for switching the filter unit 4 Oil drain screw for contaminated oil
Revision: 000-v6r4
Created: 2007-6-1
SSNr.: 1822056851000
VGNr.: 000
7-61
7.11.8.1.2 Contamination indicator
Each filter unit of the duplex filter is equipped with an opto-mechanical contamination
indicator (3).
Indicator Degree of contamina- Action

(red pin) tion
Not visible Contamination < 100% No measures required
Visible Alarm at • Switch filter to clean filter unit

100 % contamination
• Replace contaminated filter element
Note
Applicable only at oil
temperatures of
> 40 °C
Tab. 7-3 Contamination indicator, opto-mechanical
The indication is only correct at operating temperature > 40 °C. At temperatures below
i this value, no alarm is displayed. (Temperature suppression).
The contamination indicator pin is not equipped with temperature suppression and in-
dicates the alarm!
For further information regarding the contamination indicator

Î Page 8-1, Chapter 8 „Drawings and schematics”, under Oil supply, "Monitoring"
schematics (D51 and D52)
Î Page 9-1, Chapter 9.1 „Components supplier documentation”, under "Contamina-
tion indicator".
Revision: 000-v6r4
Created: 2007-6-1
SSNr.: 1822056851000
VGNr.: 000
7-62
7.11.8.1.4 Replacing filter element
Removing element with propeller at standstill
Action
1. Determine which filter unit is operational.
(The direction of flow is marked on the switch shaft.)
2. Turn switch lever (2) through 90°.
3. For pressure release carefully slacken vent screw (1) of the filter unit that is no longer
in operation and release pressure.
4. Open oil drain plug (4) of the filter unit that is no longer in operation and drain conta-
minated oil into a suitable container.
5. Open cover screws, turn cover through 45° and lift off.
6. Pull out filter element using the clamp.
7. Check filter for mechanical damage.
8. Check O-rings and replace if required.
Installing element with propeller at standstill
Action
1. Carefully position new filter element on the filter element support spigot in the hou-
sing (note clamp position on filter element!).
2. Install cover, manually install cover screws and tighten diagonally to
45 Nm.
3. Close oil drain plug.
4. Install vent screw.
5. Position switch lever in center position and fill filter unit until oil emerges from the vent
screw on the cover.
6. Close vent screw.
7. Return switch lever to one side.
8. Check filter for leaks.
For further information regarding the duplex filter Î Page 9-1, Chapter 9.1 „Compon-
ents supplier documentation”, under "Duplex filter".
i
Revision: 000-v6r4
Created: 2007-6-1
SSNr.: 1822056851000
VGNr.: 000
7-63
7.11.8.2 Checking and replacing control oil filter
7.11.8.2.1 Duplex filter
The duplex filter consists of two exchangeable filter units.
Components
R51422010
Fig. 7-23 Duplex filter, control oil
1 Ventilation screw for pressure release 3 Contamination indicator

2 Switch lever
Revision: 000-v6r4
Created: 2007-6-1
SSNr.: 1822056851000
VGNr.: 000
7-64
7.11.8.2.2 Contamination indicator
The duplex filter is equipped with an opto-mechanical contamination indicator (3).
Indicator Degree of contamina- Action

(red pin) tion
Not visible Contamination < 100% No measures required
Visible Alarm at • Switch filter to clean filter unit

100 % contamination
• Replace contaminated filter element
Note
Applicable only at oil
temperatures of
> 40 °C
Tab. 7-3 Contamination indicator, opto-mechanical
The indication is only correct at operating temperature > 40 °C. At temperatures be-
low this value, no alarm is displayed. (Temperature suppression).
The contamination indicator pin is not equipped with temperature suppression and in-
i
dicates the alarm!
For further information regarding the contamination indicator

Î Page 8-1, Chapter 8 „Drawings and schematics”, under Oil supply, drawing "Moni-
toring".
Î Page 9-1, Chapter 9.1 „Components supplier documentation”, under "Contamina-
tion indicator".
Revision: 000-v6r4
Created: 2007-6-1
SSNr.: 1822056851000
VGNr.: 000
7-65
7.11.8.2.4 Replacing filter element
Precondition
• At standstill
• Standby pump is off
Element removal
Action
1. Determine which filter unit is being used.
2. Tilt switch lever (2) by 90°.
3. For pressure release carefully slacken vent screw (1) of the filter unit that is no longer
in operation and release pressure.
4. Open oil drain plug (below the filter unit to be cleaned) of the filter unit that is no lon-
ger in operation and drain contaminated oil into a suitable container.
5. Remove cover (hex bolt A/F 36).
6. Remove filter element from filter element support spigot.
7. Check filter for mechanical damage.
8. Check O-rings and replace if required.
Element installation
Action
1. Carefully position new filter element on filter element support spigot in housing.
2. Install cover, manually insert cover screws and tighten.
3. Close oil drain plug.
4. Tilt switch lever towards the front and fill filter unit until oil emerges from the vent
screw on the cover.
5. Close vent screw.
6. Tilt switch lever back.
7. Check filter for leaks.
For further information regarding the duplex filter Î Page 9-1, Chapter 9.1 „Compon-
i ents supplier documentation”, under "Duplex filter".

Revision: 000-v6r4
Created: 2007-6-1
SSNr.: 1822056851000
VGNr.: 000
7-66
7.11.9 Oil pressure
7.11.9.1 Checking oil pressure
Interval
• Daily with propeller running
Components
p1 p2 p3
G21420010
Fig. 7-24 Pressure gauge (on propeller)
• p1: Control oil pressure

• p2: Lube oil pressure
• p3: Rotor oil pressure
Revision: 000-v6r4
Created: 2007-6-1
SSNr.: 1822056851000
VGNr.: 000
7-67
Action
Caution!
During exceptional operating conditions* rotor oil pressure p3 may be zero. If this is
the case for longer periods of time, the oil temperature in the propeller can rise and
cause damage!
Ö Observe oil temperature during exceptional operating conditions!
*Exceptional operating conditions are:

• Insufficient speed
• Excessive control system actuation
• Insufficient pump output
• Excessive oil temperature
Ö Read off oil pressure on pressure gauges p1, p2 and p3.
Result
Pressure Pressu- Permissible Alarm* Setting possibility

measuring re set- pressure deviati-
range ting* on at rated speed
Control oil 100 bar ±5 bar 70 bar On the pump unit

pressure p1
Standby 90 bar
pump
(during sole
operation)
Lube oil 2 bar +1.0/-0.5 bar 0.5 bar At the valve assem-
pressure p2 bly
Rotor oil 1 bar ±0.5 bar -

pressure p3
Tab. 7-1 Oil pressures on propeller
Revision: 000-v6r4
Created: 2007-6-1
* The stated pressures apply to operating speed and operating temperature.

SSNr.: 1822056851000
VGNr.: 000
7-68
7.11.9.2 Setting oil pressure
7.11.9.2.1 Setting control oil pressure p1
The control oil pressure is set on the main pump as well as on the standby pump.
Main pump
R51423010
Fig. 7-25 Pressure setting at the main pump (control oil)
1 Valve spindle
Standby pump
Revision: 000-v6r4
Created: 2007-6-1
1
R51423020
Fig. 7-26 Pressure setting at the standby pump (control oil)
1 Valve spindle
SSNr.: 1822056851000
VGNr.: 000
7-69
Action
1. Remove valve cap of valve precontrol.
2. Slacken locknut and readjust valve spindle (1) until the pressure on the pressure
gauge reaches the desired value.
Pressure increase
Turning clockwise results in a pressure increase.
Pressure reduction
Turning anticlockwise results in a pressure decrease.
3. Tighten locknut and install valve cap.
For further information regarding monitoring Î Page 8-1, Chapter 8 „Drawings and
i schematics”, "Monitoring system" drawing.
For further information regarding main pump and standby pump

Î Page 9-1, Chapter 9.1 „Components supplier documentation” under "Control sys-
tem".
Revision: 000-v6r4
Created: 2007-6-1
SSNr.: 1822056851000
VGNr.: 000
7-70
7.11.9.2.2 Setting lube oil pressure p2 and rotor oil pressure p3
The valves are used to set the lube and rotor oil pressure.
Components
1 2
G21423040
Fig. 7-27 Valve spindle, lube and rotor oil pressure
1 Valve spindle, lube oil pressure p2 2 Valve spindle, rotor oil pressure p3
Precondition
• Lube oil pressure p2
Carry out pressure setting at rated speed only.
• Rotor oil pressure p3
Set pressure when the oil is cold.
Action
1. Remove valve cap of the respective valve.
2. Slacken locknut and readjust valve spindle (1) until the pressure on the pressure
gauge reaches the desired value.
Pressure increase
Revision: 000-v6r4
Created: 2007-6-1
Turning clockwise results in a pressure increase.
Pressure reduction
Turning anticlockwise results in a pressure decrease.
3. Tighten locknut and install valve cap.
For further information regarding monitoring Î Page 8-1, Chapter 8 „Drawings and
schematics”, "Valves and filters" drawing.
i
SSNr.: 1822056851000
VGNr.: 000
7-71
7.11.9.3 Checking oil level
Interval
• Daily at unit standstill, approx. 10 hrs after shutting down.
Components
2
G21473000
Fig. 7-28 Elevated oil tank
1 Oil level 2 Pushbutton
Action
Caution!
Risk of oil escaping!
Oil tanks that are frequently empty can indicate oil leakage outboard. If traces of oil
are found outboard or if oil loss is found in the propeller housing, the vessel must be
docked in immediately.
Revision: 000-v6r4
Created: 2007-6-1
Ö Check blade shaft seals (Î Page 7-25, Chapter 7.4 „Blades and blade bea-
rings”).
1. Update oil level indication by pressing the pushbutton. The oil level must be visible
in the sight glass or change.

2. If no oil is visible, operate the hand pump until the tank is full.
For further information regarding the elevated oil tank Î Page 8-1, Chapter 8 „Dra-
i wings and schematics”, "Elevated oil tank" drawing.

For further information regarding the float switch Î Page 9-1, Chapter 9.1 „Compon-
SSNr.: 1822056851000
ents supplier documentation” under "Float switch".

VGNr.: 000
7-72
7.11.9.4 Hose lines
7.11.9.4.1 Checking hose lines
Interval
• every 1000 hrs
Components
2
R51443010
Fig. 7-29 Hose lines
1 Hose lines, control 2 Hose lines, control rod

Revision: 000-v6r4
Created: 2007-6-1
SSNr.: 1822056851000
VGNr.: 000
7-73
Action
Danger
Extremely severe injuries!
Inappropriate handling or choice of hose lines can result in

fatal accidents, injuries and material damage.
1. Use specified hose lines (DIN 20066).

2. During disassembly:
- Hydraulic circuits not pressurized
- Pumps switched off
- Drive unit switched off
- Entire plant secured against switching on
1. Remove indicator plate.

2. Illuminate propeller space.
3. Check hose lines for damage.
Checks to be carried out
Check Measure for Findings Recommended measure to

checking rectify fault
• Leaks • Elevated oil tank and • Leaks • Renew hose line

control oil tank must • Hose fitting loose
be filled
• Brittleness • Locally deform hose • Cracks in rubber

line
• Clearance • Check for clearance • Hose line contacts pro- • Alter installation position
• Damage • Check hose line for peller components or has • Renew hose line
signs of chaffing already been damaged. • Request customer service
Tab. 7-2 Hose line condition

Revision: 000-v6r4
Created: 2007-6-1
SSNr.: 1822056851000
VGNr.: 000
7-74
Consequences of leaking hose lines

Hose line to control rod
• During propeller operation
– less oil for heat dissipation to rotor casing
• At standstill
– oil loss in elevated oil tank
Hose lines for control

• Delayed or insufficient hydraulic cylinder adjustment
• Loss of control and lube oil
• Inability to maneuver
Service life of hose lines

Hose lines are subject to natural ageing even when stored and used correctly. Their
service life is therefore limited!
As per DIN20066 the service life of hose lines should not exceed six years (including
the shelf life of max. two years).
Service life is defined as usage and shelf life of a hose line commencing on the date
of manufacture.
For further information regarding the control hose lines Î Page 9-1, Chapter 9.1
„Components supplier documentation” under "Control system" in the "Operation ma-
nual for hydraulic units". i
Revision: 000-v6r4
Created: 2007-6-1
SSNr.: 1822056851000
VGNr.: 000
7-75
7.11.10 Checking and setting sight feed oilers to main seal
Interval
• Weekly with propeller running
Components
1 2 3
G21430000
Fig. 7-30 Sight feed oilers for lower and center shaft seal
1 Sight feed oiler for center shaft seal 5 Bleeding valve

2 Sight feed oiler for lower shaft seal 6 Bleeding valve
3 Setting screw 7 Setting screw
4 Instruction plate 8 Instruction plate
Revision: 000-v6r4
Created: 2007-6-1
SSNr.: 1822056851000
VGNr.: 000
7-76
Action
Precondition
• With the propeller running and the oil at operating temperature every sight feed oiler
should release two to three drops per minute into the lines to the lower and center
shaft seals of the main seal.
• Set sight feed oiler only with the oil at operating temperature! At propeller standstill
and when the oil is cold, the sight feed oilers do not release any oil.
1. Select sight feed oiler. Note instruction plates (4 or 8) on the propeller housing!
2. Remove protective cap of the setting screw (3 or 7).
3. Open bleeding valve (5 or 6).
4. Turn setting screw until two to three drops per minute are released into the line.
Increasing number of drops
Turn setting screw anticlockwise.
Reduce number of drops
Turn setting screw clockwise.
5. Close bleeding valve.
If the sight feed oiler does not release any oil after a short time despite being set cor-
rectly, the oil quantity in the sealing chamber is already sufficient.
As soon as the oil is used up, the release sequence automatically returns to normal. i
Revision: 000-v6r4
Created: 2007-6-1
SSNr.: 1822056851000
VGNr.: 000
7-77
7.11.11 Oil change
Interval
• Visual check (oil sample) every 1000 hrs
• Analysis and oil change every 4000 hrs
Action
Ö Check control and lube oils and analyze and/or replace as required.
Note
Do not confuse housing base for lube and control oil!
With the help of correct oil maintenance and oil testing the change intervals can be
i increased significantly.
For further information regarding lubricant and oil supply Î Page 7-50, Chapter 7.11
„Lubricant and oil supply”.
For further information regarding control oil changeÎ Page 9-1, Chapter 9.1 „Compo-
nents supplier documentation” under "Control system".
Revision: 000-v6r4
Created: 2007-6-1
SSNr.: 1822056851000
VGNr.: 000
7-78
7.11.12 Checking oil pumps
Caution!
Oil pumps failure!
Ö Follow the documentation of suppliers!
Interval
• Every 4000 hrs
Action
Ö Check oil pumps for running and flow noise and have pump replaced if required.
Always check at operating temperature and rated speed.
For further information regarding the lube oil pump Î Page 9-1, Chapter 9.1 „Compo-
nents supplier documentation” under "Gear pump"
i
For further information regarding the control oil pumps Î Page 9-1, Chapter 9.1
„Components supplier documentation” under "Control system".
7.11.13 Checking and cleaning oil cooler
Danger
Risk of scalding!
The oil and coolant circuits must have been depressurized

prior to opening the oil cooler.
Ö Never open the oil cooler with the plant running.
Interval
• As per manufacturer's instructions at standstill and depressurized cooling system
Revision: 000-v6r4
Created: 2007-6-1
For further information regarding the oil cooler

Î Page 8-1, Chapter 8 „Drawings and schematics”, "Oil cooler" drawing and
Î Page 9-1, Chapter 9.1 „Components supplier documentation” under "Oil cooler" i
For further information regarding the thermostat Î Page 7-56, Chapter 7.11.6 „Oil
temperature”.
SSNr.: 1822056851000
VGNr.: 000
7-79
7.11.14 Measuring and monitoring equipment
7.11.14.1 Checking measuring and monitoring equipment
Interval
Action
Ö All measuring and monitoring equipment installed on the propeller (e.g. pressure and
temperature sensors) must be checked using a suitable calibration device.
Result
Following prolonged use of the measuring and monitoring equipment, the deviation /
switch accuracy must not be more / less than 5 % of the indicator scale. Recalibrate
or replace the measuring / monitoring device as required.
Revision: 000-v6r4
Created: 2007-6-1
SSNr.: 1822056851000
VGNr.: 000
7-80
7.12 Drive unit
7.12.1 Shaft line
7.12.1.1 Checking shaft line alignment
Interval
Action
Ö The shaft line must be checked for compliance with the installation specifications and
aligned if required.
For further information regarding the shaft line Î Page 9-3, Chapter 9.1.3 „Shaft
line”.
i
7.12.2 Couplings
7.12.2.1 Checking couplings
Coupling maintenance and inspection must be carried out as per manufacturer's spe-
cifications.
For further information regarding the couplings Î Page 9-3, Chapter 9.1.3 „Shaft
line”.
i
Revision: 000-v6r4
Created: 2007-6-1
SSNr.: 1822056851000
VGNr.: 000
7-81
7.13 Control system
7.13.1 Checking control system
Caution!
Failure of the control system!
Ö Noticing operator’s manual of the manufacturer.
Interval
• After every undocking
• Every 5000 hrs or yearly
Action
Ö Move both joysticks to Neutral.
Result
At this setting the pointer below the indicator plate must be exactly in the center.
For further information regarding maintenance and inspection of the control system
i Î Page 9-1, Chapter 9.1 „Components supplier documentation” under "Control sys-
tem".
Revision: 000-v6r4
Created: 2007-6-1
SSNr.: 1822056851000
VGNr.: 000
7-82
7.14 Tools
The standard tools for the VSP are stored in a lockable metal toolbox. Large special
tools are supplied in a separate transport box. A list of the entire tool content is located
on the inside of the toolbox.
The tools are required by Voith personnel to carry out repair work. Missing or defective
tools significantly impair repair work and can cause delays.
7.14.1 Checking tools

i
Interval
• Every 10000 hrs in the depot or on board
Action
Ö Check tool content for completeness using the content list and replace missing or da-
maged tools if required.
Revision: 000-v6r4
Created: 2007-6-1
SSNr.: 1822056851000
VGNr.: 000
7-83
7.15 Spare parts
7.15.1 Renewing corrosion protection
External corrosion protection is via coatings:
Application Corrosion Supplier

inhibitor
European countries DINITROL 3654 DINOL GmbH

Wilhelm-Stein-Weg 2
22339 Hamburg
Germany
Phone: +49 (0) 40 5 38 20 61
ROW TECTYL 506 VALVOLINE OEL GmbH & Co.

Überseering 9
PO Box 602829
22297 Hamburg
Germany
Phone: +49 (0) 40 6 31 46 64

Tab. 7-1 Corrosion inhibitor
Interval
• Every 10000 hrs in the depot or on board
Action
Ö Carefully remove external corrosion inhibitor as per manufacturer's instructions and
reapply.
Note
Do not apply the corrosion inhibitor on top of the oil coating as several layers will be
difficult to remove prior to use of the spare part!
Revision: 000-v6r4
Created: 2007-6-1
SSNr.: 1822056851000
VGNr.: 000
7-84
7.15.2 Spare parts ordering
Caution!
Plant failure!
The use of components that have not been tested and supplied by Voith can result in
plant failure. This will void the warranty!
Ö Only original Voith parts must be used for plant repair.
Required informationen
For the order of spare parts the following data are required:
Detail Place of the information
Codeword Type plate on the housing cover
Propeller-No.
Part-No. Drawing and Schematics

Î Page 8-1, Chapter 8 „Drawings and schematics”
Order-No. Part-No. list

Î Page 10-2, Chapter 10.2 „Parts list”
Designation
Tab. 7-1 Details for the order of spare parts
Action
1. Look up part number of the part required in the relevant assembly drawing
(Î Page 8-1, Chapter 8 „Drawings and schematics”).
2. Find part number in the part-no. list (Î Page 10-2, Chapter 10.2 „Parts list”) and wri-
ting down needed data on the inquiry-/order form.
3. Sending inquiry-/order form by fax to
Voith Turbo Marine, department ams, +49 (0) 7321 37-7105
Note
Revision: 000-v6r4
A template of the inquiry-/order form is on the enclosed CD.

Created: 2007-6-1
Ordering spare parts on time before the beginning of the specified maintenance inter-
vals.
i
SSNr.: 1822056851000
VGNr.: 000
7-85
7.15.3 Storing propeller
7.15.3.1 Storage area
The storage area must meet the following requirements:

• Temperature range: 0–30 °C
• Relative humidity: 40–85 %
7.15.3.2 Measures for storing
Propellers that are stored for prolonged periods of time should be protected as follows
to prevent corrosion damage:
• Close connection openings for oil pressure lines, hand pump, drainage and ventila-
tion oil- and airtight.
• Fill rotor casing and housing with oil up to the housing cover.
• Apply a double coating of corrosion inhibitor (Rust Ban 397 or Tectyl 506) to the input
shaft spigots and wrap with oiled paper. Apply roller bearing grease to the input shaft
sealing ring on the housing.
• Store propeller in a closed area and cover with sail cloth to protect it against conta-
mination and moisture.
These measures apply to propellers used for commercial applications as well as to
i those used for marine applications!
7.15.4 Storing rubber parts
Caution!
Damage due to incorrect storing
Under unfavorable storing conditions or faulty treatment, most products made of na-
tural or vulcanized rubber, change their physical properties and are unusable for the
intended area of application.
Ö Observe the specifications on storage, cleaning and maintenance.

Revision: 000-v6r4
Created: 2007-6-1
7.15.4.1 Storage area
The storage area must meet the following requirements:

• Temperature range: 15–25 °C
• Relative humidity: 40–65 %

• Protect products from light! Do not expose to direct solar radiation and intense artifi-
cial light.
• No electromotors or other spark or electrical discharge-generating equipment
SSNr.: 1822056851000
VGNr.: 000
7-86
Even under the most favorable conditions the lifetime of rubber parts is limited!
See relevant standards such as

(Î Page 9-4, Chapter 9.2 „Standards”).
DIN 7716 for detailed information i
Revision: 000-v6r4
Created: 2007-6-1
SSNr.: 1822056851000
VGNr.: 000
7-87
7.16 Coating
7.16.1 Checking coating
Interval
Action
Ö Check all coated areas that come into contact with water and renew as per Voith gui-
deline VN1619 "Voith Turbo Marine Coatings" if required.
All coated areas that do not come into contact with sea water can also be checked
i with the vessel afloat and renewed if required.
For further information regarding coatings Î Page 9-4, Chapter 9.2 „Standards” un-
der "VN1619 - Voith Turbo Marine Coatings"
Revision: 000-v6r4
Created: 2007-6-1
SSNr.: 1822056851000
VGNr.: 000
7-88
Voith Turbo Schneider Propulsion | Operation Manual | VSP BOSPORUS 18R5 EC/150-1 Drawings and schematics
8 Drawings and schematics

The „Drawing and Schematics“ chapter contains the most important original
technical drawings as well as overviews where required.
8.1 Overview
8.1.1 Propeller
Pos. Designation Drawing/ Rev.

schematic No.
1 Main dimensions 1822061081000 A
2 Longitudinal section 1822069571000 –

Tab. 8-1 Propeller
8.1.2 Blade actuation

schematic No.
1 Blade bearings 1822069651000 –
2 Blade actuating gear, section 1822069631000
3 Blade actuating gear 1822069641000
4 Control rod 1822069821000

Tab. 8-1 Blade actuation
8.1.3 Rotor

schematic No.
1 Main bearing 1822069571000 –

Revision: 000-v6r4
Created: 2007-6-1
2 Main seal 1822069861000, Bl. 1–4

Tab. 8-1 Rotor
8.1.4 Stator

schematic No.
1 Rotor space ventilation 18220249310 –

Tab. 8-1 Stator
SSNr.: 1822056851000
VGNr.: 000
8-1
Drawings and schematics Voith Turbo Schneider Propulsion | Operation Manual | VSP BOSPORUS 18R5 EC/150-1
8.1.5 Oil supply

schematic No.
1 Pressure measuring device 82.1013.33 A
2 Pipes 1822069861000, Bl. 1–4 –, –
3 Scheme of oil circuit (Control oil) 1822065321000
4 Scheme of oil circuit (Lube oil) 1822065331000 A
5 Oil cooler (Control oil) 1822061691000
6 Oil cooler (Lube oil) 1822061841000 –
7 Elevated oil tank 18220288410
8 Monitoring, Propeller (Sensor list) 1822065301000
9 Monitoring, Gear (Sensor list) 1822065301000
10 Wiring diagram 1822065311000

Tab. 8-1 Oil supply
8.1.6 Drive unit

schematic No.
1 Shaft line 1822061201000 A

Tab. 8-1 Drive unit

schematic No.
1 Engine enable (schematic) 82.0172.02 B

Revision: 000-v6r4
Created: 2007-6-1

SSNr.: 1822056851000
VGNr.: 000
8-2
page: 1/3
VSP BOSPORUS Sensors for monitoring of the VSP date: 18.01.2007
Propeller (SS201010 / sensors for 1 VSP) remarks

application type techn. datas delay
sensor range
adj. by Voith
adj. by yard
switching
max. load
set point
part no.
sensor
analog
supply
output
power
on-off
range
alarm
delay
delay
no.
designation location
D11 482020 pressure prop. housing local 0-250 24 VDC It is possible to use the analog output or the
transducer / - indication bar contacts.
D11.1 switch X alarm low/high X 4-20mA 70 / X 400 Ohm 5s 0-60s At standstill of the propeller no output of acoustical
control oil 120 alarm
pressure bar
D11.2 X alarm low control X NC-contact 70 bar X 0,4 A 5s 0-60s
oil pressure (24 VDC)
D11.3 X alarm high X NC-contact 120 X 0,4 A 5s 0-60s
control oil bar (24 VDC)
pressure
D21 482030 pressure prop. housing local indicat. 0-16 bar 24 VDC It is possible to use the analog output or the
D21.1 transducer / - X alarm low lube oil X 4-20mA 0,5 bar X 400 Ohm 5s 0-60s contacts
switch pressure At standstill of the propeller no output of acoustical
D21.2 X alarm low lube oil X NC-contact 0,5 bar X 0,4 A 5s 0-60s alarm
pressure (24 VDC)
D21.3 alarm high lube X NC-contact 5 bar X 0,4 A 5s 0-60s
oil pressure (24 VDC)
D31 482040 pressure prop. housing local indicat. 0-16 bar 24 VDC It is not necessary to use the analog output or the
D31.1 transducer / - low rotor oil X 4-20mA 0,5 bar X 400 Ohm 5s 0-60s contacts for an alarm.
switch pressure The use of the analog output for remote indication
D31.2 low rotor oil X NC-contact 0,5 bar X 0,4 A 5s 0-60s may be useful.
pressure (24 VDC)
D31.3 high rotor oil X NC-contact 5 bar X 0,4 A 5s 0-60s
pressure (24 VDC)
D41 426020 filter fouling prop. housing local indicat. The electric contact (D41.1) has an alarm
D41.1 indication / control oil X alarm 100% X NC-contact 5 bar X 0,4 A 30s 0-60s suppression for cold oil (up to 32°C).
duplex filter pollution (24 VDC)
D51 427020 filter fouling prop. housing local indicat. At the lube oil duplex filter of the VSP, two filter
D51.1 indication / lube oil X alarm 100% X NC-contact 5 bar X 0,4 A 30s 0-60s fouling indications (D51+D52) are installed.
duplex filter pollution (24 VDC) A common alarm for D51.1 and D52.1 is possible
(side1) and recommended.
D52 427020 filter fouling prop. housing local indicat. The electric contacts (D51.1,D52.1) have an alarm
D52.1 indication / lube oil X alarm 100% X NC-contact 5 bar X 0,4 A 30s 0-60s suppression for cold oil (up to 32°C).
duplex filter pollution (24 VDC)
(side2)
continuation see page 2
codeword / type: title:

VSP BOSPORUS / VSP 18 R5 SENSOR LIST
Voith Turbo checked: wkmr/amsk plan no.:
Marine GmbH & Co. 2007-01-18 1822065291000
KG
contract no.: refer.: replaced by: replaced for:
Heidenheim
rev. date name chec
k.
page: 2/3
Propeller (SS201010 / sensors for 1 VSP / continuation from page 1) remarks

sensor range
adj. by Voith
adj. by yard
switching
max. load
set point
part no.
sensor
analog
supply
output
power
on-off
range
alarm
delay
delay
no.
L11 480130 level switch prop. X alarm low level in X NO-/NC- low X 0,4 A 30 s 0-60s
housing / control oil tank contact level (24 VDC)
control oil
tank
L21 820010 level switch elevated oil X alarm low level in X NO-/NC- low X 0,4 A 30 s 0-60s
tank elev. oil tank contact level (24 VDC)
L22 480050 level switch prop. X alarm low level in X NO-/NC- low X 0,4 A 30 s 0-60s
housing / lube oil tank contact level (24 VDC)
lube oil tank
T11 480100 resistance prop. X local indicat. 0-100
T12 480150 thermometer housing / X alarm high X Pt100 °C 80 °C X <2 mA
control oil control oil (<5 VDC)
tank temperature
T21 480020 resistance prop. X local indicat. 0-100
T22 480070 thermometer housing / X alarm high lube X Pt100 °C 75 °C X <2 mA
lube oil tank oil temperature (<5 VDC)
Control (SS205070 / sensors for 1 VSP)

K01.1 at alarm main control X alarm failure in X NO-/NC- X 0,4 A
720040 control system cabinet of main control contact (24 VDC)
VBR-D system
control
system
K01.2 at alarm redundant control X alarm failure in X NO-/NC- X 0,4 A
720040 control system cabinet of redundant contact (24 VDC)
VBR-D control system
control
system
K13 at zero position control X zero position of X NO-/NC- X 0,4 A Without VSP in zero position, the normal “propeller
720040 signal cabinet of propeller pitch contact (24 VDC) start” has to be prevented.
VBR-D An additional „emergency propeller start“-push
control button for propeller start in case of emergency
system operation has to be also provided (see drawing
82.0172.02)

Marine GmbH & Co. 2007-01-18 1822065291000
KG
Heidenheim
rev. date name chec
k.
page: 3/3
K02.1 at low voltage control X alarm low X NO-/NC- X 0,4 A

720040 alarm main cabinet of voltage in main contact (24 VDC)
control system VBR-D control system
control
system
K02.2 at low voltage control X alarm low X NO-/NC- X 0,4 A
720040 alarm redundant cabinet of voltage in contact (24 VDC)
control system VBR-D redundant
control control system
system
Remarks:
The electric indication of the alarms (visual and/or audible) on the bridge and/or in the engine control room and the required cables have to be supplied by the shipyard in accordance with the specified
standard.
The delay of the signals/alarms have to be provided in the automation-/alarm-system of the vessel (no Voith supply).
Details for propeller start (signal K13) see remarks at sensor no. K13 and drawing 82.0172.02.
Details of the sensors and the technical datas see data sheets of the sensor-subsuppliers.
Wiring of the terminal box of the alarm sensors at the VSP see drawing 1822065311000
Location of sensors see pipe layout .
proposal for alarms (which have to be installed):

VSP x: control oil pressure
VSP x: control oil temperature
VSP x: control oil level
VSP x: control oil filter fouling
VSP x: lube oil pressure
VSP x: lube oil temperature
VSP x: lube oil level (elevated oil tank)
VSP x: lube oil level (prop.housing)
VSP x: lube oil filter fouling
VSP x: failure main control system
VSP x: failure redundant control system
VSP x: low voltage main control system
VSP x: low voltage redundant control system

Marine GmbH & Co. 2007-01-18 1822065291000
KG
Heidenheim
rev. date name chec
k.
page: 1
VSP BOSPORUS Sensors for monitoring of the Kumera gearbox date: 2007-01-26
Sensors for 1 shafting remarks

sensor range
adj. by Voith
adj. by yard
switching
max. load
set point
part no.
sensor
analog
supply
output
power
on-off
range
alarm
delay
delay
no.
T71 temperature Kumera X alarm high oil X NO-/NC- 80°C X 0,4 A

switch gearbox temperature contact (24 VDC)
housing
D71 pressure Kumera X alarm low oil X NO-/NC- 3 bar X 0,4 A 5s 0-60s
switch gearbox pressure contact (24 VDC)
housing
Remarks:
The electric indication of the alarms (visual and/or audible) on the bridge and/or in the engine control room and the required cables have to be supplied by the shipyard in accordance with the specified
standard.
The delay of the signals/alarms have to be provided in the automation-/alarm-system of the vessel (no Voith supply).

VSP BOSPORUS/ VSP 18 R5 SENSOR LIST
Voith Turbo checked: Wkmr/amsk plan no.:
Marine GmbH & 2007-02-15 1822065301000
Co. KG
Heidenheim
rev. date name check.
Voith Turbo Schneider Propulsion | Operation Manual | VSP BOSPORUS 18R5 EC/150-1 Annex
9 Annex
The „Annex“ chapter contains the most important technical documents of sup-
pliers and the address to purchase the standards specified in this operation ma-
nual.
9.1 Components supplier documentation
Filed in
The individual manuals are filed in the "Component supplier documentation“ book.
i
9.1.1 Stator
Pos. Designation Type Supplier
370080 Aeration filter, ELF P7 F10W1.0 Hydac

Control oil
375050 Aeration filter,

Lube oil
390090 Non-return valve RK 44 DN50 PN16 Gestra

Tab. 9-1 Stator
9.1.2 Ölversorgung
Pos. Benennung Typ Lieferant
410012 Axial piston pump ABYAG-A10VSO 45 Bosch-

(Steueröl) Rexroth
410100 Pump unit ABVPG-A10VSO 18

(Steueröl)
410312 Gear pump R45/80 Rickmeier

(Schmieröl) FL-Z-DB16-W-SAE2-L-SO
Revision: 000-v6r4
Created: 2007-6-1
420010 Control block ABVSK-AGEV1 Bosch-

(Steueröl) Rexroth
420140 Valve assembly HB 4 A 0325 A Kracht

(Schmieröl)
SSNr.: 1822056851000
VGNr.: 000
9-1
Annex Voith Turbo Schneider Propulsion | Operation Manual | VSP BOSPORUS 18R5 EC/150-1
Pos. Benennung Typ Lieferant
425426 Double filter R 240 BN/HC 10 Hydac

(Control oil)
425427 Double filter RFLD BN/HC 501

(Lube oil)
426020 Contamination indicator VD 5 LE.1/-32C

(Control oil)
427020 Contamination indicator

(Lube oil)
460010 Oil cooler KS12-BCN-421 BC L400 HS Cooler

(Lube oil)
460465 Oil cooler RD50111 Bosch-

(Control oil) Rexroth
480020 Thermometer K422104102110 SIKA

(Lube oil)
480050 Float switch ARV-1,5-VU-L300/12 KSR Kübler

(Lube oil) -V44A-VERST
480070 Temperature sensor MBT5250 Danfoss

(Lube oil)
480100 Thermometer K422104102110 SIKA

(Control oil)
480130 Float switch ARV-1,5-VU-L225/12 KSR Kübler

(Control oil) -V44A-GL
480150 Temperature sensor MBT5250 Danfoss

(Control oil)
480240 Pressure transducer MBS5100
480300 Speed sensor FA1J-4E-70 NORIS

Revision: 000-v6r4
Tachowerke
Created: 2007-6-1
482020 Pressure switch EDS 347-4-250-SO1 Hydac

(Control oil)
482030 Pressure switch EDS 347-4-016-SO1

(Lube oil)
Tab. 9-1 Oil supply

SSNr.: 1822056851000
VGNr.: 000
9-2
Voith Turbo Schneider Propulsion | Operation Manual | VSP BOSPORUS 18R5 EC/150-1 Annex
9.1.3 Shaft line
512010 Intermediate gear FV-355 Kumera
512020 Curved-tooth coupling SBG125 Special Renk
512030 Coupling CM-7000-SCEW-60 Centa

Tab. 9-1 Shaft line
700720 Control system VBR-D control Bosch-Rex-

roth
– Oil supply Hydraulic unit

Revision: 000-v6r4
Created: 2007-6-1
SSNr.: 1822056851000
VGNr.: 000
9-3
370080 375050 370080 375050
Tank Breather Filters

ELF/BF/BL
Spare Parts List
Maintenance Instructions
INDEX
1. MAINTENANCE
INSTRUCTIONS
1.1. SAFETY INSTRUCTIONS
1.2. COMMISSIONING
1.3. EQUIPMENT REQUIRED FOR
CHANGING THE ELEMENT
2. MAINTENANCE
2.1. GENERAL
2.2. MAINTENANCE
PROCEDURES
2.3. INTERVAL BETWEEN
CHANGING ELEMENTS
3. CHANGING
THE ELEMENT
3.1. CHANGING THE ELEMENT
ELF/BF 5
3.2. CHANGING THE ELEMENT
ELF/BF 7
3.3. CHANGING THE CARTRIDGE
BL 162
Typ KHMFF DN 65
4. SPARE PARTS
4.1. SPARE PARTS ELF 3 AND 4
4.2. SPARE PARTS ELF/BF 5
4.3. SPARE PARTS ELF/BF 7
4.4. SPARE PARTS BL 162
5. REPLACEMENT
ELEMENTS
5.1. MODEL CODE
AIR FILTER ELEMENTS
In accordance with our Terms and

Conditions of Sale, guarantees are
subject to the use of original HYDAC
spares only and correct fitting as per
service and maintenance instructions. Typ KHMFF DN 80
370080 375050 370080 375050
1. MAINTENANCE 2. MAINTENANCE 3. CHANGING THE
INSTRUCTIONS 2.1. GENERAL ELEMENT
1.1. SAFETY INSTRUCTIONS This section describes For technical reasons, tank
maintenance work which should breather filters ELF/BF 3 and 4
– Maintenance work must only be
be carried out periodically. The can only be replaced as a
carried out by trained personnel
operational safety and life complete unit.
using the correct equipment.
– It is the responsibility of the expectancy of the filter, and
operator to comply with the water whether it is ready for use,
regulations of the country depend to a large degree on
concerned. regular and careful maintenance.
– Statutory accident prevention 2.2. MAINTENANCE
regulations, safety regulations PROCEDURES
and safety data sheets for fluids
– Spare parts must fulfil the
must be observed.
technical requirements specified
– When working on, or in the
by the manufacturer.
vicinity of, hydraulic systems,
This is always guaranteed for
naked flames, spark generation
HYDAC original spares.
and smoking are forbidden.
– Keep tools, working area and
– Draining trays, suction equipment
equipment clean.
and absorbent material should be
– After disassembling the filter,
to hand.
clean all parts, check for damage
– Hydraulic oils and water–polluting
or wear and replace if necessary.
fluids must not be allowed to enter
– When changing a filter element a
the soil or watercourses or sewer
high level of cleanliness must be
systems. Ensure safe and
observed.
environmentally–friendly disposal
of hydraulic oils. The relevant 2.3. INTERVAL BETWEEN
regulations in the country CHANGING ELEMENTS
concerned with regard to ground It is recommended that the air
water pollution, used oil and filter or air filter element is
waste must be complied with. changed every time the fluid filter
– Whenever work is carried out on is changed. There are two types
the filter, be prepared for hot oil to of filter: air filters, which have to
escape which can cause injury be replaced as a complete unit
due to high pressure or high (ELF/BF 3 and 4) and those
temperature. where only the filter element
1.2. COMMISSIONING (ELF/BF 5 and 7) or filter cartridge
(BL 162) needs to be replaced.
For ELF/BF 5 and 7 filters, check
whether the correct filter element
(1) is fitted. Replace cover (4, 6):
– ELF/BF 5: secure cover with
hexagonal nut
– ELF/BF 7: screw on cap by
hand
– BL 162: screw on filter cartridge
(1) by hand
1.3. EQUIPMENT REQUIRED FOR
CHANGING THE ELEMENT
ELF/BF 5: spanner SW 17
ELF/BF 7: none
BL 162: strap wrench
2
370080 375050 370080 375050
3.1. CHANGING THE ELEMENT 3.2. CHANGING THE ELEMENT 3.3. CHANGING THE CARTRIDGE
ELF/BF 5 ELF/BF 7 BL 162
– Remove nut – Unscrew cap (6) manually by turning – Unscrew filter cartridge (1) by turning
– Remove washer anti–clockwise anti–clockwise using
– Lift off cover (4) – Remove element (1) a strap wrench (2)
– Remove element (1) – Fit new element – Screw on new filter cartridge
– Fit new element – Screw on cap by hand
– Replace cover
– Replace washer
– Tighten nut
3 3
370080 375050 370080 375050
4. SPARE PARTS
4.1. SPARE PARTS ELF 3 AND ELF 4
(BF 3 and BF 4 are only available as complete filters)
ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ
ÁÁÁÁÁÁÁÁÁÁÁÁÁ
ÁÁÁÁÁÁÁ
Item
Designation
ÁÁÁÁÁÁÁ Consists of Stock no.
ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ ÁÁÁÁÁÁÁ
ÁÁÁÁÁÁÁ
1 seal kit–E ELF....3 F 1.0 2 cardboard seals 00318971
ÁÁÁÁÁÁÁ
seal kit–E ELF....3 F 1.0 /–RV 2 Perbunan seals 00318968
ÁÁÁÁÁÁÁ
seal kit–E ELF....4 F 1.0 2 cardboard seals 01261598
ÁÁÁÁ
2
filler strainer–E
ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ ÁÁÁÁÁÁÁ
strainer E ELF....3 F 1.0
ÁÁÁÁÁÁÁ
filler strainer
2 cardboard seals
6 screws
01261627
ÁÁÁÁÁÁÁ
ÁÁÁÁÁÁÁ
2 filler strainer–E
strainer E ELF....4 F 1.0 filler strainer 01261628
2 cardboard seals
ÁÁÁÁ
4
ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ
ÁÁÁÁÁÁÁ 3 screws
370080 375050 370080 375050
4.2. SPARE PARTS ELF 5 AND BF 5
ÁÁÁÁÁ
ÁÁÁÁÁÁÁ
ÁÁÁÁÁÁÁ
ÁÁÁÁÁ ÁÁÁÁÁÁÁ
Stock no. Stock no
ÁÁÁÁÁ
Item Designation ELF....5... BF....5...
ÁÁÁÁÁ
1 for filter elements see point 5, Spare elements
ÁÁÁÁÁ
0005 L 003 P 00309450
ÁÁÁÁÁ
0005 L 010 P 00306097
ÁÁÁÁÁ
ÁÁÁÁÁÁÁ
ÁÁÁÁÁÁÁ
0005 L 003 P /–V 00315827
ÁÁÁÁÁ
ÁÁÁÁÁÁÁ
ÁÁÁÁÁÁÁ
0005 L 010 P /–V 00314189
ÁÁÁÁÁ
ÁÁÁÁÁÁÁ
ÁÁÁÁÁÁÁ
2 ELF 5 G XX W 2.0 (without element ) 00308862 –
ÁÁÁÁÁ
ÁÁÁÁÁÁÁ
ÁÁÁÁÁÁÁ
ELF 5 G XX W 3.0 (without element ) 00312424 –
ÁÁÁÁÁ
ÁÁÁÁÁÁÁ
ÁÁÁÁÁÁÁ
ÁÁÁÁÁ
ÁÁÁÁÁÁÁ
ÁÁÁÁÁÁÁ
ÁÁÁÁÁ
ÁÁÁÁÁÁÁ
ÁÁÁÁÁÁÁ
BF 5 G XX W 1.0 (without element ) – 00313379
ÁÁÁÁÁ
ÁÁÁÁÁÁÁ
ÁÁÁÁÁÁÁ
3 filler strainer ELF....5 G 2.0 (G 2 1/2) 00248317 –
ÁÁÁÁÁ
ÁÁÁÁÁÁÁ
ÁÁÁÁÁÁÁ
filler strainer ELF....5 G 3.0 (G 3) 00405579 –
filler strainer ELF....5 G 4.0 (G 2) 00248101 –
ÁÁÁÁÁ
filler strainer ELF....5 G 5.0 (G 1 1/2) 00246872 –
4 cover–E BF.....5 W 1.0 01250862
5
370080 375050 370080 375050
4.3. SPARE PARTS ELF 7 AND BF 7
ÁÁÁÁÁ
ÁÁÁÁÁÁÁ
ÁÁÁÁÁÁÁ
ÁÁÁÁÁ
ÁÁÁÁÁÁÁ
ÁÁÁÁÁÁÁ
Stock no. Stock no.
Item Designation ELF....7... BF....7...
ÁÁÁÁÁ
1
for filter elements see point 5, Spare elements
ÁÁÁÁÁ
0007 L 003 P 00310948
ÁÁÁÁÁ
ÁÁÁÁÁÁÁ
0007 L 010 P
ÁÁÁÁÁÁÁ 00310485
ÁÁÁÁÁ
2
ÁÁÁÁÁÁÁ
ÁÁÁÁÁÁÁ
ELF 7 G XX W 1.0 (without element without pressure gauge) 00311824 –
ÁÁÁÁÁ
ÁÁÁÁÁÁÁ
ÁÁÁÁÁÁÁ
ELF 7 G XX K 1.0 (without element with pressure gauge) 00314153 –
ÁÁÁÁÁ
ÁÁÁÁÁÁÁ
ÁÁÁÁÁÁÁ
BF 7 G XX W 1.0 (without element without pressure gauge) – 00312053
ÁÁÁÁÁ
ÁÁÁÁÁÁÁ
ÁÁÁÁÁÁÁ
BF 7 G XX K 1.0 (without element with pressure gauge) – 00313950
ÁÁÁÁÁ
3
ÁÁÁÁÁÁÁ
ÁÁÁÁÁÁÁ
pressure gauge: VMF 0.6 K.0 00307851
ÁÁÁÁÁ
4
5
ÁÁÁÁÁÁÁ
filler strainer–E ELF....3 F 1.0
ÁÁÁÁÁÁÁ
ÁÁÁÁÁÁÁ
seal kit–E ELF....3 F 1.0
01261627
00318971
–
–
ÁÁÁÁÁ
ÁÁÁÁÁ
ÁÁÁÁÁÁÁ
6
ÁÁÁÁÁÁÁ
seal kit–E ELF....3 F 1.0 /–RV
cover–E BF.....7 W 1.0 (without pressure gauge)
00318968
01250863
–
ÁÁÁÁÁ
6
cover–E BF.....7 K 1.0 (with pressure gauge) 01261600
370080 375050 370080 375050
4.4 SPARE PARTS BL 162
ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ
ÁÁÁÁÁÁÁ
ÁÁÁÁÁÁÁ
ÁÁÁÁÁ
ItemÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ
Designation ÁÁÁÁÁÁÁ
ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ ÁÁÁÁÁÁÁ
ÁÁÁÁÁÁÁ
ÁÁÁÁÁÁÁ
Stock no.
BL...162 F
Stock no.
BL...162 S
ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ
ÁÁÁÁÁÁÁ
ÁÁÁÁÁÁÁ
1 filter cartridge: 0160 MU 010 P 00248055
ÁÁÁÁÁ
2
ÁÁÁÁÁÁÁ
ÁÁÁÁÁÁÁ
connection tube–E BL...162..2.0 00318824 00318825
ÁÁÁÁÁ
3
ÁÁÁÁÁÁÁ
ÁÁÁÁÁÁÁ
seal kit–E ELF....3 F 1.0 01261627 –
5. REPLACEMENT ELEMENTS
5.1. MODEL CODE FOR AIR FILTER ELEMENTS
(also order example)
0005 L 010 P
Size
0005
0007
Type
L for air filter element
Filtration in micron
003 = 3 µm absolute
010 = 10 µm absolute
Filter material
P for paper absolute filtration NOTE:
All details in this brochure are
subject to technical modifications.
7
390090 390090
Issue Date: 1/03
GESTRA® DISCO Non-Return Valves · Product Range Group A2
RK 44
Non-Return Valve RK 44
for flanges PN 6 / 10 / 16
ASME 125 /150
Application for liquids, gases, vapours.

Pressure /Temperature Rating for valves with metal-to-metal seat
Nominal sizes DN [mm] 15 – 100 125 – 200

[in] ½–4 5–8
Nominal pressure PN 16 1)
∅D
[barg] 16 14 13 16 14 13
Max. ser vice pressure
[psig] 230 200 185 230 200 185
[°C] 120 200 250 120 200 250
Related temperature
[°F] 248 392 482 248 392 482
Minimum temperature –200 °C (–328 °F) 1) –10 °C (14 °F) 1)
1) Minimum temperature at nominal pressure rating.
Soft seats
EPDM (ethylene propylene): – 40 to +150 °C (–58 to +302 °F) for water, condensate and steam.
L
FPM (fluoro rubber): – 25 to +200 °C (–13 to +392 °F) for oils, gases and air.
But also note valve pressure/temperature rating in the above table. DN 15 –100 mm
(½ – 4")
Tightness with soft seats of EPDM and FPM in accordance with DIN 3230, part 3, leakage rates
BN 1, BO 1. Permissible leakage rates with metal-to-metal seat in accordance with DIN 3230, part 3,
leakage rates BN 2, BO 3.
Chemical resistance see GESTRA data base “Chemical Resistance”.
Connections of wafer-type valves 2)

Standard valves for fitting between flanges to
DIN BS ASME
∅D
DIN 2501 (BS 4504) B 16.1 class 125 FF
BS 10 tables D, E, F
PN 6/10/16 B 16.5 class 150 RF3)
2) DN 15 –100 mm (1/2 – 4") with universal centering ring.
3) ASME class 150 RF only suitable for DN 125 – 200 mm (5 – 8").
Dimensions
[mm] 15 20 25 32 40 50 65 80 100 125 150 200
DN 1/ 2 3/4
[in] 1 11/4 11/2 2 21/2 3 4 5 6 8
4
Dimensions L ) 16 19 22 28 31.5 40 46 50 60 90 106 140 L
[mm] D 42 49 58 74 84 97 117 132 152 184 209 264 DN 125 – 200 mm
(5 – 8")
Weight [kg] 0.1 0.2 0.25 0.5 0.7 1.1 1.4 2 3.2 7.7 11 22
4) Overall ^ DIN 3202, part 3, series K 4).
length according to DIN EN 558-1, table 11, series 49 (=
Materials
DN 15 – 100 mm (½ – 4") DIN reference ASTM equivalent
Body, seat and guide ribs CuSn 10 – Cu CC480K-GS B 584 C90 500
Valve disc, spring retainer A 182 F 316
X6CrNiMoTi 17 12 2 1.4571
Spring A 313 Type 316
Centring ring X12CrNi 17 7 1.4310 A 313 Type 302
DN 125 – 200 mm (5 – 8")
Body EN-GJL-250 EN-JL 1040 A 126 Class A
Seat, valve cone and spindle
Guide suppor t CuSn10 – Cu CC480K-GS B 584 C90 500
Spindle guide
Spring X6CrNiMoTi 17 12 2 1.4571 A 313 Type 316
390090 390090
DISCO Non-Return Valve RK 44
for flanges PN 6 / 10 / 16
ASME 125/150
Opening pressures Pressure Drop Chart ρ

V̇w = V̇ ·
Differential pressures at zero volume flow. The curves given in the chart are valid for water 1000
at 20 °C. To read the pressure drop for other
DN Opening pressures [mbar] fluids the equivalent water volume flowrate V̇w = Equivalent water volume flow
Direction of flow must be calculated and used in the graph. in [l/s] etc.
without The values indicated in the chart are applicable ρ = Density of fluid (operating condition)
mm in with springs in [kg/m³] etc.
springs to spring-loaded valves with horizontal flow.
➝
➝
➝
With vertical flow insignificant deviations occur V̇ = Volume of fluid (operating condition)
15 ½ 2.5 25 22.5 20 only within the range of partial opening. in [l/s] etc.
20 ¾ 2.5 25 22.5 20
25 1 2.5 25 22.5 20
32 1¼ 3.5 27 23.5 20
40 1½ 4.0 28 24.0 20
50 2 4.5 29 24.5 20
65 2½ 5.0 30 25.0 20
80 3 5.5 31 25.5 20
100 4 6.5 33 26.5 20
125 5 12.5 35 22.5 10
150 6 14.0 38 24.0 10 When selecting valve please consider
200 8 13.5 37 23.5 10
Partial opening = instable range Full opening = stable range
1 mbar = 0.0145 psi = 10 mm w.g. = 0.4 in w.g.
On request at extra charge, special springs for lmp. [m³/h] [l/s] DN
opening pressures: gal/min. mm
700 200
■ between 5 and 1000 mbar
2000
for DN 15–50 mm (½–2"),
■ between 5 and 700 mbar 100 200
for DN 65 and 80 mm (2½–3"), 1000
■ between 5 and 500 mbar 60 150
for DN 100–200 mm (4–8"). 600
40
125
400 100 30
Enquiry Specification 100
300
GESTRA DISCO non-return valve RK 44, 20 80
PN 6 /10 /16 . 200 65
Wafer design with extremely short overall
10
length to DIN EN 558-1, table 11, series 49. 100 50
Suitable for fitting between flanges to DIN, BS
6 40
or ASME. Indications on pressure, nominal size
60
(DN), body material. Metal-to-metal seat or soft 4 32
seat (EPDM or FPM). 40 3
10
30 25
2
Order Specifications
20
Type RK 44, DN... 20
Metal-to-metal or soft seat (EPDM or FPM). 1
10
Fluid, flowrate, pressure and temperature.
Type of pipe flanges. 0.6 15
6
Note 0.4
The valves should not be used on compressors 4 0.3
1
or where pulsating flow exists. 3
0.2
For these applications please consult us.
2
0.1
1
0.6 0.2 0.06

Volume flow V̇w
These products comply with the requirements

of the EC Pressure Equipment Directive (PED) 0.04
0.4
97/23/eec. DN 65–200 with CE marking. 0.1 0.03
0.3
DN 15–50 are excluded from the scope 0.02
of this Directive and not entitled to bear the 0.6 0.01 0.02 0.03 0.04 0.06 0.1 0.2 0.3 0.4 0.5 bar
CE marking.
Supply in accordance with our general terms of 0.1 0.2 0.3 0.4 0.6 1 2 3 4 5 6 7 psi
business.
Pressure drop [∆p]
®
GESTRA GmbH
P. O. Box 10 54 60, D-28054 Bremen
Münchener Str. 77, D-28215 Bremen
Telephone +49 (0) 421 35 03 - 0, Fax +49 (0) 421 35 03 - 393
E-Mail gestra.gmbh@flowserve.com, Internet www.gestra.de
810009-02/103c · © 1975 GESTRA GmbH · BREMEN · Printed in Germany

410312 410312
−−−−−−−−−−−−−−−−−−−−−−−−−−−−−−−−−−−−−−−−−−−−−−−−−−−−−−−−−−−−−−−−−−−−−−−−−−−−−−−−−−−−−−
RICKMEIER WP Page 1
GEAR PUMP Date 08.02.07
R45/80 FL−Z−DB16−W−SAE2−L−SO Rev.0/16.06.04
−−−−−−−−−−−−−−−−−−−−−−−−−−−−−−−−−−−−−−−−−−−−−−−−−−−−−−−−−−−−−−−−−−−−−−−−−−−−−−−−−−−−−−
Object−no. : 421542
Flow diagr. :
Documentation : FZ3−1003−330160−3
−−−−−−−−−−−−−−−−−−−−−−−−−−−−−−−−−−−−−−−−−−−−−−−−−−−−−−−−−−−−−−−−−−−−−−−−−−−−−−−−−−−−−−
Pos Qty Description Object−no. Rev.
−−−−−−−−−−−−−−−−−−−−−−−−−−−−−−−−−−−−−−−−−−−−−−−−−−−−−−−−−−−−−−−−−−−−−−−−−−−−−−−−−−−−−−
1 1 DRIVING COVER 186228−3
R45 FL−W−L−SO
EN−GJS−400−18−LT
2 1 GEAR CASING 185546−9
R45/80 SAE2−L−SO
3 1 PRESSURE RELIEF VALVE 182030−7

R45 DB16
4 1 DRIVING GEAR SHAFT 168018−0
R45/80 Z−SO
16MNCRS5+FP
5 1 GEAR SHAFT 167821−8

R45/80
16MNCRS5+FP
9 4 HEXAGON HEAD SCREW 250313−4
DIN 931−M12X140−8.8
STAHL
10 2 PARALLEL PIN 253108−5
DIN 7−8M6X28−ST
STAHL
11 1 CIRCLIP 252925−3
WP−N 8−1274−40X1,75
FEDERSTAHL
12 1 KEY 253856−9
DIN 6885−A8X7X40
C45+C
15 2 O−RING 258150−2
DIN 3771A−101,27X2,62−NBR70 (2−155)
NBR70
16 1 ROTARY SHAFT SEAL 259199−8
WP−N 8−1585/01−SV30X40X7−NBR
NBR

P %
QR k"%$ )!V!g ZK l ` )

8_? )j r\s thuQv?wjQRx#Qy y x#zV{| #} P y ~Q

@ $ 6 "%BA3:?>3C -D,?93=0;EF>3,?=. - S " T UV!WXZY[$'! N 2
]F:?:=3I?7039?:3_`& "%+ a7930- 03,-- #N$ )R )
& WX
)!V 2F:=<-L,

!#"%$ &'
(')
*&' +,- . ,, @ $ 6 GHA3:?>3C -D,?93=0;EF>3,?=. ,I 2
]F:?013:--^,?I3_`& "%+ a,3>7?73::?: *bdc e @R. S "NmJ![ f /%J!Kn7[/ $' ?
l6 & )
6#!! a
R /%. 011- ,32#$ 4 J!. KL $ "%
& & M; ? + N *bdc e @R. S "N Sgf 2#WX/%J!e`eh:0I c 2'Wg[i/J>98::=I8709:L--7980V-%0,j-- S ! )
&'
X* !(!$ UpY_` $ . #Up & N"% 6
5'")
& 6 879;:<- OLOLO + + N c 2'Wg[i/JR7,8:01:j--,IL-,>787:::j-- k ! & X*%oV )
)
p qKn_ Kn & $ N pk/\KLW
/%. 01=?>=32#$ 4 2
]F:?0130?7<-^,-^_`& "%+ a>7-L7=-L=> )
&'. c N[ + a/\J87?,00?19?1:I

410312 410312
BA2-0NNN-112
Operating and Maintenance Instructions for Gear Pumps and Units AN-ZU: 01
Series R25, R35, R45, R65, R95 Bearb.: Web/31.05.06
Gepr.: Lü/09.06.06
English name/date
page 1 (8)
Contents Page Contents Page
Important General Information 1 5.2 Sense of rotation and direction of flow 5
1 Using gear pumps 2 5.3 Reversing the sense of rotation 5
2 Flow medium 2 6 Commissioning 5
3 Operating dangers 2 7 Operation/Function 6
3.1 Safety-conscious working procedure 2 7.1 Pressure relief valve 6
3.2 Dangers in case of failure to observe 2 7.2 Dry running 6
safety precautions 7.3 Environmental protection 7
3.3 Using pressure relief valve R25, R35 3 8 Dismantling 7
4 Transport and storage 3 9 Maintenance/Service 7
4.1 Storage 3 10 Conversion/Changes to gear pump 7
4.2 Lifting pump/pump unit 3 11 Decommissioning 7
5 Setup/Installation/Mounting 4 12 Malfunctions/Causes/ 7
5.1 Suction pipe design, NPSHR value 4 Troubleshooting Measures
Important General Information

In addition to the information provided in these operating instructions, the following
documents must also always be observed:
1. The order data sheet from RICKMEIER GmbH shipped with the product.
2. In case of a planned deviation from the operating conditions in the order data sheet, please
observe the operating instructions and limits for use in the applicable RICKMEIER GmbH
pump catalog.
3. Other instructions (for pump units, e.g. the operating instructions of the drive motor).
4. When using in a potentially explosive environment, the ATEX operating instructions
BA2-0NNN-113 from RICKMEIER GmbH must also be observed. The information provided
there on the use of the pump have priority over the corresponding information of these
operating and maintenance instructions.
This documentation must always be available at the operating location of the machine so that
dangers or injuries and damage can be prevented to the greatest extent possible. For storage,
transport, commissioning, operation, maintenance/service or decommissioning, the respectively
applicable national, local and system-specific regulations must be observed.
Special designs and design variants may differ in their technical details! In case of unclear points, it
is urgently recommended that RICKMEIER be consulted with specification of the rating plate data
from the pump/pump unit.
Basic Safety Rules
Installation, commissioning, operation, maintenance and decommissioning may only be carried out
by persons, who
1. have carefully read and understood the operating/installation instructions
2. have received special training for the planned work and are authorized by your company to
perform such work
3. comply with the EC Directive 89/655/EEC Minimum Safety and Health Requirements for
the Use of Work Equipment by Workers at Work.
Form 229589-7
410312 410312
BA2-0NNN-112
Gepr.: Lü/09.06.06
English name/date
page 2 (8)
Information attached directly to the pump, such as the rotating direction arrow or markings of
the fluid connections must always be observed. These must always be kept in completely legible
condition.
Following operating instructions apply additionally with pump units:
1. without motor : operating instruction clutch
2 with motor : operating instruction motor, operating instruction clutch.
1 Using gear pumps
RICKMEIER gear pumps may only be used to feed lubricating media.
The data relevant for operation will be specified in the RICKMEIER order data sheet, if necessary
with separate data sheets, drawings or similar documents. Should the stipulated conditions be
deviated from during later operation, then this must be coordinated with RICKMEIER, as otherwise
the any and all warranty claims shall be voided. Use in a potentially explosive environment is only
permissible when the pump/pump unit is marked accordingly!
2 Flow medium
As a condition for a longer service life and maximum operating safety, the flow medium is to have
lubricating properties (kinematic viscosity of the flow medium under all occurring operating
conditions always > 5 mm2/s). The soiling of the flow medium should not be greater than the Purity
Class 21/19/17 according to ISO 4406:1999. The flow medium must always be free of hard solid
particles. The percentage of undissolved gases (bubbles) in the feed stream should not exceed
10 % by volume. Otherwise increased noise emissions can result.
3 Operating dangers
3.1 Safety-conscious working procedure
The safety precautions listed in these operating instructions, the existing national regulations for
accident prevention and internal working, operating and safety regulations of the operator must be
observed.
3.2 Dangers in case of failure to observe safety precautions
Failure to observe the safety precautions can result in hazards to persons, the environment and
machines. Failure to observe the safety precautions can lead to the loss of any and all warranty
claims and claims to damages.
In particular, failure to observe the precautions can, for example, result in the following hazards:
1. Endangering of persons, e.g. due to a danger of burns and poisoning
2. Leaks (e.g. of the shaft seal) of dangerous flow mediums (e.g. explosive, toxic, hot) must be
discharged so that no hazard to persons and the environment results. Legal regulations must
always be complied with.
3. If hot or cold machine parts lead to dangers, then these parts must be secured by the
customer against touching.
4. Failure of important functions of the machine/system
5. Shortening of the expected service life of the machine/system
6. Failure of specified maintenance and service methods
Never remove safety equipment or deactivate it by making modifications to the machine!
Form 229589-7
410312 410312
BA2-0NNN-112
Gepr.: Lü/09.06.06
English name/date
page 3 (8)
3.3 Using pressure relief valve R25, R35
The pressure relief valve is used to protect the pump against impermissible loads. It is set to the
required opening pressure at the factory and should only react occasionally and briefly during
operation.
R25 R35
Tightening torque [Nm] 70 100
Table 1: Tightening torques
Fig. 1: Pressure relief valve R25, R35
In the case of later pressure adjustment, the following must be observed:
1. Remove cap nut Item 4 (32 mm).
2. Loosen hexagon nut Item 6 (32 mm).
3. Make pressure setting by adjusting the spindle (slot). Caution! During the pressure adjustment
the spindle (Item 3) may only be screwed in clockwise (pressure increase), as otherwise the
dangers specified in 3.2 will occur.
The spindle is not secured against unscrewing!
4. Replace Cu sealing ring (2 each) Item 9 (DIN 7603-A21x26-Cu).
5. Tighten hexagon nut Item 6 according to Fig. 1, hold spindle at slot with screwdriver.
6. Mount cap nut Item 4 according to Fig. 1.
4 Transport and storage
Dispose of the packing material after unpacking according to the applicable legal regulations.
4.1 Storage
Always protect the pump against impairments due to moisture, dust, water and/or other contami-
nants. Store the pump in a clean, dry place (relative humidity < 70%) at temperatures between
– 25 °C and 40 °C; unpainted parts should stored with a relative humidity < 40%. Pumps with a
rotary shaft seal should be put into operation 6 months after shipping at the latest. Storage
conditions which differ from this must be agreed upon separately.
The top coating provided by RICKMEIER is a base coating which is only intended to protect
against corrosion during transport and storage. Do not damage the coating.
4.2 Lifting pump/pump unit
The pump must be lifted with securely attached 60° < α < 90°
lifting belts. The center of gravity must lie α
between the belts to prevent the pump from α
tipping (see Fig. 2).
A suitable hoist must be used!
Fig. 2: Transport/lifting
Form 229589-7
410312 410312
BA2-0NNN-112
Gepr.: Lü/09.06.06
English name/date
page 4 (8)
5 Setup/Installation/Mounting
The pump must be set up as stipulated when ordering. The drive of the gear pumps must be
adjusted to their power input.
The piping must be installed with as little tension as possible. For the suction and pressure
connections of the series with an inside thread, only screw-in parts with an exactly matching,
cylindrical thread may be used. When screwing in, make sure that the pump is not twisted. The
connections must be sealed in accordance with the operating conditions (medium, pressure,
temperature). The connection flange surfaces of the pump and the corresponding mating surfaces
may not be damaged and must be free of paint residues and other soiling.
Drive elements such as clutches and gearwheels must be fit on the pump shaft with ISO fitting H7.
These parts may not be driven on with hammer blows, as the pump can be damaged in the
process.
When aligning the pump shaft to the drive machine, the permissible differences of the clutch may
not be exceeded (see related clutch operating instructions).
Ensure even contact, good base or flange mounting and exact alignment!
For pump series without factory clutch protection, corresponding touch protection must be provided
by the customer (for example, see the Machinery Directive 98/37/EC Paragraph 1.3.8).
Suitable precautions must be taken against the long-term effects of dust, water and exposure to
the direct sunlight (e.g. large-area protection).
All parts which come into contact with the flow medium must be free of impurities. With hot-bent
pipes or pipes belt by welding, it is particularly important to ensure that no residues are present in
the pipes during commissioning.
5.1 Suction pipe design, NPSHR value
For proper operation, it is necessary that the static pressure directly at the entrance into the pump
is never less than -0.4 bar (equivalent to 0.6 bar absolute) under any operating conditions.
Deviations from this must be expressly agreed upon with RICKMEIER when placing the order.
It is therefore advisable to calculate or measure the lowest possible static pressure at the pump
entrance during operation. When doing so, all hydraulic resistances in the planned suction pipe
must be taken into account. This is especially important when a filter is provided in the suction pipe
which can become clogged in the course of time. In this case, it is recommended that the pump
inlet pressure be monitored with a pressure
measuring device as close to the pump as
possible and that regular filter maintenance be
conducted.
If no measuring connection is available in the
suction pipe, the pressure gauge connection
facing the suction side can also be used for this
purpose for pumps with a pressure relief valve.
Otherwise, the suction pipe must be absolutely
leak-tight so that no air can be aspirated.
The NPSHR value of the pumps frequently used
for comparison with the NPSHA value of a
system is provided in Fig. 3. Fig. 3: NPSHR Density of flow medium [kg/m 3]
Form 229589-7
410312 410312
BA2-0NNN-112
Gepr.: Lü/09.06.06
English name/date
page 5 (8)
5.2 Sense of rotation and direction of flow
Before commissioning the pump, it must be ensured that the direction of drive rotation matches the
direction of pump rotation. To check the rotating direction of the drive machine, it is practical to
detach the clutch so that the pump is not driven. If this is not possible, then at least the pipe
connections must be removed so that the pump cannot be damaged by an incorrect rotating
direction.
When checking the direction of drive rotation, a pressure buildup in the suction pipe must be
prevented (e.g. caused by an integrated non-return valve). Otherwise the shaft seal may be
damaged in the case of an incorrect rotating direction.
rechtsdrehend = clockwise linksdrehend = counter-clockwise
Sense of rotation, identification arrow Direction of delivery
L, R: Sense of rotation, view on shaft end: R = clockwise, L = counter-clockwise

Fig. 4: Sense of rotation and direction of flow
5.3 Reversing the sense of rotation
The pumps of the sizes R25 to R65 are designed so that the sense of rotation can be changed
later. The direction of flow is then also reversed. Prior to conversion to another sense of rotation,
and with it the reversal of the feed direction, the manufacturer must be consulted.
The direction of rotation cannot be altered late at pumps with mechanical sealing. The rebuilding
on another direction of rotation and so the reversion of the direction of flow must occur by
RICKMEIER.
6 Commissioning
Before starting up, the pump and the suction or supply pipe must be filled with the flow medium. If
the pump is installed so that the gear wheels lie above each other, a small quantity of flow medium
remains in the pump even at a standstill. As a result, the pump retains its suction capacity for
restarting even after longer standstills.
When operating two pumps in parallel which are secured against each other with non-return
valves, both pumps should be bled on the pressure side. The same applies to a pump working
against a closed system (loaded non-return valve etc.). Feeding against a closed pressure pipe is
not permitted due to possible impermissible temperature increases in the pump.
Form 229589-7
410312 410312
BA2-0NNN-112
Gepr.: Lü/09.06.06
English name/date
page 6 (8)
With difficult suction conditions, the pump should be installed so that the driving gear shaft and the
gear shaft are located above each other. This installation position ensures a better priming after
longer standstills due to the residual oil quantity which remains in the pump. The gear pump is
prevented from running dry when a non-return valve is present in the suction pipe. This can also
be achieved by laying suction and pressure pipes on the pump in the form of a siphon.
7 Operation/Function
Gear pumps are rotary displacement pumps. When the gear wheels turn, the medium enclosed in
the space between the teeth is transported from the suction to the pressure side. Then the
displacement toward the pressure side is carried out by the intermeshing teeth (see Fig. 5). The
transport of the flow medium results in a pressure drop on the suction side of the pump. The flow
medium compensates this pressure drop by flowing in, maintaining the feed process.
Suck Transport Displace

Fig. 5: Gear pump delivery principle
This process is the same for both gaseous and liquid media. As a result, the pump is capable of
bleeding the suction pipe itself until it is completely filled with liquid flow medium.
7.1 Pressure relief valve
The pressure relief valve integrated in the end cover of the pump as an option is designed as a
spring-loaded valve. It may only be used as an occasionally, briefly actuated valve for pressure
limitation. If a larger partial quantity of the flow must be drained off over larger periods, a separate
valve with a return pipe to the suction tank in the pipe (e.g. RICKMEIER valves of the type
RSn, DBV40, DBV80, DB9) or another form of pressure relief must be provided. This also applies
when the pressure pipe can become completely blocked during pump operation. Special designs
and variants may differ in their technical details.
7.2 Dry running
Dry running is always to be avoided, i.e. the pump must be filled with the flow medium before being
put into operation.
Exceptions: Dry running frequently occurs during start-up with unfilled suction pipe or during
operation when the supply of flow medium has been interrupted. Pumps wetted with flow medium
inside beforehand can be operated for up to 20 minutes under the following conditions:
1. Pump driven via clutch, i.e. free of radial forces
2. Pressure at pump inlet and outlet approximately equal
On pumps driven via a pinion, chain or belt, dry running is not permissible and must be avoided by
the operator (fill pump with flow medium prior to start-up).
Form 229589-7
410312 410312
BA2-0NNN-112
Gepr.: Lü/09.06.06
English name/date
page 7 (8)
7.3 Environmental protection
During installation work with the pump not completely drained, flow medium can get onto the floor
under the pump. The shaft seals can also show signs of wear after longer operating periods. If the
seals are not replaced in the course of maintenance work performed on schedule, drip leaks are
also possible. To prevent any possible consequential damage by the flow medium, appropriate
measure should be provided for safety's sake, e.g. a catch pan etc. under the pump.
8 Dismantling
Depending on the flow medium, the liquid escaping can present a hazard to people and the
environment. Therefore, the required measures must be carried out in accordance with the safety
data sheets of the flow liquids. In addition, the recommendations given in 7.3 must also be
observed.
9 Maintenance/Service
RICKMEIER gear pumps usually require little maintenance when operated within the permissible
operating limits. If a gear pump becomes unusable as the result of wear, it must be replaced. The
installation of replacement parts generally does not restore the original performance.
The service life of the shaft seals is mainly dependent on the manner of operation of the pump and
the purity and quality of the flow medium. As a result, in many cases no reliable prediction as to the
time of failure can be made. For pumps with shaft seals, it is therefore recommended that they be
subjected to an external visual inspection for drip leaks at regular intervals (recommendation: after
48 hrs, then every 4,000 operating hours). If a high danger potential exists due to the flow medium,
a check should be made at shorter intervals.
When using in a potentially explosive environment, the maintenance intervals of the related
ATEX operating instructions BA2-0NNN-113 apply.
The maintenance of pump units also requires compliance with the maintenance intervals and work
of the clutch and the motor.
10 Conversion/Changes to gear pump
Conversion of or changes to the gear pump are only permitted after consulting with RICKMEIER.
Genuine spare parts and accessories authorized by RICKMEIER help ensure safety. The use of
other parts can result in the voiding of any liability for the resulting consequences. When ordering
spare parts, please always specify the data provided on the rating plate.
11 Decommissioning
When decommissioning the pump, it must be ensured that no pressure greater than atmospheric
pressure exists in the pump, and that the pump drive cannot start up accidentally. In addition, the
recommendations in section 7.3 must also be observed. For environmental protection reasons,
pumps/pump units may only be disposed of by licensed specialized companies.
12 Malfunctions/Causes/Troubleshooting Measures
The following tabular overview is to be regarded as instruction to the removal for eventual occuring
troubles and their possible causes. If faults occur which are not named here, we recommend
consulting RICKMEIER. If it is necessary to remove the pump for troubleshooting, the
recommendations given in the sections 7.3, 8 and 11 must be observed.
Form 229589-7
410312 410312
BA2-0NNN-112
Gepr.: Lü/09.06.06
English name/date
page 8 (8)
Fault
Insufficient feed quantity or exit
Pump is loud during operation
Pump does not start up, stops
Pressure relief valve causes

Outlet pressure too high
Pump does not draw in
Pump does not bleed
abruptly of jams up
pressure too low
noises
Measure
Compare sense of rotation with identification arrow on pump; reverse
motor polarity if necessary.
Check whether pump is filled with flow medium.
Connections may be leaky. Check suction pipe and shaft seal for leaks.
In case pressure relief valve existing: condition of the sealing rings
checks, renews if necessary
Pressure drop in suction pipe too great; if possible, increase line cross-
section, shorten suction pipe or raise liquid level on intake side – if filter
is installed: clean and enlarge if necessary.
Does the set opening pressure match the order data sheet?
If necessary, increase opening pressure by approx. 10 %.
Check whether the pressure relief valve is soiled or damaged; does
valve piston move smoothly?
Bleed pump pressure side.
Check switching type, speed and current consumption of drive motor.
Compare voltage and frequency with motor rating plate.
In case of pressureless feeding of thin media, charge pump with
1-2 bar.
Has maximum permissible speed according to order data sheet been
exceeded?
When feeding media with a high vapor pressure (gasoline, solvent,
paints etc.), the medium is to flow to pump.
Avoid gas bubbles in flow media (e.g. have return pipes end below oil
level of tank).
Is motor output at least in accordance with order data sheet?
Check whether flow medium has lost lubricity due to excessively high
temperature.
Check whether relief hole from sealing chamber to suction chamber is
clogged.
Check whether viscosity of flow medium matches information on order
data sheet.
Too small a pump was chosen.
Pump piping may not be tension-free. Remove pump and check piping.
Table 2: Troubleshooting
Form 229589-7
410312 410312
410312 410312
410312 410312
420140 420140
420140 420140
420140 420140
KRACHT GmbH - Gewerbestr.20 - D-58791 Werdohl - Tel.02392/9350 - Fax 935277
Ersatzteilliste
Ausgabe: 22.07.2004
Seite: 1
Typ VENTILBLOCK
HB 4 A 0325 A
Teilenummer P.0158390001
Zeichnungs-Nr. 34158393-Ä00
===========================================================================
Pos Menge Einh Bezeichnung Teile-Nr.
===========================================================================
10 1 STCK VENTILBLOCK HB 4 A 0325 A E.0218350001
20 1 STCK VENTILKEGEL SPV 50 E.9359050001
30 2 STCK ABSCHLUSSSCHRAUBE SPV 50 E.9199500001
40 1 STCK FEDERFÜHRUNG ZUM SPV 40/50 E.9359120001
50 1 STCK FEDERFÜHRUNG ZUM HB 4 A 0217 B E.0174760001
60 1 STCK VENTILKEGEL HB 4 A 0217 B E.0177030001
70 2 STCK DRUCKFEDER 30,9X4,0X115,0 E.9193840001
80 1 STCK TYPENSCHILD 40X20X0,8 E.9192100001
90 2 STCK GEWINDESCHUTZKAPPE 44X58 E.9348020001
100 2 STCK GEWINDESTIFT M12X70-45H N.0009140017
110 2 STCK ZYLINDERSCHRAUBE M5X6 8.8 N.0009120084
120 2 STCK HALBRUND-KERBNAGEL 2X5-AL BLANK N.0014760002
130 2 STCK O-RING 48,0X2,5 NB90 L.0017010006
140 2 STCK DICHTRING 5,0X9,0X1,0-CU N.0076030035
150 2 STCK BUNDMUTTER SEAL-LOCK M12 L.0014120003
160 1 STCK VERSCHLUSSSCHRAUBE VSTI G1-ED L.0023000058
170 2 STCK VERSCHLUSSSCHRAUBE VSTI G1 1/4-ED L.0023000066
420140 420140
KRACHT GmbH - Gewerbestr.20 - D-58791 Werdohl - Tel.02392/9350 - Fax 935277
ISSUED: 22.07.2004
SHEET: 1
TYPE VALVE HOUSING
HB 4 A 0325 A
PART-NO. P.0158390001
DRAWING NO. 34158393-Ä00
===========================================================================
ITEM OUANT UNIT DESCRIPTION PART NO.
===========================================================================
10 1 PCS VALVE HOUSING E.0218350001
20 1 PCS POPPET E.9359050001
30 2 PCS HIGH END PLUG E.9199500001
40 1 PCS SPRING GUIDE E.9359120001
50 1 PCS SPRING GUIDE E.0174760001
60 1 PCS POPPET E.0177030001
70 2 PCS COMPRESSION SPRING E.9193840001
80 1 PCS NAME PLATE E.9192100001
90 2 PCS PROTECTION CAP E.9348020001
100 2 PCS HEADLESS SCREW M12X70 45H N.0009140017
110 2 PCS HEX.SOCKET HEAD CAP SCREW M5X6 8.8 N.0009120084
120 2 PCS NOTCHED NAIL 2X5 AL N.0014760002
130 2 PCS O-RING 48,0X2,5 NB-90 L.0017010006
140 2 PCS SEALING RING 5,0X9,0X1,0 SF-CUF20 N.0076030035
150 2 PCS HEX.SEAL LOCK NUT L.0014120003
160 1 PCS SCREW PLUG VSTI G1-ED L.0023000058
170 2 PCS SCREW PLUG VSTI G1 1/4-ED L.0023000066
425426 425426
HYDAC FILTERTECHNIK GmbH Industriegebiet, D-66280 Sulzbach/Saar
Bearbeitung: Bärbel Schön / Abt.: FFVI / Tel.: 06897/509-784, Fax.: 06897/509-300, E-Mail: baerbel.schoen@hydac.com
Customer: Voith Turbo Marine

Order-no.: 4500340729 / 008
Code word: VSP BOSPORUS
Com.-no.: 8302083334
Filter type: Filter 03236825 R 240 BN/HC 10 LE.1 /-Z-GL-32C-OE-A5-B6-VOITH

Article-no.: 01289560
In accordance with our Terms and Conditions of Sale,

guarantees are subject to the use of original HYDAC spares
only and correct fitting, as per service and maintenance
instructions.
Index
1. MAINTENANCE INSTRUCTIONS
1.1 Instructions for Use of Filter
1.2 Installation
1.3 Commissioning
1.4 Tools required for maintenance work
1.5 Torque rating for clogging indicators
2. MAINTENANCE
2.1 General
2.2 Maintenance Measures
2.3 Filter Element Changing Frequency
2.3.1 Removing the element
2.3.2 Fitting the element
3. SPARE PARTS
3.1 Spare parts drawing
3.2 Spare parts list
E_3236825_1289560 / 04.05.07
425426 425426
1. Maintenance instructions
1.1 Instructions for Use of Filter
This pressure vessel must only be commissioned in conjunction with a machine or

system.
The pressure vessel must only be used in conjunction with the refering Operation
and Maintenance Manual of the machine or system.
This pressure unit has to be used with hydraulic- or lubrication fluid only.
The user must ensure appropriate actions to avoid air formation (e.g. venting)
Repairs, maintenance and commissioning must only be carried out by specialist

staff. Do not touch the pressure vessel until cool. Follow the instructions of the
Operation & Maintenance Manual of the machine or system.
Attention pressure vessel: please ensure for all works at the pressure vessel that
the referring side of the pressure vessel (filter housing) is released of pressure.
No modifications shall be made to the pressure vessel (welding, drilling, forced

opening..).
The operator/owner is to ensure adherence to the National Water Resources Act as

well as local water resources laws and other related regulations.
Adherence is to be maintained to statutory accident prevention regulations, safety

regulations and safety data sheets for fluids.
When working directly on or in the vicinity of hydraulic systems, there is to be no

smoking or open flames/fire, with every effort being taken to prevent the generation
of sparks.
Hydraulic media and water-polluting fluids must not be allowed to soak into the soil,
seep into bodies of water or the sewage system. Ensure that hydraulic media and
fluids are disposed of in an environmentally safe manner. Adherence is to be
maintained to pertinent national and local regulations pertaining to groundwater
protection, disposal of waste/spent oil and (hazardous) waste.
Work on filters may involve leaking hot oil which may cause injury and scalding as
result of its high pressure and/or temperature.
E_3236825_1289560 / 04.05.07 Seite 2

425426 425426
1.2 Installation
Before fitting the filter into the hydraulic system check that the permissible operating
pressure of the system corresponds with that shown on the filter label.
Important: For safety reasons, when using filters without bypass valve and operating
pressures higher 30 bar, stable filter elements of the type BH/HC.
1.3 Commissioning
Check whether the correct filter element (1) is fitted. Screw in cover plates and then
unscrew by one quarter-turn (the sealing effect will not be improved by
overtightening). Switch on hydraulic system. Then move the control lever (3) to either
of the filter sides.
Loosen the air bleeding screws (5.6) of the cover plates; pull the lever (3) until oil
exits at the air bleeding screws. Cloose the air bleeding screws and check filter for
leackage.
1.4 Tools required for maintenance work

size Spanner for Allen key for oil Allen key for air
cover plate drain plug bleeding screw
(VSTI G ½) (VSTI G 1/8)
03236825 SW 36 SW 10 SW 5
1.5 Torque rating for clogging indicators

TYPE max. torque rating
VD... 50 Nm
E_3236825_1289560 / 04.05.07 Seite 3

425426 425426
2. Maintenance
2.1 General
This section contains a description of the periodical maintenance work to be

performed. The operability, operational reliability and serviceable life of the filter
essentially depend on regular careful maintenance.
· Spare parts are to conform to the technical requirements specified by the

manufacturer. This is always ensured when using original HYDAC spare parts.
· Keep tools, working area and equipment clean.
· After dismantling the filter clean all components, check for damage or wear, and
replace, if necessary.
· When replacing a filter element make sure that everything is kept as clean and dirt-free
as possible in order to prevent the filter from being contaminated.
We generally recommend to change the filter element at least once a year.

The filter element can be monitored via the installed clogging indicator (visual -
analogical).
When the clogging indicator responds, the filter element has to be changed.
When the filter element is subjected to high dynamic loads it is be necessary to change
the element more frequently. The same applies after commissioning, repair work, oil
changes etc. in the hydraulic system.
Standard clogging indicators only indicate when there is flow through the filter. With
electrical clogging indicators, the signal can also be processed and indicated as a
continous warning on the control panel. In this case it is necessary to delete the
warning at cold start or after changing the filter element.
If the clogging indicator only responds at cold start, a filter element change may not be
necessary.
E_3236825_1289560 / 04.05.07 Seite 4

425426 425426
2.3.1 Removing the element
1. Do not switch off the hydraulic system. Turn the changeover lever (3) by 90° degrees,
the filter is now changed over to the other side.
2. Loosen the air blending screw (5.6) on the filter side currently not in operation in order
to relieve the pressure.
3. Remove the oil drain plug (5.7 below the side to be cleaned), and drain the
contaminated oil into a suitable receptacle.
4. Unscrew cover plate.
5. Remove filter element (1) from location spigot (examine surface of element for dirt
residue and larger particles, these can indicate damage to the components).
2.3.3 Fitting the element
1. Fit the new filter element (1) carefully onto the element location spigot.
2. Screw in cover plate. Unscrew cover plate by one quarter-turn.
3. Screw in the oil drain plug (5.7).
Venting:
4. Pull the lever (3) until oil exits at the air bleeding screw (5.6).
5. Cloose the air bleeding screw (5.6) and check filter for leackage.
NOTE: Filter elements which cannot be cleaned must be disposed of in accordance

with environmental regulations.
E_3236825_1289560 / 04.05.07 Seite 5

425426
4. Spare parts
4.1 Spare parts drawing Filter 03236825 R 240 BN/HC 10 LE.1 /-Z-GL-32C-OE-A5-B6-VOITH
2.1 5.7 5.7
4.2/5.5
2.2/5.3
2.3/5.4 1.1
5.6
1.2/4.1/5.
5.1
3 2.3/5.4
2.1
5.9
2.2/5.3
5.8 5.7
E_3236825_1289560 / 04.05.07
425426
425426 425426
1.1 Spare parts list Filter 03236825 R 240 BN/HC 10 LE.1 /-Z-GL-32C-OE-A5-B6-VOITH
Item cons. Designation Qte Order-no.
of
1 Filter element
0240 R 010 BN3HC /-B6-01201279 1 (2) 01283524
1.1 Filter element 1 0240 R...
1.2 O-ring 1 34 x 3,5
2 Clogging indicator 1
VD 5 LE.1 /-32C-OE-SK 01286307
or Locking screw VD 0 A.1 1 00305932
2.1 Clogging indicator / locking screw 1 VD...
2.2 Profile sealing ring 1 VD...
2.3 O-ring 1 15 x 1
3 Change-over lever FLND/FMND 1 03095722
4 Seal kit-E FILTER 03016665 W.1 1 *)
4.1 O-ring (element) 2 34 x 3,5
4.2 O-ring (cover) 2 84,5 x 3
5 Repair kit-E FILTER 03016665 W.1 1 *)
5.1 O-ring (Housing) 2 98,02 x 3,53
5.2 O-ring (element) 2 34 x 3,5
5.3 Profile sealing ring (VA) 1 VD...
5.4 O-ring (Clogging indicator) 1 15 x 1
5.5 O-ring (Cover) 2 84,5 x 3
5.6 Locking screw VSTI (Venting) 2 G 1/8 NA
5.7 Locking screw VSTI (Drainage) 2 G ½ NA
5.8 Locking screw VSTI 1 G¼
5.9 Locking screw VSTI 2 G1
*) the article-no. will be fixed if necessary !
NOTE
The information in this brochure relates to the operating conditions and
applications described. For applications or operating conditions not described,
please contact the relevant technical department. Subject to technical
modifications.
Hydac Service GmbH

D-66273 Sulzbach / Saar
Postfach 1251
Werkanschrift:
D-66125 SB-Dudweiler
Rehgrabenstraße 3
Kundendienst: Ölservice:
Tel: +49 (0)6897/509-1478 Tel: +49 (0)6897/509-412
Fax: +49 (0)6897/509-423 Fax: +49 (0)6897/509-634
E_3236825_1289560 / 04.05.07
Hydac Filtertechnik GmbH Bärbel Schön
Postfach 1251 STÜCKLISTE Abt. FFVI
D-66272 Sulzbach/Saar Tel. 06897/509784
425426
E-Mail: baerbel.schoen@hydac.com
Item QTE ME Material no. Designation Drawing DIN Material Remarks

5 1 ST 3027939 Drawing Filter 03016665
6 1 ST 3236825 Dimensional drawing Filter 03236825
8 1 ST 3025324 Certification drawing Filter 03016665
20 2 ST 1283524 Filter element 0240 R 010 BN3HC /-B6-01201279
30 1 ST 305932 Locking screw VD 0 A.1
31 1 ST 1286307 Clogging indicator VD 5 LE.1 /-32C-OE-SK
35 1 ST 305932 Locking screw VD 0 A.1
100 2 ST 3016752 Filter housing 3016665 size 240
110 2 ST 603673 O-ring 98,02x 3,53 NBR -70Sh
150 2 ST 3027472 Cover filter 03016665 3.1 B
160 2 ST 613045 O-ring 84,5 x 3 NBR -80Sh
170 2 ST 411773 Locking screw G..1/8 NA
190 2 ST 613759 Thread pin-i6kt.-M10x 16-45H ISO4028
200 1 ST 3236826 Head filter 03236825 GGG40 3.1
210 2 ST 403302 Locking screw G..1/2 NA
220 2 ST 607168 Locking screw VSTI G1 -ED- St /NBR
240 1 ST 608658 Locking screw VSTI G 1/4-ED- St /NBR
400 1 ST 411300 Type label HYDAC deut./engl. V2A
410 2 ST 405459 Interruptor stopper RFLD.... Type label 9S20K
420 1 ST 406495 Label LFDK..60 AL
430 1 ST 406494 Label LFDK..60 AL
440 6 ST 635276 Grooved pin ISO8746- 2 x 4-A AL
700 1 ST 3111188 Segment valve FLND/FMND 160 1.1 complete
710 1 ST 612935 O-ring 32 x 3 NBR -80Sh
720 1 ST 628486 O-ring 70 x 2 NBR -80Sh
730 2 ST 619572 Axial-needle roller bearing -AXK 3552
740 1 ST 609587 Thread pin-i6kt.-M 4x 10-45H ISO4027
Customer: Voith Turbo Marine GmbH & Co. KG consist of Sheet-no. Material-no. 1289560
2 Sheet 1
Code word: VSP BOSPORUS Date Name
set up ######## B. Schön
Kom.-no.: 8302083334 checked
Designation FILTER 03236825 R 240 BN/HC 10 LE.1 /
E_1289560 Blatt 1 von 2

425426
425426
valid from name Order-no: 4500340729 / 008 Z-GL-32C-OE-A5-B6-VOITH
E_1289560 Blatt 1 von 2

425426
425426
Item QTE ME Material no. Designation Drawing DIN Material Remarks

745 4 ST 619571 Axial-disc -AS 3552
750 1 ST 3027693 Distance piece Filter 03016665
760 1 ST 615467 O-ring 64,77x 2,62 NBR -90Sh
770 1 ST 3095722 Change-over lever FLND/FMND
780 1 ST 601576 Cylinder pin - 6 m6x 25 ISO2338 ST
790 1 ST 627666 Decal information Symbol- directional arrow
900 2 ST 400428 Plate MDF..330 Graupappe
910 8 ST 600165 Locking plug -GPN610 U 5 HN49-01
1500 1,25 KG 630106 Eisenglimm.-Dickbesch.326-Permatex-EP
1510 0,25 KG 630104 Accelerator Permatex 3326/00
2000 1 ST GL invide for inspection
2010 1 ST 1200504 Leakage test
2015 1 ST 1202817 HMBD/CONSTRUCTION AND PRESSURE TEST HFT-STANDARD
2016 1 ST 417130 Across Construction test Filter
2020 1 ST 403983 Pressure test Filterhousing
2030 1 ST 1202818 3.1 / INSPECTION CERTIFICATE 3.1
Customer: Voith Turbo Marine GmbH & Co. KG consist of Sheet-no. Material-no. 1289560
2 Sheet 1
Code word: VSP BOSPORUS Date Name
set up 2007-03-05 B. Schön
Kom.-no.: 8302083334 checked
Designation FILTER 03236825 R 240 BN/HC 10 LE.1 /
valid from name Order-no: 4500340729 / 008 Z-GL-32C-OE-A5-B6-VOITH
E_1289560 Blatt 2 von 2

425426
425426 425426
Technical Documentation Special Filter
Customer: Voith Turbo Schneider

Order-no.: 4500311398 / 008
Code word: VSP BOSPORUS
Kom.-no.: 8302083484
Filter typ: RFLD BN/HC 501 DAL 20 LE 1.0 /-Z-DE-32C-OE-A5-B6-03198054
Artikle-no.: 01283566
The warranty offered pursuant to our Terms of Sale and Delivery is applicable
only in the event that original HYDAC components are used and work is carried
out solely by properly trained and qualified personnel.
CONTENTS
1. Preliminary Remarks
1.1 Instructions for Use of gas loaded Filter
1.2 Installation
1.3 Commissioning
1.4 Tools Required for Maintenance Work / Torques
2. Maintenance Instructions
2.1 General Remarks
3. Changing the Filter Element

3.1 Removing the element
3.2 Fitting the element
4. Spare Parts
4.1 Spare Parts Drawing
4.2 Spare Parts List
E501_6 / 01.06.07
1. Preliminary Remarks
1.1 Instructions for Use of gas loaded Filter
This pressure vessel must only be commissioned in conjunction with a machine or

system.
Under the provisions the pressure vessel must only be used according to the
operating instructions of the machine or system.
This pressure unit has to be used with hydraulic- or lubrication fluid only.
The user must ensure appropriate actions to avoid air formation (e.g. venting)
Repairs, maintenance and commissioning must only be carried out by specialist

staff. Do not touch the pressure vessel until cool. Carry out the directions in the
operating instructions of the machine or system.
Attention pressure vessel: please ensure for all works at the pressure vessel that the
referring side of the pressure vessel (filter housing) is released of pressure.
No modifications may be made to the pressure vessel (welding, drilling, forced

opening..).
The operator/owner is to ensure adherence to the National Water Resources Act as

well as local water resources laws and other related regulations.
Adherence is to be maintained to statutory accident prevention regulations, safety

regulations and safety data sheets for fluids.
When working directly on or in the vicinity of hydraulic systems, there is to be no

smoking or open flames/fire, with every effort being taken to prevent the generation
of sparks.
Hydraulic media and water-polluting fluids must not be allowed to soak into the soil,
seep into bodies of water or the sewage system. Ensure that hydraulic media and
fluids are disposed of in an environmentally safe manner. Adherence is to be
maintained to pertinent national and local regulations pertaining to groundwater
protection, disposal of waste/spent oil and (hazardous) waste.
Work on filters may involve leaking hot oil which may cause injury and scalding as
result of its high pressure and/or temperature.
Filter housings must be grounded.
At use of electrical clogging indicators, the unit has to be free of voltage before
demounting of the clogging indicator plug.
E501_6 / 01.06.07
1.2 INSTALLATION
Before installing the filter in the hydraulic system check to see whether the permissible
operating pressure of the system corresponds to the value indicated on the rating plate.
It is to be made certain, that the filter is tastened without tension and no piping torces will
transfer to the filter. With the attachment, system forces at the filter must be excluded. Tasten
ehe filter with stand elevice to the background only it a compendator, an extension loop, a
dampins element or similar were built into the piping.
1.3 COMMISSIONING
Make sure that the designated filter elements (1) have been installed. Set the cover plate on
top and tighten the cover plate screws using the proper torque (cf. section 1.4).
Move the control lever (3) to the middle position and fill the filter unit via the system (both sides
of the filter are to be filled). Then move the control lever (3) to either of the filter sides and
check the filter for leaking.
1.4 TOOLS REQUIRED FOR MAINTENANCE WORK
size Cover plate Int. hex. Torque

screws rating
SW
RFLD 501 M10 x 25 SW 8 45 NM
E501_6 / 01.06.07
2. Maintenance
2.1 GENERAL
This section contains a description of the periodical maintenance work to be

performed. The operability, operational reliability and serviceable life of the filter
essentially depend on regular careful maintenance.
2.2 MAINTENANCE MEASURES
Spare parts are to conform to the technical requirements specified by the

manufacturer. This is always ensured when using original HYDAC spare parts.
Keep tools, working area and equipment clean.
After dismantling the filter clean all components, check for damage or wear, and
replace, if necessary.
When replacing a filter element make sure that everything is kept as clean and dirt-
free as possible in order to prevent the filter from being contaminated.
2.3 FILTER ELEMENT CHANGING FREQUENCY
We recommend that the filter elements are changed at pre-defined intervals, however
at least once a year.
The filter element is monitored by equipping the filter it with a clogging indicator
(optical-analogical)
When the clogging indicator responds, the filter element has to be changed or
cleaned immediately.
When the filter element is subjected to high dynamic loading it may prove necessary
to change the element more frequently. The same applies to commissioning, repair
work, oil changes etc. in the hydraulic system.
Standard clogging indicators respond only, if there is a flow through the filter. As to
electrical clogging indicators, the signal can also be processed and indicated on the
control panel continuously until acknowledging the fault by eliminating it (i.e. changing
the filter element and cold-starting the system).
If the clogging indicator only responds upon cold-starting, the filter element may not
yet require changing.
E501_6 / 01.06.07
Hydraulic media and water-polluting fluids must not be

allowed to soak into the soil, seep into bodies of water or the
sewage system. Ensure that hydraulic media are disposed of
in an environmentally safe manner. Adherence is to be
maintained to pertinent national and local regulations
pertaining to groundwater protection, disposal of
waste/spent oil and (hazardous) waste.
3. Changing the Filter Element

3.1 Removing the Filter Element
1. Turn the changeover lever (3) by 90° degrees, the filter is now changed over to the other side.
2. Loosen the air blending screw (A) on the filter side currently not in operation in order to relieve
the pressure. Undo the oil drain screw (B) on the filter side currently not in operation and drain
the contaminated oil into a suitable receptacle. (The oil may not be reused for refilling unless
having been properly filtered/purified first).
3. Undo the cover plate screws and lift it up.
4. Pull out the filter element (1) by the strap (Examine the surface of the filter element for
contamination residue and large-sized particles. This may be an indication of damage to
components.)
5. Replace the filter element.
6. Clean the housing and cover plate as may be necessary.
7. Check the filter for mechanical damage/wear, paying special attention to the apperance of
sealing surfaces.
8. Check the o-rings. If necessary, change them.
3.2 Installing the Filter Element
1. Wet the sealing surfaces on the filter housing and the cover plate including the seals with clean
hydraulic medium as needed.
2. When installing a new filter element check to see whether the designation of the new filter
element corresponds to that of the old one.
3. Carefully mount the filter element (1) on the filter element pin in the housing (check the position
of the strap on the element).
4. Set the cover plate on top and screw in the cover screws by hand; tighten them by tightening
the screws in opposite corners (for the proper torque, please refer section 1.4)
5. Close the oil drain screw (B)
6. Turn the changeover lever (3) to the clean filter side, until oil exits at the air bleeding screw.
7. Screw the air bleeding screw (A) back in.
8. Return the changeover lever (3) to the other filter side and check the filter for leaking.
Note: Filter elements which cannot be cleaned are to be disposed of in an

environmentally safe manner in accordance wirh environmental protection
regulations.
E501_6 / 01.06.07
4. Spare Parts
4.1 Spare Parts Drawing RFLD BN/HC 501 DAL 20 LE 1.0 /-Z-DE-32C-OE-A5-B6-03198054
E501_6 / 01.06.07
4.2 Spare Parts List RFLD BN/HC 501 DAL 20 LE 1.0 /-Z-DE-32C-OE-A5-B6-03198054
cons. RFLD 501 DAL
Item Designation Qte.
of
1. Filter element 0500 R 020 BN3HC /-B6-01201279 1(2) 01283525
1.1 Filter element 1 0500 R...
1.2 O-ring 1 48 x 3
2. Clogging indicator 01283565
VD 5 LE.1 /-Z-32C-OE-03038901 1
3. Lever SW 17 1 00270383
4. Seal kit-E RFLD.331 F 1.1 1 00303967
4.1 O-ring (element) 2 48 x 3
4.2 O-ring (cover) 2 105 x 5
Other spare parts on request
NOTE:
The information in this brochure relates to the operating conditions and applications
described.
For applications or operating conditions not described, please contact the relevant
technical department.
Subject to technical modifications.
Kundendienst: Ölservice:
HYDAC International Hydac International
Zentraler Kundendienst, Werk 6 Servicetechnik, Werk 6
Industriegebiet Industriegebiet
66280 Sulzbach / Saar 66280 Sulzbach / Saar
Tel.: 06897/509-412 Tel.: 06897/509-333
Fax: 06897/509-634 Fax.: 06897/509-846
E501_6 / 01.06.07
426030 426030
Data sheet clogging indicator
Article-no.: 01287488
Weight: 198 g
Perm. Temperature range: -10°C to +100°C
VD 5 LE.1 /-Z-40C-OE-SK
Perm. Operation pressure: 420 bar
Setting pressure: 5 bar, tolerance - 10 %
Type of indication: visual, red pin and electrical
1 electrical switching contact at 100%
of the cracking pressure
Inspection: Function inspection
Designation: Cold start suppression of switching outputs
up to 40 °C
Switch type: N/O contact
Accessorie: Protective gage
Max. switching voltage: 115 V

Electrical connection: Plug connection PG 11, socket to DIN 43650
Max. making capacity at resistive load: 15 W =, max. 15 VA ∼
Switching capacity: ohmic 1 A at 15 V =, ohmic 1 A at 15 V ∼
Safety type (to DIN 40050): IP 65 (only if the plug is wired and fitted correctly)
Symbol: Dimensions:
Profile sealing ring VD
O-ring 15 x 1,5
Spare parts:
Designation Article-no.
Seal kit-E VD/VM/VR 00319648
Plug-E LE.0 /-OE-40C
D_E_VD5LE / 07.12.06
460010 460010
INSTALLATION
AND
OPERATING MANUAL
Compact Heat Exchanger

Product Line K
Type : KS12-BCN-421BC L400

Order No. : A06-3697
Serial No. : A06-3697A to D
Customer : Voith Turbo Marine
Order No. : 4500345472/008 Pos.30+50
Project : VSP BOSPORUS
460010 460010
Table of Contents
GENERAL 4
Operational Range 4
Service 4
Guarantee 4
Conservation 4
Transportation 4
STRUCTURAL BUILD-UP 5
Tube bundle 5
Shell 5
Bonnets 5
Seals 5
Accessories/spare parts 5
SERVICE 6
Installation 6
Screw fasteners 6
Type plate 6
Starting up 7
Operating instructions 7
Switching off/standstill of the unit 7
MAINTENANCE 7
Periodic inspections 7
Dismounting 7
Assembly 8
Cleaning 8
Installation and Operating Manual for Compact Heat Exchangers of Product Line K Page 2 of 10
Stand: 23.08.2004 Instruction Manual-English.doc
460010 460010
TROUBLESHOOTING 9
To low performance!/outlet temperature to high! 9
Leaky tubes! 9
Leaky rolling connection! 9
Leaky O-ring! 9
CONTACTS 9
Cleaning 9
Repair/spare parts 10
APPENDIX
Type plate
Data sheet
Drawings
Parts list
460010 460010
INSTALLAT ION AND OPERAT ING M ANUAL

FOR COMPACT HEAT EXCHANGERS OF PRODUCT LINE K
General
Operational Range
Heat exchanger of product line K were developed in particular for application in the field of the
industrial and maritime cooling. The present device is a high efficient heat exchanger on the principle
of shell and tube, in compact and lightweight design. The apparatus of this product line can be
adapted to different conditions of use by particular combination of material and components. The field
of application include all possible uses of cooling, in particular turbines, compressors, refrigeration
units, hydraulic plants, in the range of engines, gears etc. Service life of the devices is essentially
influenced by proper maintenance and operation. For this reason, observe strictly these instructions.
Service
For all service inquiries, please contact directly our factory, our sales force or your contracting party.
In the case of spare part orders, please indicate always the designation of the device and/or the spare
part. The necessary specifications can be taken from the enclosed drawings and from parts lists.
Guarantee
Warranty claims are to be taken from our general supply and payment terms, providing no other
individual agreements were made.
Repairs of defective parts at a later stage may only be carried out with our approval. If circumstances
should not permit asking our approval, you can ignore it. In this case you must inform us immediately
at the nearest occasion.
In principal any changed service conditions must be approved by us in writing.
Conservation
Under normal conditions are internal surfaces of the devices protected for a duration of 6 months. A
post-preserving is necessary after 6 months. The preserving liquid and the note on safety can be
provided by us. The used preservative is well compatible with all mineral lubricants. The removal of
these substances can be done by using any known solvent (check material compatibility!). The
devices should only be stored in closed rooms. Condensation through strong variation of temperature
must be avoided.
Transportation
A damage of the device must be by all means avoided. The transportation of the unpacked device
when using lifting systems has to be carried out with sufficient number of transportation straps set
around the casing. Please note the dead weight of the device indicated on the current data sheet or
the type plate.
460010 460010
Structural build-up
Tube bundle
The tube bundle consists of two opposite identical tube plates with three grooves. The tubes are rolled
into the tube plate wholes. Between the tube plates at the outer side of the tubes, the surface is
enlarged forming fins which are in connection with the tubes. The result is a compact finned bundle. At
the outer side of the finned bundle, there are grooves across the whole length which are used to take
up sealing straps. In the finned bundle, a different number of baffles can be installed. A groove is
milled in the top of the baffle which contains a spring and a sealing plate. The interior O-ring grooves
in the tube plates seal against the casing in assembled state. The external seals are used for sealing
the bonnet. In this way, a intermixing of the media is avoided if a seal becomes defective and a
leakage localization is simplified. In the central groove, sheets are positioned which fix the tube plate
in assembled state and allow a thermal expansion for the opposite tube plate. With two path devices,
the fixation must be at the side of the connections. In any case, the side of fixation is marked by an
imprinted 'F' at the flange of the casing in the area of the flanges M1 or M2. The fixation must be
positioned at this side when in working condition.
Shell
The shell is used for taking up the tube bundle and forms the shell side casing. It consists of end
pieces which are circular-welded with the shell tube. The end pieces can be placed in such a way
that the connections are positioned at one side or rotated by 180°. The shell tube is a
precision tube with restricted allowances. Changes must not be carried out on the casing.
!
At the starting area of the end pieces, the interior groove of the tube plates seals by
means of an O-ring. This area must be treated carefully in order to guarantee a sealing effect.
The mounting brackets grip around the shell tube. These allow an optional assembly position of the
device.
Casings of model KK are cast casings in standardized, fixed version.
Bonnets
The bonnets consist of different materials (see part list), depending on version of the device. The
bonnet forms together with the tube bundle the chamber of the cooling medium and is fixed to the
casing by screws. At one side of the device, sheets are inserted between bonnet and casing which fix
the tube plate. At the other side, washers form a spacer.
The one path version has two identical bonnets positioned opposite each other. With the two path
version, one bonnet with two connections is mounted at one side of the device, at the other side there
is a reversing cover. To seperate the two chambers in the bonnet, a plastic or aluminium path partition
is inserted into the tube plate at the connection side. In assembled state, the path partition seals
bonnet and tube plate, i.e. it splits the flow of tubeside medium through the device.
Seawater resistant versions contains sacrificial anodes.
Seals
All tube plate seals consist of O-rings.
All pipe threads are sealed by copper or aluminum rings.
The tube bundle is sealed at the side along its length with a sealing strip against the casing. The
sealing strips consist of the same material as the O-rings. All seals are available from our factory with
indication of the drawing number.
Accessories/spare parts
Accessories and spare parts can be taken from the enclosed drawings and part lists. Drawing and
identification numbers of components which are necessary for ordering, are also listed there. Price
lists for the spare parts and not listed accessories can be requested via our marketing department or
directly from factory.
460010 460010
Service
Installation
The following items must be considered during the installation of the device:
• Protective caps fitted to connections must be removed. If there is no protective cap on a
connection, check whether it has been pushed into the connection or foreign parts have
penetrated the device.
• Foreign bodies must not penetrate the openings of the connections.
• The connection of the pipes must be tension-free to ensure that no inadmissibly high
thermal or mechanical tensions affect the device in service.
!
• All circuits must be designed to avoid penetration of dirt and dust. We recommend the
assembly of dirt traps and suitable filters.
• Tubes must be correctly installed so that air locks cannot built up.
• The assembly can be horizontal or vertical.
• Sufficient space should be available to ensure easy accessibility to all screw connections. Take
particular care for providing enough space for remove the tube bundle. You can take the
necessary space dimensions for remove the tube bundle from the sketch. It is possible to remove
the tube bundle from both sides of the device.
• . The direction of flow is to be taken from the enclosed sketch and from the datatsheet
• Before startup, the device must be completely bled.
• Never weld or modify the cooler.
• In case of using the device as oilcooler before startup, clean/flush the oil circuit but not the
lubricated points.
• Orifice plates must only be installed at the outlet side of the device.
Screw fasteners
To ensure a safe operation and a long service of fastening elements, the screw fastenings should be
only torqued. The table below lists the torque figures for used screws. Through influence of various
factors, the specified values may show a deviation which in individual cases require lower or higher
values.
Connection shell/bonnet Connection flanges
type screw/ torque [Nm] screw/ material of torque [Nm]

strength strength thread
K12 M12 5.6 38 M12 5.6 aluminium 30

M12 8.8 80 red bronze 30
K20 M16 5.6 95 M16 5.6 aluminium 75
M16 8.8 200 red bronze 75

K25 M20 5.6 180 cast steel 100
M20 8.8 400 M24 5.6 cast steel 300
Type plate
The type plate is at the side of the device and is permanently fixed. You can find a copy of the type
plate in the appendix.
460010 460010
Starting up
At first the apparatus must be filled up with the intended medium, then the entire system must be
checked for leakage. For watercooled devices use only clean water at the tube side. Before
the actual starting up of the system, make sure that the cooling medium is circulated.
Operating the device without flow of ! cooling medium is not permissible.
Only for watercooled units:
If the flow adjustment is carried out by a control, we recommend a oil-sided control, especially when
operating with river or sea water.
Discuss the control of cooling water with our factory, because factors like material and quality of
cooling water are very important to avoid later problems.
The use of additives in the cooling water has to be confirmed through HS-Cooler GmbH.
Operating instructions
During the operation, make sure by suitable means that pre-set parameters for which the
devices are designed are kept. !
If reserve devices with switch- over valves are present, switch these devices periodically on
(all 2-3 days) or load the reserve device daily for some time with the full water volume.
Switching off/standstill of the unit for watercooled units

With a short-term standstill (<4 days) of the unit, the apparatus can remain filled.
When switching off the unit, the water must be removed. In the case of operating the device with sea
water or aggressive water, flush the unit additionally with clean water. The tube bundle should as far
as possible be dried inside with compressed air. Further, if a drainage is not possible, then a flow of
the correct amount of cooling water must be maintained.
Maintenance
Periodic inspections
Devices of product line K are normally reliable and easy to maintain. However, some periodic
inspections of the device are necessary to provide a safe, continuous operation. Normally inspections
on the tubeside (waterside) predominate. The shellside is less inclined to pollution so that an
inspection can be carried out based on the experience of the operator.
The following inspections should be practiced:
• When operating with sea water, sacrificial anodes are installed in the bonnets/covers.
These should be checked in the initial phase all 3 months. If the anodes are used
up, they must be replaced by new ones. ! In the case of excessively fast consumption
of the anodes, water quality and the electrical potential of the system must be checked.
• The device should be cleaned at the water side at least once a year. An excessive pollution of the
tubes must by all means be avoided. The bonnets can be removed without depressurerizing the
shell side. The intervals are to be shortened during long ship operation in harbors or in other
polluted waters and depending on the experience of the operator.
• At shorter intervals the device must be subject to an externally visual inspection, in order to
identify leakage or other problems early. Through the double O-ring sealing, leakages can be
precisely located and the relevant expenditure can be estimated.
Dismounting
Proceed as follows when dismounting the apparatus:
• Lock-up any pipelines
• Empty the apparatus at the tube side, if a removal of the tube bundle is necessary, empty also the
shell side.
• Remove the pipelines at the tube side.
• Remove the bonnets/covers. For this purpose, the screws at the bonnet/casing connection must
be loosened. Between the bonnet/cover there are 4 fixing plates or washers. These must be
460010 460010
replaced at the same side again during re-assembly. The marking on the casing flange must be
here observed.
• If you want to dismount without remove the tube bundle, the bonnet/cover without fixing
plates must be disassembled first in order to protect the tube bundle against
displacement, before you remove the ! fixing plates. This can be done with another
set of fixing plates or with similar aids.
Dismounting without remove the tube bundle:
• Remove the O-rings from the external groove of the tube plates and secure the tube bundle to the
casing with four screws and the four fixing plates in the middle groove of the tube plates. The tube
side can now be inspected and cleaned mechanically. The shell side can remain under pressure.
Dismounting with remove the tube bundle:
• Remove the O-rings from the external groove of the tube plates. At one tube plate, a marking of
the fixed position in relation to the casing is attached. A half of a ‘X’ is stamped at the front of the
tube plate and the adjacent casing flange. Check the position of the marking. Push the tube
bundle (where appropriate with auxiliary tools) so far sideways until the O-ring of the interior
groove becomes visible. Remove the O-ring from the interior groove. Pull out the tube bundle in
the opposite direction. Remove the tube bundle carefully from the casing without damaging the
fins. As far as possible suspend the tube bundle with the help of large-surface
transportation straps. The grooves taking the O-rings must not be damaged. During
dismounting of the tube bundle the ! sealing plate and the spring can drop out of the
baffle groove. The spring and the sealing plate have to be installed during assembly
of the bundle by pressing them into the groove whilst the baffle passes the inlet of the shell.
• When dismounting vertically fixed devices, make sure in any case that the tube bundle does not
slips down after removal of the fixing plates. We recommend to provide an additional
set of fixing plates and to start the removal at the side where no fixing plates are mounted.
There the bundle must be secured first. After dismounting the second bonnet,
the bundle can be removed carefully. While ! assembling, only one set of fixing
plates is permittedat the side of the marking.
Assembly
The assembly is carried out in reversed order as dismounting. The following must also be considered:
• Generally use new O-rings and clean O-ring grooves.
• Note the marking for proper assembly of the tube bundle (X).
• Note the marking for correct assembly of the fixing plates (F).
• At the side of the tube bundle there are sealing straps. These should only be replaced
when damaged. When pushing-in the tube bundle take care that the sealing straps are
not displaced or twisted. ! Before assembling the tube bundle, the sealing straps should
be greased. You can use the operating medium. The sealing straps must be
effective along the entire length of the tube bundle.
• Insert the sealing plate and the spring into the baffle groove and press down during insertion of the
tube bundle
• Lubricate O-rings with suitable O-ring grease.
• During insertion of the tube plate into the sealing faces, make sure that the O-rings do not shear.
The bonnets/covers must be set up in parallel onto the tube plate and must be pushed evenly onto
the O-ring; ensure also that the O-ring does not shear.
• With two path devices, a path partition must be fitted at the side of the bonnet with the two
connections. At this side, the fixing sheets must also be installed later.
• When assembling the two path bonnet, make sure that the path partition is correctly placed.
• Then continue as described under 'Operation'.
Cleaning
In the case of only small amount of fouling, the tube side can be mechanically cleaned. Disassemble
the device as described under 'dismounting without remove the tube bundle' and clean with
a suitable nylon brush (do not use metal brushes) each tube inside, then clean with water.
Never remove stuck deposits or ! coarse dirt by force.
In the case of stuck deposits, the tube bundle must be cleaned chemically. This can be
460010 460010
carried out by rinsing the tube in the assembled state or submerging in disassembled state. Such a
cleaning must only be practiced by specialists. Only suitable solvents must be used. To select a
suitable agent, refer to the added part list. Take the materials of the plastic separator strip and O-rings
in the assembled state into consideration. Under 'Contacts' you find some companies offering
respective agents or carrying out a complete cleaning.
Provided that the type designation gets a C at the 11th position (example: KS12-BCN-821C L1000),
then it is a coated tube bundle. To prevent a damage caused by corrosion this bundle is coated on the
inside of the tubes and on the tubesheets. When dismounting the bundle and during cleaning make
sure that the coating will not be damaged or destroyed. Use only nylon cleaning brushes and
approved cleaning agents. If there are any doubts about suitability of an agent, please contact our
service department.
Troubleshooting
To low performance!/outlet temperature to high!

• Check all temperatures and material flows in accordance with the design data?
• Are foreign bodies in pipe or in device causing obstruction?
• Is the tube bundle correctly assembled, check marking?
• Are the path partition and the fixing plates correctly assembled in the two path bonnet?
• Are all pressure rooms vented?
• Are tube side or shell side too dirty (too thick deposits)?
• Are more than 10% of the tubes plugged?
Leaky tubes!
If the presumption exists that tubes have become leaky, proceed as with 'dismounting without remove
the tube bundle'. The shell side can remain under pressure. After cleaning the tube plates, you can
identify the defective tube by the state of the emerging medium. Lock the leaky tube at both ends with
our ‘Tubelock’-Repairset. Alternative you can use a conical copper or aluminium plug or a conical hard
wood plug. The plug must not be pushed too strong since otherwise adjacent rolling connections can
be damaged. You can lock 10% of the tubes at the most without noticeable reduction in performance.
Dismounting the defective tube is not possible.
Leaky rolling connection!

If it is found during the check for leaky tubes that a rolling connection is leaky, it can be rolled again
with a specific rolling tool. This work however is only to be carried out by specially trained personnel.
Since defects of this type are uncommon, a check of the complete bundle in our factory is
recommended.
Leaky O-ring!
If a leakage is found between bonnet/cover and casing, an O-ring of the tube plate is defective. The
kind of the emerging medium defines at which groove of the tube plate the defect developed. In the
case of a defect on the tube side, proceed as described under 'dismounting without remove the tube
bundle'. In the case of a defect at the shell side, proceed as described under 'dismounting with
withdrawing the tube bundle'. In this case the tube bundle does not need to be removed completely
from the casing. Assemble the O-ring as described in 'Assembly'.
Contacts
Cleaning
Suppliers for cleaning agents:
• Ashland Chemicals – www.ashchem.com
• Henkel Oberflächentechnik- www.henkel.com
460010 460010
• Ondeo Nalco – www.ondeo-nalco.com
Contractors for complete cleaning

• Vecom – www.vecom.nl
• - Ondeo Nalco – www.ondeo-nalco.com
Repair/spare parts
Repairs must only be carried out by specially trained personnel. However we recommend to carry out
any repair in our factory.
You can purchase spare parts directly from us with indicating the sketch and serial number. Please
contact our head offices or our sales office.
HS-Cooler GmbH Wittenburg is not liable for any defect resulting from any adverse use
of the product.
We reserve the right to adapt this operating manual at any time without prior notice
to include the latest developments.
460010 460010
- Ergänzung zu Kapitel ‚Wartung/Demontage/Demontage ohne Herausziehen des - Aanvulling bij het hoofdstuk
Rohrbündels‘. Bei Zusammenbau müssen die Fixierplatten wieder an der richtigen ’Onderhoud/demontage/
Seite des Wärmetauschers eingebaut werden - siehe dazu die Bedieungsanleitung! demontage zonder uittrekken van
de buizenbundel‘. Bij de montage
- Addition to chapter ’Maintenance/Dismounting/Dismounting without moeten de fixeerplaten opnieuw aan de
remove the test bundle‘. During assembly the fixing plates have to be correcte zijde van de warmtewisselaar
assembled to the correct side of the heat exchanger – see the instruction manual! worden ingebouwd – zie ook de
gebruiksaanwijzing!
- En complément du chapitre « maintenance/démontage/démontage sans
tirer vers l‘extérieur le faisceau tubulaire ». Lors de l’assemblage les dalles de - Komplettering av kapitel
fixation doivent être encastrées dans le côté exact de l’échangeur de chaleur - voir à cet ’Skötsel/demontage/
effet l’instruction d’exploitation. demontage utan att dra ut rörpaketet‘.
Vid sammansättningen måste
- Complemento al capítulo “Mantenimiento/Desmontaje/Desmontaje sin fixerplattorna åter monteras på rätt sida
extraer el haz de tubos”. Al realizar el montaje, las placas fijadoras se han av värmeväxlaren - se bruksanvisningen
de volver a colocar en el lado correcto del intercambiador de calor - ver para ello las om detta!
instrucciones de servicio.
- Supplement til kapittel
- Completamento del capitolo ’Manutenzione/Smontaggio/Smontaggio senza Vedlikehold/demontering/
estrazione del fascio tubolare‘. Nella fase di assemblaggio, le piastre di fissaggio demontering uten uttrekking av
devono essere rimontate sul corretto lato dello scambiatore di calore – vedi a questo rørbunt. Ved sammensetting må
proposito le istruzioni per l’uso! posisjoneringsplatene monteres på
korrekt side av varmeveksleren - se
- Suplemento do capítulo „Manutenção/Desmontagem/Desmontagem sem bruksveiledningen!
extracção do feixe de tubos“. No momento da montagem, as placas de fixação
deverão ser outra vez aplicadas no lado correcto do permutador térmico -- consulte o - Täydennys lukuun ’Huolto/
manual de instruções! Purkaminen/purkaminen ilman
putkinipun ulosvetämistä’. Koottaessa
on kiinnityslevyt asennettava taas
oikein lämmönvaihtimen sivulle – katso
käyttöohje!
A - Дополнение к главе
´Техобслуживание/демонтаж/
демонтаж без выдергивания пучка
труб´ - При сборке все фиксирующие
пластины должны монтироваться в
правильной стороне теплообменника
– смотри касательно этого инструкцию
по эксплуатации!
- Uzupełnienie do rozdziału
‘Konserwacja/Demontaż/
Demontaż bez wyciągania wiązki rurowej’.
Przy montażu, płyty ustalające muszą zostać
znowu wbudowane po właściwej stronie
wymiennika ciepła – patrz: Instrukcja obsługi!
- Dodatek k poglavju
- Vzdrževanje/Demontaža/
demontaža brez izvleka snopa cevi. Pri
sestavi je potrebno fiksirne ploščice spet
vgraditi nazaj na pravilni strani toplotnega
izmenjevalnika – glejte k temu navodila
za upravljanje!
- Dodatok ku kapitole
„Údržba/demontáž/demontáž
bez vyťahovania zväzku trubiek“.
Pri montáži je potrebné fixačné dosky
znovu namontovať na správnu stranu
B
výmenníka tepla – pozri v tejto súvislosti
návod na obsluhu!
1. 2.
Stand: 01.11.2006
460010 460010
3. 4.
5. 6.
7. 8.
9. 10.
Stand: 01.11.2006
460010 460010
460010 460010
Pos. Quantity Unit Description Part/Standard Number Remark
1 1 pc. Shell GS12 - 1

2 1 pc. Tube Bundle RL12 - C N - 4 2 1
G-CuSn5PbZn
3 1 pc. Waterbox 1 1/2" SAE KL12-B-002 (3.1B)
4 2 pc. Anode 3/8" KL-1021

G-CuSn5PbZn
5 1 pc. Cover KL12-B-003 (3.1B)
6 1 pc. Anode 3/8" KL-1021
7 2 pc. Sealing Plug DIN 910 - G 1/8" A Brass
8 2 pc. Sealing Ring DIN 7603 - A 10 x 13.5 x 1 Copper
9 4 pc. Fixation Plate KL12-0-108 Steel galv.
10 2 pc. Angle Bracket KL12-0-113 Steel

Steel galv.
11 8 pc. Hex Bolt ISO 4014 - M12 x 60 - 5.6 AD-W7 (Stamped)
Steel galv.
12 8 pc. Hex Nut ISO 4032 - M12 - 5-2 AD-W7 (Stamped)
13 12 pc. Washer DIN 125 - A 13 Steel galv.
14 1 pc. Type Plate Aluminium
DATE NAME
DRAW 29.11.99 Garbe
CHECK 29.11.99 Graulich

Parts List
NORM
K S 1 2 - BCN - 4 2 1 BC
Sheet
SYM REVISION DATE NAME FILE: Parts List KS12.doc
1 of 1
460010 460010
Pos. Quantity Unit Description Part/Standard Number Remark
CuZn38Sn1 F34
AD-W6/2 (3.1B)
1 2 pc. Tubesheet KL12 - C - 052 CuAl10Fe5Ni5-C
DIN EN 1982 (3.1B)
CuNi10Fe1Mn F29
2 72 pc. Tube LR = L + 28mm 7.5mm x 0.5mm AD-W6/2 (3.1B)
3 L/1.4 pc. Fin 1.4 KL12-0-105 Aluminium
4 4 pc. O-Ring KL-1510 NBR
5 2 pc. Sealing Strip L x 13 x 3 NBR
6 1 pc. Baffle KL12-0-106 Aluminium
7 1 pc. Water Partition KL12-0-107 Polypropylen
DATE NAME
DRAW 02.11.99 Garbe
CHECK 02.11.99 Graulich

PARTS LIST
NORM
R L 1 2 - CN - 4 2 1C Sheet
1 of 1
SYM REVISION DATE NAME FILE: Parts List RL12.doc
480020 480020
480100 480100
480020 480020
480100 480100
480050 480050
480130 480130
Montage- und Betriebsanleitung

Mounting and operating instructions
Instructions de montage et de service
Bitte für künftige Verwendung aufbewahren

Please retain for future use
Veuillez conserver pour un usage futur
Schwimmer - Magnetschalter
Magnetic operated float switches
Interrupteurs magnètiques à flotteur
Rev.3 / 26.07.99 Irrtümer und Änderungen vorbehalten

480050 480050
480130 480130
Folgende Symbole werden in dieser Betriebsanleitung verwendet:

The following symboles are be used in this manual:
Les symboles suivant sont utilisès dans ce manuel:
Warnhinweis.
Hinweise zur fachgerechten Montage und den
bestimmungsgemäßen Betrieb des Schwimmer - Magnetschalters.
Eine Nichtbeachtung kann zu Fehlfunktionen oder der Zerstörung
der Reedkontakte führen.
Warning
Instructions for proper installation and use of magnetic float
switches. Disregard may lead to malfunction or destruction of reed
contacts.
Signal d’avertissement
Instructions qui permettet le montage et l’utilisation correctes des
régulateurs de niveau á flotteur. Un mépris de ces instructions
peut conduire au mauvais fonctionnement ou á la detruction des
contacts à lame souple.
Gefahrenhinweis
Hinweise zur Vermeidung von Personen- oder Sachschäden.
Danger
Instructions to avoid personal or property damage.
Signal de danger
Instructions qui permettet d’éviter de porter atteinte á des
personnes ou á des biens.
Hinweise zur elektrischen Installation

Angaben für eine fachgerechte elektrische Installation.
Electrical installations
Instructions for proper electrical installation.
Installation électrique
Indications qui permettet une installation électrique correcte.
-1-
480050 480050
480130 480130
Funktionsbescheibung
Schwimmer - Magnetschalter arbeiten nach dem Schwimmer-
prinzip mit magnetischer Übertragung. Ein im Gleitrohr (5) bzw.
Kontaktrohr (8) eingebauter Reedkontakt wird durch das Ma-
gnetfeld eines Permanentmagneten bei Erreichen eines vorge-
gebenen Schaltpunktes betätigt. Der Permanentmagnet befindet
sich in einem Schwimmer (7), der seine Höhenlage mit dem Pegel
des zu überwachenden Mediums verändert. Der Schaltzustand
des Reedkontaktes kann durch eine nachgeschaltete
Steuereinrichtung ausgewertet und weiterverarbeitet werden.
Die Anzahl und Anordnung der Schwimmer ist abhängig von der
Anzahl der vorgegebenen Schaltpunkte, deren Kontaktfunktion
sowie dem Abstand der Schaltpunkte.
Einsatzbereich
Schwimmer - Magnetschalter sind ausschließlich zur Füll-
standssteuerung bzw. -überwachung von flüssigen Medien zu
verwenden.
Die Flüssigkeiten dürfen keine starke Verschmutzungen oder
Grobteile aufweisen und nicht zum Auskristallisieren neigen. Es ist
sicherzustellen, daß die medienberührenden Werkstoffe des
Schalters (Schwimmer, Gleitrohr) gegen das zu überwachende
Medium ausreichend beständig sind.
Montage
Ausführungen für vertikalen Einbau (Fig. 1)

• KSR Schwimmer - Magnetschalter entsprechend der Ausfüh-
rung (Flansch o. Gewinde [3]) einbauen.
• Bei Flanschausführungen sind die zum Flansch passenden
Schrauben und Muttern zu verwenden. Zum Abdichten ist eine
geeignete Dichtung (4) vorzusehen.
• Es ist auf korrekte Einbaulage zu achten. (Max. Abweichung
aus der vertikalen ± 30° ).
• Bei Einbauöffnungen die kleiner als der Durchmesser des
Schwimmers sind, ist der Schwimmer (7) vor dem Einbau des
Schalters abzunehmen.
• Die Position der Stellringe (6) ist vor dem Abnehmen zu mar-
kieren (z.B. mit einem wasserfesten Stift).
• Sofern die Schwimmer nicht gekennzeichnet sind, ist die Ein-
baulage entsprechend zu kennzeichnen (z.B. "Oben")
• Nach dem Einbau des Schwimmer - Magnetschalters ist der
Schwimmer im Inneren des Tanks wieder aufzusetzen
(Einbaulage beachten!).
• Die Stellringe (6) sind anschließend an den markierten Stellen
wieder zu befestigen.
• Die Anzahl der Schwimmer sowie die Position der Stellringe
sind vom Maß und der Anzahl der Schaltpunkte abhängig.
-2-
480050 480050
480130 480130
Ausführungen für horizontalen Einbau (Fig. 2)

Schwimmer - Magnetschalter für horizontale Einbaulage sind ge-
mäß Fig.2 einzubauen.
Bei Flanschausführungen sind die zum Flansch passenden
Schrauben und Muttern zu verwenden. Zum Abdichten ist eine
geeignete Dichtung (4) vorzusehen. Es ist auf korrekte Einbaulage
zu achten. (Der Schwimmer muß im unbetätigten Zustand nach
unten gekippt sein). Beim Einbau in Stutzen muß gewährleistet
sein, daß der Schwimmer in seiner Kippbewegung nicht
beeinträchtigt wird.
Beim Einbau in ferromagnetische Stutzen wird die Funktions-

fähigkeit des Schalters beeinträchtigt.
Gefahr von Sachschäden durch fehlerhaftes Schaltverhalten des
Reedkontaktes.
Der Schwimmerschalter ist so einbauen, daß sich das Kontaktrohr
außerhalb eines ferromagnetischen Stutzens befindet.
Elektrischer Anschluß
Der elektrische Anschluß ist entsprechend den im Errichtungsland

geltenden Errichtungsbestimmungen durchzuführen und darf nur
von Fachpersonal durchgeführt werden.
Zur Erhöhung der Lebensdauer der Kontakte wird der Betrieb an
einem Kontaktschutzrelais empfohlen.
Der elektrische Anschluß ist entsprechend dem jeweiligen am

Schalter angebrachten Anschlußschema vorzunehmen.
(Ausführungen mit nur einem Öffner oder Schließerkontakt
enthalten kein Anschlußschema.)
Die Kabeldurchführung (2) am Anschlußgehäuse (1) ist abzu-
dichten.
-3-
480050 480050
480130 480130
Der Betrieb der Schwimmer - Magnetschalter an induktiver oder

kapazitiver Last kann eine Zerstörung des Reedkontaktes zur
Folge haben. Dies kann zu einer Fehlfunktion der nachgeschal-
teten Steuerung und zu Personen- oder Sachschäden führen.
Bei induktiver Belastung sind die Schwimmer - Magnetschalter
durch Beschaltung mit einem RC Glied gem. Anhang bzw. einer
Freilaufdiode zu schützen.
Induktive Last an Induktive Last an

Wechselspannung Gleichspannung
S1 S1
+
R RC-Glieder je nach Freilaufdiode
24 - 230V AC Betriebsspannung 24 - 250V DC z.B. 1N4007
siehe Tabelle
C
-
Bei kapazitiver Belastung, Leitungslängen über 50m oder dem An-

schluß an Prozeßleitsystemen mit kapazitivem Eingang ist zur Be-
grenzung des Spitzenstromes ein Schutzwiderstand von 22Ω bzw.
47Ω (bei 10VA-Kontakten) in Serie zu schalten.
Bei Anschluß an elektronische Zeitrelais muß ein Widerstand von
220 Ohm in Serie geschaltet werden.
Strombegrenzung bei Strombegrenzung bei
kapazitiver Last elektronischen Zeitrelais
z.B. SPS, PLS und Leitungen >50m
S1 Rs S1 Rs
+ Rs = 22 Ohm Rs = 220 Ohm
C1 (47Ω bei Kontakten 230V AC
24V DC C1 (230V AC)
bis 10VA) Zeit-
- SPS C1 = innere Kapazität C1 = innere Kapazität
relais
Eine Überlastung des Schwimmer - Magnetschalters kann eine

Zerstörung des eingebauten Reedkontaktes zur Folge haben. Dies
kann zu einer Fehlfunktion der nachgeschalteten Steuerung und
zu Personen- oder Sachschäden führen. Die im Kapitel
"Technische Daten" und im KSR-Typenblatt 1003 angegebenen
Maximalwerte für die Schaltleistung sind einzuhalten.
Spitzenstrommessung mit Oszilloscope
S1 I (A)
ohne Strombegrenzung
C RE 4
24V DC 3
mit Strombegrenzung
2
RM
nicht zul. Bereich
1
zul. Bereich
Beispiel: C = 0,33µF/230V AC 3-10 t (µs)
Bei Schwimmer - Magnetschaltern mit Anschlußkabel ohne

Schutzleiteranschluß kann der Schalter im Fehlerfall spannungs-
führend sein. Bei Berührung können schwere Körperschäden oder
tödliche Verletzungen auftreten. Diese Schalter dürfen nur an
Schutzkleinspannung nach VDE0100 betrieben werden (z.B. an
einem KSR Kontakt-schutzrelais) oder sind so zu montieren, daß
der Schwim-mer - Magnetschalter mit dem Potentialausgleich elek-
trisch verbunden ist.
-4-
480050 480050
480130 480130
Inbetriebnahme / Funktionsprüfung
Versorgungsspannung der angeschlossenen Steuerungsein-
richtung einschalten, Behälter füllen und die Schaltpunkte des
Schwimmer - Magnetschalters auf Funktion prüfen. Die Funk-
tionsprüfung kann auch manuell bei ausgebautem Schalter erfol-
gen.
Es ist sicherzustellen, daß durch die Funktionsprüfung keine

unbeabsichtigten Prozeßabläufe eingeleitet werden.
Wartung
Schwimmer - Magnetschalter arbeiten bei bestimmungsgemäßem
Gebrauch wartungs- und verschleißfrei.
Bei extremen Einsatzbedingungen sollte der Schalter im Rahmen
der durchzuführenden Revisionen einer Sichtkontrolle unterzogen
werden.
Hinweise
Beim Betrieb im Ex - Bereich der Zone 1 oder 2 sind die
Reedkontakte an eigensicheren Stromkreisen zu betreiben.
Schwimmerschalter aus Kunststoff dürfen nicht im Ex - Bereich

der Zone 1 oder 2 eingesetzt werden.
Schwimmerschalter nicht in unmittelbarer Nähe von starken

elektromagnetischen Feldern bzw. in unmittelbarer Nähe von
Einrichtungen, die durch Magnetfelder beeinflußt werden können,
betreiben (Abstand min. 1m).
Die Schaltpunkte der Schwimmer - Magnetschalter können nicht

verstellt werden.
Schwimmer - Magnetschalter nur in Medien einsetzen gegen die

der Werkstoff des Gleitrohres und des Schwimmers beständig ist
Die Schalter dürfen keinen starken mechanischen Belastungen

(Stoß, Verbiegen, Vibrationen) ausgesetzt werden.
-5-
480050 480050
480130 480130
Technische Daten
Kontaktfunktion :Öffner / Schließer
Max. Spannung :250V AC / DC
Schaltstrom :2A AC / 1A DC
Schaltleistung :100 VA, cosϕ >0,7 / 50 W
Kontaktfunktion :Umschalter
Max. Spannung :250V AC / DC
Schaltstrom :1A AC / 0,5A DC
Schaltleistung :40 VA, cosϕ > 0,7 / 20 W
Mini Schwimmerschalter
Kontaktfunktion :Öffner / Schließer

Spannung :250V AC / DC
Schaltstrom :0,5A AC / 0,25A DC
Schaltleistung :10 VA , cosϕ > 0,7 / 5 W
-6-
480050 480050
480130 480130
Functional Description
Magnet-operated float switches operate according to the float
principle with magnetic transmission. A reed contact built into the
slip pipe (5) or contact pipe (8) is activated by the magnetic field of
a permanent magnet on reaching a preset switching point. The
permanent magnet is located in a float (7) which changes its
height with the level of the medium being monitored. The switching
state of the reed contact can be evaluated and processed by a se-
ries-connected control unit.
The number and arrangement of the floats depends on the
number of preset switching points, their contacting function and
the distance apart of the switching points.
Area of Application
Magnet-operated float switches are used exclusively for level
control and monitoring of liquid media.
The liquids may not be heavily contaminated and should not have
a tendency to crystallize. Make sure that the materials of the
switch (float, slip pipe) which come into contact with the medium
being monitored are suitably resistant.
Assembly
Versions for vertical installation (Fig. 1)
• Install KSR magnet-operated float switches according to their
type (flange or thread [3]).
• Use the screws and nuts suitable for the flange for flange
types. Fit a suitable gasket (4) for sealing. Make sure it is
installed in the right position. (Max. deviation from the vertical ±
30°).
• The float (7) must be removed before installation in openings
with a diameter smaller than the diameter of the float.
• Mark the position of the set collars (6) before removing.
• If top and bottom of the floats are not already marked, please
do so now.
• Replace the float inside the tank after installing the magnet-
operated float switch.
• Then fix the set collars (6) back in the same position.
• The number of floats and position of stop rings are dependent
on the switching positions and number of switch points.
Versions for horizontal installation (Fig. 2)

Magnet-operated float switches for horizontal operation must be
installed as shown in fig. 2.
Use the screws and nuts suitable for the flange for flange types.
Fit a suitable gasket (4) for sealing. Make sure it is installed in the
right position. (The float must be tilted downwards in the
unactivated state). When installing in the union, make sure that the
tilting of the float is not affected.
-7-
480050 480050
480130 480130
When mounted inside ferromagnetic surroundings the function

could be restrained. This may cause a malfunktion and harm to
goods.
The magnet operated float switch must be mounted outside
ferromagnetic surroundings.
Electrical Connection
All cabling and electrical connections must be carried out in ac-
cordance with the regulations applicable in the country where the
equipment is installed and by personnel qualified to do.
Operation on a contact protection relay is recommended to
prolong the life of the contacts.
The electrical connection is made according to the wiring

diagram printed on the switch.
(Types with only one normally closed or normally open contact
contain no wiring diagram.)
The cable bushing (2) in the connection enclosure (1) must be
sealed.
Use of magnetic float switches with inductive or capacitive load

may lead to the destruction of the reed switch. This may cause a
malfuction to the control circuitry and harm to persons or goods.
With inductive load, magnetic switches have to be connected to a
RC Network (acc. to appendix).
Inductive Load AC Inductive Load DC
S1 S1
+
R RC-Modules Shunt diode
24 - 230V AC acc. to table 24 - 250V DC e.g. 1N4007
C
-
-8-
480050 480050
480130 480130
With capacitive load, connecting cables longer than 50m or

connection to a PLC with capacitive input circuit, a 22Ω resp. 47Ω
(10 VA contacts) resistor is required to be connected in series to
limit current spikes. A 220Ω resistor shall be used when connected
to an electronic timer.
Current limitation with Current limitation with

capacitive load electronic timers
e.g. PLC and cables > 50m
S1 Rs S1 Rs
+ Rs = 220 Ohm
C1 Rs = 22 Ohm (230V AC)
24V DC 230V AC C1
C1 = internal C1 = internal
- SPS timer
capacitance capacitance
Overloading the magnetic float switches may lead to the de-

struction of the reed switch, which may cause a malfunktion to the
control circuitry and harm to persons or goods. The maximum
switch capacity values given in the chapter "Technical data" and
the Technical bulletin 1003 must not be exceeded.
Current measurement with oscilloscope

S1 I (A)
without current limitation
C RE 4
24V DC 3
with current limitation
2
RM not allowed
1
allowed
Example: C = 0,33µF/230V AC 3-10

t (µs)
Magnetic float switches with connecting cable including no

protective earth may be live under fault conditions. Touching
the housing may cause harm to persons or even be lethal.
These switches must only be used with protective low voltage
acc. to VDE 0100 ( f. e. use a KSR contact protection relay) or
have to be mounted in such way, that the switch is earthed.
Commissioning / Function Test

Switch on the power supply to the connected control unit. Fill
the vessel and check the function of the switching points of the
magnet-operated float switch.
The function test can also be conducted manually on the removed
switch.
Note
Make sure that the function test does not accidentally set any
processes in motion.
-9-
480050 480050
480130 480130
Maintenance
The magnet-operated float switches operate free of maintenance
and wear when used properly.
The switch must be eye-checked within the scope of the
necessary inspections under extreme operating conditions.
Notes
The reed contacts must be operated on intrinsically safe circuits
when operating in "e" areas of zone 1 or 2.
Float switches made of plastic may not be used in the "e" areas of
zone 1 or 2.
Do not operate float switches in the immediate vicinity of strong

electromagnetic fields (distance away at least 1m).
The switching points of the magnet-operated float switches cannot

be adjusted.
Magnet-operated float switches can only be used in media to

which the material of the slip pipe and the float is resistant.
The switches may not be exposed to heavy mechanical stresses

(shock, bending, vibrations).
Technical data
Switching behaviour :Norm close / Norm open
Max. voltage :250V AC / DC
Max. current :2A AC / 1A DC
Max. power :100 VA, cosϕ >0,7 / 50 W
Switching behaviour :change over

Max. current :1A AC / 0,5A DC
Max. power :40 VA, cosϕ > 0,7 / 20 W
Magnet operated Mini Float Switches
Switching behaviour :Norm close / Norm open

Max. current :0,5A AC / 0,25A DC
Max. power :10 VA , cosϕ > 0,7 / 5 W
- 10 -
480050 480050
480130 480130
Description fonctionnelle
Les interrupteurs magnétiques à flotteur fonctionnent suivant le
principe des flotteurs à transfert magnétique. Un contact Reed
logé dans le tube de glissement (5) ou dans un tube de contact (8)
est actionné par le champ magnétique d'un aimant permanent
lorsqu'un point de commutation prédéterminé est atteint. L'aimant
permanent est monté dans un flotteur (7) qui change sa position
en hauteur avec le niveau du milieu à surveiller. L'état de
commutation du contact Reed peut être évalué et traité par un
dispositif de commande monté en aval à circuit de courant de
commande à sécurité intrinsèque.
Le nombre et la disposition des flotteurs dépendent du nombre de
points de commutation prédéterminés et de leur fonction de
contact ainsi que de l'écart des points de commutation.
Domaine d'application
Les interrupteurs magnétiques à flotteur servent exclusivement à
commander ou à surveiller le niveau de remplissage de milieux
liquides.
Les liquides à surveiller ne doivent pas contenir de fortes
pollutions ou de particules grossières et ne doivent pas avoir
tendance à se cristalliser. Il faut s'assurer que les matériaux de
l'interrupteur (flotteur, tube de glissement) au contact du milieu
résistent suffisamment au milieu à surveiller.
Montage
Exécutions pour un montage à la verticale (fig. 1)
• Monter les interrupteurs magnétiques à flotteur KSR con-
formément à l'exécution (bride ou filetage [3]).
• Pour les exécutions à bride, il convient d'utiliser les vis et les
écrous adaptés à la bride. Pour étouper, il convient de prévoir
un joint adéquat (4).
• Veiller à ce que la position de montage soit correcte. (Ecart
maximal par rapport à la verticale ± 30° ).
• En présence d'ouvertures de montage plus petites que le dia-
mètre du flotteur, il convient d'enlever le flotteur (7) avant le
montage de l'interrupteur.
• Dans la mesure où les flotteurs ne portent pas de marquage, la
position de montage adéquate (par exemple en „haut“) doit
être indiquée.
• Il convient de marquer la position des bagues de réglage (6)
avant l'enlèvement.
• Après avoir monté l'interrupteur magnétique à flotteur, il
convient de replacer le flotteur à l'intérieur du réservoir.
• Les bagues de réglage (6) doivent être ensuite fixées de
nouveau au même endroit.
• Le nombre de flotteurs ainsi que la position des anneaux de
règlage dèpendent de la position et du nombre des contacts.
- 11 -
480050 480050
480130 480130
Exécutions pour un montage à l'horizontale (fig. 2)

Les interrupteurs magnétiques à flotteur destinés à un mon-tage à
l'horizontale doivent être montés conformément à la figure 2.
Pour les exécutions à bride, il convient d'utiliser les vis et les
écrous adaptés à la bride. Pour étouper, il convient de prévoir un
joint adéquat (4). Veiller à ce que la position de montage soit
correcte. (Le flotteur doit être basculé vers le bas à l'état non
actionné).
Pour un montage dans des tubulures, il faut assurer que le flotteur
ne soit pas gêné dans son mouvement de basculement
Le montage dans des tubes ferromagnétiques entraîne un

mauvais fonctionnement du commutateur. Danger de dommages
matériels en raison de mauvaises commutations du contact reed.
Le commutateur du flotteur doit être monté de telle sorte que la
tubulure de contact se trouve à l'extérieur d'un tube ferroma-
gnétique.
Raccordement électrique
Il faut respecter les dispositions relatives aux installations
électriques en vigueur dans le pays d'exécution. Seul le personnel
spécialisé est autorisé à travailler sur les installations électriques.
Pour augmenter la durée de vie des contacts, nous recom-
mandons le fonctionnement avec un relais de protection des
contacts.
Le raccordement électrique doit être réalisé conformément au

schéma des connexions apposé sur l'interrupteur.
(Les exécutions avec un seul contact d'ouverture ou de fermeture
n'ont pas de schéma des connexions.)
- 12 -
480050 480050
480130 480130
Il convient de s'en tenir aux prescriptions en vigueur pour les

installations électriques dans le pays d'installation.
Il convient d'étouper le passe-câble (2) sur le boîtier de
raccordement (1).
L'utilisation des interrupteurs magnétiques á flotteur sous charge

inductive ou capacitive peut provoquer la destruction du contact
reed. Ceci peut entraîner le mauvais fonctionnement de la com-
mande située en aval ainsi que des dommages corporels ou
matériels.
Sous charge inductive, les interrupteurs magnétiques doivent être
protégés par un circuit RC (voir annexe) ou par une diode de
dérivation.
Charge inductive sous tension Charge inductive sous tension

alternative alternative
S1 S1
+
R Circuits RC selon
Diode de dérivation
24 á 230V AC tension d’alimentation 24 à 250V DC p. ex. 1N4007
(voir tableau)
C
-
En cas de charge capacitive, de conduites de plus de 50 m de

long ou de raccord à des systèmes d'automatisme industriel à
entrée capacitive, il faut monter en série une résistance protectrice
de 22 ohms ou de 47 ohms (avec des contacts de 10 VA) afin de
limiter de courant de crête. Une résistance de 220 Ohm montée
en série doit être utilisée lors d’un raccordement à un minuteur
éléctronique.
Limitation du courant pour Limitation du courant pour

charge capacitive minuteurs électroniques
p. ex. poste de commande programmable
ou câbles > 50 m
S1 Rs S1 Rs
+ Rs = 22 Ohm Rs = 220 Ohm
C1 (47 Ohm pour (230 V~)
24V DC contact de 10 VA) 230V AC C1
PCP C1 = capacité interne Minuteur C1 = capacité interne
-
Une surcharge du commutateur magnetique peut provoquer la

destruction du contact reed intégré. Ceci peut entraîner le mauvais
fonctionnement de la commande située en avai ainsi que des
dommages corporels ou matériels. Il faut respecter les valeurs
maximales de puissance de rupture indiquée dans le chapitre
"Données techniques" ainsi que dans la fiche technique KSR
1003.
- 13 -
480050 480050
480130 480130
Mesure de pointe de courant à l’oscilloscope

S1 I (A)
sans limitation de courant
C RE 4
24 V= 3
avec limitation de courant
2
RM domaine interdit
1 domaine permis
Exemple: C = 0,33 µF / 24 V= 3 à 10
t (µs)
Avec des interrupteurs magnétiques á flotteur à boîtier

métallique sans prise de terre, le boîtier peut être sous ten-
sion en cas de perturbation. De graves lésions corporelles ou
des blessures mortelles sont possibles en cas de contact.
Ces commutateurs ne peuvent être utilisés qu'avec une
basse tension de protection selon VDE 0100 (KSR relais de
protection des contacts) ou bien doivent être montés de telle
sorte que le boîtier du interrupteur mag-nétique á flotteur soit
relié à une compensation de potentiel.
Mise en service / Contrôle fonctionnel

Mettre la tension d'alimentation du dispositif de commande
raccordé en circuit. Remplir le réservoir et vérifier le
fonctionnement des points de commutation de l'interrupteur
magnétique à flotteur.
Le contrôle fonctionnel peut aussi être réalisé manuellement
lorsque l'interrupteur est démonté. Ce faisant, il convient de veiller
à ce qu'aucun déroulement de processus ne soit involontairement
déclenché.
Avertissement!
Il faut s'assurer que le contrôle de fonctionnement ne déclenche
pas une étape de process involontaire.
Entretien
A condition d'être utilisés de manière conforme, les interrupteurs
magnétiques à flotteur fonctionnent sans usure et ne nécessitent
pas d'entretien.
En cas de conditions d'utilisation extrêmes, l'interrupteur devrait
être soumis à un contrôle visuel dans le cadre des révisions à
réaliser.
- 14 -
480050 480050
480130 480130
Remarques
Pour une exploitation dans la zone explosive 1 ou 2, les contacts
Reed doivent être exploités sur des circuits de courant à sécurité
intrinsèque.
Les interrupteurs à flotteur en matière plastique n'ont pas le droit

d'être utilisés dans la zone explosive 1 ou 2.
Ne pas utiliser les interrupteurs à flotteur à proximité directe de

puissants champs électromagnétiques (distance minimale: 1m).
Ne pas changer le positionnement des bagues de réglage ou ne

pas les enlever du tube de glissement.
Les points de commutation des interrupteurs magnétiques à

flotteur ne peuvent pas être déréglés.
Les interrupteurs magnétiques à flotteur ont uniquement le droit
d'être utilisés dans des milieux contre lesquels le matériau du tube
de glissement et du flotteur est résistant.
Les interrupteurs n'ont pas le droit d'être soumis à de fortes

sollicitations mécaniques (chocs, torsion, vibration).
Caractéristiques techniques
Fonction de contact : :ouverture / fermeture
Tension commutée :250V AC / DC

Courant commuté :2A AC / 1A DC
Pouvoir de coupure :100 VA, cosϕ >0,7 / 50 W
Fonction de contact :inverseur

Courant commuté :1A AC / 0,5A DC
Pouvoir de coupure :40 VA, cosϕ > 0,7 / 20 W
Mini régulateurs de niveau
Fonction de contact : ouverture / fermeture

Courant commuté :0,5A AC / 0,25A DC
Pouvoir de coupure :10 VA , cosϕ > 0,7 / 5 W
- 15 -
480050 480050
480130 480130
RC-Glieder zur Schutzbeschaltung

Protective RC-Modules
Circuits RC de protection de contacts
RC-Glieder sind, je nach Betriebsspannung, ausschließlich entsprechend

untenstehender Tabelle zu verwenden.
Andere als die hier aufgeführten RC-Glieder führen zur Zerstörung des
Reedschalters.
Please use RC-modules according to the table below. Rating of the switches and
supply voltage will determine the type to be used.
Other types might lead to destruction or lower service life of the reed contacts.
Selon la tension d’alimentation, les circuits RC de protection de contacts listés dans

le tableau ci-dessous doivent être utilisés.
L’utilisation d’autres circuits RC conduit à la destruction des contacts à lame
souple.
Für Schutzgaskontakte von 10-40VA Für Schutzgaskontakte von 40-100VA

For reed contacts 10-40VA For reed contacts 40-100VA
Pour contacts à lame souple de 10 à 40VA Pour contacts à lame souple de 40 à 100VA
Kapazität Widerstand Spannung Typ Kapazität Widerstand Spannung Typ
Capacitance Resistance Voltage Type Capacitance Resistance Voltage Type
Capacité Résistance Tension Type Capacité Résistance Tension Type
0,33 µF 100 Ohm 24 V~ A 3/24 0,33 µF 47 Ohm 24 V~ B 3/24
0,33 µF 220 Ohm 48 V~ A 3/48 0,33 µF 100 Ohm 48 V~ B 3/48
0,33 µF 470 Ohm 115 V~ A 3/115 0,33 µF 470 Ohm 115 V~ B 3/115
0,33 µF 1500 Ohm 230 V~ A 3/230 0,33 µF 1000 Ohm 230 V~ B 3/230
d d d
l
l
l
Litze wire
200
fils de
200
200
raccordement
d = von ø16mm- ø25mm d = OD 16mm - 25mm d = Ø 16 mm à 25 mm

l = von 26mm- 58mm l = 26mm - 58mm l = 26 mm à 58 mm
- 16 -
480050 480050
480130 480130
1
2
3
4
max. 30°
Fig.1
7 8 4 3 2 1
Fig.2
- 17 -
480050 480050
480130 480130
NIVEAU-MESSTECHNIK AG
KSR KUEBLER Niveau-Messtechnik AG

Im Kohlstatterfeld 17 D-69439 Zwingenberg
Tel. (+49) 62 63/87-0 Fax (+49) 62 63/8799
http://www.ksr-kuebler.com e-mail: ksr-de@ksr-kuebler.com
KSR KUEBLER (UK) Level Measurement & Control Ltd

GB-Molesey Surrey KT8 1QZ
KSR KUEBLER (SINGAPORE)

Level Measurement & Control PTE LTD
#01-18/21 German Centre Singapore 609916
KSR KUEBLER (USA)

Level Control Products of America Inc.
Raleigh, NC 27613
SHANGHAI KSR KUEBLER

Automation Instrument Co. Ltd
Shanghai/China
KUBLER FRANCE S.A.

F-68700 Cernay
KÜBLER SUOMI OY
SF-01301 Vantaa
480070 480070
480150 480150
Data sheet
Temperature sensors
types MBT 5250, 5260 and 5252
May 2000 DKACT.PD.P30.B1.02

520B0337
480070 480070
480150 480150
Temperature sensors, types MBT 5250, 5260 and 5252
Features and application · For temperature measurement and

regulation in piping systems and
refrigeration plants on ships – or
points where reliable, robust and accurate
equipment is required
· Gaseous or liquid media, e.g. air, gas,
vapour, water or oil.
· Up to +200°C media temperatures
· Pt100 or Pt1000 resistance element
· Can be used with 2- or 3-wire connections
· Gold plated male and female connector
· MBT 5250 with interchangeable measuring
insert
· MBT 5260 with fixed measuring insert
· Approvals
- Lloyds Register of Shipping, LR
- Germanischer Lloyd, GL
- Bureau Veritas, BV
- Det Norske Veritas, DNV
1) Measuring insert for 1) - Nippon Kaiji Kyokai, ClassNK
MBT 5250 - Registro Italiano Navale, RINA
- American Bureau of Shipping, ABS
- Korean Register of Shipping, KRS
Dimensions
Without extension length

Plugs
PG 9, PG 11 PG 13.5
Gasket
With extension length
Please note:
· Tightening torque for the mounting screw
at the rear end of the electrical connection
plug: 25 Ncm
· Tightening torque for the union
(position “E”): 17 Nm
Solid drilled with extension
length
1) Process connection Width across

flats
A = Extension length
B = Insertion length G 1/4 A HEX 22
C = Protection tube G 1/2 A, 1/2 - 14 NPT, M18 ´ 1.5, G 3/8 A HEX 27
D = Process connection 1)
All dimensions in millimeters E = Union M24 ´ 2, G 3/4 A HEX 32
2 DKACT.PD.P30.B1.02 ã Danfoss A/S, 05-2000

480070
480150
Temperature sensors, types MBT 5250, 5260 and 5252 480070
Technical data Response times
480150
Indicative response times
according to VDI/VDE 3522
Type Protection tube Water 0.2 m/s Air 1 m/s
t0.5 t0.9 t0.5 t0.9
Æ8 ´ 1 mm 9s 33 s 95 s 310 s
Æ8 ´ 1 mm, filled with heat conductive compound 1) 3s 10 s 90 s 300 s
MBT 5250 with Æ10 ´ 2 mm 12 s 42 s 111 s 391 s
interchangeable Æ10 ´ 2 mm, filled with heat conductive compound1) 4s 14 s 96 s 323 s
measuring insert
Solid drilled 12 s 36 s 220 s 900 s
Solid drilled, filled with heat conductive compound 1) 5s 15 s 210 s 850 s
MBT 5260 with Æ8 ´ 1 mm 2s 6s 82 s 260 s
fixed meas. ins. Solid drilled 4s 13 s 225 s 850 s
1)
The sensors are supplied without heat conductive compound
Materials
Protection tube in contact with media W.no. 1.4571 (AISI 316 Ti)
Process connection W.no. 1.4571 (AISI 316 Ti)
Extension length W.no. 1.4571 (AISI 316 Ti)
Union Nickel plated brass
Gasket Silicone
Plug DIN 43650 PA 6.6 (max 125°C)
Mechanical and environmental specifications

Sensor tolerance EN 60751 Class B: ± (0.3 + 0.005 ´ t) t = temperature of
1
/3 EN 60751 Class B: ± (0.1 + 0.005 ´ t) medium, numerical
1
/6 EN 60751 Class B: ± (0.05 + 0.005 ´ t) value
Vibration stability Shock: 100 g in 6 ms
Vibrations: 4g sine function 5 - 200 Hz, measured acc. to IEC 68-2-6
Enclosure IP 65 according to IEC 529
Cable entry DIN 43650 PG 9, PG 11 or PG 13.5
Max. temperature (Ext. length “None”) Max. load on protection tube (Æ8 ´ 1,
Plug DIN 43650 Æ10 x 2) acc. to DIN 43763
L = Insertion length
Permissible Air 25 m/s

Tm = Media temperature media velocity Water 3 m/s
Tp = Temperature for electric plug
TA = Ambient temperature
Process G 1/4 A – G 1/2 A G 3/4 A
connection G 3/8 A – M18 M24
Note: for extension length = 50 mm no limitations
up to 200 °C media temperature and 90 °C Max. tightening
torque 50 Nm 100 Nm
ambient temperature
ã Danfoss A/S, 05-2000 DKACT.PD.P30.B1.02 3

480070 480070
480150 480150
Electrical connections
2-wire, 3 terminals
(l: Not connected)
MBT 5250 ordering
Standard programme
· Measuring range: –50 to +200°C · Extension length: None
· Resistance value: 1 ´ Pt100 · Tolerance: EN 60751, Class B
· Protection tube: Æ8 ´ 1 mm, W. No. 1.4571 (AISI 316 Ti)
Electrical connection
Insertion length [mm] Process connection PG 9 PG 11 PG 13.5
Code no. Code no. Code no.
50 G 1/2 A 084Z8011 084Z8036
100 G 1/2 A 084Z8012 084Z8039
150 G 1/2 A 084Z8010 084Z8008
200 G 1/2 A 084Z8022 084Z8043
50 G 3/4 A 084Z8037 084Z8058
100 G 3/4 A 084Z8006 084Z8013
150 G 3/4 A 084Z8041 084Z8014
200 G 3/4 A 084Z8044 084Z8218
1
50 /2 – 14 NPT 084Z8066
1
80 /2 – 14 NPT 084Z8019
1
100 /2 – 14 NPT 084Z8067
1
150 /2 – 14 NPT 084Z8065
1
200 /2 – 14 NPT 084Z8068
Other specifications on request
MBT 5260 ordering
Standard programme
· Measuring range: –50 to +200°C · Extension length: None
· Resistance value: 1 ´ Pt100 · Tolerance: EN 60751, Class B
· Protection tube: Æ8 ´ 1 mm, W. No. 1.4571 (AISI 316 Ti)
Insertion length [mm] Process connection PG 9 PG 11
Code no. Code no.
50 G 1/2 A 084Z8033 084Z8229
100 G 1/2 A 084Z8021 084Z8132
150 G 1/2 A 084Z8034 084Z8096
200 G 1/2 A 084Z8238
Other specifications on request

480070
480150
480150
Features and application · For measuring and regulating temperature
in piping systems and refrigeration plant on
ships - or at all points where reliable, robust
and accurate equipment is required.
· Gaseous or liquid media, e.g. air, gas,
vapour, water or oil.
· Up to +400°C media temperatures.
· Pt100/ Pt1000 resistance element.
· Available with built-in transmitter.
· Approvals
- Lloyds Register of Shipping, LR
- Germanischer Lloyd, GL
- Bureau Veritas, BV
- Det Norske Veritas, DNV
1) MBT 5252 - Nippon Kaiji Kyokai, ClassNK
Measuring insert type MBT 152 1) 2) 3)
2) with terminal block
- Registro Italiano Navale, RINA
3) with temperature transmitter - American Bureau of Shipping, ABS
- Korean Register of Shipping, KRS
Dimensions
Also available with:
Insertion length Extension length
Union nut
Welded
Type: BM
Protection tube
Æ10 x 2
Process connection
Transmitter type MBT 9110,

as terminal block
Connection head, type B
PG 16
Screw-cap
Process Width across

connection flats
G 1/2 A, ½-14 NPT HEX 27
All dimensions in millimeters
G 3/4 A HEX 32

480070 480070
480150 480150
Technical data (continued) Weight

Process connection
Insertion length Electrical Transmitter setting G 1/2 A G 3 /4 A ½-14 NPT
[mm] connection Weight [g] Weight [g] Weight [g]
50 430 480 430
100 Sensors are 460 510 460
2-wire,
150 without transmitter 490 540 490
3 terminals
200 520 570 520
250 550 600 550
50 4 - 20 mA, 420 470 420
100 2-wire universal 450 500 450
150 temperature 0 ® +100°C 480 530 480
200 transmitter 510 560 510
250 540 590 540
Max. load on protection tube according to DIN 43763

Æ 11 ´ 1, Æ 15 ´ 3 Æ 8 ´ 1, Æ 10 ´ 2
L = Insertion lenght
Protection tube Æ 10 ´ 2
Max. tightening torque G 1/4 - M18 50 Nm
Air 25 m/s
Permissible Steam 25 m/s
media velocity
Water 3 m/s
Materials
Protection tube in contact with media W. no. 1.4571 (AISI 316 Ti)
Process connection in contact with media W. no. 1.4571 (AISI 316 Ti)
Extension length W. no. 1.4571 (AISI 316 Ti)
Union nut Nickel plated brass
Connection head Die cast aluminium
Mechanical and environmental specifications

Max. temperature 1) Ambient: 90°C for sensors without temperature transmitter
Transmitter: 85°C for sensors with temperature transmitter
Sensor tolerance EN 60751 Class B: ± (0.3 + 0.005 ´ t) t = temperature of medium,
numerical value
1
/3 EN 60751 Class B: ±(0.1 + 0.005 ´ t)
1
/6 EN 60751 Class B: ±(0.05 + 0.005 ´ t)
Vibration stability Shock: 100 g in 6 ms
Vibrations: 4g sine function 2 - 100 Hz, measured acc. to IEC 68-2-6
Enclosure IP 65 according to IEC 529
Cable entry B-head/screw-cap PG 16
Cable entry BM PG 9
Temperature transmitter Supply voltage: 8 - 35V d.c.
MBT 9110 Output: 4 - 20 mA
1)
The temperature of the temperature transmitter is influenced by media temperature, ambient temperature and
ventilation in the engine room. If the temperature of the temperature transmitter exceeds the max. allowed
temperature the temperature transmitter must be placed in a separated enclosure, as described in the separate data
sheet for MBT 9110.

480070
480150
480150
With temperature transmitter Without temperature transmitter Without temperature transmitter
1 x Pt100 2 x Pt100
Ordering MBT 5252 Extension length: 50 mm

Standard programme Element: Pt 100, EN 60751, Class B
Connection head: B-head
Protection tube: Low temperature range: Æ 10 x 2 mm
High temperature range: Æ 11 x 1 mm
Process connection
Temperature Insertion Connection Transmitter Transmitter G ½A G 3/4 A ½-14 NPT
range length output setting
[°C] [mm] Code no. Code no. Code no.
50 084Z8210 084Z8230 084Z6165
80 084Z6140 084Z6164 084Z6166
100 084Z82111) 084Z82311) 084Z61671)
150 2-wire, 3 terminals None None 084Z82121) 084Z82321) 084Z61681)
200 084Z82131) 084Z82331) 084Z61691)
250 084Z6139 084Z6141 084Z6170
-50 to 200
50 084Z8214 084Z8234 084Z6171
80 084Z6142 084Z6144 084Z6172
100 084Z82151) 084Z82351) 084Z61731)
150 2-wire 4 - 20 mA, standard 0 to +100°C 084Z82161) 084Z82361) 084Z61741)
200 084Z8217 1) 084Z8237 1) 084Z61751)
250 084Z6143 084Z6145 084Z6176
50 084Z6272 084Z6148 084Z6154
80 084Z6146 084Z6149 084Z6155
100 2-wire 3 terminals None None 084Z6273 084Z6150 084Z6156
150 084Z6274 084Z6151 084Z6157
200 084Z6275 084Z6152 084Z6158
250 084Z6147 084Z6153 084Z6159
-50 to 400
50 084Z6276 084Z6162 084Z6181
80 084Z6160 084Z6163 084Z6182
100 2-wire 4 - 20 mA, standard 0 to +400°C 084Z6277 084Z6177 084Z6183
150 084Z6278 084Z6178 084Z6184
200 084Z6279 084Z6179 084Z6185
250 084Z6161 084Z6180 084Z6186
1) Preferred versions

480070 480070
480150 480150
MBT programme Danfoss offers a complete range of MBT gas sensors, universal sensors, bearing
temperature sensors for all types of sensors, cargo sensors, stern tube sensors
applications. The range consists of exhaust as well as general purpose sensors.
General features · Fixed or replaceable measuring insert

· Pt100, Pt1000 resistance element or
thermocouple
· Wide temperature range
- up to +800°C with thermocouple
- up to +600°C with resistance element
Further information Further information about our temperature

sensors type MBT can be found in separate
data sheets, which can be ordered by
contacting your local Danfoss representative.

480240 480240
Pressure and Temperature Controls
Data sheet
Pressure transmitters
MBS 5100 and 5150
Danfoss block
components
The block concept has been developed to The range contains pressure controls,
save space, weight, and costs. pressure transmitters, test valves and
The product is intended for use in many accessories.
applications, for example: monitoring, alarm
indication, shut-down, diagnosing on The concept meets the strict demands on ma-
equipment such as motors, gears, thrusters, rine equipment, including EU stipulations on
pumps, filters, compressors, etc. such products.
MBS 5100 and MBS 5150 MBS 5100 and MBS 5150 are block transmit- Advantages
block transmitters ters designed for use in the marine industry. • Compact design
MBS 5150 has a built-in pulse-snubber. • Low installation costs
The transmitters can be easily mounted • Fast and easy to operate
directly on the MBV 5000 block test valve or • Version with pulse-snubber (MBS 5150)
the threaded pressure connection can be used. • Zero point and span adjustment
• Ten ship approvals
• High accuracy and small thermal drift
Approvals • Lloyd’s Register of Shipping • Bureau Veritas

• Det Norske Veritas • NKK, Nippon Kaiji Kyokai
• Germanischer Lloyd • Polski Rejestr Statków
• RINA, Registro Italiano Navale • MRS, Maritime Register of Shipping
• American Bureau of Shipping • Korean Register of Shipping
Dimensions
Plug Pg 13.5, DIN 43650 Plug Pg 9-11, DIN 43650
February 2001 DKACT.PD.P20.Q2.02

520B0787
480240 480240
Data sheet Pressure transmitters MBS 5100 and MBS 5150
Technical data Performance

Accuracy (Incl. non-linearity, hysteresis and repeatability) ±0.1% FS (typ.)
±0.3% FS (max.)
Non-linearity (Best fit straight line) < ±0.2% FS
Hysteresis and repeatability £ ±0.1% FS
Thermal zero point shift £ ±0.1% FS/10K (typ.)
£ ±0.2% FS/10K (max.)
Thermal sensitivity (span) shift £ ±0.01% FS/K (typ.)
£ ±0.02% FS/K (max.)
Response time < 4 ms
Max. operating pressure See ordering table, page 4
Burst pressure See ordering table, page 4
Electrical specification
Rated output signal 4 to 20 mA
Supply voltage, Vsupply (polarity protected) 10 to 32 V d.c.
Voltage dependency < 0.01% FS/V
Current limitation (linear output signal up to 1.5 ´ nom range) 28 mA (typ.)
V supply - 10 V
Max. load, RL RL £ ____________ -10 [W]
0.02 A
Environmental conditions
Operating temperature range -40 to 85°C
Compensated temperature range 0 to 80°C
Transport temperature range -50 to 85°C
EMC - Emission EN 50081-1
Air 8 kV EN 50082-1 (IEC 801-2)
Electrostatic discharge
Contact 4 kV EN 50082-1 (IEC 801-2)
field 10 V/m, 26 MHz - 1 GHz EN 50082-1 (IEC 801-3)
EMC - Immunity
RF conducted 3 Vrms, 150 kHz - 30 MHz EN 50082-1 (IEC 801-6)
conducted 1 Vrms, 10 kHz - 50 MHz RINA, Lloyds Reg.
LF conducted 3 Vrms, 50 Hz - 10 kHz RINA, Lloyds Reg.
burst 4 kV (CM), Clamp EN 50082-1 (IEC 801-4)
Transient
surge 1 kV (CM,DM) at Rg = 42W EN 50082-1 (IEC 801-5)
Insulation resistance > 100 MW at 100 V d.c.
Mains frequency 500 V, 50 Hz SEN 361503
Sinusoidal 20 g, 25 Hz - 2 kHz IEC 68-2-6
Vibration stability
Random 7,5 g rms, 5 Hz - 1 kHz IEC 68-2-34, IEC 68-2-36
Shock Shock 500 g / 1 ms IEC 68-2-27
resistance Free fall IEC 68-2-32
Enclosure IP 65 - IEC 529
Mechanical specification
Pressure connection G 1/4, ISO 228/1 or flange
Electrical connection DIN 43650 plug
versions without flange connection AISI 316L, W.no 1.4404
Pressure connection AISI 316L
Wetted parts,
Plug ETG 88 Zn 10F
material versions with flange connection
Plug gasket W.no. 1.0388 Sn5
O-ring for flange NBR
Housing material Anodized AIMgSiPb
Weight 0.4 kg
2-wire, 4 - 20 mA
1. Supply +
2. Supply -
3. Function test
Connected to MBS transmitter enclosure
2 DKACT.PD.P20.Q2.02 ã Danfoss 02-2001

480240 480240
MBS 5150 with integrated MBS 5150 has an integrated pulse snubber
pulse snubber for protection of the sensor element against
extreme pressure peaks and pulsations. Such
conditions may be caused by pumps or fast
operating valves in both high and low pres-
sure plants.
The integrated pulse snubber is designed as

an 0.3 mm orifice mounted in the pressure
connection. The medium should not contain
particles which may clog up in the orifice. The
viscosity has only little effect on the response
time. Even at viscosities up to 100 Cst. the
response time will not exceed 4 msec.
Mechanical connection
Thread Flange
Adjustment
Span
–5 ... + 5 % FS
Zero
Pressure range Adjustment
0-1 to 0-10 bar –5 ... +20 % FS
0-16 to 0-40 bar –5 ... +10 % FS
0-60 to 0-600 bar –5 ... +2.5 % FS
DKACT.PD.P20.Q2.02 ã Danfoss 02-2001 3

480240 480240
Ordering of standard
MBS 5100 and MBS 5150
Relative pressure version, G 1¤4 with flange connection, DIN 43650 Pg 11 plug, 4 - 20 mA output
Pressure Max. operating Min.burst MBS 5100 MBS 5150
range pressure pressure
bar bar2) bar1) Type no. Code no. Type no. Code no.
0 to 1 2 50 MBS 5100-1011-1DB04 060N1032 MBS 5150-1011-1DB04 060N1081
0 to 2,5 8 50 MBS 5100-1411-1DB04 060N1033 MBS 5150-1411-1DB04 060N1083
0 to 4 8 50 MBS 5100-1611-1DB04 060N1034 MBS 5150-1611-1DB04 060N1084
0 to 6 20 50 MBS 5100-1811-1DB04 060N1035 MBS 5150-1811-1DB04 060N1063
0 to 10 20 50 MBS 5100-2011-1DB04 060N1036 MBS 5150-2011-1DB04 060N1064
0 to 16 50 100 MBS 5100-2211-1DB04 060N1037 MBS 5150-2211-1DB04 060N1065
0 to 25 50 100 MBS 5100-2411-1DB04 060N1038 MBS 5150-2411-1DB04 060N1085
0 to 40 80 800 MBS 5100-2611-1DB04 060N1039 MBS 5150-2611-1DB04 060N1066
0 to 60 200 800 MBS 5100-2811-1DB04 060N1040 MBS 5150-2811-1DB04 060N1086
0 to 100 200 800 MBS 5100-3011-1DB04 060N1041 MBS 5150-3011-1DB04 060N1087
1)
200 bar for abs. pressure versions
2)
FS £ 300 bar min. 2 x FS; FS > 300 bar min. 1,5 x FS
Ordering of customized
types Type no: MBS 5100- xx x x- x xxxx
Type no: MBS 5150- xx x x- x xxxx
Measuring 0 - 1 bar 10 CA05 M 10 ´ 1 female Pressure

range 0 - 1.6 bar 12 CA07 M 12 ´ 1.5 female connection
0 - 2.5 bar 14 CB02 G 1/8 female
0 - 4 bar 16 CB04 G 1/4 female
0 - 6 bar 18 CC04 NPT 1/4 female
0 - 10 bar 20 DA05 M 10 ´ 1 female with flange
0 - 16 bar 22 DA07 M 12 ´ 1.5 female with flange
0 - 25 bar 24 DB02 G 1/8 female with flange connection
0 - 40 bar 26 DB04 G 1/4 female with flange connection
0 - 60 bar 28 DC04 NPT 1/4 female with flange connection
0 - 100 bar 30
0 - 160 bar 32
0 - 250 bar 34 0 No plug (DIN 43650 A) Electrical
0 - 400 bar 36 1 Pg 11 plug (DIN 43650 A) connection
0 - 600 bar 38 2 Pg 13.5 plug (DIN 43650 A)
Others xx 3 Pg 9 plug (DIN 43650 A)
Pressure Relative 1 1 4-20 mA Output

reference Absolute 2 signal
An order form has been worked out The order form with code no. 991L1099 can
PRESSURE SWITCH TYPE
Specification form
Order specification MBC5000 and MBC5100
DSC Contact person Customer
Order No. Order date Quantity
Code No. Type No. Delivery week

0 6 1 B M B C 5 0 0 - -
Approvals Pressure connection

No approvals ............................................. 0 C A 0 5 M10 x 1 female *
Ship-approvals .......................................... 1 C A 0 7 M12 x 1,5 female *
Other ** ..................................................... X C B 0 2 G1/8 female *
C B 0 4 G1/4 female
C C 0 4 NPT 1/4 female *
to facilitate specification of special be ordered from Danfoss.

Measuring range D A 0 5 M10 x 1 female with flange *
-1 - 1 bar ..................................................................... 1 0 D A 0 7 M12 x 1,5 female with flange *
-1 - 4 bar ..................................................................... 1 2 D B 0 2 G1/8 female with flange connection *
-1 - 10 bar ..................................................................... 1 4 D B 0 4 G1/4 female with flange connection
1-6 bar ..................................................................... 2 2 D C 0 4 NPT 1/4 female with flange connection *
1 - 10 bar ..................................................................... 2 4 X X X X Other **
5 - 20 bar ..................................................................... 3 2
5 - 30 bar ..................................................................... 3 4
5 - 40 bar ..................................................................... 3 6 Electrical connection
10 - 100 bar ..................................................................... 4 2 0 No plug (DIN 43650 A)
Other ** ........................................................................... X X 1 Standard plug (DIN 43650 A), PG11
2 GL approved plug (DIN 43650 A), PG13,5
X Other **
Type
Low pressure below (-1 - 10 bar) ............................................... 1
High pressure below (-1 - 30 bar) ............................................... 2
Low pressure diaphragm (1 - 20 bar) ......................................... 3 Microswitch
MBS block transmitters.

High pressure diaphragm (5 - 100 bar) ...................................... 4 1 0,1A, 250V (AC11); 12W, 125V (DC11)
Other ** ....................................................................................... X X Other **
* On request
** Please state below
Application Medium Medium temperature
Comments / special requirements

991L1100 udg. 12.94
For DN use only

OB-nr. Dato Bekræftet uge Prod. spec. udsendt dato NSP AG-S sign.
ISO 9001 quality approval

Danfoss A/S is certificated in accordance with international standard ISO 9001.
ISO This means that Danfoss fulfils the international standard in respect of product develop-
9001 ment, design, production and sale.
4 DKACT.PD.P20.Q2.02 ã Danfoss A/S AC-TMP 02-2001

480300 480300
482020 482020
482030 482030
Electronic Pressure Switch

EDS 300
for shipbuilding and offshore
Approvals:
• American Bureau
of Shipping
No::00-ES19976-X
• Lloyds Register
of Shipping
No.: 00/20048
• Det Norske Veritas

No.: A-7710 (895.10)
• Germanischer Lloyd
No.: 15519-00HH
• Bureau Veritas
No.: 10343/A0 BV
1. Functions of the EDS 300
date: 29.08.2001 page 1/13

482020 482020
482030 482030
The unit offers the following functions:
• Measure and display of the current relative pressure (normal operation), the maximum
pressure since the last reset or one of the switch points.
• Switching the 2 switching outputs according to the relative pressure and the pre-set
switching points and hystereses.
• Analogue output 4..20 mA
• Menu for basic settings (adapting the EDS 300 to the particular application)
• Two different types of programming enable
2. Mounting
The EDS 300 can be mounted directly onto a hydraulic block via the pressure connection.
The electrical connection should be carried out by a qualified electrician according to the
relevant regulations of the country concerned and also according the rules given by the ship
approval society's. The pressure switch housing must be earthed properly at the same time.
When fitted into a hydraulic block it is sufficient if the block is earthed via the hydraulic
system. In the case of Minimess hose-mounting, the housing must be earthed separately.
Additional assembly notes which, from experience, reduce the effect of electromagnetic
interference:
• Make line connections as short as possible.

• Use screened lines.
• The cable screening must be fitted by qualified personnel subject to the ambient
conditions and with the aim of suppressing interference.
• Direct proximity to connecting lines of user units or electrical or electronic units causing
interference must be avoided as far as possible.
3. Operating keys on the membrane keypad
HYDAC EDS 300
4-digit
digital display
SP1 PSI SP2
mode keys for setting switching

points, switch-back points and
additional functions
date: 29.08.2001 page 2/13

482020 482020
482030 482030
4. Digital display
After switching on the supply voltage, the unit briefly displays “EdS” and then displays the
current pressure.
2s
In the basic settings the display can be altered. Example: It is possible that the unit displays
the maximum value permanently. The maximum value is the highest pressure value that has
occurred since the unit was switched on or since the last re-set. It is also possible that the
unit displays a switching point permanently, or the display is dark. Depending on the setting,
"TOP", "S.P. 1", "S.P. 2" or "OFF" appears briefly on the display following the switch-on
message. The current pressure can be displayed briefly by pressing the or the key. By
doing this, the maximum value is re-set.
Notes:
• If the current pressure exceeds the nominal pressure of the unit, it can no longer be
displayed and the display begins to flash.
• If the current pressure is below 1 % of the nominal range, then 0 is displayed.
5. Output function
5.1 Switching outputs
The EDS 300 has 2 switching outputs. One switching point and one hysteresis can be set for
each switching output. The respective output switches when the pre-set switching point is
reached and switches back when the pressure falls below the switch-back point. The switch-
back point is determined by the pre-set hysteresis (switch-back point = switching point minus
hysteresis).
Abbreviations: "S.P.1", "S.P.2" = switching point 1 or 2

"H.Y.1", "H.Y.2" = hysteresis 1 or 2
5.2 Analogue output
The EDS 300 has one analogue output with a 4...20 mA signal.
date: 29.08.2001 page 3/13

482020 482020
482030 482030
5.3. Setting the switching points and hystereses
• Press "mode" key

• "S.P.1" is displayed
• Keep pressing the "mode" key until the required parameter is displayed ("S.P.1",
"H.Y.1", "S.P.2" or "H.Y.2").
• After 2 seconds the current setting flashes.
• Use the or the keys to alter the setting.
• Use the "mode" key to call up other parameters, if required, and alter the setting using
the and the keys.
• If no keys are pressed for 3 seconds, the display changes back and the settings are saved.
mode
+ mode
pressure
display
press “mode” key until

the required
display
2s
set switching point

=smaller value
* 3s
parameter is reached. =larger value
Notes:
• If "LOC" appears in the display when trying to alter the settings, programming is disabled.
Corrective action: set programming enable to "ON"
(see point 7 "Programming enable")
• If the or the key is held down during alteration, the value automatically advances.
• If a setting has been altered, "PRG" appears briefly in the display when the display is
switched over. The new setting is then saved in the unit.
5.4 Setting ranges of the switching points and hysteresis
Measuring range Switching point Hysteresis Increment *

in bar in bar in bar in bar
0 .. 16 0.3 .. 16 0.1 .. 15.8 0.1
0 .. 100 1.5 .. 100 0.5 .. 99.0 0.5
* All ranges given in the tables are adjustable by the increments shown.
5.5 Presettings of the switching points and hysteresis for Modifikation "-S01"
Type Switching point 1 Hysteresis 1 Switching point 2 Hysteresis 2

EDS 347-4-016-S01 0,7 bar 0,2 bar 5,0 bar 0,2 bar
EDS 347-4-100-S01 13,0 bar 1,0 bar 35,0 bar 1,0 bar
date: 29.08.2001 page 4/13

482020 482020
482030 482030
6. Basic settings
In order to adapt the unit to a particular application, the function of the EDS 300 can be
altered via several basic settings. These are combined in a menu.
6.1 Altering the basic settings
Switch off supply voltage or disconnect the unit from the supply voltage.
+
mode
+
mode mode
*
3s 2s
press "mode" key and display press "mode" key until the use or to alter
hold down. Switch (release required menu point appears setting, then select next
on supply voltage "mode" in the display (for summary menu point.
(hold key down for key) see 6.2)
3 s)
To close the basic setting menu

Call up the menu point "END", set to "YES", now the EDS 300 is automatically in the menu
for the swichpoint settings (see point 5.3). If no switchpoints or hystereses changes are
made, the EDS 300 returns to the normal display mode after 3 seconds.
Note:
• If the display mode is changed from "bar" to "psi" or from "psi" to "bar", the EDS 300 did
not change or calculate automatically to the switchpoint and hysteresis settings with the
new unit. It is necessary to change that settings by hand.
• If no keys have been pressed in the basic settings menu after 50 seconds, the basic
settings menu automatically closes down. Any changes which may have been made will
not be saved. Also than the menu for switchpoint settings is automatically reached.
date: 29.08.2001 page 5/13

482020 482020
482030 482030
6.2 Summary of the basic settings / Presettings
Setting Display Setting Pre-

range setting
Determining the display range BAR/ PSI BAR
"bar" The pressure is displayed in bar.
"psi" The pressure is displaed in psi.
If the unit is changed from bar to psi on a version with
standard setting in bar, all 7 seconds the new unit
(psi) flash in the display.
If the unit is changed from psi to bar on a version with
standard setting in psi, all 7 seconds the new unit
(bar) flash in the display.
Switching direction switching output 1 (S 1) ON/ OFF ON
“ON”: The switching output is activated when the
switching point is reached, and deactivated
when the pressure falls below the switch-
back point (normally open function).
“OFF”: The switching output is activated in the
quiescent state (0 bar), and deactivated
again when the switching point is reached
(normally closed function).
Switch-on delay switching output 1 (Ton 1) 0.00..75s 0.00
Time in seconds which must elapse, once the switching point
has been reached or exceeded, before switching will occur.
Switch-off delay switching output 1 (Toff 1) 0.00..75s
Time in seconds which must elapse, once the pressure has
fallen below the switch-back point, before switching will occur.
Presetting for EDS 347-4-016-S01 10.0
Presetting for EDS 347-4-100-S01 5.0
Switching direction switching output 2 (S 2) ON/ OFF OFF
“ON”: The switching output is activated when the
switching point is reached, and deactivated
when the pressure falls below the switch-
back point (normally open function).
“OFF”: The switching output is activated in the
quiescent state (0 bar), and deactivated
again when the switching point is reached
(normally closed function).
Switch-on delay switching output 2 (Ton 2) 0.00..75s 0.00
Time in seconds which must elapse, once the switching point
has been reached or exceeded, before switching will occur.
Switch-off delay switching output 2 (Toff 2) 0.00..75s 0.00
Time in seconds which must elapse, once the pressure has
fallen below the switch-back point, before switching will occur.
Setting Display Setting Pre-
range setting
date: 29.08.2001 page 6/13

482020 482020
482030 482030
Primary display (Primary) ACT/ ACT.

Display value which should remain permanently in the TOP/
display: S.P.1/
S.P.2/
“ACT.”: base pressure OFF
"TOP": pressure maximum value
“S.P.1” or “S.P.2”: switching point 1 or 2
“OFF”: display dark (for function, see
point 4 ” Digital display”)
Calibration of sensor zero point (Calibrate) YES/ NO NO
“YES”: The base pressure is saved as the new zero
point. This is possible in the range +/- 3 % of
the unit’s nominal pressure range.
“new” appears in the display when a calibration is
carried out in the permissible range, otherwise “Err” is
displayed. This function is useful for example if there
is always a residual pressure in the system which
should however be displayed as 0 bar.
Please note:
Following a zero point adjustment, for example, on a
600 bar unit, a pressure of up to 18 bar is displayed as
0 bar. Before any work is carried out on the hydraulic
system, ensure that the system is de-pressurised.
Version number (Version)
Display of the current software version (for reference
only)
To close basic settings (End) YES/ NO NO
date: 29.08.2001 page 7/13

482020 482020
482030 482030
7. Programming enable
The unit has 2 types of programming enable which must both be set to "ON" to change the
settings. The operating programming enable can be set or removed during operation. It
provides protection from unintentional alteration. A programming disable via the main
programming enable has the effect that no change to the settings can be carried out during
operation. This serves, for example, as a safety function or as protection against
unauthorised alterations.
7.1 Altering the operating programming enable
mode mode
pressure
display
* * *
3s 3s
press both arrow display use or to alter setting,

keys simultaneously (release ON = programming possible
and hold down for 3 s arrow keys) OFF = programming disabled
7.2 Altering the main programming enable
Switch off supply voltage or disconnect the unit from the supply voltage.
mode mode
pressure
display
* * *
3 s "main program state" 3s
press both arrow display use or to alter setting,

keys simultaneously (release ON = programming possible
and hold down. arrow keys) OFF = programming disabled
Switch on supply
voltage (hold keys
down for 3 s)
Note:
• If a setting has been changed "PRG" is displayed briefly when the display is switched
over. The new setting is then saved in the unit.
date: 29.08.2001 page 8/13

482020 482020
482030 482030
8. Error messages
If an error is detected, then a corresponding error message appears which must be

acknowledged by pressing any key. Possible error messages are as follows:
E.01 The switching points and hystereses have been set in such a way that the resulting
switch-back point is no longer within the permissible setting range.
Example:
Switching point is set to 180 bar, the hysteresis to 200 bar.
Corrective action: Correct the settings
E.10 A data error has been detected in the saved settings. Possible causes are strong
electromagnetic interference or a component fault.
Corrective action: Press a key, the basic settings menu will be reached
automatically now. Check all the settings (basic settings,
switching points, switch-back points and programming enable)
and correct these if necessary. If the errors occur frequently,
please contact Hydac Service.
E.12 An error has been detected in the stored calibration data. Possible causes are
strong electromagnetic interference or a component fault.
Corrective action: Switch off and on again the supply voltage. Is the error
massage still there, the unit must be returned to the
manufacturer for re-calibration or repair.
E.20 A short-circuit has been detected on a switching output.
Corrective action: Eliminate the short circuit.
date: 29.08.2001 page 9/13

482020 482020
482030 482030
9. Technical specifications
Input data::
Measuring ranges in bar: 16, 100 bar
Overload pressures in bar: 32, 200 bar
Burst pressure: 400 % FS
Output data:
Accuracy (display, analogue output) ≤ ±1.0 % FS max.
Repeatability: ≤ ±0.5 % FS max.
Temperature drift: ≤ ±0.3 % / 10 K zero point max.
≤ ±0.3 % / 10 K range max.
Analogue output: 4 .. 20 mA, ohmic resistance ≤ 400 Ω
Switching outputs:
Type: 2 relay contacts normally open
Switching voltage: 10 mV .. 60 V (AC or DC)
Switching current: 0,01 mA .. 1 A
Max. switching power: 30 W / 30VA
(for inductive load: use varistor)
Life expectancy of contacts: 20 million (min. load)
0,5 million (max. load)
Reaction time: approx. 10 ms
Ambient conditions:
Temperature range of medium: -25 .. + 80 °C
Ambient temperature range: -25 .. + 80 °C
Storage temperature range: -40 .. + 80 °C
Nominal temperature range: -10 .. + 70 °C
- mark: EN 50081-1 and -2, EN 50082-1, EN 61000-6-2
Vibration resistance: 5 .. 25 HZ : 3,2 mm
25 .. 500 Hz : 4 g
Other data:
Supply voltage: 20 .. 32 VDC
Electrical connection: plug to DIN 43651 (6-pole + earth)
Current consumption: approx. 100 mA
Safety type: IP 65
Hydraulic connection: G¼ A DIN 3852 (torque rating approx. 20 Nm)
Parts in contact with medium: stainless steel, seal: FPM
Material of housing: tube: stainless steel
keypad housing: PA6.6 Gf30
Display: 4-digid, 7-segment LED, red,
Weight: approx. 300 g
Note: FS (Full Scale) = relative to the full measuring range
date: 29.08.2001 page 10/13

482020 482020
482030 482030
10. Circuit diagram

PE 3
SP 1
2
+ 1
SP 2
20..32 V 6
- 4 5
analogue
I = 4..20 mA
RL
11. Accessories
11.1 For electrical connection
ZBE 10 Right-angled plug DIN 43651, 6 pole + earth
Order No.: 654527
11.2 For mechanical connection
ZBM 11 connection adaptor G¼" female thread - G¼" male thread for optimum
alignment of the pressure switch
Order No.: 258055
date: 29.08.2001 page 11/13

482020 482020
482030 482030
12. Dimensions
Plug DIN 43651

6 pole + earth
HYDAC ELECTRONIC GmbH

Hauptstr. 27
D-66128 Saarbrücken
Tel.: 0681/7099-0
Fax: 0681/7099-202
e-mail: electronic@hydac.com
date: 29.08.2001 page 12/13

512010 512010
INSTRUCTION MANUAL FOR
NORGEAR TYPE FVE-355
FRONT-END GEAR
SERIAL NO. N92876
CEKSAN Gemi Insa Celik

SHIPYARD
HULL NO. 41
512010 512010
512010 512010
1 GENERAL DATA
Gearbox serial number N92876

Gearbox type Norgear FVE-355
Year built 2007
Classification Society GL
Hull No. 41
Yard CEKSAN Gemi Insa Celik
EXW delivery 21 2007
2 TECHNICAL DATA
Part list N3897B

Dimension drawing N3-90554
Assembly drawing N1-01331A
Hydraulic diagram N3-03434
Terminal connection drawing N4-00381
Torsional diagram N4-01444
Direction of rotation C. C. W.
Input power 780 kW

Input speed 1500 RPM
Ratio (step-down) 2.590: 1
Admissible input torque 4966 Nm
Oil group ISO VG150

Oil quantity 35 litres
Required water flow through oil cooler 26 l/min
Max water flow through cooler 45 l/min
Cooling water inlet temperature 32 deg. C, seawater
Cooling water maximum pressure 16 bar
Correct orifice size (mm) for max water flow through oil cooler
3 bar 4 bar 5 bar 6 bar 7 bar 8 bar 9 bar 10 bar 12 bar

8 7.5 7 6.5 6.3 6.2 6 6 5.5
System oil pressure alarm setting 3 bar

High oil temperature alarm setting 80 deg. C
Gearbox weight (without oil) 1200 kg
Norgear Gearbox Without Clutch 3

512010 512010
3 GENERAL DESCRIPTION
This NORGEAR gearbox is designed as a speed increasing or speed

reduction unit, depending upon the application. Please refer to Section 2 for
the exact gear ratio.
The gear case sections are manufactured in grey cast iron or fabricated steel.
Gearwheels are single helical case hardened steel with ground tooth flanks.
All bearings are anti-friction type supplied from leading manufacturers.
The gearbox has been built to the Rules and under Survey of the
Classification Society indicated in Section 1.
4 INSTALLATION
Adjustable units (i.e. pressure limiting valves and lubrication control valves)
have been set for the specified pressure and oil flows during the Works test.
The gearbox is delivered with lifting eyebolts in place.
The gearbox seating should have a machined top surface and machined
supporting chocks should be used. “Chock fast” or other approved resin
compounds may be used if accepted by the surveyor. It is imperative that the
gearbox seating bearers are fully supported on their entire surface area
before the foundation bolts are tightened down. If not, the casing may be
distorted and gear tooth contact will suffer.
To simplify the alignment, the bearers are provided with threaded boltholes
for jacking screws at each corner.
Round discs or shim plates arranged one upon the other must not be used as
fitted pieces. The gearbox must be secured on the foundation against
displacement by four fitted bolts at the corners. When tightened all bolts must
be secured.
When a flexible coupling is fitted, alignment must be within the limits set by
the coupling manufacturer. If in doubt, please contact Kumera AS technical
department. This also applies to the output shaft and the connection to the
driven equipment.
If the driven equipment is mounted to the gearbox by a spigoted flange, the

correct alignment is ensured by our machining tolerances.
No axial loads are allowed on input or output shafts.
Installation also includes connection of cooling water supply to the oil cooler.
When installing a sea water cooling system it is required to install a good
filtration system ensuring not to clog the oil cooler. Ensure to install correct
orifice on water outlet side.

512010 512010
In addition installation includes electrical power to the clutch control solenoid

valve. Please refer to Section 2 for the required information on the above-
mentioned points.
The total oil charge is contained within the gear case. Oil filling and breathing
connections are provided. The oil grade and quantity will be found in Section
2 and on the identification plate attached to the gear case.
5 LUBRICATION SYSTEM
While running, all bearings and gear mesh are lubricated and cooled by the
mechanically driven oil pump, or electric driven oil pump if supplied. The
system comprises an oil pump, cooler and filter.
Pump
The mechanical oil pump is usually assembled on the end of the input shaft
but another continuously running shaft may be used in special situations.
Oil cooler
The tubular oil cooler is placed on the pressure side of the oil pump. It is
mounted on the gear case and must have a continuous water supply. An
orifice ring must be fitted to control the water flow within the design limits of
the cooler. It is recommended to mount this on the outlet side of the cooler.
Filter
The oil filter includes a fibreglass cartridge, relief valve and a mechanical
indicator that shows when the cartridge must be replaced. The cartridge is
disposable - do not try to wash and re-use it.
6 CONTROL AND ALARM SYSTEM
Local reading gauges are provided for:

System oil pressure
System oil temperature
Alarm switches are provided for:

Low system oil pressure
High system oil temperature
Oil pressure will vary with speed and oil temperature. Typical settings:
Oil pressure 3 to 7 bar
Oil temperature 40 to 70 deg. C
For alarm set points - please see Section 2.

The alarm sensors are wired out to a terminal box mounted on the gear case,
see Section 2.
Additional sensors for remote oil pressure and temperature will be provided
when specified.

512010 512010
7 OPERATING INSTRUCTIONS
Oil level
The gearbox is not filled with oil when delivered. The oil level can be checked
by means of the dipstick when the gearbox is stationary. Approximate
quantity is specified on the identification plate on the gear case and also the
recommended grade of oil.
Lubricating oil circulation

The gearbox lubrication oil spray from the internal nozzles may be observed
through the inspection windows.
Cooling water
Check that the cooling water is passing through the oil cooler at the required
rate of flow. The water inlet and outlet connections on the cooler are
interchangeable on a two-pass cooler.
Oil recommendation
A high quality mineral gear oil with EP additives, having good anti wear
performance with low corrosion, oxidation and foaming properties must be
used. The oil must meet the FZG A/8,3/90 load stage 12+.
The oils listed below have been used with good experience. If you wish to use
other equivalent gear oils, contact your oil supplier, ensuring the mentioned
requirements are met.
Note: Any extra additives must not be used. In such case our warranty will
not be valid.
Approved oils
BP Energol GR-XP 150

Castrol Alpha SP 150
Esso Spartan EP 150
Exxon Mobil Mobilgear 629
Shell Omala oil 150
Texaco Meropa 150
Synthetic oil grades meeting the above requirements in addition to be

compatible with mineral oils may be used. Contact your oil supplier for
recommended grade.
Oil temperature
Normal oil temperature in the gearbox sump will range from 40 - 70 deg. C.
The temperature switch is set at 80 deg. C and it will initiate an alarm at
higher temperatures.

512010 512010
8 MAINTENANCE
Oil change
The oil in the gearbox must be changed after approximately the first 300
hours of operation and thereafter at each 5000 hours or annually.
Oil analysis
Regular monitoring of the oil condition should be carried out every 3 months
by sample analysis.
Oil filter
The oil filter cartridge must be changed at each oil change. Also replace the
cartridge if the mechanical indicator shows that it is necessary. The cartridge
is a disposable design; do not try to wash it.
Oil cooler
Check the appearance of the oil in the gearbox on a regular basis. A greyish
colour indicates that the oil has become contaminated with water. The oil
must then be changed immediately and the filter cartridge renewed.
A leaking oil cooler causes the trouble. The cooler must be removed from the
gearbox and checked. To check the tightness between the oil and water
sections one of the sections should be pressurised with compressed air to a
maximum pressure of 10 bar.
A leaking oil cooler may also cause a flow of oil into the water section should
the oil pressure exceed the water pressure. The result is of course, loss of oil
from the gearbox. Again it is necessary to check the tightness as described
above.
If pressure testing reveals a leakage, the cooler should be dismantled and

thoroughly inspected. If both the tube stack and the end covers are badly
corroded, the whole cooler must be replaced. If the tube stack is acceptable
and the end covers defective, it may be sufficient to change the end covers
only.
Pump couplings / spline sleeves

Pump couplings should be inspected once a year and re-greased if
necessary with an NLGI 2 grease with long fibres.
Inspections
We recommend yearly regular inspections to be carried out on the units. This
is an extended inspection offered by Kumera AS and are recommended in
addition to owners maintenance programme.
Overhaul
We recommend regular overhaul to be carried out by Kumera AS or by an
official authorized Kumera Service partner. This should be done in
accordance with classification requirements and bearing lifetime or at least
every third year.

512010 512010
9 SPARE PART KIT
We strongly recommend you keep in stock onboard basic spare parts to

avoid any shutdown during operation.
Such parts should include:
Oil filter elements

Oil cooler
Oil pump
Pressure gauge
Temperature gauge
Pressure switch
Temperature switch
Breather plug
Shaft seals
Only original spare parts must be used. Please contact our After Sales department to
ensure original spare parts are being supplied.
10 SERVICE
Kumera AS offers worldwide service and planned inspections. Please do

contact our After Sales department if you need assistance.
Tel: +47 33 48 54 48
Fax: +47 33 48 54 55
E-mail: sales@kumera.no
11 STORAGE
The inside of the housing is anti-corrosion protected only intended for short
time protection during transportation and a short storage time if stored in a
covered dry place.
All bright parts, i.e. flanges and drive shafts, are coated with a preservative
before shipment from Kumera AS, intended for short time protection only
during transportation and short time storage in a covered dry place.
Connections i.e. oil and water, which cannot be completed until the unit has
been installed are closed with plugs at our Works. Any connections or pipes
that must be modified in the course of installation should definitely be
acidified and cleaned before use.
If the gearbox cannot be installed immediately on delivery to the shipyard, it

should be stored in a dry and temperate place. Ensure protection of both
inner and outer parts. For long time storage the unit should be filled
completely with oil, the breathing plug sealed, and the shafts must be turned
every second month so all shafts rotates minimum a half turn. Other additives
intended for long time storage may be used.

512010 512010
12 GUARANTEE
Please see the Contract for the particular gearbox regarding terms and
conditions.
Following additional Kumera AS terms are always part of our deliveries:
Guarantee covers replaced parts only.

Guarantee covers working hours used by Kumera AS service
personnel only.
Guarantee does not cover travel expenses, hotel, daily allowance and
other related costs.
Guarantee does not cover any indirect loss, loss of profit and/ or any
consequential damage.
Any modifications and/ or work done on the unit by unauthorised personnel

without a written consent of Kumera AS will make the guarantee invalid.
Kumera AS shall have copy of aligning data together with a report after
start up of the system for the guarantee to be fully valid.
For the guarantee to be valid, all instructions in this manual must be

followed!

512010
512010
MANUFACTURERS ADDRESS AND PHONE NUMBER
KUMERA AS Tel: + 47 33 48 54 54
Gneisveien 11 Fax: + 47 33 48 54 55
P. O. Box 2043 E-mail: sales@kumera.no
3202 SANDEFJORD
NORWAY
KUMERA DRIVES LTD. Tel: + 358 20 755 4200

Kumerankatu 2 Fax: + 358 20 755 4220
11100 RIIHIMÄKI E-mail: drives@kumera.com
FINLAND
THE WORLD WIDE SERVICE NETWORK

ICELAND
VELAR OG SKIP EHF. Tel: + 354 562 0095

Holmaslod 4 Fax: + 354 562 1095
101 REYKJAVIK E-mail: maggi@velarogskip.is
ICELAND Att.: Mr. Magnus Petursson
BELGIUM AND THE NETHERLANDS
PROMAC BV Tel: + 31 418 68 33 33

Van Voordenpark 14 Fax: + 31 418 68 33 55
P. O. Box 22 E-mail: info@promac.nl
5300 AA ZALTBOMMEL Att.: Mr. Marcel Moerland
THE NETHERLANDS
UNITED KINGDOM
ALAN IRVING- MARINE CONSULTANCY Tel: + 44 1 505 86 21 83

Sunnegga, Gledstane Road Fax: + 44 1 505 86 32 21
Bishopton PA7 5AU E-mail: irving.a@ntworld.com
STRATHCLYDE Att.: Mr. Alan Irving
SCOTLAND
FRANCE
SOCIETE MARINE DE SERVICE Tel: + 33 16424 9004

Allèe Caumartin Fax: + 33 16424 9646
P. O. Box 5 E-mail: smsjmseinlary@aol.com
77250 VILLECERF Att.: Mr. Jean-Michel Seinlary
FRANCE
1
512010
512010
SPAIN
ECONOR HISPANIA S. L. Tel: + 34 91 850 2996

Apartado de Correos, 96 Fax: + 34 91 851 5876
28400 Collado Villalba E-mail: econor.hispania@wanadoo.es
MADRID Att.: Mr. Carlos Bravo
SPAIN
INDIA
ARIES TECHNICAL SALES & SERV. PVT. LTD. Tel: + 91 22 2820 2434
D-2, Udyog Sadan 3, MAROL MIDC. Fax: + 91 22 2820 6611
Andheri (East) E-mail: kirti@ariestech.co.in
400 093 MUMBAI Att.: Mr. Kirti Sethia
INDIA
SINGAPORE
VIKING ENGINEERING PTE. LTD. Tel: + 65 6777 5055

184 Pandan Loop Fax: + 65 6779 2176
SINGAPORE 128374 E-mail: info@viking.sg
SINGAPORE Att.: Mr. Sune Johansson
2
512010 512010
PART LIST N3897B
FVE-355
Customer Voith Turbo Marine Released date 24.11.2006
Project no. N92876, N92877, N92878, N92879 Made by DH
Gear ratio 2.593 : 1 Revision date 04.06.2007
Assembly drawing N1-01331A TVC diagram N4-01444
Dimension drawing N3-90554 Hydraulic diagram N3-03434
Classed by GL
Pos Qty. Name, type Drawing no. Part no.
1 1 HOUSING MACHINED FV-355 N1-01330A N300117

2 1 SHAFT FIXED N2-01177 N2025309
3 1 SHAFT FIXED N2-01178 N2025298
4 1 GEAR WHEEL FIXED, Z=27 N3-03436 N2025287
5 1 GEAR WHEEL FIXED, Z=31 N3-03437 N2025276
6 1 SPLINE SLEEVE N3-02079 N101149
7 1 SLEEVE N4-01544 N2036705
8 1 COVER SEALED N3-03186 N2006184
9 1 COVER SEALED N3-03438 N2025266
10 1 COVER END N3-03267 N2013897
11 1 PUMP BRACKET N3-03189A N2006244
12 2 SPACER N3-01738-ITEM 2 N2006243
13 1 SPACER N4-01450 N2025316
14 1 SPACER N4-01451 N2025315
15 1 SPHERICAL ROLLER BEARING N101872
16 1 SPHERICAL ROLLER BEARING N102067
17 2 CYLINDRICAL ROLLER BEARING N101810
18 1 RECTANGULAR KEY NS 83 N2025311
19 2 RECTANGULAR KEY NS 83 N2025310
20 2 OIL SEAL N103206
21 2 OIL SEAL N103218
22 1 O-RING N102885
23 1 LOCK WASHER N102197
24 1 LOCK WASHER N102203
25 1 SHAFT NUT N102159
26 1 SHAFT NUT N102165
27 2 CIRCLIP SEEGER DIN 471 N102410
28 1 BREATHER PLUG N101068
29 1 DIP STICK PLUG N101065
30 3 DOWEL PIN DIN 1481 N2002902
31 4 EYE BOLT DIN 580 N100880
32 8 CAP SCREW DIN 912 N100359
33 3 CAP SCREW DIN 912 N100194
34 4 TAPER PIN DIN 7977 N100858
35 24 HEX.HEAD SCREW DIN 931 N100480
41 1 PLUG N2000072
42 1 FITTING N2000074
43 2 GREASE NIPPLE N2000356
44 4 OIL NIPPLE N2001057
45 1 COVER INSPECTION N2000075
46 1 COVER INSPECTION N2006197
47 1 OIL FILTER - DUPLEX N2025279
Page 1 of 2
512010 512010
PART LIST N3897B
FVE-355
Customer Voith Turbo Marine Released date 24.11.2006
Project no. N92876, N92877, N92878, N92879 Made by DH
Gear ratio 2.593 : 1 Revision date 04.06.2007
Assembly drawing N1-01331A TVC diagram N4-01444
Dimension drawing N3-90554 Hydraulic diagram N3-03434
Classed by GL
Pos Qty. Name, type Drawing no. Part no.
48 1 OIL COOLER SEAWATER N101113

49 1 PRESSURE GAUGE N101050
50 1 PRESSURE SWITCH N101012
51 1 TEMPERATURE GAUGE N103284
52 1 TEMPERATURE SWITCH N101060
53 1 TEST VALVE 1 IN-1 OUT N101027
54 1 TERMINAL BOX N4-00381 N2013040
55 1 OIL PUMP CCW, 23CCM N102561
56 1 SPACER N4-01545 N2036704
Page 2 of 2
512010 512010
512010 512010
512010 512010
512010 512010
512010 512010
512010 512010
Data sheet
Pressure test valve
MBV 5000
Danfoss block
components
The block concept has been developed to The range contains block pressure controls,
save space, weight, and costs. block pressure transmitters, block test valves
The product is intended for use in many and accessories.
applications, for example: monitoring, alarm
indication, shut-down, diagnosing on The concept meets the strict demands on ma-
equipment such as motors, gears, thrusters, rine equipment, including EU stipulations on
pumps, filters, compressors, etc. such products.
Block valve MBV 5000 MBV 5000 is a block valve designed in many Advantages
different configurations for use in the marine • Compact design
industry. • Light material
The valve meets demands for fast installation, • Many configuration possibilities
simple isolation, and easy test pressure • Low installation costs
connection. • Fast and easy to operate
Dimensions Test valve
Outputs 1 2 3 4 5
L1 36 mm 76 mm 116 mm 156 mm 196 mm
Adapters
Angleway Straightway
Cover adapter adapter
August 2000 DKACT.PD.P15.B1.02

520B0383
512010 512010
Data sheet Pressure test valve MBV 5000

Overload pressure 180 bar
Pressure Burst pressure 250 bar
Operating pressure 0 to 120 bar
Operating temperature –20 to 120°C
Temperature Ambient temperature –20 to 120°C
Temperature of medium –20 to 120°C
Mechanical
Housing Anodized AIMgSi1
Nipple AIMgSi1
Material Ball 1.4571
Gasket PEEK/FPM
Input G 1 /4
Pressure connection Output Flange / M5 × 8
Specification and code Pressure connection: G 1⁄4 . Test pressure connection: M16 × 2
numbers for standard Output Weight Length Height Width
types Symbol Type Type no. Code no.
no. kg mm mm mm
Output
×1 0.4 36 80 40 MBV5000-1111 061B7000
×2 0.8 76 80 40 MBV5000-1211 061B7001
1 ×3 1.2 116 80 40 MBV5000-1311 061B7002
×4 1.6 156 80 40 MBV5000-1411 061B7003
×5 2.0 196 80 40 MBV5000-1511 061B7004
Input
Output
×2 0.8 76 80 40 MBV5000-2211 061B7005
×3 1.2 116 80 40 MBV5000-2311 061B7006
2
×4 1.6 156 80 40 MBV5000-2411 061B7007
×5 2.0 196 80 40 MBV5000-2511 061B7008
Input
Output
×2 0.7 76 80 40 MBV5000-3211 061B7009
Test pressure connection ×3 1.0 116 80 40 MBV5000-3311 061B7010
3
×4 1.3 156 80 40 MBV5000-3411 061B7011
Shut-off valve
×5 1.6 196 80 40 MBV5000-3511 061B7012
Input
Code numbers for standard Description Code no.

flange → G 1⁄ 8 adapters Cover 061B7200
Angleway adapter 061B7201
Straightway adapter 061B7202
Ordering special versions Type no: MBV 5000- x x x x

Type Pressure connection
Separate inputs and separate test functions 1 1 G 1/ 4
Common input and separate test functions 2 2 M10 × 1
Common input and common test function 3 x Other
Other X
Number of outputs (n) Test pressure connection
1 Output (only for type 1) 1 0 Hole plug G 1 /4
2 Outputs 2 1 Pressure gauge connection M16 × 2
3 Outputs 3 X Other
4 Outputs 4
5 Outputs 5
Other X
2 DKACT.PD.P15.B1.02 Danfoss A/S AG-SP.ER 08-2000 CCB

512010 512010
Data sheet
Heavy duty pressure controls

MBC 5000 and MBC 5100
Features x Designed for use in severe industrial
environments
x High vibration stability
x Part of the block system, consisting of
MBC pressure controls, MBS pressure transmitters
and MBV test valves
x MBC 5100 with all major ship approvals
x High repeatability
x Optimal compact design for machine
building purposes
x Intended for alarm indication, shut down,
control and diagnostics in many
applications - motors, gears, thrusters,
pumps, filters, compressors etc.
Ship approvals Lloyd’s Register of Shipping BV, Bureau Veritas

MBC 5100 Germanischer Lloyd American Bureau of Shipping
RINA, Registro Italiano Navale KRS, Korean Register of Shipping
NKK, Nippon Kaiji Kyokai RMRS, Russian Maritime Register of Shipping
DNV, Det Norske Veritas
Approvals EN 60947-4-1 CCC, China Compulsory Certificate

EN 60947-5-1

± 0.2 % FS (typ.)
Repeatability Bellows versions ± 0.5 % FS (max.)
Diaphragm versions ± 0.5 % FS (typ.)
± 1 % FS (max.)
Piston versions ± 1 % FS (typ.)
± 1 % FS (max.)
Response time < 4 ms
Max. switch frequency 10/min (0.16 Hz)
Differential see page 3
Permissible operating pressure see page 3
Burst pressure see page 3
Mechanical for diaphragm and bellows > 400,000 cycles
Life time Mechanical for piston type >1 million cycles
Electrical at max. contact load > 100,000 cycles
Electrical specifications
Switch SPDT
AC 1 10 A, 250 V AC 15 0.5A, 250 V
Contact load
AC 3 3A, 250 V DC 13 12 W, 125 V
Environmental conditions
Bellows versions -40 to +85 °C
Operation
Temperature Diaphragm versions -10 to +85 °C
Piston versions -40 to +85 °C
Bellows versions -50 to +85 °C
Transport Diaphragm versions -50 to +85 °C
Piston versions -40 to +85 °C
Enclosure IP 65, IEC 529
20 g, 25 Hz - 2 kHz IEC 68-2-6
Vibration stability Sinusoidal
piston type 4.4g, 25-200 Hz
IEC 60068-2-27
INDUSTRIAL CONTROLS IC.PD.P10.A2.02- 520B2217

512010 512010
Data sheet Pressure controls, types MBC 5000 and MBC 5100
Technical data Mechanical characteristics

(continued) Pressure connection Standard G 1/4 female (ISO 228/1) or flange
Option see specification form, page 3
Electrical connection Plug DIN 43650, Pg 9 / Pg 11 / Pg 13.5
Housing Anodized AIMgSi1
Bellows Stainless steel 1.4306 (18/8)
Wetted parts material Diaphragm Viton
Piston Stainless steel 1.4028 (3H13)
O-ring NBR
Housing AIMgSi1
Enclosure material Plug fixture Glass filled polyamid, PA 6.6
Contact system Silver (AG) microprofile
Weight 0.4 kg
Adjustment
Mechanical difference
One full turn (360°) of MBC setting screw is approx. equal to 7% of the setting range
Mechanical connection
Thread Flange connection
on MBV Test Valve
Not applicable for piston type
2 IC.PD.P10.A2.02- 520B2217
512010 512010
How to choose To achieve the best operating conditions for MBC pressure controls, it is recommended to apply the
following rules of thumb:
Choose: • the MBC type/types which meet the demands for the operating pressure
• the MBC version with the lowest possible setting range
• a diaphragm type, if pressure peaks and pulsations occur in the system
(if possible)
• bellows types, if low differential is needed
• piston type for high pressure
Ordering
standard types
Type: Setting Fixed Permissible Min. Type MBC 5100 MBC 5000
LP = Low pressure range differential operating burst designation Ship approved Standard
HP = High Pressure Pe [bar] Pe [bar] pressure pressure MBC 5000-/
(typ) Pe [bar] Pe [bar] MBC 5100- Code no. Code no.
LP bellows -0.2 to 1 0.15 to 0.451) 15 30 1011-1DB04 061B000566 061B200566
LP bellows -0.2 to 4 0.15 to 0.451) 15 30 1211-1DB04 061B0004662) 061B200466
LP bellows -0.2 to 10 0.15 to 0.601) 15 30 1411-1DB04 061B0002662) 061B200266
LP bellows -0.2 to 10 0.15 to 0.601) 15 30 1411-1CB04 061B000066 061B200066
LP bellows 0.5 to 3 0.15 to 0.301) 15 30 2011-1DB04 061B002966
LP bellows 1 to 6 0.15 to 0.451) 15 30 2211-1DB04 061B000766
HP bellows 5 to 30 0.40 to 1.51) 45 90 3421-1DB04 061B0003662) 061B200366
LP diaphragm 0.5 to 3 0.25 to 0.801) 150 300 2031-1DB04 061B101766
LP diaphragm 1 to 6 0.30 to 2.01) 150 300 2231-1DB04 061B100966
LP diaphragm 1 to 10 0.30 to 2.01) 150 300 2431-1DB04 061B1004662) 061B300466
LP diaphragm 5 to 20 0.4 to 2.51) 150 300 3231-1DB04 061B1002662) 061B300266
LP diaphragm 5 to 25 0.4 to 2.51) 150 300 3331-1DB04 061B102466
HP diaphragm 5 to 40 1.0 to 7.01) 150 300 3641-1DB04 061B1005662) 061B300566
HP diaphragm 10 to 100 1.7 to 141) 150 300 4241-1DB04 061B1003662) 061B300366
HP piston 16 to 160 12 to 301) 600 1200 5251-1CB04 061B510066 061B500266
Lowest differential at min. setting range, highest differential at max. setting range
1)
Preferred versions
2)
Ordering MBC 5000- -

customized types
MBC 5100- -
Pressure connection
Setting range C A 0 5 ............... M10x1 female
-0.2 - 1 bar ..................................................................... 1 0 C B 0 4 ............... G 1/4 female
-0.2 - 4 bar ..................................................................... 1 2 D A 0 5 ............... M10x1 female with flange connection
-0.2 - 10 bar................................................................... 1 4 D B 0 4 ............... G 1/4 female with flange connection
0.5 - 3 bar ..................................................................... 2 0 x x x x ............... Others
1 - 6 bar ..................................................................... 2 2
1 - 10 bar................................................................... 2 4 Electrical connection
2 - 6 bar ..................................................................... 2 6 0 ........................................................ No plug (DIN 43650 A)
5 - 20 bar................................................................... 3 2 1 ........................................................ Pg 11 plug (DIN 43650 A)
5 - 25 bar................................................................... 3 3 2 ........................................................ Pg 13.5 plug (DIN 43650 A)
5 - 30 bar................................................................... 3 4 3 ........................................................ Pg 9 plug (DIN 43650 A)
5 - 40 bar................................................................... 3 6 x ........................................................ Others
10 - 100 bar ................................................................ 4 2
16 - 160 bar ................................................................ 5 2 Microswitch
25 - 250 bar ................................................................ 5 4 1 ....................................................................... 0.5 A, 250 V (AC 15)
40 - 400 bar ................................................................ 5 6 ....................................................................... 12 W, 125 V (DC 13)
Others ................................................................................. x x x ....................................................................... Others
Type
Low pressure bellows (-0,2 to 10 bar) ............................................. 1
High pressure bellows (2 to 30 bar) ................................................. 2
Low pressure diaphragm (0.5 to 25 bar) ........................................ 3
High pressure diaphragm (5 to 100 bar) ........................................ 4
High pressure piston (40 to 400 bar) ............................................... 5
IC.PD.P10.A2.02- 520B2217 3
512010 512010
Dimensions
4 IC.PD.P10.A2.02- 520B2217
512010 512010
Data sheet
Thermostats type MBC 8000 and MBC 8100
Description MBC thermostats are temperature controlled

switches designed for use in severe industrial
environments. It consists of the standard series
MBC 8000 and the special series MBC 8100 with
ship approvals. In MBC thermostats special
attention has been given to meeting demands
for:
• compact design
• a high level of enclosure
• robust and reliable construction
• resistance to shock and vibration
• low differential and high repeatability
The MBC thermostats is part of the block
controls programme consisting of MBC
pressure controls and thermostats, MBS pressure
transmitters and MBV test valves.
The thermostats are suitable for use in monitoring
and alarm systems in factories, diesel plant,
compressors, power stations and on board ship.
Approvals CE marked acc. to EN 60 947-5-1

CCC, China Compulsory Certificate
Ship approvals, Bureau Veritas, France
MBC 8100 only Det norske Veritas, Norway Registro Italiano Navale, Italy
American Bureau of Shipping Nippon Kaiji Kyokai, Japan
Lloyds Register of Shipping, UK KRS, Korean Register of Shipping
Germanischer Lloyd, Germany RMRS, Russian Maritime Register of Shipping
Standard types
Setting Fixed Max. Cap.- Capillary tube Armoured capillary tube Sensor Rigid sensor
range diff. sensor length pocket
temp.
Type Type Type

C° C° C° m Code no. Code no. mm Code no.
MBC 8100 MBC 8100 MBC 8100
−10 - 30 3 80 2 061B820166 1221-1A02000 061B810166 1231-1A02000
20 - 60 3 130 2 061B810266 1431-1A02000
20 - 60 3 130 75 061B800266 1411-1A00075
50 - 100 4 200 2 061B820366 2221-1A02000 061B810366 2231-1A02000
50 - 100 4 200 75 061B800366 2211-1A00075
70 - 120 5 220 2 061B810466 2431-1A02000
70 - 120 5 220 75 061B800466 2411-1A00075
60 - 150 6 250 2 061B820566 2621-1A02000 061B810566 2631-1A02000
60 - 150 6 250 75 061B800566 2611-1A00075
INDUSTRIAL CONTROLS IC.PD.P10.D2.02-520B2392

512010 512010
Data sheet Thermostats type MBC 8000 and MBC 8100
Ordering of customized
types
MBC - -
Length
Type 02000 .............Capillary tube length [mm]
Industrial Thermostat................................... 8000 00075 .............Rigid sensor - pocket length in [mm]
Ship Approved Thermostat........................ 8100
xxxxx .............Other
Setting range Temperature connection

-10 - 30°C ........................................................................................... 1 2 A .............................................................M18 x 1.5
20 - 60°C ........................................................................................... 1 4 x ..............................................................Other
50 - 100°C ....................................................................................... 2 2
70 - 120°C ....................................................................................... 2 4 Electrical connection
60 - 150°C ....................................................................................... 2 6 0 .........................................................................No plug
100 - 200°C ........................................................................................ 2 8 1 .........................................................................Pg 11 plug (DIN 43650)
Others ..................................................................................................... x x
2 .........................................................................Pg 13.5 plug (DIN 43650)
3 .........................................................................Pg 9 plug (DIN 43650)
Type x .........................................................................Other
Rigid sensor ............................................................................................................... 1
Capillary tube ........................................................................................................... 2 Microswitch
Armoured capillary tube....................................................................................... 3 1 ....................................................................................0.5 A, 250 V (AC 15)
12 W, 125 V (DC 13)
x ....................................................................................Other
Technical data Contact load (Alternating current): Enclosure

Inductive: 0.5 A, 250 V, AC15 IP 65 to IEC 529 and DIN 40050.
Direct current: 12 W, 125V, DC 13 Anodized Al Mg Si 1.
Ambient temperature –40 to +70 °C Electrical connection

DIN 43650 plug, Pg 9, Pg 11, Pg 13.5
Shock resistance:
50 g / 6 ms, 500 g / 1ms Switch
acc. to IEC 68-2-27 Single-pole changeover switch (SPDT).
Free fall acc. to IEC 68-2-32
Vibration resistance
Sin 4 g, 5Hz o200 Hz acc. to IEC 68-2-6. *)
Properties acc. to EN 60947
Wire dimensions
Solid/stranded 0.2 - 1.5 mm2
Flexible, w/out ferrules 0.2 - 1.5 mm2
Flexible, with ferrules 0.2 - 1 mm2
Tightening torque max. 1.2 Nm
Rated Impuls voltage 4 kV
Pollution degree 3
Short circuit protection, fuse 2 Amp
Insulation 250 V
IP-index 65
*) If higher vibrations are present in the system/installation, thermostats with capillary tube or
armoured capillary tube are recommended.
2 IC.PD.P10.D2.02-520B2392
512010 512010
Accessories: Sensor pockets Sensor A Thread Code no. Sensor A Thread Code no.
for MBC thermostats pocket mm B pocket mm B
1
75 /2 NPT 060L326466 Steel 18/8 75 G 1/2 A 060L326766
75 G 1/2 A 060L326266
Brass 75 G 3/4 A 060L326666
75 G 1/2 A (ISO 228/1) 060L328166
1
110 /2 NPT 060L327066 Steel 18/8 110 G 1/2 A 060L326866
110 G 1/2 A 060L327166 110 1
/2 NPT 060L327066
Brass
110 G 1/2 A (ISO 228/1) 060L340666
110 G 3/4 A (ISO 228/1) 060L340366
Supplied without gland nut, 160 G 1/2 A 060L326366 Steel 18/8 160 G 1/2 A 060L326966
Brass 160 G 3/4 A (ISO 228/1) 060L340566
gaskets and washer
Part Description Code no.
017-420466
Clamping band For thermostats with remote sensor (L = 392 mm)
For thermostats with sensor fitted in a sensor pocket.

Heat -conductive Compound for filling sensor pocket to improve heat
compound transfer between pocket and sensor. Application 041E0114
(4.5 cm3 tube) range for compound:
–20 to +150 °C, momentarily up to 220°C.
Gasket set
For MBC thermostats without armoured capillary tubes 060L327366
Gasket set For MBC thermostats with armoured capillary tubes 060L036666
Dimensions
Rigid sensor Cap. tube version
IC.PD.P10.D2.02-520B2392 3
512010 512010
Setting point correction The sensor on MBC 8100 thermostats contains an

adsorption charge. Therefore its function is not Factor for setting
affected whether the sensor is placed warmer or point deviation
colder than the remaining part of the thermo-
static element (bellows and capillary tube). How-
ever, such a charge is to some extent sensitive to
changes in the temperature of the bellows and
capillary tube. Under normal conditions this is of
no importance, but if the thermostat is to be used Relative
in extreme ambient temperatures the setting scale
point might change. setting
in %
The deviation can be compensated for as follows:
Setting point correction = Z x a
Z can be found from fig. 1, while a is the

correction factor from the table below.
Regulation Correction factor a for thermostats

range with 2 and 5 m Fig. 1
°C with rigid sensor
capillary tube
-10 o+30 1.1
20 o 50 1.0 1.4
50 o100 1.5 2.2
70 o120 1.7 2.4
60 o150 3.7
100 o200 6.2
Example Relative setting:

A MBC 8100 with capillary tube length 2 m and
range 50 o 100°C must cut out at 75°C in 70°C Factor for setting point deviation Z (fig. 1).
ambient temperature. At which cut out tempera- Z - 1.2
ture should this thermostat be set at in 20°C ambi- Correction factor a (table under fig. 1) a = 2.2
ent temperature?
Setting point correction Z x a = 1.2. x 2.2 = 2.6°C
The relative setting Z can be calculated from the
following formula: The MBC must be set at 75 + 2.6 = 77.6°C in
20°C ambient temperature in order to cut out
Setting value min. range at 75°C ambient temperature.
x 100%
max. range - min. range
Relative setting: 75 - 50 x 100 = 50%

100 - 50
4 IC.PD.P10.D2.02-520B2392
512010 512010
Installation Installation Sensor position

MBC thermostats are designed to withstand the As far as possible the sensor should be positioned
shocks that occur, e.g. in ships, on compressors and so that its longitudinal axis is at right angles to the
in large machine installations. MBC thermostats direction of flow. The active part of the sensor is
with remote sensor are fitted with 5 mm screws to 13 mm x 50 mm long on thermostats with rigid
bulkheads or similar. See fig. 2 sensors and 2 m capillary tube.
MBC thermostats with rigid sensor are self-support-
ing from the sensor pocket.
For permissible media pressure see fig. 3.
Brass Stainless steel
Fig. 3. Permissible media pressure on the sensor

pocket as a function of temperature
Setting
When the top cover screw at the thermostat is
Fig.2 removed, the range can be set with the setting
screw. The differential is non-adjustable.
Resistance to media
Material specifications for sensor pockets:
Sensor pocket, brass

The tube is made of Ms 72 to DIN 17660, the
threaded portion of So Ms 58Pb to DIN 17661.
Sensor pocket, stainless steel 18/8

Material designation 1.4305 to DIN 17440.
Mech. diff.
Fig. 4
IC.PD.P10.D2.02-520B2392 ® Danfoss A/S 11-2005 IC-MC/mr

512010 512010
5102
512020 5102
512020
5102
512020 5102
512020
5102
512020 5102
512020
5102
512020 5102
512020
5102
512020 5102
512020
5102
512020 5102
512020
5102
512020 5102
512020
5102
512020 5102
512020
5102
512020 5102
512020
5102
512020 5102
512020
5102
512020 5102
512020
5102
512020 5102
512020
5102
512020 5102
512020
5102
512020 5102
512020
5102
512020 5102
512020
5102
512020 5102
512020
5102
512020 5102
512020
5102
512020 5102
512020
5102
512020 5102
512020
5102
512020 5102
512020
5102
512020 5102
512020
5102
512020 5102
512020
5102
512020 5102
512020
5102
512020 5102
512020
512020
5103 5103
512020
Schmierstofftabelle für
Bogenzahn-Kupplungen®
mit Schmierstofffüllung
Table of lubricants for Curved Tooth Couplings with lubricant filling.

Tableau de lubrifiants pour accouplements a denture bombée avec remplissage d'lubrifiant.
Table de lubricantes para acoplamientos de dientes arquedos con llenado de lubricante.
Ölschmierung Fettschmierung
Oil lubrication Grease lubrication
Die Angaben auf den Produkt-
Lubrification á l' huile Lubrification á la graisse
Lubrificación con acaite Lubrificación con grasa datenblättern bzw. Sicherheits-
datenblättern der Schmierstoffe
AGIP Blasia 460 AGIP GR MU/EP 1 sind unbedingt zu beachten. Die
aktuellen Datenblätter liefert der
Schmierstoffhersteller.
Degol BG 460, Degol BMB 460 Aralub HLP 1
Für Anfragen bezüglich RENK
Degol PAS 460 Aralub FDP 0
Longlife Grease gilt die unten-
Energol GR-XP 460 stehende Anschrift.
Energrease LS-EP 1
Enersyn HTX 460
It is of utmost importance to
Alpha SP 460 observe the details stated on
Spheerol EPL 1 the product data sheets or
Alphasyn T 460
safety data sheets of the lubri-
Gear Compound EP 460 cant. The presently valid data
Coupling Grease sheets are available from the
Meropa 460
lubricant supplier.
Falcon CLP 460 Please send inquiries for

RENK Longlife Grease to the
address mentioned below.
SPARTAN EP 460
Les spécifications sur les feuil-
les de données et des feuilles
RENOLIN CLP 460
RENOLIT SO-GFO 35 de sécurité des lubrifiants doi-
RENOLIN UNISYN CLP 460 vent être soigneusement obser-
vées. Les feuilles de données
STRUCTOVIS BHD MF actuelles peuvent être obtenues
Klüberlub BE 41-1501
Klüberoil GEM 1-460 chez le fournisseur du lubrifiant.
Mobiltemp SHC 460 Special Pour les renseignements sur la

Mobilgear 634 graisse RENK Longlife Grease
Mobilith SHC 1500
veuillez contacter RENK à
l’adresse mentionnée ci-dessous.
Longlife Grease
Será de respeto absoluto lo

Wintershall Ersolan 460 indicado en las hojas de datos
técnicos y de seguridad
correspondientes a los agentes
Omala 460, Omala F 460 Alvania EP(LF) 1 de lubricación. Los productores
Omala HD 460 Cassida Grease EPS 1 de estos agentes podrán proveer
las hojas de datos más actuales.
Carter EP 460 Respecto del agente RENK

Longlife Grease, hágase
referencia a la direccion
señalada al pie de la hoja.
B003723-01/11.02 (RR008)
RENK Aktiengesellschaft Werk Rheine ⋅ Postfach 1953 ⋅ 48409 Rheine ⋅ Telefon +49 5971 790 0 ⋅ Fax +49 5971 790 208
E-Mail info.rheine@renk-ag.com
512020
512030 512030
CENTAMAX®-S
Montageanleitung fitting instructions
Flanschbauformen Flange types

SB/SC/SD und SBE/SCE/SDE SB/SC/SD and SBE/SCE/SDE
Der äußere Leichtmetallring The outer toothed aluminium

wird mit Drehmoment TA2 an das ring is bolted to the engine fly-
Motorschwungrad geschraubt. Die wheel with tightening torque TA2.
innere Nabe wird auf die anzutrei- The driven hub is mounted onto
bende Welle montiert, danach wird the driven shaft. The rubber disc
die Gummischeibe mit einvulkani- with the vulcanized ring is then
siertem Ring auf die Nabe mon- assembled to the driven hub with
tiert, wobei die Schrauben mit dem bolts which must be tightened with
vorgeschriebenen Drehmoment the correct torque TA1 (types SB,
TA1 (SB, SC, SD) bzw. TA3 (SBE, SC, SD), or TA3 (types SBE, SCE,
SCE, SDE) angezogen werden SDE).
müssen.
Care must be taken to secure
Bei Bauform SB und SBW mit the driven hub on the shaft (eg by
Konusnabe: die Schrauben in meh- set-screw etc.).
reren Etappen über Kreuz gleich- For types SB and SBW with
mäßig solange anziehen, bis bei tapered hub:
allen Schrauben das vorgeschrie- The bolts must be tightened alter-
bene Anzugsmoment erreicht ist. nately in several steps until they
Danach Kontrolle des Anzugsmo- have all reached the correct tighte-
ments aller Schrauben reihum vor- ning torque TA1. Finally the tighte-
nehmen. Es muß auf sichere axiale ning torque of al bolts must be
Fixierung der inneren Nabe auf der checked all around.
Welle geachtet werden.
Wellenbauformen Shaft to Shaft types
Bei den Bauformen SBEW, On the types SBEW, SCEW,

SCEW and SDEW sowie SCW und SDEW and SCW/SDW, the bolts on
SDW Schrauben an der Nabe mit the hub must be tightened to tor-
Anzugsmoment TA3 anziehen. que TA3. On the types 240-2400
Bei den Bauformen 240-2400 SBW (tapered hub) the bolts on the
SBW (mit Konusnabe) die Schrau- inner hub must also be tightened to
ben an der inneren Nabe mit Dreh- torque TA1 in the same way as
moment TA1 anziehen und dabei described above for Type SB. For all
vorgehen wie oben für Bauform SB shaft to shaft types, screws on
beschrieben. outer bolts of aluminium ring must
Bei allen Wellenbauformen: be tightened with torque TA4.
Schrauben an äußeren Bolzen bzw. Normally the driven machine is
äußeren Aluring mit Anzugsdreh- flange-mounted to the driving ma-
moment TA4 anziehen. chine, and when offered up, the
Beim Zusammenbau des Aggre- rubber disc engages in the toothed
gats wird die Gummischeibe in den outer ring. There is a very small
äußeren Zahnring eingeschoben. amount of clearance between the
Zwischen diesem Zahnring und der driving and driven teeth to allow
Gummischeibe besteht ganz gerin- easy assembly, but this clearance
ges Spiel für eine bequeme Mon- is taken up when running by centri-
tage. Im Betrieb wird die Gummi- fugal force, expanding the rubber
scheibe durch die Fliehkraft etwas teeth against the outer ring, thus
geweitet, dadurch legt sie sich an making the connection free of
den äußeren Zahnring an und backlash.
macht somit diese Verbindung The rubber disc is free to float
spielfrei. axially in the outer ring and no
Die Kupplung ist axial frei ein- axial forces are generated by the
stellbar und frei von drehmoment- transmission of torque.
bedingten axialen Kräften.
M-CM-S-05-05
512030 512030
Schraubenanzugsmomente
CENTAMAX® Bolt-tightening torques
TA1 Schraubenanzugsmomente an der Nabe
Bauformen: SB, SC, SD
TA1 Tightening torque of bolts on the inner hub
Types: SB, SC, SD
Kupplungs coupling 120 SB 240 SB 400 SB 800 SB 1600 SB 2600 SC 4000 SC 4000 SD 8000 SC 12000 SC 8000 SD 12000 SD
Größe size 1200 SB 2400 SB 2800 SC 5000 SC 10000 SC 18000 SC 10000 SD 18000 SD
3500 SC 6000 SC
Konusnabe 7000 SC
Schrauben bolts M 6x20 M 8x20 M 8x20 M 10x20 M12x25 M 16x40 M 16x40 M16x55 M 20x50 M 20x50 M 20x80 M 22x80
ISO 4762 ISO 4762 8.8 8.8 8.8 8.8 8.8 10.9 10.9 10.9 10.9 10.9 12.9 10.9
Anzugs- tightening
moment torque
TA1 (Nm) TA1 (Nm) 9,5 23 23 46 79 280 280 280 490 490 700 670
6 6 8 8 8 8 12 24 12 24 24 24
Stückzahl quantity
TA2 Schraubenanzugsmomente am Flansch

Bauformen: SB, SC, SD, SBE, SCE, SDE
TA2 Tightening torques of bolts on flywheel flange
Types: SB, SC, SD, SBE, SCE, SDE
SAE SAE 6½ 7½ 8 10 11½ 14 16 18 21 24
metrisch Schrauben metric bolts M8 M8 M 10 M 10 M 10 M 12 M 12 M 16 M 16 M 18

8.8 TA2 (Nm) 8.8 TA2 (Nm) 23 23 46 46 46 79 79 195 195 245
Zoll Schrauben Inch bolts 5
/16-18 5
/16-18 3
/8-16 3
/8-16 3
/8-16 ½-13 ½-13 5
/8-11 5
/8-11 ¾-10
TA2 (Nm) UNC TA2 (Nm) 23 23 42 42 42 102 102 195 203 366
(inch-lbs.)
(inch-lbs.) 208 208 372 372 372 903 903 1726 1797 3240
Diese Schrauben gehören nicht zum Lieferumfang These bolts are not included.
TA3 Schraubenanzugsmomente an der Nabe

Bauformen: SBE, SCE, SDE
TA3 Tightening torque of bolts on inner hub
Types: SBE, SCE, SDE
Kupplungs coupling 240 SB 800 SB 1600 SB 2800 SC 2600 SC 4000 SC 5000 SC 4000 SD 8000 SC 8000 SD 12000 SC 12000 SD
Größe size 10000 SD 18000 SC 18000 SD
400 SB 1200 SB 2400 SB 3500 SC 6000 SC 10000 SC
7000 SC
Schrauben bolts M 8x25 M 10x30 M 12x30 M 16x40 M 16x50 M 16x35 M 16x50 M 16x70 M 20x50 M20x100 M 20x60 M 22x110
ISO 4762 ISO 4762 10.9 10.9 10.9 10.9 10.9 10.9 10.9 10.9 10.9 12.9 10.9 10.9
Anzugs- tightening
moment torque 34 68 117 280 280 280 280 280 490 700 490 670
TA3 (Nm) TA3 (Nm)
12
Stückzahl quantity 16 16 8 8 12 12 24 12 24 24 24
16
TA4 Schraubenanzugsmomente am Flansch

Bauformen: SBEW, SCEW, SDEW, SBW, SCW, SDW
TA4 Tightening torque of bolts on flange hub
Types: SBEW, SCEW, SDEW, SBW, SCW, SDW
Kupplungs coupling 400 SB 1600 SB 2600 SC

Größe size 240 SB 800 SB 2400 SB 2800 SC 3500 SC 4000 SC 8000 SC 8000 SD 12000 SC
1200 SB 5000 SC 10000 SD 18000 SC
6000 SC
7000 SC
Schrauben bolts M 8x55 M 10x60 M 10x70 M 10x70 M 12x80 M 12x70 M 14x90 M 14x200 M 16x140
ISO 4762 ISO 4762 10.9 10.9 10.9 10.9 10.9 10.9 10.9 8.8 8.8
Anzugs- tightening
moment torque 34 68 68 68 117 117 185 125 195
TA4 (Nm) TA4 (Nm)
Stückzahl quantity 24 24 24 24 24 24 24 24 24
512030 512030
Wellenversatz
Außerdem bieten wir CENTAX-
Kupplungen, die ganz erheblichen
Ventilation
Versatz ohne jeden Verschleiß aus-
gleichen. Nutzen Sie bitte unsere Die CENTAMAX-Kupplungen
umfangreiche Erfahrung und Bera- werden aus speziellem Gummi
tung für kritische Einsatzfälle. gefertigt, welches eine höhere
Temperaturbeständigkeit als nor-
males Gummi besitzt. Es ist jedoch
Ausrichten unvermeidlich, daß jedes Gummi
unter dem Einfluß von höheren
Das Ausrichten von frei aufge- Temperaturen im Laufe der Zeit
stellten, nicht geflanschten Aggre- härter wird, und daß sich die me-
gaten soll nach den üblichen Me- chanischen Eigenschaften ver-
thoden erfolgen, z.B. Abfahren mit schlechtern. Daher ist es immer
Für den zulässigen Versatz gel- einer Meßuhr über eine Umdrehung sehr vorteilhaft, wenn bei ge-
ten folgende Richtwerte: und Ermittlung des radialen und flanschten Aggregaten durch mög-
axial : mehrere mm (wie in den winkeligen Versatzes zwischen An- lichst große und zahlreiche Öffnun-
Maßtabellen angegeben) und Abtriebsseite. gen im Flansch und Schwungrad-
winkelig: 0,5 Grad Als Bezugsfläche soll dabei auf gehäuse eine gute Ventilation
radial : 0,5 mm einer Seite die innere Nabe dienen gewährleistet ist. Dadurch wir die
Die Werte für den winkeligen und auf der anderen Seite die Temperatur abgesenkt und die Le-
und radialen Wellenversatz bezie- Flanschnabe (bei Wellenbaufor- bensdauer der Kupplung wesentlich
hen sich auf 1500 min-1. Für ande- men) bzw. eine bearbeitete Fläche erhöht.
re Drehzahlen müssen sie nach fol- am Schwungrad oder Schwung-
gendem Diagramm umgerechnet radgehäuse (bei den Schwungrad-
werden. bauformen).
Bei elastisch gelagerten Moto-
Zulässige Winkel- und Radialverlagerung ren sollte das Ausrichten frühe-
in Abhängigkeit von der Drehzahl bei Ausnut- stens 2 Tage nach dem Aufsetzen
zung der Nennleistung
des Motors auf die elastischen La-
ger erfolgen, weil dann bereits das
Setzen dieser elastischen Lager
weitgehend erfolgt ist. Als zusätzli-
che Maßnahme sollte das angetrie-
bene, starr gelagerte Aggregat um
einen gewissen Betrag (ca. 0,3
mm) tiefer gelegt werden als der
elastisch gelagerte Motor, so daß
beim weiteren Setzen des elastisch
gelagerten Motors eine weitere
Da jeder nennenswerte radiale Verbesserung der Fluchtung erfolgt
und winkelige Fehler zu Relativbe- bzw. der Motor nach längerer
wegungen, d.h. zu Verschleiß zwi- Betriebszeit nicht wesentlich tiefer
schen Gummielementen und Alu- liegt als das angetriebene Aggre-
miniumring führt, müssen - im In- gat. Das künftige Setzen des Mo-
teresse einer langen Lebensdauer tors wird somit vorweggenommen
der Gummielemente - die tatsäch- und teilweise kompensiert.
lichen winkeligen und radialen Bei der jährlichen Revision soll-
Fluchtungsfehler möglichst klein te die Ausrichtung überprüft und
gehalten werden, d.h. kleiner als nötigenfalls korrigiert werden.
obige Werte. Als Ausrichtgenauig-
keit bei nicht geflanschten Anla-
gen empfehlen wir:
winkelig : 0,1 Grad
radial : 0.2 mm
Diese Werte gelten für Dauer-
betrieb. Kurzzeitig (z.B. beim An-
und Abstellen des Motors, bei
schwerem Seegang usw) sind für
die winkelige und radiale Verlage-
rung fünffach höhere Werte zuläs-
sig.
Bei frei aufgestellten, nicht ge-
flanschten Einheiten kann durch
einfache konstruktive Maßnahmen
an der Kupplung der zulässige Ver-
satz in vielen Fällen deutlich erhöht
werden.
512030 512030
Misalignment
Furthermore we offer the CEN- Ventilation
TAX couplings which easily com-
pensate for considerable misalign- The CENTAMAX couplings are
ments without wear. Make use of produced of special rubber which
our extensive experience and has a higher temperature resistan-
counsel for critical application. ce than normal rubber. However, it
is a fact, that every rubber beco-
Alignment mes harder with time under the
influence of high temperature, and
The alignment of free mounted, its mechanical properties are redu-
non-flanged drives should be ced. Therefore it is always advan-
checked in the usual way, f.i. by tageous with flange mounted in-
The couplings can accomodate
checking the radial and angular stallations to ensure, that the flan-
the following maximum misalign-
misalignment between driving and ge and flywheel housing have
ment:
driven side with a dial indicator. many, rather large ventilation
axial : several mm (as stated in
As reference surface, the inner holes, in order to provide adequate
dimension tables)
hub should be used on one side, airflow. The temperature will then
angular: 0.5 degrees
the flange hub (or shaft to shaft be reduced and the life of the coup-
radial : 0.5 mm
types) on the other, or a machined ling element considerable increa-
These values for angular and
surface of the flywheel or flyheel sed.
radial misalignment are based on
housing (on flywheel-shaft types).
1500 rpm. For other speeds con-
If the engine is placed on flexi-
vert according the following dia-
ble mounts, the alignment should
gramm:
be checked at the earliest 2 days
Permissible angular and radial misalignment
offset misalignment is dependant upon the speed when after the engine has been put on its
utilizing the nominal torque capacity.
flexible mounts, because only then
will these mounts have taken most
of their permanent set.
In addition, the rigidly mounted
driven unit should be placed about
0.3 mm lower than the flexibly
mounted engine. In this way, upon
further settling of the engine, a
misalignment improvement can be
achieved and the engines position
after some running time will not be
Since radial and angular misa-
essentially lower than the driven
lignment cause relative movement,
unit. Further settling of the engine
that means wear between the rub-
is thus anticipated and compensa-
ber elements and the outer alumi-
ted if necessary.
nium ring, it is advisable to keep
the alignment as low as possible -
better than above values - in order
to ensure long coupling life and
smooth running. For non-flanged
drives we recommend following
effective range of max. misalign-
ment:
angular:0.1 degree
radial :0.2 mm
Above values are for continuous
duty. For short time (f.i. during
starting and stopping the engine,
at heavy sea, etc.) up to five times
higher values for radial and angular
misalignment are allowable.
For independantly mounted,
non-flanged units the allowable
misaligment values can easily be
increased in many cases by a sim-
ple optional design change, without
extra costs. Please ask us.
512030
Annex Voith Turbo Schneider Propulsion | Operation Manual | VSP BOSPORUS 18R5 EC/150-1
9.2 Standards
Factory standards in English or German are made available on request by Voith Turbo
Schneider Propulsion GmbH & Co. KG.
DIN standards and other general standards must be procured by the operator.
Standard Title
VN103 Requirements and guidelines regarding hydraulic fluids
VN105 Requirements and guidelines regarding VSP oils
VN1619, Sheet 1 Voith Turbo Marine Coatings
DIN 7716 Products made of natural or vulcanized rubber

Demands storage, cleaning and maintenance
Tab. 9-1 Standards
Procurement from
• Voith Turbo Schneider Propulsion GmbH & Co. KG
Alexanderstraße 18
89522 Heidenheim
Germany
Phone: +49 (0) 73 21 / 37 - 65 54
Fax: +49 (0) 73 21 / 37 - 71 05
Mobil: 01 73 / 3 29 01 95
E-Mail: vspmarine@voith.com
Internet: www.voith.com
• DIN-Standards can be procured from:

Beuth-Verlag
Burggrafenstraße 6
10787 Berlin
Germany
Revision: 000-v6r4
Created: 2007-6-1
Internet: www.beuth.de
SSNr.: 1822056851000
VGNr.: 000
9-4
Voith Turbo Schneider Propulsion | Operation Manual | VSP BOSPORUS 18R5 EC/150-1 Standard lists
10 Standard lists
10.1 Overview
Standard list Position
Parts list Î Page 10-1, Chapter 10 „Standard lists”

Tab. 10-1 Standard lists
Revision: 000-v6r4
Created: 2007-6-1
SSNr.: 1822056851000
VGNr.: 000
10-1
Standard lists Voith Turbo Schneider Propulsion | Operation Manual | VSP BOSPORUS 18R5 EC/150-1
10.2 Parts list
Part-No. Order-No. Quantity Description/ Value Unit

Dimension
182.2056581000 1,000 shipset 1,000 KG

1-4 18R5
111010 182.20586610G0 5,000 blade 244,600 KG

1953x472x183
111020 H82.002262 5,000 gland ring 2,500 KG

205/183X49
111030 H82.003035 5,000 bearing ring 2,380 KG

150/130X70
111040 H01.152784 5,000 self-al.roller bearing 12,550 KG

23034EASM
DIN 635-2
111050 H82.101122 5,000 junk excluder 2,300 KG

279,5/188X14
111060 182.2071751000 5,000 spacer ring -- 0,800 KG

189/170x12,5
111070 H82.101017 5,000 spacer ring -- 0,300 KG

182/155X28
111080 H01.008028 10,000 o-ring 0,010 KG

165X5
VN 3014
111090 H01.008036 5,000 o-ring 0,010 KG

245X5
VN 3014
111100 H82.101124 5,000 packing ring --- 1,000 KG

312/236X47
Revision: 000-v6r4
Created: 2007-6-1
111110 H82.101123 5,000 retaining ring 2,000 KG

305/240X10
111120 H01.000426 30,000 socket head screw 0,009 KG

M8X20
DIN 7984
111130 H01.004391 10,000 o-ring 0,023 KG

290X5
VN 3014
SSNr.: 1822056851000
VGNr.: 000
10-2

Dimension
111140 H01.098612 10,000 shaft seal ring 0,450 KG

205X250X16
VN 3057
111160 H01.071790 1,000 grease KG

OPTIPIT-NLGI 3
111170 H01.085640 10,000 screw plug - 0,026 KG

G 3/8A
VN 1638
112010 182.2058701000 5,000 blade bearing cap 37,000 KG

462X120
112020 H82.101126 5,000 upper bearing bush 3,200 KG

172/150X67,5
112030 H01.064081 5,000 o-ring 0,030 KG

375X5
VN 3014
112040 H82.101019 5,000 bearing carrier 7,800 KG

305/190X24

M8X35
ISO 4762
112060 H01.072414 60,000 washer --- 0,002 KG

8,4
DIN 125-2

M8X100
ISO 4762
112080 182.2057181000 5,000 actuating lever - 25,454 KG

Revision: 000-v6r4
Created: 2007-6-1
120X235X331
112090 H82.101198 5,000 tightening screw 1,000 KG

M30X3,5X100
112100 H82.101012 5,000 axle support 0,600 KG

10X97X110
112110 H01.000109 10,000 hexagon bolt 0,037 KG

M12X25
DIN 933
SSNr.: 1822056851000
VGNr.: 000
10-3

Dimension
112120 H01.068919 10,000 lock washer 0,003 KG

NL12
VN 3204

M16X16
ISO 4762
112140 H01.020030 5,000 hexagon bolt 0,021 KG

M10X16
DIN 933
112150 H01.068918 5,000 lock washer 0,002 KG

NL10
VN 3204
112160 H01.056968 5,000 washer --- 0,003 KG

10
ISO 7089
130010 182.2059741000 1,000 main coupler 33,500 KG

215X305X576,5
130020 182.2059811000 2,000 inner coupler 28,700 KG

215X305X576.5
130030 182.2059861000 2,000 outer coupler 28,700 KG

215X305X576.5
130040 H82.101163 4,000 bush 1,900 KG

237/212X39
130050 H82.000880 10,000 bush 0,800 KG

80/58X70
130062 182.2064911000 5,000 rocking arm 26,000 KG

410x191x328
Revision: 000-v6r4
Created: 2007-6-1
130070 H82.101168 10,000 bearing ring 4,100 KG

95/85X44
130080 H82.101142 5,000 pin 5,400 KG

68X265
130090 H82.003544 5,000 retaining segment 0,065 KG

6X30X60
130100 H82.101013 10,000 pin 1,700 KG

46X137
SSNr.: 1822056851000
VGNr.: 000
10-4

Dimension
130110 H82.101204 5,000 flat piece 0,170 KG

10X40X60
130120 H82.016942 5,000 connecting rod 9,200 KG

63,5X85X850
130130 H82.000857 20,000 bush 0,255 KG

64/46X35
130140 H82.101014 1,000 upper brg plate 77,000 KG

975/242-82,5
130150 H82.101015 1,000 lower brg plate 77,000 KG

710/200X37
130160 H82.101130 1,000 lower stop ring 3,000 KG

282/216X20
130170 H82.000889 10,000 bush 0,975 KG

120/95X42
130180 H82.101164 1,000 coupler sleeve 21,400 KG

235/172X225
130190 H82.101165 1,000 flange - 4,800 KG

225/8X20
130200 H01.006522 12,000 hexagon bolt 0,015 KG

M8X30
ISO 4017
130210 H01.072414 12,000 washer --- 0,002 KG

8,4
DIN 125-2
130220 H82.001705 1,000 key 0,016 KG

12X8X22
Revision: 000-v6r4
Created: 2007-6-1
130230 H01.085666 1,000 key KG

12X8X20
DIN 6885-1

M10X20
DIN 7984
130250 H01.068918 10,000 lock washer 0,002 KG

NL10
VN 3204
SSNr.: 1822056851000
VGNr.: 000
10-5

Dimension
130260 H01.000076 10,000 hexagon bolt 0,020 KG

M10X25
DIN 933
130270 H01.068918 10,000 lock washer 0,002 KG

NL10
VN 3204

M16X35
ISO 4762
130290 H01.055901 15,000 washer --- 0,007 KG

17
DIN 433-2
130300 H01.064090 1,000 o-ring 0,080 KG

940X5
VN 3014
130310 H01.000117 25,000 hexagon bolt 0,047 KG

M12X40
DIN 933
130320 H01.072416 25,000 washer --- 0,007 KG

13
DIN 125-2
130330 H82.007002 7,000 straight pin 0,088 KG

20X36
130340 H01.002138 7,000 circlip 0,076 KG

20X1,2
DIN 471
130350 H01.006523 8,000 hexagon bolt 0,027 KG

M10X30
Revision: 000-v6r4
Created: 2007-6-1
DIN 933
130360 H01.068918 8,000 lock washer 0,002 KG

NL10
VN 3204
140010 H82.100599 1,000 control rod 86,000 KG

190/30X1020,5
140020 182.2067251100 2,000 bottom bolt 0,900 KG

24x50
SSNr.: 1822056851000
VGNr.: 000
10-6

Dimension
140030 182.2067261100 2,000 bolt,centre 0,300 KG

28x103
140040 182.2067421100 1,000 spher.bush.,lower 5,800 KG

145/92X90 Kug.110
140050 H82.101135 1,000 intermed.bush 10,000 KG

172/100X160
140060 H82.101136 1,000 flange - 0,700 KG

145/111X12
140070 H82.101137 1,000 fixing buttstrap 0,200 KG

142x40x5
140080 H01.084849 8,000 hexagon bolt 0,050 KG

M8X125
ISO 4014
140090 H01.072414 8,000 washer --- 0,002 KG

8,4
DIN 125-2
140100 H82.008043 1,000 spher.bush.,central 16,300 KG

245/168,26X115
140110 H01.064078 1,000 o-ring 0,055 KG

184X5
VN 3014
140120 H01.058050 1,000 artic.joint bearing 2,600 KG
140130 182.2064151000 1,000 axle 1,890 KG

87/31,1X154
140140 H82.006807 1,000 joint head 1,500 KG

100X65X80
Revision: 000-v6r4
Created: 2007-6-1
140150 182.2064171000 1,000 cover -- 0,500 KG

65/37
140160 H01.066708 2,000 o-ring 0,003 KG

48X3
VN 3014
140170 H01.085638 1,000 screw plug - 0,130 KG

G1 A
VN 1638
SSNr.: 1822056851000
VGNr.: 000
10-7

Dimension
140180 182.2064161000 1,000 pitch indicator 0,110 KG

19X21,9X80

M5X10
ISO 4762
140200 H82.007174 1,000 push rod sleeve 5,900 KG

170/130X80
140210 H01.095778 1,000 key 0,012 KG

12X8X16
DIN 6885-1
140220 H82.007184 2,000 flange - 1,100 KG

180/118X10
140230 H82.007185 2,000 spacer ring -- 0,380 KG

129/118,8X15
140240 H01.000076 12,000 hexagon bolt 0,020 KG

M10X25
DIN 933
140250 H01.068918 12,000 lock washer 0,002 KG

NL10
VN 3204
140260 H82.101125 1,000 retaining sleeve 18,300 KG

290/203,8X268
140270 H01.004376 1,000 o-ring 0,020 KG

230X5
VN 3014
140280 H01.045969 6,000 hexagon bolt 0,029 KG

M10X35
Revision: 000-v6r4
Created: 2007-6-1
DIN 933
140290 H01.068918 6,000 lock washer 0,002 KG

NL10
VN 3204
150010 182.20055910G0 2,000 hydraulic cylinder 61,000 KG

165X312X720
150020 182.20166810G0 4,000 hose line 1,000 KG

2SC10N45/N45-.
SSNr.: 1822056851000
150030 H82.100606 2,000 cover -- 33,000 KG

350X173
VGNr.: 000
10-8

Dimension
150040 H82.006101 2,000 pin 3,130 KG

63X164
150050 H82.006102 2,000 axle support 0,170 KG

8X25X80
150060 H82.101228 2,000 laminum disc 0,320 KG

350/275X3,2
150070 H01.032197 24,000 hexagon bolt 0,100 KG

M16X55
ISO 4017
150080 H01.070196 24,000 washer --- 0,011 KG

17
DIN 125-2
150090 H01.040869 6,000 hexagon bolt 0,060 KG

M16X20-RIB
ISO 4017
150100 H82.100602 1,000 fork head 25,300 KG

150X270X325
150110 H82.100604 1,000 pivoted head 23,000 KG

150X290X335
150120 H82.007166 1,000 bush 1,500 KG

192/170X40
150130 H82.101226 2,000 flange - 7,500 KG

50X150X250
150140 H82.101356 2,000 spacer ring -- 0,050 KG

70/46X3,5
150150 H01.021382 8,000 hexagon bolt 0,178 KG

M20X50
Revision: 000-v6r4
Created: 2007-6-1
ISO 4017
150160 H01.070198 8,000 washer --- 0,004 KG

25
DIN 125-2
210012 182.20579710G2 1,000 rotor casing 1420,00 KG

Fertigteil CW 0
210020 H82.014867 120,000 stud - 0,079 KG

M16X1,5XL=66
SSNr.: 1822056851000
VGNr.: 000
10-9

Dimension
210030 H01.027132 12,000 hexagon nut 0,030 KG

M16X1,5
DIN 934
210040 182.20579910G0 36,000 stud - 0,456 KG

M30X2X105
210050 H01.027130 36,000 hexagon nut 0,200 KG

M30X2
DIN 934
210060 H82.018445 5,000 reactive anode 9,870 KG

45X160X405
TYPE:20-Z
210214 H82.000005 1,000 oil drain device 0,500 KG
214010 H01.047754 1,000 screw plug - 0,300 KG

G1 1/4A
DIN 908
214020 H01.004475 1,000 seal ring 0,007 KG

42X49
DIN 7603
214030 H82.000647 1,000 spring plate -- 0,134 KG

50X20
214040 H01.008794 1,000 cyl.compr.spring 0,030 KG

2,5X31,5X50
N-536/57
214050 H82.000031 1,000 cover -- 0,150 KG

80X4
214060 H01.020013 4,000 hexagon bolt 0,010 KG

Revision: 000-v6r4
Created: 2007-6-1
M8X16
ISO 4017
214070 H01.068917 4,000 lock washer 0,002 KG

NL 8
VN 3204
220010 182.20571010G0 1,000 driving sleeve 550,000 KG

1105/330X334
220020 H82.101063 1,000 gland ring 26,500 KG

695/655X145
SSNr.: 1822056851000
VGNr.: 000
10-10

Dimension
220030 182.20570810G0 1,000 thrust plate -- 437,000 KG

1175/410x134
220040 182.2059481100 72,000 sliding shoe 1,350 KG

80X47,5
220050 182.2059531100 1,000 retaining ring 176,000 KG

1288/1015X74
220060 H82.101065 1,000 bearing flange - 144,000 KG

950/750X212
220070 H01.152786 1,000 cyl.roller bg. 94,080 KG

NU18/630 -M1A...
DIN 5412-1
220080 H82.101066 1,000 bearing retaining 8,800 KG

ring
830/765X17
220090 H01.15451700G 18,000 hexagon bolt 2,760 KG

M42x220
ISO 4014
220100 H82.014991 18,000 washer --- 0,183 KG

78/45x7
220110 H01.045557 3,000 hexagon bolt 0,120 KG

M20X25
ISO 4017
220120 H01.064096 2,000 o-ring 0,090 KG

647,1X7
VN 3014
220130 H01.008363 1,000 straight pin 0,030 KG

12M6X28
Revision: 000-v6r4
Created: 2007-6-1
DIN 7
220140 H01.022576 48,000 hexagon bolt 0,277 KG

M20X90
ISO 4014
220150 H01.070197 48,000 washer --- 0,014 KG

21
DIN 125-2

M10X20
SSNr.: 1822056851000
ISO 4762
VGNr.: 000
10-11

Dimension
220170 H01.068918 12,000 lock washer 0,002 KG

NL10
VN 3204
220180 H01.057067 1,000 o-ring 0,130 KG

830X7
VN 3014
220190 H01.057066 2,000 o-ring 0,125 KG

810X7
VN 3014

695X770X30
VN 3057
220220 H82.101265 1,000 intermediate ring 7,000 KG

770/720X16
220230 H82.101175 1,000 intermediate ring 6,400 KG

770/720X14
220240 H82.101067 1,000 protective ring 16,200 KG

820/697X24
220250 H01.045543 12,000 hexagon bolt 0,024 KG

M10X25
DIN 933
220260 H01.021382 24,000 hexagon bolt 0,178 KG

M20X50
ISO 4017
220270 H01.070197 24,000 washer --- 0,014 KG

21
DIN 125-2
Revision: 000-v6r4
Created: 2007-6-1
240010 H01.20031700G 24,000 hexagon bolt 0,670 KG

M30x90
ISO 4017
240020 H82.101092 4,000 segment 1,100 KG

4X184,2X637,1
240030 H01.077921 1,000 self-al.roller bearing 8,600 KG

22318E/C3
DIN 635-2
SSNr.: 1822056851000
VGNr.: 000
10-12

Dimension
240040 H01.002203 1,000 circlip 0,044 KG

90X3
DIN 471
240050 H82.101195 1,000 bearing flange - 120,000 KG

540/240X406
240060 H01.156141 1,000 taper roller bearing 48,000 KG

32232 J2/DF
240070 H82.101219 1,000 flange ring 8,500 KG

360/240X20
240080 H82.101261 1,000 spacer ring - 0,840 KG

360/290X3
240090 H01.006530 12,000 hexagon bolt 0,065 KG

M16X40
ISO 4017
240100 H01.070196 12,000 washer --- 0,011 KG

17
DIN 125-2
240110 H01.096476 1,000 o-ring 0,035 KG

415X5
VN 3014
240120 H82.101262 1,000 spacer ring - 2,000 KG

540/425X3,2
240130 H01.022598 16,000 hexagon bolt 0,200 KG

M20X60
ISO 4017
240140 H01.070197 16,000 washer --- 0,014 KG

21
Revision: 000-v6r4
Created: 2007-6-1
DIN 125-2
240150 H82.101220 1,000 spacer ring -- 0,800 KG

186/150,2X10
240160 H82.101260 1,000 tightening nut 1,200 KG

180X20
240170 H82.101197 1,000 cover -- 0,400 KG

150X10
240180 H82.008123 1,000 gasket 0,010 KG

SSNr.: 1822056851000
150/110X2
VGNr.: 000
10-13

Dimension
240190 H01.000043 4,000 hexagon bolt 0,014 KG

M8X25
ISO 4017
240200 H01.072414 4,000 washer --- 0,002 KG

8,4
DIN 125-2
240210 H82.101196 1,000 sealing cover - 22,000 KG

385/130X37
240220 H01.013475 1,000 o-ring 0,002 KG

320X5
VN 3014
240230 H01.006522 6,000 hexagon bolt 0,015 KG

M8X30
ISO 4017
240240 H01.072414 6,000 washer --- 0,002 KG

8,4
DIN 125-2

130x160x12
240260 H01.004799 1,000 con.lubrication 0,041 KG

nipple
M 8X1
DIN 71412
240270 H01.030237 1,000 hexagon bolt 0,026 KG

M12X10-RI
DIN 933
242010 182.20572211G2 1,000 bevel pinion shaft 165,000 KG

289,99X998
Revision: 000-v6r4
Created: 2007-6-1
242020 182.20572310G2 1,000 bevel gear rim 480,000 KG

1270/755X109,5
310012 182.20606810G2 1,000 propeller housing 1610,00 KG

2405/825x930 0
310020 H82.101022 1,000 control rod support 350,000 KG

1370/245X516
310030 H01.006532 49,000 hexagon bolt 0,100 KG

M16X50
SSNr.: 1822056851000
ISO 4017
VGNr.: 000
10-14

Dimension
310040 H01.070196 49,000 washer --- 0,011 KG

17
DIN 125-2
310050 H01.018611 4,000 taper pin 0,151 KG

16X85
ISO 8737
310060 H01.001036 4,000 hexagon nut 0,033 KG

M16
DIN 934
310070 H01.070196 4,000 washer --- 0,011 KG

17
DIN 125-2
350010 H82.101371 1,000 blind flange 0,750 KG

(KN129) 220X 2,5
350020 H01.000008 3,000 hexagon bolt 0,004 KG

M6X12
ISO 4017
350030 H01.068916 3,000 lock washer 0,001 KG

NL 6
VN 3204
350040 182.2059311100 1,000 rotary palm 10,200 KG

300/190X40
350050 H01.000084 12,000 hexagon bolt 0,036 KG

M10X45
DIN 931-1
350060 H01.072415 12,000 washer --- 0,002 KG

10,5
DIN 125-2
Revision: 000-v6r4
Created: 2007-6-1
360012 182.2064261002 1,000 housing cover 81,000 KG

1470/315X20
370010 H82.101353 2,000 mounting cover 17,300 KG

670x490x8
370020 H82.101355 2,000 seal - 0,130 KG

670x490x3
370030 H82.008421 1,000 cover -- 2,800 KG

240X8
SSNr.: 1822056851000
VGNr.: 000
10-15

Dimension
370040 H82.008422 1,000 gasket 0,080 KG

240/185X3
370050 H01.000074 38,000 hexagon bolt 0,022 KG

M10X20
DIN 933

M10X20 DIN912
370070 H01.047416 10,000 split pin 0,005 KG

3,2X25
ISO 1234
370080 H82.006813 1,000 aeration filter 0,380 KG

116X181
370090 182.2063241000 1,000 cover -- 10,000 KG

530x370x25
370100 182.2063251000 1,000 seal - 0,060 KG

530x370x2
370110 H01.000109 12,000 hexagon bolt 0,037 KG

M12X25
DIN 933
370120 182.2063261000 1,000 cover -- 4,100 KG

250x290
370130 182.2063271000 1,000 gasket 0,020 KG

250/180x2
370140 H90.115159 2,000 magnetic filter rod 1,200 KG
370150 H01.001032 2,000 hexagon nut 0,010 KG

M12
Revision: 000-v6r4
Created: 2007-6-1
DIN 934
370160 H01.000109 6,000 hexagon bolt 0,037 KG

M12X25
DIN 933
370170 H01.033737 2,000 screw plug - 0,110 KG

G1A
DIN 908
370180 H01.004471 2,000 seal ring 0,005 KG

SSNr.: 1822056851000
33X39
DIN 7603
VGNr.: 000
10-16

Dimension
370190 H01.000840 2,000 screw plug - 0,070 KG

G1/2A
DIN 910
370200 H01.008083 2,000 seal ring 0,020 KG

21X26
DIN 7603
370210 H01.009858 1,000 screw plug - 0,124 KG

G3/4A
DIN 910
370220 H01.004466 1,000 seal ring 0,004 KG

27X32
DIN 7603
370230 H01.007265 1,000 screw plug - 0,305 KG

G1 1/4A
DIN 910
370240 H01.004475 1,000 seal ring 0,007 KG

42X49
DIN 7603
370250 H01.076870 1,000 core plug - 0,005 KG

45,5
VN 3066
370260 H01.040870 3,000 hexagon bolt 0,110 KG

M20X20-RIB
ISO 4017
370270 H01.003962 1,000 flange - 2,840 KG

DN 50/PN 16
EN 1092-1
370280 H01.068897 1,000 gasket - 0,030 KG

Revision: 000-v6r4
Created: 2007-6-1
DN 50 PN40X2
EN 1514-1
370290 H01.003959 1,000 flange - 2,030 KG

DN 32/PN 40
EN 1092-1
370300 H01.068896 1,000 gasket - 0,020 KG

DN 32 PN40X2
EN 1514-1
SSNr.: 1822056851000
VGNr.: 000
10-17

Dimension
370310 H01.084835 2,000 screw plug - 0,027 KG

M 18X1,00
DIN 7604
370320 H01.004453 2,000 seal ring 0,001 KG

18X22
DIN 7603
370330 H82.008790 1,000 end cover -- 0,150 KG

90X3
370340 H82.008791 1,000 seal - 0,030 KG

90/60X2
375010 H01.000112 36,000 hexagon bolt 0,040 KG

M12X30
DIN 933
375020 H01.072416 36,000 washer --- 0,007 KG

13
DIN 125-2
375030 H01.088665 1,000 socket head screw KG

M12X12
ISO 4762
375040 H01.030237 3,000 hexagon bolt 0,026 KG

M12X10-RI
DIN 933
375050 H82.006813 2,000 aeration filter 0,380 KG

116X181
375060 H82.005248 1,000 blind flange 1,000 KG

(KN129) 240x 8
375070 H82.005549 1,000 gasket 0,020 KG

Revision: 000-v6r4
Created: 2007-6-1
240/180X2
375080 H01.000076 8,000 hexagon bolt 0,020 KG

M10X25
DIN 933
375090 H01.057327 8,000 washer --- 0,003 KG

10
ISO 7090
375100 H01.093245 1,000 nameplate KG

63x6x265
SSNr.: 1822056851000
VN 2000-2
VGNr.: 000
10-18

Dimension
375110 H01.068973 4,000 countersunk screw 0,001 KG

M4X10
DIN 965
390010 H01.075761 1,000 flanged valve 12,000 KG
390020 H01.068897 2,000 gasket - 0,030 KG

DN 50 PN40X2
EN 1514-1
390030 H01.000156 4,000 hexagon bolt 0,083 KG

M16X35
ISO 4017
390040 H01.014399 1,000 flange - 2,530 KG

DN 50/PN 16/60,3
EN 1092-1
390050 H01.032197 4,000 hexagon bolt 0,100 KG

M16X55
ISO 4017
390060 H01.001036 4,000 hexagon nut 0,033 KG

M16
DIN 934
390070 H01.058544 1,000 bend 0,920 KG

3-60,3X2,9W
DIN 2605-1
390080 H01.014399 1,000 flange - 2,530 KG

DN 50/PN 16/60,3
EN 1092-1
390090 H90.130540 1,000 non-return valve - 2,700 KG

Revision: 000-v6r4
Created: 2007-6-1
390100 H01.068897 2,000 gasket - 0,030 KG

DN 50 PN40X2
EN 1514-1
390110 H01.006532 4,000 hexagon bolt 0,100 KG

M16X50
ISO 4017
410012 182.20601110G1 1,000 axial piston pump 21,000 KG

A10VSO45...
SSNr.: 1822056851000
VGNr.: 000
10-19

Dimension
410020 H82.101278 2,000 laminum disc 0,150 KG

180X128X3,2
410030 H01.004312 1,000 o-ring 0,002 KG

98X3
VN 3014
410040 H01.000112 2,000 hexagon bolt 0,040 KG

M12X30
DIN 933
410050 H01.072416 2,000 washer --- 0,007 KG

13
DIN 125-2
410100 182.20601310G2 1,000 pump unit 65,000 KG

340X520X945
410110 H01.000112 11,000 hexagon bolt 0,040 KG

M12X30
DIN 933
410312 H82.101281 1,000 gear pump 16,000 KG

300x156,5x135
410320 H82.101279 2,000 laminum disc 0,160 KG

135X135X3,2
410330 H01.004320 1,000 o-ring 0,002 KG

110X3
VN 3014
410340 H01.045973 4,000 hexagon bolt 0,042 KG

M12X35
DIN 933
410350 H01.072416 4,000 washer --- 0,007 KG

Revision: 000-v6r4
Created: 2007-6-1
13
DIN 125-2
410420 H82.101221 1,000 spacer ring -- 1,400 KG

180/140X18
410430 H82.101291 2,000 laminar ring 0,100 KG

180/140,5X3,2
410440 H82.101238 1,000 pressure sleeve KG

170/140X38
SSNr.: 1822056851000
410450 H82.101240 1,000 thrust ring - 2,700 KG

215/142X16
VGNr.: 000
10-20

Dimension
410460 H01.021372 12,000 hexagon bolt 0,016 KG

M8X35
ISO 4017
410470 H01.072414 12,000 washer --- 0,002 KG

8,4
DIN 125-2
410480 H01.000036 2,000 hexagon bolt 0,012 KG

M8X20
ISO 4017
413010 H82.101236 1,000 bevel pinion - 1,060 KG

94,255/9X45
413020 H82.101237 1,000 bevel pinion - 1,080 KG

94,255/9X51
413030 H82.101235 1,000 bevel gear rim 21,000 KG

319,2/140X68,8
420010 182.20068210G0 1,000 valve block 120,000 KG

CA.350X400X600
420020 H01.000121 4,000 hexagon bolt 0,054 KG

M12X50
DIN 931-1
420030 H01.072416 4,000 washer --- 0,007 KG

13
DIN 125-2
420040 H01.034134 1,000 o-ring 0,020 KG

260X5
VN 3014
420050 182.20244210 1,000 cover plate 5,200 KG

Revision: 000-v6r4
Created: 2007-6-1
540x421,4x3
420060 182.20244310 4,000 spacer -- 0,300 KG

SW17x165
420070 H01.020030 4,000 hexagon bolt 0,021 KG

M10X16
DIN 933
420080 182.20352410 1,000 cable holder 0,500 KG

220x76x40,5
SSNr.: 1822056851000
420090 182.20352510 1,000 cable holder 0,500 KG

220x76x40,5
VGNr.: 000
10-21

Dimension
420100 182.20348710 2,000 plate - 0,200 KG

100x40x8
420110 H01.020013 2,000 hexagon bolt 0,010 KG

M8X16
ISO 4017
420120 H01.068917 2,000 lock washer 0,002 KG

NL 8
VN 3204
420140 H82.101138 1,000 valve set 43,000 KG

352X105X190
420150 H01.034121 1,000 o-ring 0,020 KG

190X5
VN 3014

M16X40
ISO 4762
425010 H01.000108 4,000 hexagon bolt 0,003 KG

M12X20
DIN 933
425020 H01.068919 4,000 lock washer 0,003 KG

NL12
VN 3204
425030 H01.045971 2,000 hexagon bolt 0,030 KG

M12X25
DIN 933
425040 H01.068919 2,000 lock washer 0,003 KG

NL12
VN 3204
Revision: 000-v6r4
Created: 2007-6-1
425426 182.20138910G0 1,000 duplex filter 45,000 KG

Hydac 03236825...
425427 H82.101342 1,000 duplex filter 40,000 KG

RFLD..501...
426010 H82.101344 2,000 filter element 0,500 KG
426020 H82.101345 1,000 contam.indicator 0,200 KG

93x82x37
SSNr.: 1822056851000
VGNr.: 000
10-22

Dimension
427010 H82.101347 2,000 filter element 1,100 KG
427020 H82.101345 2,000 contam.indicator 0,200 KG

93x82x37
430030 H01.098623 1,000 SAE flange 1,600 KG

106/90G
430070 H01.078394 2,000 EW-pipe connection KG

S 25
ISO 8434-4

25 S
VN 1143-8
430090 H01.156070 1,000 tr union 0,610 KG

S 25X20X25
VN 1143-7
430110 H01.156068 1,000 intermediate branch KG

20S
VN 1143-15

20 S
VN 1143-8

S 20
ISO 8434-4
430140 H01.084946 1,000 adjust.elbow fitt. KG

25 S
VN 1143-4
Revision: 000-v6r4
Created: 2007-6-1
430150 H01.215393 1,000 straight fitting KG

S 25
ISO 8434-1
430160 H01.096953 1,000 SAE flange 0,001 KG

106G100
430170 H01.058156 1,000 clip - 0,041 KG

K 3 R-25
DIN 3015-1
SSNr.: 1822056851000
VGNr.: 000
10-23

Dimension
430180 H01.076312 2,000 supporting rail nut 0,040 KG

M6
DIN 3015-1
430250 H01.098623 1,000 SAE flange 1,600 KG

106/90G
430260 H01.078427 1,000 red-thread adaptor 0,337 KG

1-1/2X1
VN 1143-7
430270 H01.078366 1,000 str.male st.fitting KG

S 25XG1A,TYPE B
ISO 8434-1
430280 H01.156091 1,000 str.male st.fitting 0,480 KG

S 25XG3/4A,TYPE
B
ISO 8434-1

L 12XG1/2A,TYPE B
ISO 8434-1

L 28XG3/4A,TYPE B
ISO 8434-1
430370 H01.084942 1,000 adjust.elbow fitt. 0,694 KG

28 L
VN 1143-4

1-1/2X1
VN 1143-7
430390 H01.058067 1,000 clip - 0,140 KG

Revision: 000-v6r4
Created: 2007-6-1
K 4 R-28
DIN 3015-1

M6
DIN 3015-1

28 L
VN 1143-4
SSNr.: 1822056851000
VGNr.: 000
10-24

Dimension
430470 H01.045272 1,000 straight fitting 0,072 KG

L 28
ISO 8434-1
430480 H01.068143 1,000 equal tee - 0,691 KG

L 28
ISO 8434-1
430490 H01.078390 1,000 EW-pipe connection 0,400 KG

L28
ISO 8434-4
430500 H01.058067 2,000 clip - 0,140 KG

K 4 R-28
DIN 3015-1

M6
DIN 3015-1

L
12XM22X1.5,TYPE
B
ISO 8434-1

12L
VN 1143-15
430580 H01.085082 1,000 ET-Union KG

L12
ISO 8434-4
430590 H01.156070 1,000 tr union 0,610 KG

S 25X20X25
Revision: 000-v6r4
Created: 2007-6-1
VN 1143-7
430600 H01.094081 1,000 Red.adapter KG

C-S 20-12
ISO 8434-4

L 12XG1/4A,TYPE B
ISO 8434-1
430620 H82.014981 1,000 deaeration valve 0,220 KG

SW22X58/ G1/4"
SSNr.: 1822056851000
VGNr.: 000
10-25

Dimension

L 12
ISO 8434-1
430690 H01.154544 1000,000 pipe - 0,002 KG

42X2
EN 10305-4
430700 H01.154365 6000,000 pipe - 0,001 KG

25X2,5
DIN 2391-1
430710 H01.155584 500,000 pipe - 0,001 KG

20X2,5
EN 10305-4
430720 H01.155318 6000,000 pipe - 0,001 KG

28X2
EN 10305-4
430730 H01.154577 3000,000 pipe - 0,001 KG

12X2
EN 10305-4
440010 H01.093642 1,000 SAE flange 1,190 KG

2XAD60,3
VN 1557
440015 H01.058544 1,000 bend 0,920 KG

3-60,3X2,9W
DIN 2605-1
440020 H01.022875 1,000 bend 0,490 KG

3-60,3X2,9W
DIN 2605-1
440025 H01.081176 2,000 branch - 0,100 KG

Revision: 000-v6r4
Created: 2007-6-1
G 1/2X30
VN 629
440030 H01.004458 2,000 seal ring 0,002 KG

22X27
DIN 7603
440035 H01.000840 2,000 screw plug - 0,070 KG

G1/2A
DIN 910
SSNr.: 1822056851000
VGNr.: 000
10-26

Dimension
440040 H01.091393 1,000 SAE flange 1,300 KG

2-1/2XAD60,3
VN 1557
440055 H01.093642 2,000 SAE flange 1,190 KG

2XAD60,3
VN 1557
440060 H01.022875 2,000 bend 0,490 KG

3-60,3X2,9W
DIN 2605-1
440065 H01.018530 1,000 branch - 0,052 KG

G 1/4X38
VN 629
440070 H01.070184 1,000 gauge coupling 0,075 KG

G 1/4 A
VN 1539
440085 H01.093642 2,000 SAE flange 1,190 KG

2XAD60,3
VN 1557

42 L
VN 1143-4

L 42XG1 1/2A,TYPE
B
ISO 8434-1
440105 H01.076945 1,000 SAE flange KG

1-1/2XG1-1/2
VN 1557
Revision: 000-v6r4
Created: 2007-6-1

35 L
VN 1143-4
440130 H01.215944 1,000 ET-Union 0,960 KG

L 35
ISO 8434-4

L 35XG1A,TYPE E
ISO 8434-1
SSNr.: 1822056851000
VGNr.: 000
10-27

Dimension

28 L
VN 1143-4

L28
ISO 8434-4
440150 H01.085013 1,000 tr union 0,610 KG

L 28X18X28
VN 1143-7
440175 H01.078422 1,000 Red.adapter 0,200 KG

C-L 28-22
ISO 8434-4

22 L
VN 1143-4

L 22
ISO 8434-1

L 22XG3/4A,TYPE B
ISO 8434-1
440195 H82.011359 2,000 throttle 0,020 KG

21,8/17,8X8

L 22
ISO 8434-4
440245 H01.084366 1,000 ET-Union KG

L18
Revision: 000-v6r4
Created: 2007-6-1
ISO 8434-4
440250 H82.011358 1,000 throttle 0,010 KG

17,8/13,8X8
440280 H01.154596 500,000 pipe - 0,001 KG

18X2
EN 10305-4
440285 H01.058064 1,000 clip - 0,095 KG

K 2 R-18
SSNr.: 1822056851000
DIN 3015-1
VGNr.: 000
10-28

Dimension

L18
ISO 8434-4
440295 H01.024130 1,000 male st.elb.fitting 0,180 KG

18
DIN 2353
440300 H82.011358 1,000 throttle 0,010 KG

17,8/13,8X8
440345 H01.215440 1,000 Red.adapter 0,400 KG

C-L 35-18
ISO 8434-4

18 L
VN 1143-4
440355 H82.011358 1,000 throttle 0,010 KG

17,8/13,8X8

S 38
ISO 8434-4

38 S
VN 1143-4
440385 H01.215880 1,000 Red.adapter KG

C-S 38-30
ISO 8434-4
440390 182.20653710D0 1,000 hose line 1,000 KG

2SC25PP-1100
Revision: 000-v6r4
Created: 2007-6-1

S 30XG1A,TYPE B
ISO 8434-1

L 28XG1A,TYPE B
ISO 8434-1
440435 H01.215786 1,000 ET-Union KG

L 22
ISO 8434-4
SSNr.: 1822056851000
VGNr.: 000
10-29

Dimension
440440 H01.078417 1,000 Red.adapter 0,200 KG

C-L 22-10
ISO 8434-4
440445 H82.011356 1,000 throttle 0,004 KG

9,8/6,8X8
440450 H01.084949 1,000 et union 0,101 KG

10 L
VN 1143-4
440455 H01.098814 2,000 intermediate branch 0,055 KG

10L
VN 1143-15
440460 H01.089544 1,000 el union 0,200 KG

10 L
VN 1143-4

L10
ISO 8434-4

L 10XG1/2A,TYPE B
ISO 8434-1
440490 H82.008467 2,000 sight feed oiler 0,225 KG

TYP: NR.255A

1/4X3/8
VN 1143-7
440500 H01.089642 2,000 t-section 0,195 KG

RP 1/4
VN 1141-2
Revision: 000-v6r4
Created: 2007-6-1
440505 H01.011868 2,000 outlet cock 0,100 KG

G1/4A
VN 841
440510 H01.024055 2,000 elbow fitting - 0,100 KG

L 10
ISO 8434-1

L 10
SSNr.: 1822056851000
ISO 8434-1
VGNr.: 000
10-30

Dimension
440520 H01.058062 5,000 clip - 0,022 KG

K 1 R-10
DIN 3015-1

M6
DIN 3015-1

L 10XG1/4A,TYPE B
ISO 8434-1
440575 H01.011235 1,000 t-section 0,060 KG

1/4
EN 10242
440580 101.000005024 1,000 pipe saw section 0,650 KG

1/4M-Wx1000
EN 10255
440585 H01.011868 2,000 outlet cock 0,100 KG

G1/4A
VN 841
440590 H01.011218 1,000 angle 0,100 KG

1/4
EN 10242
440595 H01.011206 1,000 angle 0,100 KG

1/4
EN 10242

L 10XG1/4A,TYPE B
ISO 8434-1
440635 H82.007608 3,000 drip pipe 1,000 KG

Revision: 000-v6r4
Created: 2007-6-1
18X1029,5
440640 H82.006708 3,000 fitting --- 0,129 KG

DS10 G1/2A-MOD
440645 H01.007975 3,000 o-ring 0,002 KG

8X2,5
VN 3014
440650 182.2063421000 3,000 reducing adaptor 0,090 KG

3/4X1/2
SSNr.: 1822056851000
VGNr.: 000
10-31

Dimension

60,3X2,9*3000lang
EN 10297-1
440670 H01.154544 2000,000 pipe - 0,002 KG

42X2
EN 10305-4
440675 H01.155325 2000,000 pipe - 0,002 KG

35X2
EN 10305-4
440680 H01.155318 2000,000 pipe - 0,001 KG

28X2
EN 10305-4
440685 H01.155306 4000,000 pipe - 0,001 KG

22X2
EN 10305-4
440690 H01.154596 3000,000 pipe - 0,001 KG

18X2
EN 10305-4
440695 H01.154569 9000,000 pipe - 0,001 KG

10X1,5
EN 10305-4
440725 H01.085008 2,000 tr union 0,400 KG

L 22X10X22
VN 1143-7
440730 H82.011356 2,000 throttle 0,004 KG

9,8/6,8X8

L10
Revision: 000-v6r4
Created: 2007-6-1
ISO 8434-4

L 10XG1/2A,TYPE B
ISO 8434-1
440745 H01.058062 3,000 clip - 0,022 KG

K 1 R-10
DIN 3015-1

SSNr.: 1822056851000
M6
DIN 3015-1
VGNr.: 000
10-32

Dimension

L 10
ISO 8434-1
460010 182.20616310G0 1,000 oil cooler 34,000 KG

160X214X557,3
460015 182.2061001000 1,000 brush 1,000 KG

9X120

42 L
VN 1143-4
460030 H01.000112 4,000 hexagon bolt 0,040 KG

M12X30
DIN 933
460040 H01.062910 4,000 hexagon nut 0,015 KG

M12
DIN 934
460050 H01.068919 8,000 lock washer 0,003 KG

NL12
VN 3204
460060 H82.014996 1,000 intermed.flange 4,700 KG

165/42X37

M16X40
ISO 4762
460080 H01.020880 4,000 stud - 0,082 KG

M16X40
DIN 939
Revision: 000-v6r4
Created: 2007-6-1
460090 H01.079229 1,000 temperature contr. 10,500 KG

M40TC4A-120-CA
460100 H01.014399 1,000 flange - 2,530 KG

DN 50/PN 16/60,3
EN 1092-1
460110 H01.151648 2,000 flange - 2,330 KG

DN 40/PN 40/48,3
EN 1092-1
SSNr.: 1822056851000
VGNr.: 000
10-33

Dimension
460120 H01.068897 2,000 gasket - 0,030 KG

DN 50 PN40X2
EN 1514-1
460130 H01.066757 3,000 gasket - 0,100 KG

DN 40 PN40X2
EN 1514-1
460140 H01.059618 1,000 reducer - 0,300 KG

60,3X2,9-48,3X2,6S
DIN 2616-2
460150 H01.015494 2,000 t-section 0,320 KG

60,3X2,9-...
DIN 2615-1
460160 H01.015493 1,000 t-section 0,182 KG

48,3X2,6-...
DIN 2615-1
460170 H01.098920 1,000 SAE flange 1,250 KG

2XAD60,3
VN 1557
460180 H82.005247 1,000 threaded disc 0,500 KG

75/G1,5X25

60/G1,25X25

60/G0,75X20
460210 H01.155351 300,000 pipe - 0,003 KG

48,3X2,6
EN 10297-1
Revision: 000-v6r4
Created: 2007-6-1
460220 H01.022874 2,000 bend 0,270 KG

3-48,3X2,6W
DIN 2605-1
460230 H01.006530 4,000 hexagon bolt 0,065 KG

M16X40
ISO 4017
460240 H01.006532 8,000 hexagon bolt 0,100 KG

M16X50
ISO 4017
SSNr.: 1822056851000
VGNr.: 000
10-34

Dimension
460250 H01.045964 12,000 hexagon nut 0,034 KG

M16
DIN 934
460260 H01.018532 1,000 branch - 0,110 KG

G 1/2X38
VN 629
460270 H01.082690 1,000 thermometer 0,200 KG

G-100x63
DIN 16181
460280 H01.004458 1,000 seal ring 0,002 KG

22X27
DIN 7603
465010 182.2061551090 1,000 oil to air cooler 47,100 KG

KOLP10N-1X/R-30/
M
465020 182.20310210 1,000 thermoswitch 1,000 KG

474.0320.14.1416/0
300.58
465030 182.2061521000 1,000 flange - 4,100 KG

180X36
465040 H01.023389 1,000 o-ring 0,003 KG

140X3
VN 3014
465050 H01.039386 6,000 hexagon bolt 0,010 KG

M8X20
ISO 4017
465060 H01.068917 6,000 lock washer 0,002 KG

NL 8
Revision: 000-v6r4
Created: 2007-6-1
VN 3204

L 22XG3/4A,TYPE B
ISO 8434-1

22 L
VN 1143-4
465090 H01.155306 400,000 pipe - 0,001 KG

SSNr.: 1822056851000
22X2
EN 10305-4
VGNr.: 000
10-35

Dimension
465100 H01.215595 2,000 locking cone KG

22 L
VN 1143-11
465110 H01.215382 2,000 EGE-pipe connec- KG

tion
L 22-G3/4A-TYPE E
ISO 8434-4
465120 182.2066111000 2,000 ball cock 1,210 KG

DN20
465130 H01.065414 2,000 cutting ring 0,008 KG

L 22
ISO 8434-1
465140 H01.003700 2,000 cap nut -- 0,080 KG

L 22
ISO 8434-1

L 22XG3/4A,TYPE B
ISO 8434-1

300X340X16
VN 3057
470030 H82.101131 1,000 retaining flange 2,300 KG

375/303X8
470040 H01.000036 6,000 hexagon bolt 0,012 KG

M8X20
ISO 4017
470050 H01.068917 6,000 lock washer 0,002 KG

NL 8
Revision: 000-v6r4
Created: 2007-6-1
VN 3204
470070 H01.014399 2,000 flange - 2,530 KG

DN 50/PN 16/60,3
EN 1092-1
470080 H01.068897 2,000 gasket - 0,030 KG

DN 50 PN40X2
EN 1514-1
470090 H01.022875 1,000 bend 0,490 KG

SSNr.: 1822056851000
3-60,3X2,9W
DIN 2605-1
VGNr.: 000
10-36

Dimension

60,3X2,9*500lang
EN 10297-1
470110 H01.000156 8,000 hexagon bolt 0,083 KG

M16X35
ISO 4017
470130 H01.014399 1,000 flange - 2,530 KG

DN 50/PN 16/60,3
EN 1092-1
470140 H01.068897 1,000 gasket - 0,030 KG

DN 50 PN40X2
EN 1514-1
470150 H01.000156 4,000 hexagon bolt 0,083 KG

M16X35
ISO 4017
470170 H01.151647 1,000 flange - 1,000 KG

DN 32/PN 40/42,4
EN 1092-1
470180 H01.068896 1,000 gasket - 0,020 KG

DN 32 PN40X2
EN 1514-1
470190 H01.000156 4,000 hexagon bolt 0,083 KG

M16X35
ISO 4017

18 L
VN 1143-4

Revision: 000-v6r4
Created: 2007-6-1
22 L
VN 1143-4

L 22XG3/4A,TYPE B
ISO 8434-1
470250 H01.017068 1,000 fan pump 5,900 KG

R3/4 A1
470260 H01.017122 2,000 hexagon bolt 0,030 KG

SSNr.: 1822056851000
M10X35
DIN 933
VGNr.: 000
10-37

Dimension
470270 H01.001233 4,000 washer --- 0,012 KG

10,5
DIN 7349
470280 H01.155306 1000,000 pipe - 0,001 KG

22X2
EN 10305-4
480020 H82.014894 1,000 thermometer 0,520 KG
480030 H01.008083 2,000 seal ring 0,020 KG

21X26
DIN 7603
480040 H82.006342 1,000 oil dipstick 0,260 KG

25X80X430
480050 H82.101339 1,000 float switch 0,600 KG

L=300, L1=255
480060 H01.008085 1,000 seal ring 0,050 KG

48X55
DIN 7603
480070 H82.101439 1,000 temperature sensor 0,100 KG

MBT 5250...
480100 H82.014894 1,000 thermometer 0,520 KG
480110 H01.008083 2,000 seal ring 0,020 KG

21X26
DIN 7603
480120 H82.006342 1,000 oil dipstick 0,260 KG

25X80X430
Revision: 000-v6r4
Created: 2007-6-1
480130 182.20631010G0 1,000 float switch 0,500 KG

L=225, L1=180
480140 H01.008085 1,000 seal ring 0,050 KG

48X55
DIN 7603
480150 H82.101439 1,000 temperature sensor 0,100 KG

MBT 5250...
480170 H01.215928 1,000 equal tee - KG

SSNr.: 1822056851000
S 12
ISO 8434-1
VGNr.: 000
10-38

Dimension
480180 H01.085082 1,000 ET-Union KG

L12
ISO 8434-4

12L
VN 1143-15

L12
ISO 8434-4
480210 H82.005522 2,000 ball cock 0,420 KG
480220 H01.073086 2,000 EGE-pipe connec- 0,069 KG

tion
L 12-G3/8A-TYPE E
ISO 8434-4

1/4X3/8
VN 1143-7
480240 H82.101360 2,000 pressure transducer 0,300 KG

-
94,5X34,2X90,8
480250 H82.101361 1,000 connecting strip 0,650 KG

20X40X105
480260 H01.028783 4,000 hexagon bolt 0,008 KG

M5X45
ISO 4014
480270 H01.058913 4,000 washer --- 0,002 KG

5
Revision: 000-v6r4
Created: 2007-6-1
ISO 7089
480300 H82.014036 2,000 speed detector - 0,250 KG

480310 H82.014037 2,000 cable plug 0,250 KG


M8X55
ISO 4762
SSNr.: 1822056851000
VGNr.: 000
10-39

Dimension
480440 H01.042971 4,000 washer --- 0,001 KG

8
VGN 3111
480482 H82.101334 1,000 pressure meas. dev. 7,000 KG

283X180X92

L 10XG1/4A,TYPE B
ISO 8434-1

10 L
VN 1143-4
480530 H01.058062 2,000 clip - 0,022 KG

K 1 R-10
DIN 3015-1
480550 H01.085006 1,000 tr union 0,297 KG

L 18X10X18
VN 1143-7

L18
ISO 8434-4

L10
ISO 8434-4

L 10XG1/4A,TYPE B
ISO 8434-1
480600 H01.156070 1,000 tr union 0,610 KG

S 25X20X25
Revision: 000-v6r4
Created: 2007-6-1
VN 1143-7
480610 H01.094081 1,000 Red.adapter KG

C-S 20-12
ISO 8434-4

S12
ISO 8434-4

SSNr.: 1822056851000
L 12XG1/4A,TYPE B
ISO 8434-1
VGNr.: 000
10-40

Dimension

L 12
ISO 8434-1
480640 H01.154392 2,000 clip - 0,075 KG

1 R-12
DIN 3015-1
480650 H01.154569 3000,000 pipe - 0,001 KG

10X1,5
EN 10305-4
480660 H01.154577 3000,000 pipe - 0,001 KG

12X2
EN 10305-4
482010 H82.013501 1,000 shut-off valve .. 5,500 KG

80X170X85
482020 H82.101336 1,000 pressure switch 0,300 KG

107X35X48
482030 H82.013503 2,000 pressure switch 0,300 KG

107X35X48
482040 H82.013504 3,000 adapter - 0,100 KG

ZBM 14
482050 H82.101337 3,000 connecting plug - 0,050 KG

58X30X71
490050 H01.154544 6000,000 pipe - 0,002 KG

42X2
EN 10305-4
490060 H01.154397 10,000 clip - 0,145 KG

5 R-42
Revision: 000-v6r4
Created: 2007-6-1
DIN 3015-1
490070 H01.155325 3000,000 pipe - 0,002 KG

35X2
EN 10305-4
490080 H01.058068 4,000 clip - 0,180 KG

K 5 R-35
DIN 3015-1
491492 182.20290810 1,000 adaptor housing 5,000 KG

350x290x120
SSNr.: 1822056851000
VGNr.: 000
10-41

Dimension
492010 H82.101374 1,000 terminal box 2,500 KG

350x150x120
492020 H82.101375 2,000 attachment housing 0,200 KG

HAN 24 E...
492030 H82.101377 2,000 service distributor 0,200 KG

HAN 24 E AV...
492040 H82.101376 2,000 socket housing 0,300 KG

HAN 24 E ...
492050 H90.131085 2,000 socket insert - KG
492060 H82.101378 8,000 pin - 0,003 KG
492070 H01.154690 10,000 lead-in KG

K24-Z10A-CR
DIN 89280
492080 H01.097968 10,000 nut 0,001 KG

4 24
DIN 89280
512010 182.20580510T1 1,000 intermed.gearbox 1,000 KG

NORGEAR FV-355
512020 182.20602210T0 1,000 gear coupling 354,000 KG

SBG 125 SPEZ.
512030 182.20619710T0 1,000 coupling 120,000 KG

537/100x466
602010 H82.101351 1,000 indicator plate - 1,300 KG

369,5X10
Revision: 000-v6r4
Created: 2007-6-1
602020 H82.015075 1,000 seal - 0,038 KG

369/315X1
602030 H01.000076 8,000 hexagon bolt 0,020 KG

M10X25
DIN 933
602040 H01.072415 8,000 washer --- 0,002 KG

10,5
DIN 125-2
SSNr.: 1822056851000
VGNr.: 000
10-42

Dimension

M10X16
DIN 7984
602060 H82.010359 1,000 protective plate 0,900 KG

370X3
612020 H82.012791 3,000 nameplate - 0,030 KG

1X130X202
612030 H01.052599 1,000 nameplate - 0,003 KG

A02-60
VN 597
612040 H01.032002 2,000 round head notched 0,001 KG

pin
3X6
ISO 8746
612050 H82.012218 1,000 warning plate 0,020 KG

1X74X140

pin
2X6
ISO 8746
612070 H82.013300 1,000 instruction plate - 0,004 KG

0,5X37X74

0,5X37X74
612090 H82.006927 1,000 nameplate - 1,300 G

0,5X18X52
612100 H82.006928 1,000 nameplate - 1,300 G

Revision: 000-v6r4
Created: 2007-6-1
0,5X18X52
612150 182.20051410 1,000 name & rating plate 0,060 KG

R1-105
VN 1802-12

pin
3X8
ISO 8746
SSNr.: 1822056851000
VGNr.: 000
10-43

Dimension
612170 H01.053788 1,000 nameplate - 0,100 KG

A31-110
VN 597

pin
2X6
ISO 8746
612190 H82.101526 1,000 nameplate - 0,100 KG

2X150X150
612200 H82.006928 2,000 nameplate - 1,300 G

0,5X18X52
612240 H82.006927 1,000 nameplate - 1,300 G

0,5X18X52
612250 H82.006928 1,000 nameplate - 1,300 G

0,5X18X52
612260 H82.006929 1,000 nameplate - 1,300 G

0,5X18X52
700010 H01.093203 6,000 nameplate 0,001 KG

165x25
VN 2000-1
700720 182.20585810G0 1,000 control system 150,000 KG

2-fach
720010 182.20585910G0 2,000 control panel - 7,000 KG

492 x 372 x 381
720020 182.20586010G0 2,000 control panel - 7,000 KG

492 x 372 x 381
720030 H82.017693 2,000 clamping strip KG

Revision: 000-v6r4
Created: 2007-6-1
720040 182.20586110G0 2,000 control cabinet - 30,000 KG

760x760x310
720050 182.2059231000 2,000 cam switch 0,050 KG

T0-3-15137-EZ
720060 182.2059241000 2,000 relay assembly 1,000 KG

4x 250V / 10A
SSNr.: 1822056851000
VGNr.: 000
10-44

Dimension
720070 182.2059251000 4,000 relay 0,200 KG

DILMC7-10
(24VDC)
720080 182.2059261000 4,000 relay 0,250 KG

DILMC32-01
(RDC24)
810010 H02.027767 1,000 tool case 30,000 KG

910X530X430
810020 H01.029322 1,000 toolbox 6,000 KG

530X200X200
810030 H01.031031 2,000 padlock 0,080 KG

35
810040 H02.030551 1,000 combination wrench 1,100 KG

Satz 10-24 8-tlg.
810050 H02.011948 1,000 dble-ended spanner 0,100 KG

7X8
DIN 3110

10x11
DIN 3110

27x30
DIN 3110

32x36
DIN 3110

Revision: 000-v6r4
Created: 2007-6-1
41X46
DIN 3110
810100 H01.042865 1,000 key - 1,200 KG

46x50
DIN 3110
810110 H01.013592 1,000 sgle-ended spanner 1,180 KG

55
DIN 894
SSNr.: 1822056851000
VGNr.: 000
10-45

Dimension

60
DIN 894

65X70
DIN 895
810140 H01.027799 1,000 set of sock.spanner 11,000 KG

3/4ZOLL 32EMZ
810150 H02.030378 1,000 screwdriver bit KG

IN 19 PM
810160 H01.024920 1,000 adaptor - 0,125 KG

A12,5X20
DIN 3123
810170 H01.038966 1,000 adaptor - 0,540 KG

A25X20
DIN 3123
810180 H01.024797 1,000 soc.f.socket wrench 0,100 KG

10X12,5
DIN 3124

11X12,5
DIN 3124

13X12,5
DIN 3124
810210 H02.009498 1,000 soc.f.socket wrench KG

16X12,5
DIN 3124
Revision: 000-v6r4
Created: 2007-6-1

17X12,5
DIN 3124
810230 H02.009497 1,000 soc.f.socket wrench KG

18X12,5
DIN 3124

19X12,5
SSNr.: 1822056851000
DIN 3124
VGNr.: 000
10-46

Dimension

65X25
DIN 3124
810260 H90.060192 1,000 ratchet 0,100 KG

D6,3
DIN 3122
810270 H02.030946 1,000 insert KG

6X6,3
DIN 3129
810280 H01.063654 1,000 slugg. ring spanner 1,000 KG

46
DIN 7444
810290 H02.027578 1,000 slugg. ring spanner 2,150 KG

65
DIN 7444
810300 H01.021502 1,000 single ring spanner 0,100 KG

24
DIN 3111

36
DIN 3111

46
DIN 3111

65
DIN 3111
810330 H02.028548 1,000 ring spanner 1,100 KG

Revision: 000-v6r4
Created: 2007-6-1
2A-36
810340 H02.028545 1,000 slip-on tube KG

2AR-1
810350 H02.027777 1,000 ring spanner 1,100 KG

2A-46
810360 H02.028546 1,000 slip-on tube KG

2AR-2
810370 H02.027776 1,000 ring spanner 2,400 KG

SSNr.: 1822056851000
2A-65
VGNr.: 000
10-47

Dimension
810380 H02.028547 1,000 slip-on tube KG

2AR-3
810390 H01.013698 1,000 hook wrench 1,600 KG

180-195
DIN 1810
810400 H01.002103 1,000 pliers 0,360 KG

40
DIN 5254
810410 H01.025265 1,000 combination pliers 0,260 KG

200
DIN 5244
810420 H02.004309 1,000 side cutter 0,100 KG

B160H
DIN 5238

A150
DIN 3117

A250
DIN 3117
810450 H02.004320 1,000 screwdriver 0,100 KG

C-A0,5X3
DIN 5265
810460 H02.004324 1,000 screwdriver 0,100 KG

C-A0,8X4
DIN 5265
810470 H01.019314 1,000 screwdriver 0,100 KG

C-A1X5,5
Revision: 000-v6r4
Created: 2007-6-1
DIN 5265
810480 H02.028396 1,000 screwdriver 0,500 KG

D-A1,6X10
DIN 5265
810490 H02.028397 1,000 screwdriver 0,273 KG

D-A2X12
DIN 5265
810500 H02.004311 1,000 screwdriver 0,200 KG

SSNr.: 1822056851000
B-PH1
DIN 5262
VGNr.: 000
10-48

Dimension
810510 H02.004312 1,000 screwdriver 0,200 KG

B-PH2
DIN 5262
810520 H02.011244 1,000 hex.sock.screw key 0,240 KG

SATZ 2-10
ISO 2936

14
ISO 2936

17
ISO 2936
810550 H02.006937 2,000 pin punche KG

C6
DIN 6450
810560 H02.004779 1,000 hammer 0,800 KG

800S-B
DIN 1041
810570 H02.004851 1,000 rubber mallet 1,500 KG

A600S
DIN 5128-90
810580 H02.028367 1,000 feeler gauges set 0,250 KG

0,05-1,0X300
810590 H82.005702 3,000 eye bolt 0,053 KG

M6X160
810600 H82.005703 3,000 eye bolt 0,079 KG

M8X100
Revision: 000-v6r4
Created: 2007-6-1
810610 H82.013918 3,000 eye bolt 0,238 KG

M8X500
810620 H82.005705 3,000 eye bolt 0,196 KG

M10X200
810630 H82.005707 3,000 eye bolt 0,299 KG

M12X200
810640 H82.005709 3,000 eye bolt 0,648 KG

M16X250
SSNr.: 1822056851000
810650 H82.005712 3,000 eye bolt 1,070 KG

M20X250
VGNr.: 000
10-49

Dimension
810660 H01.068584 3,000 hexagon bolt 0,020 KG

M8X35-RI-ZA
ISO 4017
810670 H01.068399 4,000 hexagon bolt 0,031 KG

M10X50-RI-ZA
DIN 933
810680 H01.068715 4,000 hexagon bolt 0,150 KG

M16X90-RI-ZA
ISO 4017
810690 H01.068591 3,000 hexagon bolt 0,240 KG

M20X90-RI-ZA
ISO 4017
810700 182.2059401000 3,000 lifting eye bolt 0,100 KG

M8

M10

M12

M16

M20

M24

M30
810770 H82.018039 1,000 eye 2,000 KG

Revision: 000-v6r4
Created: 2007-6-1
G1,5X125
810780 H82.101407 1,000 mounting-plate 19,200 KG

460/M24X16
810790 H01.022596 5,000 hexagon bolt 0,140 KG

M20X40
ISO 4017
810800 H82.006957 1,000 discharge pipe -- 0,600 KG

G1 1/4X200
SSNr.: 1822056851000
VGNr.: 000
10-50

Dimension
810830 H82.101408 1,000 guide pin 0,500 KG

29,5X100
810840 H82.101352 1,000 device 14,000 KG

245/106,1X72
810850 H01.000038 8,000 hexagon bolt 0,013 KG

M8X22
ISO 4017
810860 H01.065519 1,000 pressure gauge -- 1,000 KG

33B100G1/2B-..
EN 837-1
810870 H01.067067 1,000 measuring hose 0,300 KG

G 1/2-1500 DN2
VN 1539

210X297X0,5

210X297X0,5
810900 H01.014048 1,000 oil pump 2,200 KG

226400
VN 1067-2
810910 H01.062754 1,000 pump holder 3,000 KG

226402
VN 1067-2
810920 H01.062753 1,000 pressure gauge --- 0,300 KG

1077587
VN 1067-2
810930 H01.014050 1,000 high-pressure pipe 0,750 KG

Revision: 000-v6r4
Created: 2007-6-1
227957A
VN 1067-2
810940 H01.039959 1,000 connection nipple KG

1012783 R1/4 R3/8
VN 1067-2
810950 H01.006522 36,000 hexagon bolt 0,015 KG

M8X30
ISO 4017
810960 182.2073141000 1,000 extractor - 3,000 KG

SSNr.: 1822056851000
300/183x12
VGNr.: 000
10-51

Dimension
810970 182.2073151000 1,000 flat piece 0,670 KG

240x30x12
810990 H01.000021 2,000 hexagon bolt 0,009 KG

M6X40
ISO 4017
815010 H82.008374 1,000 elevated oil tank 31,000 KG

626x369x316
815020 H82.101244 1,000 cover -- 4,600 KG

28X300X550
815030 H82.013752 1,000 gasket - 0,082 KG

2X300X550
815040 H01.000030 16,000 hexagon bolt 0,010 KG

M8X12
ISO 4017
815050 182.20289510 1,000 oil level indicator 0,300 KG

G0,5
815060 H82.008445 1,000 pipe section - 0,200 KG

(KN069)
13X1,5X225
815070 H01.026859 2,000 laminar ring 0,001 KG

1 C 27X21,5X1,2
VN 1538
815080 H01.085639 1,000 screw plug - 0,076 KG

G 3/4A
VN 1638

L 22XG3/4A,TYPE B
Revision: 000-v6r4
Created: 2007-6-1
ISO 8434-1
815100 H01.014399 1,000 flange - 2,530 KG

DN 50/PN 16/60,3
EN 1092-1
815110 H01.068897 1,000 gasket - 0,030 KG

DN 50 PN40X2
EN 1514-1
815120 H01.000156 4,000 hexagon bolt 0,083 KG

M16X35
SSNr.: 1822056851000
ISO 4017
VGNr.: 000
10-52

Dimension
815130 H01.151647 1,000 flange - 1,000 KG

DN 32/PN 40/42,4
EN 1092-1
815140 H01.068896 1,000 gasket - 0,020 KG

DN 32 PN40X2
EN 1514-1
815150 H01.000156 4,000 hexagon bolt 0,083 KG

M16X35
ISO 4017

18 L
VN 1143-4
820010 182.20135910G0 1,000 float switch 0,500 KG

L=305; L1=260
820020 H01.008085 1,000 seal ring 0,050 KG

48X55
DIN 7603
825010 H01.018611 3,000 taper pin 0,151 KG

16X85
ISO 8737
825020 H01.070157 4,000 liquid plastic 0,300 KG

300 G
VN 1272-2
850010 H82.015247 5,000 nameplate - 0,001 KG

0,3X74X148
900020 182.20316610 1,000 instruction plate - 0,043 KG

52x18x2
Revision: 000-v6r4
Created: 2007-6-1

pin
2X6
ISO 8746
Tab. 10-1 Part-No. list

SSNr.: 1822056851000
VGNr.: 000
10-53
10-54
Standard lists

A F
Aeration filter 42 Faults 17
checking 45 Filter contamination 49
Alarms 9 Float switch, see Elevated oil tank
Anodes, see Reactive anodes
G
B Grease 51
Backlash
measuring 38
Bearing carrier, see Control rod support
H
Blade actuating gear 12
Housing cover 39
Blade actuating mechanism 7
Housing, see Propeller housing
Blades and blade bearings 10
Checking blade condition 26
Checking blade end play 27
Checking for leaks 25 I
Indicator plate 18
Input gear 35
Input shaft bearing, see Propeller housing
C
Coating 55
checking 88
renewing 88 L
Control block 45 Leakage
Control line 27 Rotor casing 29
Control oil pressure Leakage drain 30
checking 67 Lube oil pressure
setting 69 checking 67
Control rod 13 setting 69
Control rod support 38 Lube oils 50
Control system 52 Lubricant and oil supply 50
Cooler, see Oil cooler Grease 51
Corrosion Limitation of warranty 50
Leaks 29 Lube oils 50
Corrosion inhibitor 84 Lubricants 50
Corrosion protection 23 Maintenance contract 50
renewing 84 Lubricants 50
Couplings
checking 81
M
Created: 2007-6-1
Magnet filter 41
D Checking magnet filter rods 44
Revision:
Decommissioning 16 Main bearing 24

Divergence 5 Main gear
Drive unit Measuring backlash 38
Couplings 81 Main seal 25
Shaft line 81 Checking for leaks 30
Duplex filter 49 Checking sight feed oilers 76
Setting sight feed oiler 76
Measuring and monitoring equipment 49
Author:
Editor:
checking 80
E
Filter contamination 49
Eccentricity 5
Oil level 49
Elevated oil seal 32
Oil pressure 49
Elevated oil tank 48
Speed 50
VGNr.:
SSNr.:
11-1
Temperature 49 Running 6
Mounting cover 40 Having vessel towed 8
checking 42 in emergency situations 8
Starting from rest 6
Stopping 15
O
Oil consumers 46
Oil cooler S
checking 79 Servomotors 15
cleaning 79 Shaft line 51
Oil drain device 22 checking 81
Oil drain valve 22 Shaft seal
Oil level center 28
checking 58 lower 25
Oil level indicator, see Elevated oil tank upper 31
Oil pressure Sight feed oiler
checking 67 Control line 27
setting 69 for center shaft seal 29
Oil quality 52 for lower shaft seal 26
checking 52 for upper shaft seal 29
Oil supply 44 Ventilation line 27
Oil temperature 56 Spare parts 55
Checking thermostat 57 Renewing corrosion protection 84
Oil viscosity 51 Speed setting 5
Stator 36
Stopping 15
in emergency situations 15
P
normal 15
Permanent magnet filter rods 44
Support ring, see Propeller housing
Pitch 5
Pitch indicator 14
Pressure supply 44
Propeller 2 T
Propeller housing Test torque 5
checking 41 Thermostat
checking 57
Tools 55
checking 83
R
Torsional clearance 5
Reactive anodes 23
Type plate 41
checking 28
renew 28
Rotor 20
Created: 2007-6-1
Rotor casing 21 U
checking 28 Unit
Revision:
Checking reactive anodes 28 starting 2

Corrosion 29
Leakage 29
Renew reactive anodes 28
V
Rotor oil
Ventilation line 27
checking 67
Ventilation, see Elevated oil tank
setting 69
Viscosity grades 50
Author:
Editor:
Rotor space ventilation 43

checking 46
VGNr.:
SSNr.:
11-2

Voith Manualspare Part List

Uploaded by

Document Information

Copyright

Available Formats

Share this document

Share or Embed Document

Sharing Options

Did you find this document useful?

Is this content inappropriate?

Copyright:

Available Formats

Voith Manualspare Part List

Uploaded by

Copyright:

Available Formats

Voith Turbo

Voith Schneider® Propeller

Keep for future use!

SSNr.: 1822056851000 Author: VTMH amsk TLd Created: 2007-6-1

Tel. +49 (0) 7321 37-6595

Chapter C Preliminary remarks 1–1

3.1 Storage system and structure 1–1

3.2 Safety instructions 1–3

3.3 Symbols and accentuation elements 1–5

Chapter C Safety 2–1

3.1 Fundamental safety instructions 2–1

3.2 Safety instructions on specified operating stages 2–3

3.3 Notes on specific types of hazard 2–4

3.4 Safety instructions on the propeller 2–5

3.4.2 Response in the case of fire 2–5

3.4.8 Personal protective equipment 2–8

3.4.12 Work on the running unit 2–10

Chapter C Technical specifications 3–1

3.1 Vessel data 3–1

3.2 Voith Schneider propeller 3–2

3.3 Propeller 3–3

3.3.5.4 Pipes 3–19

3.3.5.5 Oil cooler 3–19

3.4 Drive unit 3–23

3.4.1.2 Intermediate gear 3–24

3.5 Control system 3–25

3.5.1 Control stand unit 3–26

3.6 Accessories 3–27

Chapter C Description 4–1

3.1 Design assemblies of the unit 4–1

3.2 Propeller 4–2

3.2.5 Oil supply 4–44

3.2.5.1 Pressure generation 4–44

3.3 Drive unit 4–51

3.4 Control system 4–52

3.5 Accessories 4–55

3.5.1 Tools 4–55

Chapter C Installation 5–1

3.1 General safety instructions concerning installation 5–1

Chapter C Operation 6–1

3.1 Start-up 6–1

3.1.6.7 Traversing to starboard 6–14

3.1.7 Stopping 6–15

3.2 Decommissioning of the propeller 6–16

3.2.2 Measures after propeller shutdown 6–16

3.3 Faults 6–17

Chapter C Maintenance 7–1

3.1 General safety instructions concerning maintenance 7–1

3.2 Maintenance and inspection 7–2

3.3 Blade actuating mechanism 7–22

3.4 Blades and blade bearings 7–25

3.4.2 Checking blade condition 7–26

3.5 Rotor casing 7–28

3.5.1 Checking rotor casing 7–28

3.6 Main bearing with main seal 7–30

3.7 Main gear 7–34

3.8 Input shaft bearing 7–40

3.9 Propeller housing 7–41

3.11 Lubricant and oil supply 7–50

3.11.3.1 Lube oils 7–50

3.11.3.2 Grease 7–51

3.11.5.4 Properties 7–54

3.11.6 Oil temperature 7–56

3.12 Drive unit 7–81