3653_245_A.PDF

TP: 3653

HULL, MECHANICAL &

ELECTRICAL

Department of Homeland Security

UNITED STATES

COAST GUARD

DISTRIBUTION STATEMENT D - Distribution authorized to DHS, USCG, DoD and their contractors to protect publications required for official use or for administrative or operational purposes only; determined on 24 JUL 2013.

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WARNING - This document contains technical data whose export is restricted by the Arms Export Control Act (Title 22, U.S.C., Sec 2751, et seq.) or the Export Administration Act of 1979, as amended, Title 50, U.S.C., App. 2401 et seq. Violations of these export laws are subject to severe criminal penalties. Disseminate in accordance with provisions of DoD Directive 5230.25.

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PUBLISHED UNDER AUTHORITY OF THE U.S. COAST GUARD

SWBS: 245

SECTION: A

TECHNICAL PUBLICATION

Z-DRIVE - MODEL 1350-

H - SERVICE MANUAL

ROLLS ROYCE

Individual Manual Application Sheet

Technical Publications Number

SWBS Number 245

SWBS Element Title PROPULSORS (MEANS PROPELLERS)

Section Identifier A

Equipment Functional Description Z-DRIVE - MODEL 1350-H - SERVICE MANUAL

Remarks

Section Applicability

Asset Subclass Hulls Notes

175-WLM 551, 552, 553, 554, 555, 556, 557, 558, 559, 560, 561, 562, 563, 564 175-WLM

LIST OF DRAWING & PARTS LISTS

PROJECT 2223-001 2223-002 P1808-001 P1946-002 P1872-001 P1872-002

DESCRIPTION DRAWING DRAWING DRAWING DRAWING DRAWING DRAWING

General Arrangement B8202396-001 B8202396-002 B8202396-001 B8202396-002 B8202396-001 B8202396-002 Driveshaft Arrangement B8108030 B8108030 B8108030 B8108030 B8108030 B8108030 Driveshaft Assembly (Fwd) B8108029 B8108029 B8108029 B8108029 B8108029 B8108029 Driveshaft Assembly (Aft) B8107120 B8107120 B8107120 B8107120 B8107120 B8107120 Thruster Cross Section B8202425 B8202425 B8202425 B8202425 B8202425 B8202425 Upper Unit Assembly D8202430-1 STBD D8202393 D8202393 D8202393 D8202393

D8202430-2 PORT

Clutch D8202364 D8202364 D8202364 D8202364 D8202364 D8202364 Clutch Adaptor Assembly D8202381 D8202381 D8202381 D8202381 D8202381 D8202381 (Clutch) Operational Data CLS4 CLS4 CLS4 CLS4 CLS4 CLS4 Steering Section Assembly B8202388 B8202388 B8202388 B8202388 B8202388 B8202388 Intermediate Section Assembly B8202365 B8202365 B8202365 B8202365 B8202365 B8202365 Steering Feedback Box Assembly B8104751 B8104751 B8104751 B8104751 B8104751 B8104751 Steering Feedback Electronic Assembly, TANO B8107187 B8107187 B8107187 B8107187 B8107187 B8107187 Feedback Box Assembly B8102328 B8102328 B8102328 B8102328 B8102328 B8102328 Steering Feedback Electronic Assembly, Z-con B8105064 B8105064 B8105064 B8105064 B8105064 B8105064 Module Assembly Modified B8202373-1 STBD B8202373-1 STBD B8202373-1 STBD

B8202373-2 PORT B8202373-2 PORT B8202373-2 PORT

Lower Unit Assembly D8202431-1 STBD D8202369 D8202369 D8202369 D8202369

D8202431-2 PORT

Propeller Shaft Seal Assembly D8202363 D8202363 D8202363 D8202363 D8202363 D8202363 Prop & Nozzle Assembly STBD B8202432/PRS21 B8202432/PRS21 B8202432/PRS21 Prop & Nozzle Assembly PORT B8202432/PRS24 B8202432/PRS24 B8202432/PRS24 Anode Assembly See Nozzle Spec NS3 See Nozzle Spec NS3 See Nozzle Spec NS3 See Nozzle Spec NS3 See Nozzle Spec NS3 See Nozzle Spec NS3 Upper Unit Hydraulics Assembly STBD B8107214-1 B8107214-1 B8107214-1 Upper Unit Hydraulics Assembly PORT B8107214-2 B8107214-2 B8107214-2 Lube Distribution Assembly STBD B8107177-1 B8107177-1 B8107177-1 Lube Distribution Assembly PORT B8107177-2 B8107177-2 B8107177-2 Pneumatic Control Assembly STBD B8202387-1 B8202387-1 B8202387-1 Pneumatic Control Assembly PORT B8202387-2 B8202387-2 B8202387-2 Steering Pump Assembly S-PUMP-1000 S-PUMP-1000 S-PUMP-1000 S-PUMP-1000 S-PUMP-1000 S-PUMP-1000

Stby Steering Pump Assembly STBD B8107012-1 B8107012-1 B8107012-1 Stby Steering Pump Assembly PORT B8107012-2 B8107012-2 B8107012-2 Hydraulic Tank Assembly STBD B8107010-1 B8107010-1 B8107010-1 Hydraulic Tank Assembly PORT B8107010-2 B8107010-2 B8107010-2 Hydraulic Control Assembly B8107003 B8107003 B8107003 B8107003 B8107003 B8107003 Steering Plumbing Diagram B8107239 B8107239 B8107239 B8107239 B8107239 B8107239 Hydraulic Schematic (Steering) B8106995 B8106995 B8106995 B8106995 B8106995 B8106995 Lube Plumbing Diagram B8107240 B8107240 B8107240 B8107240 B8107240 B8107240 Hydraulic Schematic (Lube) B8106996 B8106996 B8106996 B8106996 B8106996 B8106996 Lub Pump Assembly B8107558 B8107558 B8107558 B8107558 B8107558 B8107558 Steering Hand Pump Assembly B8106994 B8106994 B8106994 B8106994 B8106994 B8106994

LIST OF DRAWING & PARTS LISTS

PROJECT 2223-001 2223-002 P1808-001 P1946-002 P1872-001 P1872-002

DESCRIPTION DRAWING DRAWING DRAWING DRAWING DRAWING DRAWING

Steering Cooler Assembly S-COOLER-1000 S-COOLER-1000 S-COOLER-1000 S-COOLER-1000 S-COOLER-1000 S-COOLER-1000 Pneumatic Schematic B8202427 B8202427 B8202427 B8202427 B8202427 B8202427 Seal Oil Tank Assembly B8106114 B8106114 B8106114 B8106114 B8106114 B8106114 Seal Oil Plumbing Diagram B8202424 B8202424 B8202424 B8202424 B8202424 B8202424 Junction Box Assembly B8107573 B8107573 B8107573 B8107573 B8107573 B8107573

B8109564 B8109564 B8109564 B8109564 B8109564 B8109564 Junction Box Wiring Diagram B8107572 B8107572 B8107572 B8107572 B8107572 B8107572

B8109565 B8109565 B8109565 B8109565 B8109565 B8109565 Slinging Diagram B8107249 B8107249 B8107249 B8107249 B8107249 B8107249 Hose Serial Numbers STBD B8202676 B8202685 B8202616 Hose Serial Numbers PORT B8202677 B8202686 B8202617

LIST OF DRAWING & PARTS L

PROJECT

DESCRIPTION

General Arrangement Driveshaft Arrangement Driveshaft Assembly (Fwd) Driveshaft Assembly (Aft) Thruster Cross Section Upper Unit Assembly

Clutch Clutch Adaptor Assembly (Clutch) Operational Data Steering Section Assembly Intermediate Section Assembly Steering Feedback Box Assembly Steering Feedback Electronic Assembly, TANO Feedback Box Assembly Steering Feedback Electronic Assembly, Z-con Module Assembly Modified

Lower Unit Assembly

Propeller Shaft Seal Assembly Prop & Nozzle Assembly STBD Prop & Nozzle Assembly PORT Anode Assembly Upper Unit Hydraulics Assembly STBD Upper Unit Hydraulics Assembly PORT Lube Distribution Assembly STBD Lube Distribution Assembly PORT Pneumatic Control Assembly STBD Pneumatic Control Assembly PORT Steering Pump Assembly

Stby Steering Pump Assembly STBD Stby Steering Pump Assembly PORT Hydraulic Tank Assembly STBD Hydraulic Tank Assembly PORT Hydraulic Control Assembly Steering Plumbing Diagram Hydraulic Schematic (Steering) Lube Plumbing Diagram Hydraulic Schematic (Lube) Lub Pump Assembly Steering Hand Pump Assembly

P1809-001 P1808-002 P1879-001 P1809-002 P1862-001 P1862-002

DRAWING DRAWING DRAWING DRAWING DRAWING DRAWING

B8202396-001 B8202396-002 B8202396-001 B8202396-002 B8202394-001 B8202394-002 B8108030 B8108030 B8108030 B8108030 B8108030 B8108030 B8108029 B8108029 B8108029 B8108029 B8108029 B8108029 B8107120 B8107120 B8107120 B8107120 B8107120 B8107120 B8202425 B8202425 B8202425 B8202425 B8202425 B8202425 D8202393 D8202393 D8202393 D8202393 D8202393 D8202393

D8202364 D8202364 D8202364 D8202364 D8202364 D8202364 D8202381 D8202381 D8202381 D8202381 D8202381 D8202381

CLS4 CLS4 CLS4 CLS4 CLS4 CLS4

B8202388 B8202388 B8202388 B8202388 B8202388 B8202388 B8202365 B8202365 B8202365 B8202365 B8202365 B8202365 B8104751 B8104751 B8104751 B8104751 B8104751 B8104751 B8107187 B8107187 B8107187 B8107187 B8107187 B8107187 B8102328 B8102328 B8102328 B8102328 B8102328 B8102328 B8105064 B8105064 B8105064 B8105064 B8105064 B8105064

B8202373-1 STBD B8202373-1 STBD B8202373-1 STBD

B8202373-2 PORT B8202373-2 PORT B8202373-2 PORT

D8202369 D8202369 D8202369 D8202369 D8202369 D8202369

D8202363 D8202363 D8202363 D8202363 D8202363 D8202363

B8202432/PRS21 B8202432/PRS21 B8202395/PRS21

B8202432/PRS24 B8202432/PRS24 B8202395/PRS24

See Nozzle Spec NS3 See Nozzle Spec NS3 See Nozzle Spec NS3 See Nozzle Spec NS3 See Nozzle Spec NS1 See Nozzle Spec NS1 B8107214-1 B8107214-1 B8107214-1

B8107214-2 B8107214-2 B8107214-2 B8107177-1 B8107177-1 B8107177-1

B8107177-2 B8107177-2 B8107177-2 B8202387-1 B8202387-1 B8202387-1

B8202387-2 B8202387-2 B8202387-2

S-PUMP-1000 S-PUMP-1000 S-PUMP-1000 S-PUMP-1000 S-PUMP-1000 S-PUMP-1000

B8107012-1 B8107012-1 B8107012-1 B8107012-2 B8107012-2 B8107012-2

B8107010-1 B8107010-1 B8107010-1 B8107010-2 B8107010-2 B8107010-2

B8107003 B8107003 B8107003 B8107003 B8107003 B8107003 B8107239 B8107239 B8107239 B8107239 B8107239 B8107239 B8106995 B8106995 B8106995 B8106995 B8106995 B8106995 B8107240 B8107240 B8107240 B8107240 B8107240 B8107240 B8106996 B8106996 B8106996 B8106996 B8106996 B8106996 B8107558 B8107558 B8107558 B8107558 B8107558 B8107558 B8106994 B8106994 B8106994 B8106994 B8106994 B8106994

DESCRIPTION

Steering Cooler Assembly Pneumatic Schematic Seal Oil Tank Assembly Seal Oil Plumbing Diagram Junction Box Assembly

Junction Box Wiring Diagram

Slinging Diagram Hose Serial Numbers STBD Hose Serial Numbers PORT

P1809-001 P1808-002 P1879-001 P1809-002 P1862-001 P1862-002

DRAWING DRAWING DRAWING DRAWING DRAWING DRAWING

S-COOLER-1000 S-COOLER-1000 S-COOLER-1000 S-COOLER-1000 S-COOLER-1000 S-COOLER-1000 B8202427 B8202427 B8202427 B8202427 B8202427 B8202427 B8106114 B8106114 B8106114 B8106114 B8106114 B8106114 B8202424 B8202424 B8202424 B8202424 B8202424 B8202424 B8107573 B8107573 B8107573 B8107573 B8107573 B8107573 B8109564 B8109564 B8109564 B8109564 B8109564 B8109564 B8107572 B8107572 B8107572 B8107572 B8107572 B8107572 B8109565 B8109565 B8109565 B8109565 B8109565 B8109565 B8107249 B8107249 B8107249 B8107249 B8107249 B8107249 B8202487 B8202489 B8202418

B8202488 B8202490 B8202419

DESCRIPTION

General Arrangement Driveshaft Arrangement Driveshaft Assembly (Fwd) Driveshaft Assembly (Aft) Thruster Cross Section Upper Unit Assembly

Clutch Clutch Adaptor Assembly (Clutch) Operational Data Steering Section Assembly Intermediate Section Assembly Steering Feedback Box Assembly Steering Feedback Electronic Assembly, TANO Feedback Box Assembly Steering Feedback Electronic Assembly, Z-con Module Assembly Modified

Lower Unit Assembly

Propeller Shaft Seal Assembly Prop & Nozzle Assembly STBD Prop & Nozzle Assembly PORT Anode Assembly Upper Unit Hydraulics Assembly STBD Upper Unit Hydraulics Assembly PORT Lube Distribution Assembly STBD Lube Distribution Assembly PORT Pneumatic Control Assembly STBD Pneumatic Control Assembly PORT Steering Pump Assembly

Stby Steering Pump Assembly STBD Stby Steering Pump Assembly PORT Hydraulic Tank Assembly STBD Hydraulic Tank Assembly PORT Hydraulic Control Assembly Steering Plumbing Diagram Hydraulic Schematic (Steering) Lube Plumbing Diagram Hydraulic Schematic (Lube) Lub Pump Assembly Steering Hand Pump Assembly

P1911-001 P1911-002 P1844-001 P1844-002 P1795-003 P1912-002

DRAWING DRAWING DRAWING DRAWING DRAWING DRAWING

B8202394-001 B8202394-002 B8202394-001 B8202394-002 B8202394-001 B8202394-002 B8108030 B8108030 B8108030 B8108030 B8108030 B8108030 B8108029 B8108029 B8108029 B8108029 B8108029 B8108029 B8107120 B8107120 B8107120 B8107120 B8107120 B8107120 B8202425 B8202425 B8202425 B8202425 B8202426 B8202426 D8202393 D8202393 D8202393 D8202393 D8202386 D8202386

D8202364 D8202364 D8202364 D8202364 CLS1 CLS1

D8202381 D8202381 D8202381 D8202381 B8104211 B8104211

CLS4 CLS4 CLS4 CLS4

B8202388 B8202388 B8202388 B8202388 B8202388 B8202388 B8202365 B8202365 B8202365 B8202365 B8202365 B8202365 B8104751 B8104751 B8104751 B8104751 B8104751 B8104751 B8107187 B8107187 B8107187 B8107187 B8107187 B8107187 B8102328 B8102328 B8102328 B8102328 B8102328 B8102328 B8105064 B8105064 B8105064 B8105064 B8105064 B8105064

B8202373-1 STBD B8202373-1 STBD B8202373-1 STBD

B8202373-2 PORT B8202373-2 PORT B8202373-2 PORT

D8202369 D8202369 D8202369 D8202369 D8202369 D8202369

D8202363 D8202363 D8202363 D8202363 D8202363 D8202363

B8202395/PRS21 B8202395/PRS21 B8202395/PRS21

B8202395/PRS24 B8202395/PRS24 B8202395/PRS24

See Nozzle Spec NS1 See Nozzle Spec NS1 See Nozzle Spec NS1 See Nozzle Spec NS1 See Nozzle Spec NS1 See Nozzle Spec NS1 B8107214-1 B8107214-1 B8107214-1

B8107214-2 B8107214-2 B8107214-2 B8107177-1 B8107177-1 B8107177-1

B8107177-2 B8107177-2 B8107177-2 B8202387-1 B8202387-1 B8202387-1

B8202387-2 B8202387-2 B8202387-2

S-PUMP-1000 S-PUMP-1000 S-PUMP-1000 S-PUMP-1000 S-PUMP-1000 S-PUMP-1000

B8107012-1 B8107012-1 B8107012-1 B8107012-2 B8107012-2 B8107012-2

B8107010-1 B8107010-1 B8107010-1 B8107010-2 B8107010-2 B8107010-2

B8107003 B8107003 B8107003 B8107003 B8107003 B8107003 B8107239 B8107239 B8107239 B8107239 B8107239 B8107239 B8106995 B8106995 B8106995 B8106995 B8106995 B8106995 B8107240 B8107240 B8107240 B8107240 B8107240 B8107240 B8106996 B8106996 B8106996 B8106996 B8106996 B8106996 B8107558 B8107558 B8107558 B8107558 B8107558 B8107558 B8106994 B8106994 B8106994 B8106994 B8106994 B8106994

DESCRIPTION

Steering Cooler Assembly Pneumatic Schematic Seal Oil Tank Assembly Seal Oil Plumbing Diagram Junction Box Assembly

Junction Box Wiring Diagram

Slinging Diagram Hose Serial Numbers STBD Hose Serial Numbers PORT

P1911-001 P1911-002 P1844-001 P1844-002 P1795-003 P1912-002

DRAWING DRAWING DRAWING DRAWING DRAWING DRAWING

S-COOLER-1000 S-COOLER-1000 S-COOLER-1000 S-COOLER-1000 S-COOLER-1000 S-COOLER-1000 B8202427 B8202427 B8202427 B8202427 B8202390 B8202390 B8106114 B8106114 B8106114 B8106114 B8106114 B8106114 B8202424 B8202424 B8202424 B8202424 B8202424 B8202424 B8107573 B8107573 B8107573 B8107573 B8107573 B8107573 B8109564 B8109564 B8109564 B8109564 B8109564 B8109564 B8107572 B8107572 B8107572 B8107572 B8107572 B8107572 B8109565 B8109565 B8109565 B8109565 B8109565 B8109565 B8107249 B8107249 B8107249 B8107249 B8107249 B8107249 B8202433 B8202451 B8202392

B8202434 B8202452 B8202391

INTRODUCTION

This manual contains Installation, Operation and Maintenance procedures for the thruster, as well as assembly drawings and spare parts list. It is very important that all personnel responsible for installing, operating or maintaining the thruster are familiar with the contents of this manual.

NOTE: This is intended to be a generic fleetwide manual. For actual drawings and parts lists please refer to specific Service Manual Supplement under unit serial numbers (RRCL Project Numbers) When ordering spare parts, the following information must be given:

1. Name of vessel, owner and address.

2. Type of thruster and RR project number.

3. The parts' description, item number and the assembly number according to this manual.

Note: The information contained in this manual is proprietary in nature and is supplied for maintenance purposes only.

The information is strictly confidential and should be treated accordingly. Any portion, in whole or in part, may not be reproduced in any manner without the express written permission of Rolls-Royce Canada Ltd.

WARNINGS

Transportation and handling - The propeller and the lower section of thruster are free to rotate.

Storage - For storage longer than 3 months, the thruster must be filled with the recommended oil and the filler breather plugged. Refer to Long Term Storage procedure in this manual

The Z-Drive Seal Oil System must be filled with the specified lubricant prior to the vessel being launched to prevent seal damage.

The Z-Drive Seal Oil System, once filled, must be bled at the propeller seals to assure no air is trapped in the system. This must be done prior to vessel launch to prevent seal damage.

The Z-Drive Lubrication System must be filled with the specified lubricant prior to vessel launch.

If the drive leg is to be realigned by manual procedure, the electric controls to the hydraulic system must be isolated to prevent hydraulic power being applied to the drive unit, otherwise injury to personnel could result.

Operation -

Ensure proper operation of lube oil system at all times including periods of trailing, otherwise upper gearbox bearings, and gears will be damaged. Standby lubrication pump must be operational when trailing to provide lubrication to the upper gearbox gears and bearings.

Electric control to the hydraulic system must be disconnected during manual operation of steering.

With the Z-Drive lock pin engaged, drive clutch must not be activated, or damage to both drive the train and clutch will result.

TO TABLE OF CONTENTS

WARNING!!

Removal of the lock pin while vessel is underway will result in injury to personnel and damage to equipment.

Repair - When breaking the propeller free from the propeller shaft taper it must be restrained by a chain wrapped around the leg.

SAFEGUARDS

The Z-Drive is equipped with an emergency steering system. A mechanical thrust angle indicator is located at the Z-Drive feedback to determine the position of propeller thrust.

A drive train lockpin is provided to prevent Z-Drive rotation should it be necessary to prevent the Z- Drive from rotating.

PROJECT DETAILS

Model : 1350

No. of Thrusters/Shipset : 2

Unit Serial No.'s : see specific supplement see specific supplement

Year of Manufacture : 201 /201

Classification : ABS, Ice Class BO, USCG

UML Project No. : et al

Type of Vessel : USCG Buoy Tender

Shipyard na.

Hull No. : see specific supplement

Vessel Name : na

Owner

United States Coast Guard

Thruster Manufactured By Address

Rolls-Royce Canada Ltd.

96 North Bend Street Coquitlam, B.C

V3K 6H1 CANADA

Telephone Telefax

(604) 942-1100

(604) 942-1125

Manual Revision:

Rev Date By Apr Pages Revised Description

0 10/10/2012 TH ML ALL New Document

Manual Distribution:

Distribution List No. of copies

Sent information Sent information

Rev Date Rev Date

USCG 0

Rolls-Royce Canada Ltd. (Vancouver) 0

Note: Any future updates of manuals will be provided by the RRC Vancouver office.

CONTENTS

1. SPECIFICATIONS

2. DESCRIPTION OF OPERATION

3. INSTALLATION

4. COMMISSIONING

5. MAINTENANCE

6. ASSEMBLY - DISASSEMBLY

7. DRAWINGS & PART LISTS

APPENDIX A

APPENDIX B

1.0 SPECIFICATIONS

1.1 THRUSTER

Model : 1350H Rating : 745 kW (999 HP) @ 1600 RPM Rotation (Viewed from Input Hub Face) : CW Normal Stbd Unit : CCW Reverse Port Unit Reduction Gearsets

Upper : 1.56:1 (36/23) Lower : 2.54:1 (33/13) Overall : 3.97:1 Steering : 4.42:1 (12/53)

Propeller Speed : 403RPM Diameter : 1450 mm (57.1") No. of Blades : 4 Nozzle Type : 19A Material : Stainless Steel liner Rotation (Viewed from Aft) : CW Normal Stbd Unit

: CCW Reverse Port Unit Clutch

Model :

Operation : Pneumatic Required Pressure : 6.2 bar (90 psi)

Steering Speed (Max.) : 3 RPM

1.2 DRIVESHAFTING

Intermediate Shafts No./Thruster : 2 Diameter : Diameter 4-7/16” Type : Pillow Block Bearings : Split Cylindrical Roller Bearings No./Thruster : 1 Fixed/4 Floating Universal Shafts No./Thruster : 1

RETURN

1.3 PRIMEMOVER

Model : Caterpillar 3508 Speed, Idle/Full : 650/1600 RPM PTO Ratio : 1.33:1

1.4 HYDRAULICS

Steering

Main Steering Pump Prime Mover : Engine PTO Type : Pressure compensated, load sensing piston pump Displacement : 0-8 cu.in./rev.

Rotation (Viewed from Shaft End) : CW

Standby Steering Pump

1.5 CONTROLS

Electronic Remote Control System Primary:

1.6 LUBRICANT CAPACITIES/TYPES

Thruster Lubricating Oil : 400 litres (106 U.S. Gal) approx.

Main Steering and Lube/Clutch Pump’s Seal Oil Tank : 50 litres (13 U.S. Gal) Steering Hydraulic Oil : 350 litres (92 U.S. Gal.)

Universal shaft, Clutch Adaptor Bearings Driveshaft Bearings : Shell Alvania EP2 grease or eq.

Electric Motor Bearings : Shell Dolium R grease or eq.

Note: See Appendix A.10 for approved lubricant types.

1.7 ALARMS

Alarm Setting

Low Cooling Water Flow 8gpm

Low Lube Oil Pressure 0.6 bar (8 psi)

High Lube Oil Temperature 60°C (140°F)

Low Clutch Air Pressure 5.5 bar (80 psi)

High Driveshaft Bearing Temperature

80°C (176°F)

Notes: --All of the above sensors are switches, (potential free contacts)

1.8 PRESSURE/TEMPERATURE SETTINGS (OTHER THAN ALARMS)

Description Setting

Steering Pump Pressure Compensator Setting 172 bar (2500 psi)

Steering Pump Standby Pressure Setting 21 bar (300 psi)

Steering Counterbalance Valves 28 bar (400 psi)

Steering Motor Crossover Relief Valve 103 bar (1500 psi)

Low Steering Oil Pressure Auto Start Standby 17 bar (250 psi)

Lube Oil Relief Valve 6.9 bar (100 psi)

Low Lube Oil Pressure Switch - Autostart Standby Pump 0.7 bar (10 psi)

Lube Oil Pressure Switch -Auto-Stop Standby Pump if equipped TBA

Clutch Indication Pressure Switch 5.5 bar (80 psi)

1.9 WEIGHTS (PER THRUSTER)

Description Weight

2.0 DESCRIPTION OF OPERATION

2.1 Z-DRIVE MODULE (REFERENCE DWG. B8202373)

2.2 Z-DRIVE, MODEL 1350-H

WARNING!

Drive lubrication oil must be drained before opening of these ports.

Always ensure the waste container is of sufficient size to hold waste fluid.

Avoid spilling of waste into the environment

CAUTION!!

Supply air must be dry and free from dirt and oil.

Air supply pressure must be maintained at 90 PSI ± 2 PSI.

2.3 DRIVESHAFTING

2.4 THRUSTER

2.5 STEERING AND LUBRICATION

2.6 LUBE/CLUTCH

The thruster is filled with lubricating oil up to the level of the steering gear; a dipstick is provided for checking the level. Oil from the thruster is withdrawn by a gear pump.

Oil is sent to the lube distribution assembly, which filters and distributes the oil to the upper gearset and bearings.

The distribution assembly consists of:

Filter Relief valve to bypass oil in case of a blockage Pressure gauge Two (2) pressure switches Check valve to provide constant upstream pressure for low lube oil pressure switch, and prevent false actuation of alarm at engine idle.

2.7 LONG TERM STORAGE PROCEDURE

3.0 INSTALLATION

CAUTION

Extreme care must be taken when lifting the equipment. The Z-Drive and module are supplied to the yard assembled. Lifting eyes are supplied on the module. When the complete assembly (Module and Z-Drive) are to be located in the vessel, use only the lifting eyes provided on the module.

It is important that each sling takes equal amount of load so that the complete assembly lifts vertically. See Sling Diagram, Drawing #B8107249.

3.1 ALIGNMENT

ALIGNMENT DATA & CENTERING TOOL DIMENSIONS

4.0 COMMISSIONING

Z Drive Propulsion Installation Check.

Note Port Done Stbd Done

Indicate height in metres (or feet)

Brand and grade

Total oil in unit

Note conditions of drive and drive installation observed

Z Drive Lubrication System Note Port Done Stbd Done

Findings and Observations

Z-Drive Hydraulic Steering System

Note Port Done Stbd Done

Quantity of oil used (Lt/Gal us) part number and micron rating part number and micron rating

Hydraulic Steering Pump and Lube Pump Start-up

Note Port Done Stbd Done

Fill hydraulic pump(s) case with system hydraulic oil brand and grade of oil

Quantity used (Lt/Gal us) brand and grade of oil

Quantity used (Lt/Gal us) psi (bar)

Check at each Z-Drive lubrication point for adequate lube oil flow

Check Hydraulic steering Note Port Done Stbd Done

(Yes)(No)

( CLUTCH DISENGAGED )

max psi (bar), rotation cw

( CLUTCH DISENGAGED )

max psi (bar), rotation ccw main pump stand-by pump cut-in pressure psi (bar) max psi (bar) cw max psi (bar) ccw

(Yes)(No)

Shut Off Hydraulics

Alarm System Note pressure setting psi level setting level setting

Dock Trials Note Port Done Stbd Done

Permission must be obtained from vessel trial superintendent and Engine representative prior to starting of engines and or equipment.

Rolls-Royce Canada commissioning engineers must not start equipment not supplied by Rolls-Royce Canada

Start Main Engines Note Port Done Stbd Done

Engine representative prior to starting of engines.

360 degree cw and ccw, sec

CW

CCW

CW

CCW

Idle RPM

Idle RPM of shaft

Dock Trials Cont’d Note Port Done Stbd Done

Engine representative prior to clutching in the drives at dock site.

Vessel Captain must be in the wheelhouse and wheelhouse must be in control.

Dock Trials is to be done one drive at a time Duration of dock trial one hour each drive Clutch In drive and record psi(bar) psi(bar)

Idle RPM

Idle RPM of shaft

Clutch STBD drive out and repeat with PORT drive

Sea Trials Note Port Done Stbd Done

Note:

Rolls-Royce Canada commissioning personnel are not at any time permitted to take control of a vessel.

psi(bar) psi(bar)

Cast Off

Run Up Procedure one half hour at engine idle Increase engine RPM by 200 RPM every half hour until maximum engine RPM is reached.

Steering Test Procedure

Port Stbd time to complete, sec

Port Stbd

Port and Stbd

Jog Control

Crash Stop Test Procedure

Note Drive legs must be rotated outward so that the propeller thrust is vectored outward away from each other.

time, sec time, sec

WITNESSES Rolls-Royce Canada

Date:

USCG

Date:

Hydraulic Tank Hydraulic Oil Cooler Hydraulic Oil Cooler

Engine Speed Tank Tank Oil Temp

Oil Temp

Wtr Temp

Wtr Temp

Oil Temp

Oil Temp

Wtr Temp

Wtr Temp

Temp °C

Level IN OUT IN OUT IN OUT IN OUT

F Correct G H I J K L M N

Pass Criteria

800 RPM 1.

800 RPM 2.

1120 RPM 3.

1120 RPM 4.

1360 RPM 5.

1360 RPM 6.

7.

8.

FULL 9.

LOAD 10.

TEST @ 11.

1600 RPM12.

13.

14.

15.

16.

17.

18.

19.

20.

WITNESSES: Rolls-Royce Canada USCG

Date: Date:

SEA TRIAL DATA SHEET (CONT’D)

Seal Oil

Act Drive

Engine Speed Header Lub Hyd Time Rec. RPM Tk

Level Conn Not

Conn Not

Fast. Rec Taken Recording

Correct Leaking Leaking Tight Taken By Taken Aft Comment

Pass Criteria

800 RPM 1.

800 RPM 2.

1120 RPM 3.

1120 RPM 4.

1360 RPM 5.

1360 RPM 6.

7.

8.

FULL 9.

LOAD 10.

TEST @ 11.

1600 RPM12.

13.

14.

15.

16.

17.

18.

19.

20.

WITNESSES: Rolls-Royce Canada USCG

Date: Date:

5.0 MAINTENANCE

5.1 MAINTENANCE SCHEDULE

No Item Reference Hours

Description Appendix

DAILY 200 500 1000 2000 8000

1 Check Lube, Hydraulic, and Seal Oil Levels X

Check Unit Lube Oil, Clutch Lube Oil and Clutch Engagement Pressures.

X

3 Check for Water in Seal Oil. X

Grease Cardan Shafts, Driveshaft Bearings and Bulkhead gland seals

B.2 B.3 X3

5 Change Filter Elements B.10, B.11, B.12 X1 X2

6 Check All Hoses X

7 Check Bolt Torque Where Accessible A.1 X

Change Lube Oil and Hydraulic Oils.

Check Main Pumps Drive Spline Cavities Oil Level

X2

9 Clean Lube Sprays & Orifices X

10 Change Grease in Driveshaft Pillow Block Bearings B.3 X

11 Grease Electric Motor Bearings B.7 X

Check Accumulator pre-charge and Recharge as required

B.17 X

1 First time only.

2 Or by analysis.

3 One shot of grease gun

5.2 TROUBLESHOOTING

Thruster Lubrication System

PROBLEM POSSIBLE CAUSES REMEDIES

Oil pressure less than 5 psi

Low lube oil level in thruster. Check dipstick & top up.

Leaking lines/fittings. Replace/tighten.

Lines blocked. Clean/replace.

Lube filter element blocked. Clean/replace.

Relief valve open. Adjust to open at 100 psi.

Pump malfunction. Refer to Pump Manual in Appendix B

Oil pressure more than

100 psi.

Incorrect lubricant. Replace with recommended lubricant.

Lines/lube sprays blocked. Clean or replace.

High power consumption by thruster; oil coming out of filler breather.

Oil accumulation in upper unit.

Ensure correct oil type and oil level. Ensure correct pump flow.

Seal Oil System

PROBLEM POSSIBLE CAUSES REMEDIES

Excessive oil loss from seal oil tank > 0.25 litres/day.

Leaking lines/fittings. Replace/tighten.

Worn/damaged propeller shaft seal and/or seal sleeve. Replace.

Worn/damaged steering seals and/or seal ring. Replace.

Presence of sea water in seal oil.

Damaged/eccentric propeller shaft seal and/or seal sleeve. Replace.

Steering Hydraulic System

Slow or lack of steering.

Electronic control malfunction.1 Refer to the Electronic Control Manual.

Low hydraulic oil level. Check tank sight gauges and top up.

Leaking lines/fittings. Replace/tighten.

Lines blocked. Clean/replace.

Pressure filter/return filter/servo valve filter element blocked. Clean/replace if necessary.

Manual bypass valves open. Close both valves.

Needle valve closed or nearly closed.

Open to increase steering speed.

Proportional valve spool stuck. Overhaul or replace, see Appendix B2.

Counterbalance valve malfunction.

Clean cartridge without altering setting, or replace.

Pump malfunction or pressure compensator setting too low.

Refer to Pump Manual in Appendix B.

Hydraulic motor malfunction. Refer to Motor Manual in Appendix B.

Object jammed between vessel and thruster. Remove object.

Steering gear set damaged or leg bent in collision.

Notify authorized service agents, see Appendix A.3

Steering in one direction only. Proportional valve spool stuck. Overhaul or replace, see

Appendix B.2

1. The fault lies with the electronic system if steering operates correctly through manual actuation of proportional valve.

2. It is recommended that the steering proportional valve is overhauled by a certified servo distributor as the pilot mechanism can be easily damaged.

Clutch System

Clutch drag.

Residual engagement pressure Quick-release valve malfunction.

Incorrect lubricant Check lubricant equivalents Section 1.

Clutch slippage.

Worn plates. Inspect and replace.

Low engagement pressure. Refer to details for proper adjustment.

Thruster/Driveshafting

PROBLEM POSSIBLE CAUSES REMEDIES

Excessive noise and vibration of thruster.

Lack of lubrication. Check dipstick & top up.

Damaged gears and/or bearings.

Do not operate thruster and notify authorized service agents, see Appendix A.3.

Excessive noise and vibration of driveshafting.

Misalignment and/or lack of lubrication.

Correct alignment and lubricate.

Damaged bearings. Replace.

5.3 LUBE OIL DRAINING

Remove lock wire and the hollow hex plug from the drain plug assembly. Attach a ¾” hose and globe valve to the lube oil drain fitting assembly provided in the tool kit. Connect the drain fitting to the plug. Ensure that the lock wire is welded back in place after the hollow hex plug has been reinstalled.

MALE PIPE

ANDERSON

#N10-12-12

LUBE OIL

DRAIN FITTING

DRAIN PLUG

ASSEMBLY

O-RING

Lube oil may also be drained from inside the ship. Secure the main engine. Use the standby lube pump to drain oil as far as possible. Remove plug from intermediate housing next to lube pump suction ports. Rotate Z-drive until drain port on steering tube is visible through intermediate housing port. Secure Z-drive from steering. Connect suction pump to drain port and drain remainder of oil.

6.0 ASSEMBLY AND DISASSEMBLY

6.1 GENERAL INSTRUCTIONS

1. As a rule, discard all o-rings, gaskets and seals and replace with new identical sealing components.

2. Worn or damaged parts to be replaced. Refer to section drawings and parts lists for proper part identification.

3. Clean and dry all shims. Bind each set together and identify properly for re-assembly and hang them in a safe place. Avoid damage, folding and stretching.

4. Bearings should be inspected for proper clearances, noise and smooth running before being reassembled.

5. Axial location of pinions and gears should be adjusted to achieve correct gear patterns, see Appendix A.5.

6. Key surfaces should be inspected for smoothness, cracks and proper clearances.

7. Before couplings or shafts are assembled, apply a liberal coat of molybdenum disulphide grease onto all splines and keys.

8. All bolt flanges to be thoroughly cleaned of grease and oil prior to assembly. Do not use unspecified gaskets or sealant.

9. Apply ‘Loctite Bolt Lock No. 242’ to all bolts at time of assembly.

10. Torque all bolts to torque values in accordance with their grade identification markings on the head, diameter and number of threads as listed in torque table provided in Appendix A.1.

11. All oil lines to be cleared by blowing lines.

12. Repair all damage to painted surfaces.

6.2 PROPELLER REMOVAL AND INSTALLATION

CAUTION

6.3 STEERING TUBE SEAL CHANGE PROCEDURE

Do not use heavier oils than specified as this will cause overheating.

6.4 FEEDBACK BOX

6.5 AIR CLUTCH AND ADAPTER PLATE

Do not overgrease. Do not use pneumatic grease gun as this will cause damage to the seal.

CAUTION!!

Contaminated air supply to the clutch will damage the clutch seals, which will result in clutch failure.

6.6 DRIVELINE

Grease and air relief valves must not be removed or replaced by standard grease nipples.

CAUTION!!

Do not grease with Molycote additives.

CAUTION!!

Universal shafts which have been stored for more than 6 months should be regreased in working position before operation.

6.7 DRIVELINE BEARINGS

6.8 Z-DRIVE LUBRICATION OIL CHANGE

Drive oil must be at operating temperature at time of oil change.

WARNING!!

Drive unit must be aligned correctly or difficulty with completion of this procedure will result.

CAUTION!!

Do not run pump dry; this will result in damage to the pump.

Pump waste lube oil into a suitable container of sufficient size.

Do not spill waste into the environment.

Lock out electric power to the drive motors of the lube oil and steering standby pumps. Starting and/or running these can cause damage to the equipment and/or injury to personnel.

Lock out main engine start. Starting and/or running of main engine driven lube and steering pumps can cause damage to equipment and/or injury to personnel.

CAUTION!!

Supply valve must be returned to normal run position.

Failing to do this will result in lube oil starvation of the Z-Drive at time of running the standby pump.

This will result in damage to the equipment.

Top level of oil must have been removed as described in the aforementioned procedure otherwise lube oil will spill from suction access port when opened.

CAUTION!!

Extension nipple must thread in easily. Do not force as damage to the thread will result. Do not overtighten.

6.9 PROPELLER SHAFT SEALS AND STEERING TUBE SEALS

Should these systems be drained or have lines disconnected during maintenance, it must be assured that the system is properly bled and all air is removed. Bleed vent is located at the propeller shaft seal housing

(Ref. propeller shaft seal assembly drawing D8202363 item 128).

6.10 HYDRAULIC SYSTEM

KEEP IT CLEAN!!

6.11 FILLING OF LUBRICATION OIL INTO THE Z-DRIVE

Do not overfill; this will result in overheating of drive and spillage of lubrication oil into the environment.

7.0 LIST OF DRAWING & PARTS LISTS

NOTE:

Refer to specific vessel/unit supplement for drawing list

APPENDIX –

Title Document No.

Tightening Torque Table TECH001

Paint Specification PS30

World Wide Support Centers

Mass Elastic B8108076

Gear Patterns TECH008

Conversion Standards TECH002

Contamination Tolerance Table TECH009

Cardan Shaft Alignment GWB 390.65 0.01

Centering Tool Assembly B8107277

General Piping Requirement TECH010

Approved Mineral Lubricants TECH011

Manufacturing of Hydraulic Piping 6450868-000

Fastener Torque Values

IMPERIAL FASTENERS

TORQUE VALUES FOR USE WITH LOCTITE

Grade 5 Grade 8 Size

Lb-Ft Kg-M Lb-Ft Kg-M

1/4 - 20 NC

1/4 - 28 NF

7.2 9.0

0.995 1.24

10.8 12.5

1.49 1.74

5/16 - 18 NC

5/16 - 24 NF

15.3 17.1

2.12 2.36

21.6 24.3

2.99 3.36

3/8 - 16 NC

3/8 - 24 NF

27.0 31.5

3.73 4.36|

40.5 45.0

5.60 6.22

7/16 - 14 NC

7/16 - 20 NF

45.0 49.5

6.22 6.84

63.0 72.0

8.71 9.95

1/2 - 13 NC

1/2 - 20 NF

87.5 81.0

9.33 11.2

99.0

13.7 14.9

9/16 - 12 NC

9/16 - 18 NF

99.0

13.7 14.9

18.7 21.2

5/8 - 11 NC

5/8 - 18 NF

18.7 22.4

27.4 29.9

3/4 - 10 NC

3/4 - 18 NF

32.4 37.3

47.3 52.3

7/8 - 9 NC

7/8 - 14 NF

53.5 58.5

74.7 82.1

1 - 8 NC

1 – 12 NF

1 - 14 NS

79.6 88.3 90.8

1-1/8 - 7 NC

1-1/8 - 12 NF

1-1/4 - 7 NC

1-1/4 - 12 NF

1-3/8 - 6 NC

1-3/8 - 12 NF

1-1/2 - 6 NC

1-1/2 - 12 NF

23 December 2002 Page 1 (2) TECH001.doc

Fastener Torque Values

METRIC FASTENERS

TORQUE VALUES FOR USE WITH LOCTITE

Class 8.8 Class 10.9 Class 12.9

Diameter X Pitch Kg-M Lb-Ft Kg-M Lb-Ft Kg-M Lb-Ft

M4 X 0.7 0.26 1.8 0.36 2.6 0.45 3.2

M5 X 0.8 0.51 3.6 0.72 5.4 0.9 6.3

M6 X 1.0 0.9 6.3 1.3 9 1.4 10

M8 X 1.25 2.3 16 3.2 23 3.6 26

M10 X 1.5 4.5 29 5.4 42 7.2 52

M12 X 1.75 7.2 52 11 75 12.6 90

M14 X 2.0 11.7 85 16 120 20 143

M16 X 2.0 18 130 24 176 30 212

M18 X 2.5 23 171 33 242 41 291

M20 X 2.5 32 234 46 329 55 396

M22 X 2.5 46 331 65 470 78 565

M24 X 3.0 59 423 83 598 99 715

M27 X 3.0 88 636 124 896 150 1085

M30 X 3.5 121 870 169 1221 203 1467

M33 X 3.5 183 1310 256 1847 307 2230

M36 X 4.0 244 1761 342 2472 411 3000

23 December 2002 Page 2 (2) TECH001.doc

PAINT SPECIFICATION PS 30

Written: O.D. Date: 2009-04-22 Project: 1795 & Repeats Checked: N.C.F. Date: 2009-04-23 Model: 1350H Rev: - Date: Page: 1 of 3

Checked: N.C.F. Date: 2009-04-23 Model: 1350H Rev: - Date: Page: 2 of 3

Checked: N.C.F. Date: 2009-04-23 Model: 1350H Rev: - Date: Page: 3 of 3

Notes:

Exclusions:

Gear adjustment pattern

GEAR ADJUSTMENT PATTERNS

The correct setting or adjustment of the pinion at assembly is most important. Provision is made for adjusting both the gear and the pinion axially. In is advisable to first adjust the pinion to its correct mounting determined by the design measurement. After the pinion has been positioned, the gear should be adjusted to mesh with the desired amount of backlash

The shims used in the adjustment of the gear and pinion as well as bearing preload should not be less than 0.40 (0.015”).

A gearset with no load should have a contact pattern length of at least 30-50% of the whole length of tooth.

Gear meshing is not only important at assembly but should be checked as part of a maintenance routine.

The following figures show a correct contact pattern, with the no load pattern biased slightly towards the tooth toe on the driving flank. Deflection under load causes the pattern to enlarge and move slightly towards the heel of the tooth. Inspection covers are located to permit observation of contact patterns of gearsets.

Bevel gears must be assembled to have a definite amount of backlash, which is necessary for safe operation. Gears which are set too tight or too loose will be noisy, wear excessively and possibly score on the tooth surfaces, or even break. The backlash values are etched on the gears at the tightest point of the mesh.

Gears carry the following markings to serve as a guide for proper installation:

Mounting Distance

Mating Teeth

Backlash

Set Number

The following procedure is used for checking the meshing contact pattern and making suitable adjustments to achieve the correct contact pattern.

Using a suitable marking compound, turn the gear assembly several times in the direction of operation. Contact patterns then appear as bright spots. To correct height displacement of contact pattern, move the gear and pinion as shown in Figure 2 and 3. To correct lateral displacement of contact pattern, move the gear and pinion as shown in Figure 4 and 5.

It is most important that the driving flank no load contact pattern be correct before operation.

The non-driving flank no load contact pattern may vary slightly from the ideal position without adverse effect.

15 October 2003 TECH008.doc

General Conversions Table

CONVERSIONS / STANDARDS

Multiply By To Obtain

Millimeters 0.03937 Inches Inches 25.4 Millimeters Meters 3.281 Feet Meters 39.37 Inches Miles 1.609 Kilometers

Length

Miles 1760 Yards Kilometer per Hour 0.540 Knots Kilometer per Hour 0.9113 Feet per Second

Knots 1.688 Feet per Second Speed & Velocity

Knots 1.852 Kilometer per Hour Cubic Inches 16.387 Cubic Centimeters Cubic Meters 35.315 Cubic Feet Cubic Meters 264.2 US Gallons

Imperial Gallons 4.546 Liters US Gallons 3.785 Liters

Liters 0.2642 US Gallons

Volume

Liters 1000 Cubic Centimeters Kilograms 2.2046 Pounds

Pounds 0.4536 Kilograms Pounds (force) 4.448 Newton

Metric Ton 2204.6 Pounds Ounces 28.35 Grams

Force & Weight

Slug 14.59 Kilograms Newton-Meter 0.7376 Pound-Feet

Torque Pound-Feet 1.3558 Newton-Meter

Pound per Sq. Inch 6.89476 Newton per Sq. Meter Newton per Sq. Meter 0.145 Pound per Sq. Inch Pressure

Bar 14.5 Pound per Sq. Inch Horsepower 0.7462 Kilowatts Kilowatts 1.340 Horsepower

Horsepower 550 Pound-Feet per Second BTU 778.2 Pound-Feet

Power & Heat

Horsepower-hour 2545 BTU per Hour

24 April 2003 Page 1 (1) TECH002.doc

Contamination Tolerance Ratings

CONTAMINATION TOLERENCE RATINGS

Specifications for hydraulic components include contamination tolerance ratings in the form of ISO code numbers. They indicate the appropriate cleanliness level of the fluid required for the particular components.

The attached table is a representation of such codes and corresponding contamination levels. Code numbers are shown at the left and the particles distributions are shown to the right of the code numbers.

Example: A four-way directional valve has a component contamination tolerance rating of 18/15. This indicates that the fluid should have the following cleanliness:

�� Number of particles over 5 micrometers in size per millilitre of fluid is more than 1300, but not more than 2500.

�� Number of particles over 15 micrometers in size per millilitre of fluid is more than 160, but not more than 320.

The section of the system incorporating this particular four-way valve should provide full-flow filtration that will achieve the cleanliness level of 18/15 required.

Note: Solid contaminant code conforms to ISO 4406, Hydraulic fluid power- Fluid – Method for coding level of contamination by solid particles.

Number of particles per millilitre larger than 5 �m 15 �m Code No.

More Than

Up to & Including

More Than

Up to & Including

20/17 20/16 20/15 20/14

10000 10000 10000 10000

19/16 19/15 19/14 19/13

18/15 18/14 18/13 18/12

17/14 17/13 17/12 17/11

16/13 16/12 16/11 16/10

15/12 15/11 15/10 15/9

2.5

14/11 14/10 14/9 14/8

2.5 1.3

2.5

13/10 13/9 13/8

2.5 1.3

2.5

12/9 12/8

2.5 1.3

2.5

11/8 10 20 1.3 2.5

24 April 2003 Page 1 (1) TECH009.doc

APPENDIX

CARDAN SHAFT ALIGNMENT PROCEDURE

Adjust Dimension A of centering tools to the value given in Table I.

Install centering tools in the place of cardan shafts as shown on Drawing B8106349.

Adjust angle of driveshaft such that Dimension B is within +/- 3 mm of the value given in Table I.

Using actual values for A,B,C , calculate actual tilting angle by the following equation:

CA

B ArcCos

This value should be as close as possible to the value in Table I and no more than max.

TABLE I (FWD CARDAN SHAFT)

ALIGNMENT DATA & CENTERING TOOL DIMENSIONS

GWB Cardan Shaft Size 390.65 0.01

1 3.23 max 2 8.0

A3 517.097

D 4 477.097

B 733

C 150

CCos

BA

AD

General Piping Requirements

GENERAL PIPING REQUIREMENTS

1. Stand-alone hydraulic tanks must be placed such that they provide a flooded suction for the steering pumps unless otherwise approved by Ulstein Maritime Ltd.

2. Loose lube/clutch pumps must not be placed any higher than 1 meter (3 feet) above the oil level in the drive unless otherwise approved by Ulstein Maritime Ltd.

3. Suction filters must not be used.

4. Suction line velocity must not exceed 1.2 m/s (4 FPS).

5. Pressure line velocity must not exceed 6.1 m/s (20 FPS).

6. Suction and return lines must be as short as possible with minimum number of elbows.

7. All lines must be flushed to achieve cleanliness level of ISO4406/1986 code 15/12 or cleaner for steering hydraulic system and 18/15 or cleaner for lube/clutch hydraulic system.

8. Connections to suction ports of the tank and the drive & cooling water ports of the coolers must be flexible to isolate them from vessel vibration.

9. If shut-off valves are required on suction lines, they must be full ported ball valves.

10. Drain lines must be connected to the highest case drain port on pumps and motors. If this is not possible, a siphon breaker must be fitted.

11. Pumps' case drain pressure must not exceed 1.72 bar. (25 psi)

12. Motors' case drain pressure must not exceed 3.45 bar. (50 psi)

13. Coolers' water pressure must not exceed 3.5 bar. (50 psi)

02 May 2003 Page 1 (1) TECH010.doc

Approved Mineral Lubricants

APPROVED MINERAL LUBRICANTS

System Manufacturer

Drive lube & seal oil (with hydraulic clutch)

Drive lube & seal oil (without hydraulic clutch)

Steering hydraulic oil

Mobil Mobilgear 627 Mobilgear 629*

Mobilgear 627 Mobilgear 629*

Mobil DTE 24 Mobil DTE 25*

Chevron Gear compound EP100 Gear compound EP150*

Gear compound EP100 Gear compound EP150*

Hydraulic oil AW 32 Hydraulic oil AW 46*

Exxon/Esso Imperial See note 1

Spartan EP 100 Spartan EP 150*

Nuto H 32 Nuto H 46*

Texaco See note 1 Meropa 100

Meropa 150*

Rando HD 32

Rando HD 46*

Castrol See note 1 Tribol 1100/100 Tribol 1100/150*

Tribol 943AW 32 Tribol 943AW 46*

Shell See note 1 Omala 100 Omala 150*

Tellus 32 Tellus 46*

BP See note 1 Energol GR-XP 100 Energol GR-XP-150*

Bartran HV32 Bartran HV46*

* Warm waters (above 20 o C or 68 oF)

Note 1: There are no mineral gear oil from these manufacturers which have been approved for Ortlinghaus clutches.

Note 2: Lubricants for cardan shafts, gear couplings, driveshaft bearings and electric motor bearings are to be in accordance with each manufacturer’s specification.

02 May 2003 Page 1 (1) TECH011.doc

RETURN

Note 3: Suppliers new designation for "Shell Omala 100" is now "Shell Omala S2 G 100" and for "Shell Tellus 32" new designation is now "Shell Tellus S2 MX 32"

AMENDMENT 1

MANUFACTURING OF HYDRAULIC PIPING

CONTENTS

1. PIPE MATERIAL

2. SUCTION PIPES

3. HIGH PRESSURE PIPES

4. RETURN LINES ULSTEIN AQUAMASTER UNIT BODY

5. HYDRAULIC HOSES

6. FIXING OF PIPES

7. PRESSURE TEST OF PIPES

Rev. Date Drawn Checked Approv. Changed pages Description D 2.4.2003 HOL New layout.

Page 1 ( 3 ) 6450868-D-000 U

1. Pipe material Seamless, cold drawn precision steel tube St 35.4 DIN 1629 B 1.4, or 52.4 DIN 1629 B 1.4, delivery state NBK DIN 2391 B 1.2

2. Suction pipes SAE flange joint (low-pressure, O-ring).

welding with protective gas (TIG) root cleaning by grinding solvent flushing flushing with flushing oil to cleanliness grade

NAS 1638 CETOP RP 70 H

5-15 μm 8-9 17/13 15-25 μm 7-8 17/13

In case cleanliness grade can not be measured, the flushing is to fulfil the following minimum the following minimum requirements:

filtering accuracy 12 μm ABS rate of flow Wmin = 10-12 m/s flushing time 4 h per flow direction in pipes during operation.

If the interior welding joint can not be cleaned by grinding, the procedure is as follows:

pipe filled with protective gas root welding with protective gas (TIG) solvent flushing flushing with oil as above

3. High pressure pipes Outside diameter 8 – 38 mm.

Hydraulic fittings solvent flushing flushing with oil as suction pipes

Welded flange joints as SAE flange joint of suction pipes

Page 2 ( 3 ) 6450868-D-000 U

Page 3 ( 3 ) 6450868-D-000 U

4. Return lines Ulstein Aquamaster unit body Outside diameter 8 – 42 mm.

Hydraulic fittings solvent flushing

Welded flange joints welding with protective gas (TIG) root cleaning by grinding solvent flushing

5. Hydraulic hoses Pressure hoses correct pressure class sufficient length, correct installation hose inside diameter: refer to hydraulic drawings

Suction hoses inside diameter determined according to length (see hydraulic drawings)

Flushing of hoses as the pipe to which connected

6. Fixing of pipes The pipes are to be fixed at sufficiently short intervals to prevent damages distance of clamps is determined according to pipe diameter, operating pressure, possible bends, etc.

the following values can be regarded as a recommendation dia. 8-20 mm fixing interval Lmax = 700 mm dia. 22-42 mm fixing interval Lmax = 1000 mm dia. >42 mm fixing interval Lmax = 1300 mm

7. Pressure test of pipes Pressure pipes test pressure Ptest = 1.5 x max operating pressure

Suction pipes test pressure Ptest = 2 bar, tmin = 10 minutes

NOTE! Nipples (R 1/4”) should be installed to the highest points of the pipes for removing air from the pipes.

APPENDIX – B

No. DESCRIPTION PART #

B1 Clutch Roto Coupling Quick Exhaust Valve

D8202364 B8202382 B8202428

B2 Cardan Shaft CSS3 GWB 390.65 0.01

B3 Pillow Block Bearing Pillow Block Bearing

01BCP110MMEX 2B FELT

02BCP110MMGR 4B FELT

B4 Steering Hydraulic Motor Staffa MODIFIED B8107209

HMB270-S3-SO4-PL40

B5

Lube Pump

Standby Lube Pump

PMPS5

P3000A086ADZI15-29

PMPS6

P3000A186ADZF15-14

B6 Steering Pump PMPS10

PVH131C-RF-2D-11C21V-31046

B7 Steering Hand Pump 7012-AN B8 Electric Motor EMS1 B9 Steering Proportional Valve CEI VS8640VBI31B

B10 Pressure Filter Stauff

SFT070 C10B-LUF-OPT24

B11 Return Filter FS1

TTF-230-SAE24-TXW5-CC10-B-T-22-G

B12 Lube Filters

Schroeder A25 2 only

B13 Propshaft Seal Size 240 D8202363

B14 Level Switch Murphy

DF755

B15 Pressure Switch

Herion 08-802-20 Herion 08-803-20 Herion 08-821-20

B16 Heat Exchanger HTEXS1 B17 Microswitch BZE6-2RQ

B18 RTD IS9

B19 Temperature Switch Barksdale

ML1H-H203S-WS

APPENDIX – B.1

CLUTCH D8202364

ROTO COUPLING B8202382

QUICK EXHAUST VALVE B8202428

APPENDIX – B.2

CARDAN SHAFT CSS3

Cardan Shaft Spec : CSS3

SPECIAL FEATURES: BALANCE TO ISO 1940 G6.3

APPENDIX – B.3

PILLOW BLOCK BEARING 01BCP110MMEX 2B FELT

PILLOW BLOCK BEARING 02BCP110MMGR 4B FELT

APPENDIX – B.4

STEERING HYDRAULIC MOTOR STAFFA MODIFIED B8107209

APPENDIX – B.5

Lube Pump PMPS5 P3000A086ADZI15-29

Standby Lube Pump PMPS6 P3000A186ADZF15-14

Pump Spec : PMPS5

Pump Spec : PMPS6

APPENDIX – B.6

STANDBY STEERING PMPS10

Pump Spec : PMPS10

M–2210–SRev. 2/93

PVH Piston Pumps Including Controls

Vickers®

Piston Pumps Overhaul Manual

Section 1 – Introduction

A. Purpose of Manual This manual describes basic operating characteristics and provides overhaul information for the Vickers PVH 57/74/98/131 series piston pumps. The information contained herein pertains to the latest design series as shown in the model code.

B. Related Publications Installation dimensions for the PVH series pumps and controls are not included in this manual. Individual parts numbers for the basic pumps are also not included. Refer to the related publication list below for publications that include this type of information.

PVH57 Service drawing M–2206–S PVH74 Service drawing M–2207–S PVH98 Service drawing M–2208–S PVH131 Service drawing M–2209–S PVH Series Application GB–C–2010

C. Model Code Description Variations within each basic model series are covered in the model code as shown on the next page. Service inquires should always include the complete unit model code number as stamped on the name plate, and the assembly number as stamped on the mounting flange.

Model Code

N = ISO 3014/2- Short straight E32N keyed 1 = SAE ”C” Straight

(J744-32-1) keyed 2 = SAE “C”� Splined 14 tooth

(J744-32-4) 12/24 D.P.

3 = SAE “CC” Splined 17 tooth (J744-38-4) 12/24 D.P.

12 = SAE “D” Splined 13 tooth (J744-44-4) 8/16 D.P.

13 = SAE “C Straight (J744-38-1) keyed 16 = SAE “D“ Straight

(J744-44-1) keyed

Blank = Non-thru-drive (single pump) A = Thru-drive pump with SAE

“A” 2-bolt rear flange mounting

(SAE J744-82-2)

B = Thru- drive pump with SAE “B” 2- and 4-bolt rear flange mountings♦ (SAE J744-101-2/4) C = Thru-drive pump with SAE

“C” 2- and 4-bolt rear flange mountings♦(SAE J744-127-2/4) S = Adjustable maximum volume stop (non-thru-drive and non-torque-control pumps only)

PVH *** QI * – * (*) * – ** * – 10 – C(M) ** (**) (**) – *0 – ***

** = Customer desired torque limiter setting specified in ten bar (145 psi) increments, e.g.:

8 = 80 bar (1160 psi);

18 = 180 bar (2610 psi).

The torque setting range is from 30–80% of the specified compensator setting.

C = 70-250 bar (1015-3625 psi) (standard) CM = 40-130 bar ((580-1885 psi) (optional QI version) IC =…