PLAN HISTORY ALT NO. MARK 2003.12.01 BOW THRUSTER...2018/05/02 · PROPELLER SHAFT, SUB ASSEMBLY PARTS LIST GRAVITY TANK PARTS LIST RACK GEAR FEEDBACK UNIT PARTS LIST 3327.49 6786.80

PLAN HISTORY

NO.ALT

MARKDATE DESCRIPTION CONF.BY

2003.12.01 BOW THRUSTER

FINAL DRAWING

( 137 ) SHEETS WITH A COVER

DEPT.NO: CLASS: ABS SCALE: AS SHOWN UNIT: MM DATE: 2003.12.01

TITLE : 105, OILMANAGER J. S. Park

SHIP NAME: MINERVA HELEN

S. G. Kim

OWNER: MINERVA

CHECKEDBOW THRUSTER

DRAWN H. S. Lee(TEL.:

HULL NO.: 1451DWG. NO.

SAMSUNG HEAVY INDUSTRIES CO.,LTD.

[email protected] Libris

ErmoOdessa

AlexHighlight

AlexHighlight

INSTRUCTION MANUAL

Type

Plant No.

Project No.

Shipyard

New building No.

FU-80-LTC-2250

6241

P-16081 A

Samsung Heavy Industries Co. Ltd.

2208

BRUNVOLL THRUSTER SYSTEMSBRUNVOLL AS - STRANDGT. 4-6 - N-6415 MOLDE NORWAY

Phone +47 71 21 96 00 - Fax +47 71 21 96 90 - E-mail: officeObrunvoll .nowww.brunvoll.no

[email protected] Libris

ErmoOdessa

1

2

3

4

5

6

7

8

9

10

11

12

CONTENTS

DATA SHEETSPARE PARTS

GENERAL

INSTRUCTIONS FOR USE

INSTRUCTIONS FOR SERVICEAND MAINTENANCE

CIRCUIT DIAGRAMS

DRAWINGS OF EQUIPMENT/PARTS LIST

DRAWINGS OF SEPARATE PARTS

SPARE PARTS

PERSONAL NOTES

1 CONTENTS

CONTENTS

PART1

CONTENTS 7790.72

PART 2

DATA SHEET

SERVICE - ORDERING OF SPARE PARTS

PART 3, GENERAL

GENERAL DESCRIPTION OF THE SYSTEM

PART 4, INSTRUCTION FOR USE

ESSENTIAL POINTS

OPERATING INSTRUCTIONS

PITCH CONTROL UNIT

ADJUSTMENT PROCEDURE FOR CONTROL SYSTEM

CONTROL UNIT FOR ADJUSTMENTPARTS LIST

PART 5, INSTRUCTIONS FOR SERVICE AND MAINTENANCE

MAINTENANCE PROGRAM

PRESSURE/LOAD PRESSURE DIAGRAM

START OF PUMP AGGREGATE

LUBRICATION/INSTRUCTION FOR FILLING AND DRAINAGE OF OIL

CHART OF LUBRICANTS

HYDRAULIC SERVO SYSTEM

7779.91

7280

7771.86

7767.30(1-2)

7767.30 (3-7)

6756.05(1)

7767.29(1-5)

7766.85 A019192

7779.08

7763.39 C

6763.04

7762.54 (1-2)

7739.40 C

7762.53 C (1-3)

Date 10.03.2003

BRUNVOLL AS

6415MOLDE

NORWAY

INSTRUCTION MANUAL FORBRUNVOLL THRUSTER

TYPE FU-80-LTC-2250PLANT NO. 6241

1of4

Author

Contr.

ME

7790.72

INSTRUCTION FOR START-UP/ADJUSTMENT OF VANEPUMP TYPE BOSCH FPV 17-67

INSTRUCTION TO CLEAN UP ORIFICES

7763.31

7769.74

DRAWINGS (RELATED TO INSTRUCTIONS):

THRUSTER CONTROL SYSTEM, SCHEMATIC

LUBRICATION/SERVO SYSTEMPARTS LIST

FLANGE 18/15-1/2" JIS 15A(0 22,2)FLANGE 22-3/4" JIS 20A(0 27,2)FLANGE 35-1+1/4" JIS 25A (0 34,5)FLANGE 28-1" JIS 25A (034,5)

LOCATION OF HEADER/GRAVITY TANK

DETERMINATION OF OIL HEADER/GRAVITY TANK HEIGHT

7770.37

7782.47028901

6777.256777.246777.236777.29

7786.01 A

7785.98

THRUSTER SIMPLIFIED SECTIONAL VIEW 6754.50

INSTRUCTION FOR SERVICE AND MAINTENANCE

DRAWINGS (RELATED TO INSTRUCTIONS):

FITTING/REMOVAL OF COUPLING

FITTING/REMOVAL OF PROPELLER BLADES

FITTING REMOVAL OF THRUSTER BODY

FITTING/REMOVAL OF PISTON

FITTING/REMOVAL OF PROPELLER HUB

FITTING/REMOVAL OF PROPELLER SHAFT

AXIAL MOVEMENT OF CROWN WHEEL

INSTRUCTIONS FOR ASSEMBLY OF THRUSTER'SSPIRAL BEVEL GEARS

PROPELLER TIP CLEARANCE LIMIT

ARRANGEMENT OF ZINC ANODES

7758.10(1-8)

7758.05 B

7772.57

7769.22

7758.03 A

7758.04 A

7769.23

7758.02 A

6731.22

7758.30 B

7709.64

BRUNVOLLAS

6415 MOLDE

NORWAY

INSTRUCTION MANUAL FORBRUNVOLLTHRUSTER

TYPE FU-80-LTC-2250

PLANT NO. 62412 of 4

Date 10.03.2003

Author

Contr.

ME

7790.72

PART 6, CIRCUIT DIAGRAMS

CABLE ARRANGEMENT

TERMINAL DIAGRAM

WIRING DIAGRAM, CONTROLS

WIRING DIAGRAM, START PUMP AGGREGATE

WIRING DIAGRAM, INTERFACE EL. STARTER

34-3425

34-3426(1-3)

34-3427(1-9)

34-3428

34-3429

PART 7, DRAWINGS OF EQUIPMENT/PARTS LIST

ARRANGEMENT, THRUSTER UNIT WITH EL.MOTOR

THRUSTER UNIT, THRUSTER SECTIONPIPE CONNECTIONS

PARTS LIST FOR DWG. 6780.12/6751.01 C

THRUSTER UNIT, THRUSTER BODYPARTS LIST

PINION, SUB-ASSEBLYPARTS LIST

PROPELLER SHAFT, SUB ASSEMBLYPARTS LIST

GRAVITY TANKPARTS LIST

RACK GEAR FEEDBACK UNITPARTS LIST

3327.49

6786.806751.01 C/6762.08028915

5210.33 D020988

6764.80 C021454

6749.19 D015636

6754.48 B017354

3317.32 B016920

DRIVE SYSTEM

ELECTRIC DRIVE MOTOR NOT DELIVERED BY BRUNVOLL AS

EL. MOTOR FOUNDATION 3320.07 A

ELASTIC COUPLING TYPE ROTEX 140

DIMENSIONS 7774.01

BRUNVOLL AS

6415MOLDE

NORWAY

INSTRUCTION MANUAL FORBRUNVOLLTHRUSTER

TYPE FU-80-LTC-2250

PLANT NO. 62413 of 4

Date 10.03.2003

Author

Contr.

ME

7790.72


SERVO AGGREGATE BPA W 30 RP HPFPARTS LIST

SERVO AGGREGATE, HYDRAULIC DIAGRAM

6767.13/14025490

7771.79

CONTROL SYSTEM

MAIN CONTROL PANELPARTS LIST

AUX, CONTROL PANELPARTS LIST

ELECTRONIC CABINETPARTS LIST

START CABINET, SERVO AGGREGATEPARTS LIST

FEEDBACK UNITPARTS LIST

6786.81029048

6767.33029051

6788.00029338

6786.82029052

6761.32020267

PART 8, DRAWINGS OF SEPARATE PARTS

OIL FILTER PRESSURE, PALL HH 4010

OIL FILTER, UCC.UC.MXA.1518.101

PRESSURE SWITCH, HERION

DIRECTIONAL VALVE, BOSCH NG10

EL. MOTOR MEZ

7781.94

7763.20

7763.19

7770.91

7766.48

PART 9, SPARE PARTS

SPARE PARTS FOR ELECTRIC CONTROL-/SERVO SYSTEM 028902

PART 10

PERSONAL NOTES

Date 10.03.2003

BRUNVOLL AS

6415MOLDE

NORWAY

INSTRUCTION MANUAL FORBRUNVOLL THRUSTER

TYPE FU-80-LTC-2250PLANT NO. 6241

4 of 4

Author ME

Contr.

7790.72

DATA SHEETSPARE PARTS

BRUNVOLLPROJECT NO.

SHIPYARD

NEW BUILDING NO.

THRUSTER UNIT NO.

THRUSTER UNIT TYPE

INPUT SPEED ON THRUSTER

INPUT POWER ON THRUSTER

INTERNAL GEARING RATIO

PROPELLER SPEED

DRIVE SYSTEM

SERVO SYSTEM

DATASHEET

16081 A

Samsung Heavy Industries Co Ltd

1451

6241

FU-80-LTC-2250

1180R.P.M.

1100kW

11/43

300 R.P.M

ELECTRIC DRIVE SYSTEM DELIVERED BY YARD

EL. MOTOR Hyundai Heavy Industries

VOLTAGE: 3 x 3300V-60 Hz

EFFECT: 1500 kW at 1180 rpm (6-pole motor)

FULL LOAD CURRENT: 336,9 Amp.

STARTING CURRENT: 2021,4 Amp.

AUTO TRAFO STARTER

BPAW30RPHPF

ELECTRIC MOTOR EFFECT: 4,6 kW

BRUNVOLL AS

6415MOLDE

NORWAY

DATASHEET

Date

Author

Contr.

18.10.2002

ME

7779.91

1 of 1

S E R V I C E

OUR SERVICE-DEPARTMENT IS AT YOUR SERVICE WITH ALL INFORMATIONOF THE TECHNICAL NATURE AFTER THE THRUSTER SYSTEM IS INSTALLED.

ORDERING OF SPARE PARTS:

WHEN ORDERING OF SPARE PARTS, PLEASE GIVE THE FOLLOWING

INFORMATION:

1. PLANT NUMBER OF THRUSTER.

2. SHIP'S NAME/OWNERS

3. NAME AND ARTICLE NUMBER OF PART

FOR SERVICE AND SPARE PARTS. PLEASE CONTACT:

BRUNVOLLAS

STRANDGT. 4-6

6415 MOLDE, NORWAY

TELEPHONE

TELEFAX

E-MAIL

:4771219600

:47 71 21 96 90

;service@ brunvoll.no

SERVICE AFTER OFFICE HOURS:

TELEPHONE :47 71 21 96 00/47 91 87 20 76

BRUNVOLLAS

641 5 MOLDE

NORWAY

SERVICE

ORDERING OF SPARE PARTS

Date

Create

Contr.

01,06.1999

TAB/me

72801 of 1

GENERAL

1.

2.

CONTROLS

Each thruster is an independent, self-contained unit with its own servo andcontrol system. See dwg. no. 7770.37.

The control system for each thruster is connected to a common control lever.

The thruster is activated by the "MAIN SWITCH" in the bridge main controlpanel, which will put voltage to the controls and start the servo pump unit.

The thruster is started from the bridge main control panel.

When started, the thruster can be controlled from the bridge main panel or thecommand transferred to one of the bridge wing panels. Each panel has anindicating lamp indicating that the panel is having the control.

If DP/Joystick or Autopilot is installed, the control can be transferred, andindicating lamp in main control panel indicates what to control.

The thruster has an emergency manual back-up control in case of failure in the"follow up" control system.

Pitch can be activated by operating impulse switches marked

SERVO AND CONTROL SYSTEM

The system is shown schematically in drawing no. 7770.37/7770.18 or 7771.79

The bridge controls are connected to an electronics unit.

This unit contains the necessary power module, PLC, fuses, relays, etc.

The control unit receives a feedback signal from the thruster unit indicating thepropeller pitch setting. The potentiometer feedback circuit for the controls ismonitored and an alarm is provided in the bridge panel in case of failure.

The servo pump unit (aggregate) is situated in the thruster room and containsthe servo pump with pressure relief valve, pressure switch for monitoring thepitch pump pressure, and propeller pitch solenoid valve. The latter areconnected to the control unit on the bridge.

Art.no. 021439

BRUNVOLL AS

6415MOLDE

NORWAY

CONTROL AND SERVO SYSTEM

GENERAL DESCRIPTION

VV RP aggregate/PLC (proportional)

Dato:

Sign.:

03.07.01

OL/me

7771.86

Page 1 of 3

The pitch servo system is based on a variable vane pump (see dwg. 7763.31)and a proportional directional valve.

When the proportional valve is in neutral position, the pump balances in zeroposition, and only pump leak oil "circulates" in the system. The pressure in thesystem is then determined by the pump pressure setting. When the proportionalvalve is operating, the pressure is decided by the propeller blade load andpressure drop in valve etc. Pressure set values, see. dwg. 7762.53.

When the pitch is set to a desired value, when the propeller is running, smallleakages in the servo system will slowly bring the propeller pitch out of setvalue:The feedback potentiometer will sense this deviation and the controls willcorrect the pitch to set and hold value by "proportionally open the valve".

The proportional valve can also be controlled directly from the bridge in the"Hand" emergency mode.

Finally, the valve can be operated manually, locally in the thraster room, bypushing the end knobs of the solenoids by a suitable non sharp tool.

3. LUBRICATION / SERVO OIL SYSTEM

The system is shown schematically in the lubrication system drawing and the"Simplified sectional view" (see part 5 of the manual).

The thruster has three (3) oil systems which are connected to the same gravitytank.

1) Lubrication of the gearbox and mechanical transmissions in the hub. Port"E".

2) Lubrication of the shaft seal. Port "A".

3) Servo oil system. Port "S" and compensation filling pipe "C" and leak oilpipe "L".

Oil quality, see Lubrication Chart.

-3-Art. no. 021439

BRUNVOLL AS

6415 MOLDE

NORWAY


GENERAL DESCRIPTION


Dato:

Sign.:

03.07.01

OL/me

7771.86

Page 2 of3

The gear housing including the propeller hub, is completely oil filled and undergravity pressure.

The propeller shaft seal has an outer axial shaft seal and an inner double lipseal. The cavity between the outer and the inner seal barrier is oil filled andsubject to gravity pressure from the gravity tank via port "A". This cavity canbe drained via port "B". In this way, the oil is renewed and the condition of theouter shaft seal can be checked (water ingress observed).

The gear housing can be drained (water can be removed) via port "H". Thisport is also for collecting oil samples.

NOTE: The thruster shall not be emptied as long as the ship is afloat. Theoil system should then always be kept under gravity pressure toavoid ingress of water.

The servo system for controlling the propeller pitch is filled with the same oilas the lube, system of the thruster. There are several dynamic seals in thissystem. One of the seals in the shaft distribution unit for servo oil has a smallbut intended internal leakage where the oil goes from the servo system to thelubricant system to provide proper lubrication of oil distribution unit.

The excess oil returns to the gravity tank. This slight leakage results in atendency of the propeller blades under load to be moved out of operatingposition. The electro hydraulic control system monitors the position of theblades and automatically moves the propeller blades to correct operatingposition.

The adjustments are of minor magnitude which are barely visible on the pitchindicator on the bridge. The magnitude of the deviation may be limited byadjusting the sensitivity of the control system.

The exchange of oil between the servo oil system and the gearbox is also a partof the cooling of the servo oil.

Art. no. | 021439

BRUNVOLL AS

6415MOLDE

NORWAY


GENERAL DESCRIPTION


Dato:

Sign.:

03.07.01

OL/me

7771.86

Page 3 of3

INSTRUCTIONS FOR USE

ESSENTIAL POINTS

A. The ship will move in the direction of the control lever. Pushing thecontrol lever to port will make the ship move to port and vice versa.

B. The propeller pitch indicator will indicate the propeller pitch setting and will always follow thecontrol lever.

The propeller will not produce thrust unless the motor is running.

C. The push-button marked "CONTROL HERE" transfers control to the panel at which the push-buttonis activated for taking over control.

It is not possible to transfer control to the bridge wing panels unlessthe thruster motor is running.

D. In case of feedback failure, alarm lamp in bridge panel "Feedback pitch", the propeller pitch (load)will be blocked at the present load situation, and cannot be controlled further by the user. Thethruster should either be stopped or activate switch "PITCH MANUAL" control for separatemanual control.

E. The switch "PITCH MANUAL" shall always be-activated unless the control system has a failure.

Activated "PITCH MANUAL" will cut out the follow-up system, and the thruster will not respondto the control lever.

F. The thruster shall not be stopped by de-activating the "MAIN SWITCH".

The thruster pitch should always be set to neutral, then stopped by pushing"STOP", in order to let the starter circuit breaker operate with lowestpossible amperage.

Art. no. : | 19272

BRUNVOLL A.S

6415MOLDE

NORWAY

Prod. Gr. |

CONTROL SYSTEM


SIDE THRUSTER

Date:

Sign.:

28.09.2000

RF/me

7767.30

1 of 7

G. The rechargeable battery in the memory module in the PLC prevents loss of data when thepower supply to the controller is switched off.

If the memory module have been unpowered (the power supply have been switched off orthe memory module have been taken out) for a period of time longer than 2 months, thereis a risk of losing data stored in the memory module.If data have been lost, parameters adjusted at ADDR. 0-7 have to be readjusted according toadjustment procedure for control system.

The "Batt" LED (Light Emitting Diode) on the front panel of the supply modulePCD4.N210 shows the battery state (PLC powered on):

LED "Batt" = offLED "Batt" = on (red)

Battery OKBattery LOW

DATA:

Fully charged battery power reserve inunpowered memory module : 2 monthsBattery charge-up time : 15 hoursLife expectancy : 5 yearsNominal voltage : 2.4V

CHANGING THE BATTERY

When changing the battery the PLC must be powered on.To lift off the plastic cover only (not the board), a screw is removed from the side.Lift off the cover and take out the battery from the side of the socket.Insert new battery and screw back cover on printed circuit board.

See drawing no. 6756.05

Art. no. : 19272

BRUNVOLL A.S

6415MOLDE

NORWAY

Prod. Gr.

CONTROL SYSTEM


SIDE THRUSTER

Dato:

Sign.:

28.09.2000

RF/me

7767.30

2 of?


1. ACTIVATING THE THRUSTER:

Press push-button "MAIN SWITCH".Servo pump will start.

Following control lamps will be fully illuminated:

"MAIN SWITCH""STOP""CONTROL HERE"

"READY FOR START" will illuminate when the following conditions are fulfilled:

a) Servo pressure available.b) Pitch in neutral positionc) Starter for el-motor ready.d) Power available.

2. START-UP

The thruster can be started by pressing the push-button marked "START".Starter will be activated, el.-motor will start and accelerate to full speed.

So far start lamp will be flashing. Pitch will be blocked in zero until start lamp will be fullyilluminated.

Lamp "START" will be flashing until el.-motor has reached full speed.Lamp "READY FOR START" and "STOP" will go out.Lamp "FAN RUN" will illuminate (if installed).

3. MANOEUVRING

The thruster is now ready for operation.

The propeller pitch is controlled by the control lever, and the pitchsetting will follow the lever, and may be left in any position betweenneutral and full.

The control lever has a distinct neutral position.The pitch setting is indicated by the pitch indicator.

The vessel will follow the direction of the lever.When moving the lever to port side of neutral, the ship will move toport and vice versa.

Art.no.: 19272

BRUNVOLL A.S

6415 MOLDE

NORWAY

Prod. Gr.

CONTROL SYSTEM


SIDE THRUSTER

Dato:

Sign.:

28.09.2000

RF/me

7767.30

3 of 7

4. CONTROL TRANSFER

The push-button marked "CONTROL HERE" transfers control to thepanel at which the push-button is activated for taking over control,

a) Control here pickup ON.The lamp will flash until the control lever is set to the same positionas indicated by the pitch indicator. Then the control is picked up and thelamp will be fully illuminated.

b) Control here pickup OFF.Make a connection from terminal -X2:4 to Input 47 of the PLC (module no. 5, terminal 15). Thepush-button marked "CONTROL HERE" transfers control to the panel at which the push-button isactivated for taking over control. The lamp "CONTROL HERE" will be light up. The pitch will goto same position as the control lever.

c) Control transfer to DP/JOYSTICK (if installed)Before control transfer to DP/JOYSTICK can take place, the propeller must be started, and theemergency selector switch must be set to "AUTO".Set selector switch on DP/JOYSTICK system to position "DP'V'JOYSTICK"Lamp "CONTROL HERE" will go out, and lamp "DFY"JOYSTICK"will beilluminated on main control panel. The pitch setting can now be controlled by the"DFY"JOYSTICK"system.

d) Control transfer from DP/JOYSTICKSet selector switch on DP/JOYSTICK system to pos. "MAN".Lamp "DP'V'JOYSTICK" will go out, and lamp "CONTROL HERE" will beilluminated on main control panel. The pitch setting can now be controlled from themain control panel.

5- STOP OF MAIN EL.-MOTOR

Propeller pitch is set to neutral position before the el.-motor is stopped.Press push-button marked "STOP", and el.-motor will stop.

Lamp "START" will go off, and lamp "STOP" and "READY FOR START" will be illuminated.

Stopping is possible from all control panels.

6- EMERGENCY CONTROL

In case of failure in the control system (no pitch control from control lever),(for instance "FEEDBACK PITCH") alarm), the switch marked "MAN/AUTO" locatedon the left side of the main control panel is switched to position "MAN".Pitch can now be activated by operating impulse switches marked "< " " >".

Art. no. : 19272

BRUNVOLL A.S

6415MOLDE

NORWAY

Prod. Gr.

CONTROL SYSTEM


SIDE THRUSTER

Dato:

Sign.:

28.09.2000

RF/me

7767.30

4 of 7

When this system is in use, the propeller pitch will move as long as one of the impulse switches areoperated.Since the follow-up control is out of action the propeller pitch has to bewatched at all times at the indicator, and the propeller pitch is kept incorrect position by activating the impulse switches. (See. also section 10).

7. ALARMS

The following alarms are indicated for the main control panel:

7.1 Alarm "SYSTEM FAILURE" is activated:

LEDs (Light Emitting Diodes) located on the front panels of modules PC.D4.N210 andPCD4.M110 showes the operating states of the PLC:

a) LED "Batt"LED "Reset"LED "Watch Dog"LED "Run"LED "Halt"LED "Error"

b) LED "Batt"LED "Reset"LED "Watch Dog"LED "Run"LED "Halt"LED "Error"

c) LED "Batt"LED "Reset"LED "Watch Dog"LED "Run"LED "Halt"LED "Error"

d) LED "Batt"LED "Reset"LED "Watch Dog"LED "Run"LED "Halt"LED "Error"

offoffoffoffonoff

offonoffononon

onoffononoffoff

offoffoffoffoffoff

Indicates serious error in user programor hardware error in the PLC.

The supply voltage to the PLC is too low.

Battery low.The control system will function normally,but the battery in the memory module hasto be replaced with a new one as soon aspossible.Changing of battery: See page 2.

Fuse on front panel of modulePCD4.N210 may be blown.

Art. no. : | 19272

BRUNVOLL A.S

6415MOLDE

NORWAY

Prod. Or.

CONTROL SYSTEM


SIDE THRUSTER

Dato:

Sign.:

28.09.2000

RF/me

7767.30

5 of 7

7.2 Alarm "POWER ALARM CENTRAL" is activated:

No voltage (24V DC) to alarm system. Fuse for power alarm central in control cabinetis blown.

7.3 Alarm "OIL LEVEL" is activated:

Low oil level in gravity tank.

7.4 Alarm "OVERLOAD" is activated:

High temperature in main el-motor.

7.5 Alarm "FEEDBACK PITCH" is activated:

Failure in feedback unit.

7.6

7.7

7.8

Alarm "SERVO PRESS" is activated:

Low servo pressure.Servo pump stopped.

Alarm "MOTOR COOLER LEAKAGE" is activated:(For watercooled el-motor only)

Water leakage in the cooling system for el-motor.

Alarm "AUTOSTOP" is activated:

a) El-motor has stopped due to high temperature.Alarm "OVERLOAD" will also be activated.

b) El-motor has stopped because motor protection relay has tripped out.

Art.no. : | 19272

BRUNVOLL A.S

6415MOLDE

NORWAY

Prod. Gr. |

CONTROL SYSTEM


SIDE THRUSTER

Date:

Sign.:

28.09.2000

RF/me

7767.30

6 of 7

8. AUTOSTOP OF EL-MOTOR

The thruster motor is automatically stopped by the following functions:

a) Alarm "AUTOSTOP" is activated.See section 7.8.

b) Alarm "SERVO PRESS" is activated.El-motor has stopped due to low servo pressure.See section 7.6.

9. LOAD CONTROL

Lamp "OVERLOAD" illuminates without sound from the buzzer.

The propeller absorbs 1-10 % over max. power. The pitch will automatically reduceto max. power and "OVERLOAD" lamp will go out.

10. FEEDBACK FAILUREIn case of failure in the feedback circuit, the control system "freezes" the present pitchsetting (load) to avoid an uncontrolled run against full power and overload.At the same time "FEEDBACK PITCH" alarm in bridge panel is activated.

When this situation occurs the operator shuold either stop the thruster, or switch over tomanually control by setting the emergency selector switch to "PITCH MANUAL".

Art. no. : | 19272

BRUNVOLL A.S

6415 MOLDE

NORWAY

Prod. Gr. |

CONTROL SYSTEM


SIDE THRUSTER

Date:

Sign.:

28.09.2000

RF/me

7767.30

7 of 7

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o o o ob~qo o o o o o o o o o o o o o

o o o o o o o ob

Measuring instrument: Digital voltmeter.

Switch "ADDR.", and push buttons "SET" / "RESET", see dwg. 7766.85.

1- ADJUSTMENT OF PITCH

Before adjusting a parameter set "ADDR" switch to wanted position,and press "RESET" button.

ADDR. 0: NOT TO BE USED

ADDR. 1: GAIN STARBOARD

Adjustment of max. thruster load to starboard.

Move the control lever to starboard until the propeller absorbs max. load.

Electrical driven propellerHydraulic driven propellerDiesel driven propeller

Read motor running current.Read pressure.Read drop of RPM.

When max. load is absorbed, press "SET" button.

ADDR. 2: GAIN PORT

Adjustment of thruster load to port.

Move the control lever to port until the propeller absorbs max. load.

Electrical driven propellerHydraulic driven propellerDiesel driven propeller

Read motor running current.Read pressure.Read drop of RPM.

When max. load is absorbed, press "SET" button.

Art. no. : | 19271

BRUNVOLL A.S

6415MOLDE

NORWAY

Prod. Gr.

ADJUSTMENT PROCEDURE

FOR CONTROL SYSTEM,

SIDETHRUSTER

PCD4

Dato:

Sign.:

01.03.2000

RF/me

7767.29

Side 1 of 5

ADDR. 3: PITCH REDUCTION 1

Adjustment of pitch reduction when alternators are overloaded.The pitch can be reduced by an adjustable step if the control system is conneted toa pot.free contact from alternators which closes when alternators are overloaded.The pot.free contact is connected to terminals -X2:4 and -X2:37 in electroniccabinet.

Adjust as follows:Drive motor stopped.Move control lever to 100% starboard.Reduce control lever the step you want the pitch to reduce when alternators areoverloaded. Then press the "SET" button.

ADDR. 4: LOAD CONTROL (Electrical driven propeller only)

Adjustment of permitted overload of drive motor.Overload is adjustable from 0% to max. 10% by setting the pitch control lever to aposition between neutral and 100% starboard direction and then pressing the"SET"-button.e.g.Pitch control lever set at neutral +"SET" : 0% overload permitted.Pitch control lever set at 50% st.b. +"SET" : 5% overload permitted.Pitch control lever set at 100% st.b. +"SET" : 10% overload permitted.and so onIf "RESET" is pressed : 5% overload permitted.

ADDR. 5: LINEARIZATION

Linearization OFF : Press "RESET"Linearization ON : Press "SET"

Linearization means that propeller thrust varies linearly to command signal.

ADDR. 6: PITCH SPEED (Proportional valve only)

Adjustment of max. pitch speed signal, port and starboard direction.Max. pitch speed signal can be adjusted to max. +-10V by setting the pitchcommand lever to a position between neutral and 100% starboard direction andthen pressing the "SET"-button.

e.g.Lever set at 50 % st.b. + "SET" : max. +/- 5V speed signalLever set at 80 % st.b. + "SET" : max. +/- 8V speed signalLever set at 100 % st.b. + "SET" : max. +/- 10V speed signaland so on.If "RESET" is pressed : max. +/- 10V speed signal

Art. no. : 19271

BRUNVOLL A.S

6415MOLDE

NORWAY

Prod. Or.


FOR CONTROL SYSTEM,

SIDETHRUSTER

PCD4

Dato:

Sign.:

01.03.2000

RF/me

7767.29

Side 2 of 5

ADDR. 7: DEAD ZONE (on/off valve only)

Dead zone means: The sector of the movement of the control lever that hasno effect on the servo system.

Adjust dead zone as follows:

Drive motor stopped. Press "RESET".If the LEDs on outputs no. 49 and 50 (marked "PILOT VALVE SLOW" onthe control unit in electronic cabinet) are flashing:Move control lever more than 30 % to st.b direction (see pitch indicator) andthen press the "SET" button. Repeat this operation with small increases inmovement until the correct dead zone is set. (No flashing on output 49 and50)."RESET" gives normally the correct value.

ADDR. 7 DEAD ZONE (proportional valve only)

Adjustment of step in command signal from PLC to electronic amplifier cardfor proportional valves, necessary for proportional valve to open. The step isadjustable by setting the pitch command lever to a position between neutraland 100% starboard direction and then pressing the "SET" button.

Pitch control lever set at neutral +"SET" : min. stepPitch control lever set at 100% st.b. +"SET" : max. step"RESET" gives normally the correct value.

2. Potmeter marked "PITCH INDICATOR Rl 1"

Adjustment of pitch indicator (100 %) when control lever is set to max. portor starboard direction.

3. Adjustment of "OVERPITCH LIMIT SWITCHES"

(Propeller not running)

When pitch indicator has been adjusted, limit switches in feedback unit maybe adjusted.

Set switch "MAN/AUTO" in main control panel to position "MAN". Set pitchto 105% starboard direction by operating manual control push buttons marked

with arrows "< " and " >". Stop servo pump and adjust cam forstarboard direction in feedback unit to the point where limit switch is justopening. Secure cam set screw.Carry out same procedure to port. Check that limit switches break signal tothe corresponding solenoids for each direction.

Art. no. : 19271

BRUNVOLL A.S

6415MOLDE

NORWAY

Prod. Gr.


FOR CONTROL SYSTEM,

SIDETHRUSTER

PCD4

Dato:

Sign.:

01.03.2000

RF/me

7767.29

Side3 of 5

4. ADJUSTMENT OF CONTROL LEVER

4.1. MAIN CONTROL PANEL:

Drive motor not running.Connect voltmeter between terminals -X2:3 (0V) (COMMON on voltmeter)and -X2:25 in electronic cabinet.When control lever in zero., measured value should be 0V (+/- 0.2V).If deviation is greater, mid-position of potmeter in control lever should beadjusted mechanically. Max. deflection of control lever to be adjusted by end-position stoppers (socket head cap screw M3) in lever until measured value tostarboard is +10V and -10V to port.

4.2. AUX. CONTROL PANEL 1:

Drive motor not running.Connect voltmeter between terminals -X2:3 (OV) (COMMON onvoltmeter) and -X2:26 in electronic cabinet.Continue as described under section 4.1.


Drive motor not running.Connect voltmeter between terminals -X2:3 (OV) (COMMON on voltmeter)and -X2:27 in electronic cabinet.Continue as described under section 4.1.


Drive motor not running.Connect voltmeter between terminals X2:3 (OV) (COMMON on voltmeter)and -X2:28 in electronic cabinet.Continue as described under section 4.1.

Art. no. : 19271

BRUNVOLL A.S

6415 MOLDE

NORWAY

Prod. Gr.


FOR CONTROL SYSTEM,

SIDETHRUSTER

PCD4

Dato:

Sign.:

01.03.2000

RF/me

7767.29

Side 4 of 5

5. REPLACEMENT OF DEFECT POT.METER IN CONTROL LEVER

See mechanical drawing of control lever. Switch off power supply toelectronic cabinet, and disconnect the wires connected to the defect pot.meter.Set conrol lever in neutral position. Adjust the new pot.meter so that equalresistance is measured between wiper and both endpomts.Connect the wires back to the new pot.meter. (Be sure that the wires areconnected to the same pin-numbers as on the old potmeter).Switch on power supply to electronic cabinet.Final adjustment as described under section 4.

REPLACEMENT OF DEFECT POT.METER IN FEEDBACK UNIT

See mechanical drawing of feedback unit.Switch off power supply to electronic cabinet. Start pump aggregate fromthruster room. Operate mechanically one of the pilot valves to move the pitchto zero position, indicated on the indicator disc in feedback unit. Disconnectthe wires to the pot.meter on terminal block inside feedback unit, and replacethe defect potmeter with a new one.Adjust the new pot.meter so that equal resistance is measured between wiperand both endpoints. (Be sure that the wires are connected to the same terminalnumbers as on the old pot.meter)Switch on power supply to electronic cabinet.Start drive motor and check max. load to port and starboard.If thruster load has to be adjusted, see section 1 ADR.l and ADR.2 for settingof max. load to port and starboard.

Art. no. : 19271

BRUNVOLL A.S

6415MOLDE

NORWAY

Prod. Gr.


FOR CONTROL SYSTEM,

SIDETHRUSTER

PCD4

Dato:

Sign.:

01.03.2000

RF/me

7767.29

SideS of 5

o 0

GAIN ST.BGAIN PORTPITCH RED.iLOAD CONTR,LINEARISATIONPITCH SPEEDDEAD ZONE ADDR.

SET RESET

O

RllPITCH INDICATOR100X ADJUSTMENT O

BRUNVOLL A.S

Ddto 22.11.93Utfwt LO.Godkjent T.G.

CONTROL UNIT FOR ADJUSTMENT

Prosjekt nr.

Mdleslokk

11

Art.nr.19192

Tegn.nr.

7766.85 ABlad

Ant, 1

~~.T •*.' --, if f f*«

INSTRUCTIONS FOR SERVICEAND MAINTENANCE

MAINTENANCE PROGRAM

THRUSTER BODY

1. General

1.1 The thruster body has two oil systems, the inner oil system, or gear housing,and the outer oil system, or shaft sealing. Both systems are connected to thesame gravity tank. (See drawing of lubrication system and instruction forfilling and drainage of oil).

1.2 The gravity tank gives statical over-pressure in both oil systems, and mustalways be filled up to recommended level.

1.3 The outer oil system forms an extra barrier to prevent seawater leakage intothe gear housing.

1.4 The gear housing and propeller hub are internally connected in a common oilsystem.

1.5 A drainage pipe from the bottom of the gear housing gives possibility tocheck the condition of the oil. (Point H).

1.6 The vital components of the thruster body are not accessible for inspectionduring operation, and routines are limited to checking for leakages.

2. Routine inspection

2.1 Leakage in the propeller shaft sealing or gear housing may result in loss ofoil and/or ingress of water.Loss of oil may be registered as a lower oil level in the gravity tank.The oil level is monitored by a level switch.

2.2 Ingress of water may be detected by draining of oil from the outer oilsystem (point B) and/or the gear housing (point H).

2.3 The routine check for leakages is performed as described above as well asby visual inspection of sealing on pinion shaft.

Art.no. :

025328

BRUNVOLL AS

6400 MOLDE

NORWAY

MAINTENANCE PROGRAM

F37C-F45C-F63C-F80C-F100C

FIXED SUB SEA UNIT

BPA VVRP PLC CONTROL

Dato:

Sign.:

03.08.01

OL/os

7779.08

Page 1 of4

2.4 There are several dynamic seals in this system. One is a labyrinth seal in theshaft distribution unit for servo oil which has a small but intended internalleakage where the oil goes from the servo system to the lubricant system toprovide proper lubrication of the oil distribution unit. The excess oil returns tothe gravity tank.

The slight leakage results in a tendency of the propeller blades under load to bemoved out of demand position. The electro-hydraulic control system monitorsthe blade position and will, with a small deviation, hold the blades in position.The diviation are normally of minor magnitude which are barely visible on thepitch indicator on the bridge. Magnitude of the deviation may be limited byadjusting the sensitivity of the control system.

The size of deviation between demand and actual blade position under fullload, gives an impression of magnitude of the internal leakages in the servosystem. A periodical registration of size of deviation will indicate changes inthe condition of these seals.

2.5 Wear on bearings or gear wheel may be controlled by moving the propellerand/or the pinion when accessible.

Control routines

3.1 Weekly:

3.2 Quarterly:

Wl Control of oil level in gravity tank.

W2 Draining of oil from propeller shaft sealing(point B) for control of possible water content.

Ql Approx. 10 litres of oil is drained from thegear housing (point H).New oil is filled to correct level.

Yl Take oil sample for chemical analysis of drainedoil. Interval for total change of oil to bedecided on basis of the quality of oil sample.

Y2 Visual check of elements in the elastic coupling.To be changed if necessary.

Y3 Check that oil level switch is functioning.

Art.no. :

025328

BRUNVOLL AS

6400 MOLDE

NORWAY

MAINTENANCE PROGRAM


FIXED SUB SEA UNIT


Date:

Sign.:

03.08.01

OL/os

7779.08

Page 2 of4

SERVO PUMP UNIT

Routine inspection

When the servo pump unit is operating and has tempered oil in the system, thefollowing should be checked:

Oil level

If there is leakage in the lubricant and sealing system, the level of oil will mostlikely be lowered in the oil tank unit. (Ref. item 2.4, page 2). Check the pipeconnections for possible leakage. Refill oil to correct level.

Filter condition

Filters have indicator which shows when replacement is necessary. If theindicator "shows contaminated element" when the system is in operation andthe oil is tempered, filter element should be replaced by a new one.

IMPORTANT: When running the servo pump unit with cold oil, thepressure drop through the filter will be so large that theindicator points to replacement, this means whenthe temperature is lower than about 35 degrees C.

3. Oil pressure

See drawing nos. 7763.39 (pressure/load pressure diagram) and 7763.31(mode of operation pilot operated pump).

Art.no. :

025328

BRUNVOLL AS

6400 MOLDE

NORWAY

MAINTENANCE PROGRAM


FIXED SUB SEA UNIT


Date:

Sign.:

03.08.01

OL/os

7779.08

Page 3 of 4

Set values:

Propeller type Pump pressure Relief valve Pressure switch

F37CF45CF63CF80CF100C

35 bar35 bar35 bar45 bar45 bar

43-45 bar43-45 bar43-45 bar53-55 bar53-55 bar

approx. 6 - 7 barapprox. 6 - 7 barapprox. 6 - 7 barapprox. 6 - 7 barapprox. 6 - 7 bar

Routine inspections

Weekly: Wl Check oil level in oil tank.

Quarterly: Ql Check the return filter's condition attempered oil. To be replaced if necessary.

Q2 Check the oil pressure in the servo system.(See above table). To be adjusted if necessary.

Half yearly: HI Check that pressure switch is operated atcorrect value.

Yearly: Yl Check that level switch in oil tank is inworking order.

ELECTRONIC REMOTE CONTROL

Routine inspection

When the system is operating, inspection is limited to observation of the variousfunctions.

Normally, the system will require no further adjustment after commissioning.

For safety reasons, a check should be made every week that alarm lamps are inworking order.

Weekly: Wl Check alarm lamps ("lamp test").

Art.no. :

025328

BRUNVOLL AS

6400 MOLDE

NORWAY

MAINTENANCE PROGRAM


FIXED SUB SEA UNIT


Dato:

Sign.:

03.08.01

OL/os

7779.08

Page 4 of 4

60

50

40

A

ro-u

30

20

- 10QJE_COC/JQJ

For thruster type: FSO, FIOO, SPR, SPA

For thruster type: F37. F45, F63

Pumpetrykk, settverdtPump pressure, set value

Overtrykks-ventil, settverdiRelief valve, set value Design pressure.

Trykkbryter, min. trykk, settverdi (v. fallende trykk)Pressure switch, min, pressure, set value (at decreasing pressure)

F100 add. 30.06.95 OL

to approx. 6bar 11.11.93 OL

SPA add. 19.05.93 OLProdgrp-

Rev. Forandring/Change

MSI/Scale

Date/Sign.

Trykkdiagram, pitch VV (R) —

Pressure diagram, pitch VV (R)-

F 37-45-63-80-100-SPR-SPA

Settverdier

Set values

ART. NO.

17822

BRUNVOLL ASBredr. Brunvoll Motortabril* AS

Utf.av/'Prepared23.04.92 OLGodk/Appr.

Tegn./Draw. no7763.39

Rev,c

PITCH CONTROL DIAGRAM (Schematic shown)

Valve:Nan operated Operated

Proportional valveOmstyringshastignel:Pitch change speed:Tid. maks til maks pitch ca. 10-18 sek.Time. max. to max. pitch ca. 10-18 sec.Avpasses etter thruster/bStst0rrelse

3) To be proportioned size of thruster/vesselStart pt.

Innstilles i PLS, se egen instr.To be set on PLC, see PLC. instr.

Etlerfylling" fra gravita-sjonslank til pumpe| 2) Rampe; programmer! i PLS

Ramp: Programmed in PLC "Compensation" filling fromgravity tank to pump.

Alt. leak oil pipesee Lub. servo diagramHandbetjening av ventil

Hand operating of valve

Proporsjonal valve (NG 6 / 10)

tutting/ aviapping

Prnoorlional valve ( CETOP 1 or PUMP PRESSUREJustering av pumpetrykkPump pressure adjustmentPUMP FLOW:Overtr. vent, (juslering)

Relief valve (adjustment) For 3 holde et jevnl pumpetrykk utenpiker av betydning, s3 skaljusteringsskrue far "pumpeflow" sl3 imaks. flow posisjon. Ifabrikkinnsl.)

To hold a constant pump pressurewithout significant peaks, the pump flowadjusting screw should be set to max.flow position (factory setting)

PITCH SERVO CYLINDERTolal volume.

CONTENTS

1. GENERAL 1

2. FILLING OF OIL

2.1. Filling the thruster when ship is in a dry dock.2.2. Filling the thruster with the ship afloat

3. DRAINAGE OF OIL

3.1. Drainage of the gravity tank3.2. Drainage of the thruster when ship is in dry dock.3.3. Drainage of the thruster with the ship afloat

4. AMOUNT OF OIL IN UNITS 4

1. GENERAL

The propeller shaft sealing system, gear housing and hub are to be completely filledwith oil prior to launching of vessel to prevent ingress of water in the system.

Normally, the system should be filled-up with oil through the gravity tank, and a 3 myfilter. See the aclual drawing of lubrication- and servo-system.

Ensure use of the correct type of oil shown on the lubricant chart.

With the ship in operation change of oil should be planned to occur at regular docking.

NOTE!If a filling pump unit is used this unit must be equipped with a suitable (3my)filter. Additionally, the following precautions should be duly noted:

WARNING!

If a filling pump is connected directly to the gear housing (H-pipe), make sure notto pressurise above normal gravity pressure, maximum 1 bar.This can be achieved by keeping air ventilation (K-pipe) open and securing thepump pressure with a suitable relief valve. Excessive pressure can damage orblow out the blade seals.

It is prohibited to connect pumping devices to the shaft sealing units A or B pipeports.

Art. no.: 017358

BRUNVOLL AS

6415 MOLDE

NORWAY

INSTRUCTION FOR FILLING

F3

BI

AND DRAINAGE OF OIL

7C-F45C-F63C-F80C-F100CJA VV PUMP AGGREGATE

DateCreate

Contr.

22.07.03IH

KA

7762.54

1 of 4

2.

2.1.

2.2.

FILLING OF OIL

The filling of oil should always be through a 3my filter.

Filling the thruster when ship is in a dry dock

a) Turn the propeller until the breather plug on the propeller hub is at its highestpoint, and remove the plug.

b) Fill oil into the gravity tank until the hub is completely filled with oil, and oil freeof air comes out.

Refit the breather plug, and remember the monel washer.

Table for tightening torque:

UF45C

65 NmM16

UF80CM20

309 Nm

c) Open the valves marked K (for air bleeding gear housing), B (for bleedingpropeller shaft seal unit) and H (for bleeding the pipeline to gear housing).

d) Continue with filling oil on the gravity tank until oil free of air comes out ofvalves K, B and H, and then close the valves.

e) When the gear housing is filled up, bearing housing for the pinion is bled throughpoint K 1, and the rack gear is bled through point K 2.(Point K 1 concerns UF45C and UF63C).

f) Continue with filling until you can sec oil in the middle oil level indicator on thegravity tank, marked FILL LEVEL.

Filling the thruster with the ship atloat

If draining and filling of the thruster unit have to be carried out with the ship afloat specialprecautions have to be taken in order to avoid water ingress and to ensure air evacuation afterfilling of oil.

With the ship afloat it is necessary to maintain the header tank pressure on thepropeller shaft seal system (Pipe A) at all times.

Emptying of the thruster lubrication system at sea should preferable be carried out with theship alongside a quay (calm waters), and should only be carried out if absolutelynecessary. The reason being a certain risk of limited water ingress and the need for specialprecautions to evacuate air in the thruster unit.

Art. no.: 017358

BRUNVOLL AS

6415 MOLDE

NORWAY

IN

F3

BI

STRUCTION FOR FILLING

AND DRAINAGE OF OIL

7C-F45C-F63C-F80C-F100C

>A VV PUMP AGGREGATE

DateCreate

Contr.

22.07.03IH

KA

7762.54

2 of 4

V.

VI.

Vll.

If a filling pump unit is used, the procedure for filling is:

i. Connect PE (Pump Emptying Port) on the pump with the PE port on the "clean oil tank",and PF (Pump Filling Port) on the pump with the PF-port on the gravity tank.

ii. Open the valves marked K (for air bleeding gear housing) and H (for bleeding the pipelineto gear housing).

iii. Fill the thruster through the gravity tank.iv. Open the valves marked B (for bleeding propeller shaft seal unit), and continue filling oil

into the gravity tank until oil free of air comes out of valves K, B and H. Then close thevalves.

Since there is no access to the air-bleeding plug on the hub when the ship is afloat, it isnecessary to conduct additional air bleeding procedures.

Subsequent to the filling and initial air bleeding, the Hydraulic Power Unit is first started.Then the pitch is activated from full PS to full SB, and continued repeated air bleeding (K-pipe) is conducted.Then the thruster is started and run for a period of approx. 30 minutes at zero pitch. Duringthis period the air-bleeding valve is repeatedly opened to check for air.Subsequently, when the thruster is operated with load (preferably from full PS to full SBpitch) air bleeding is again conducted. This procedure should be repeated during the first 3to 4 hours of operation to minimise the risk of entrapped air in the lubrication and servosystem.

3. DRAINAGE OF OIL

3.1. Drainage of the gravity tank

The gravity tank is drained through the valve point H.

If the gravity tank is not to be drained, but only the gear housing and the propeller sealsystem, the valve under the tank must be closed.

3.2. Drainage of the thruster when ship is in dry dock

The gear housing is drained through the plug on the cover under the gear housing, andthe propeller hub through the breather plug on the propeller hub. The propeller bladesare turned so that the plug is on the lower side.

The valve point K must be open for air bleeding. The speed of the draining could besomewhat controlled by restricting the airflow through the filling point on top ofgravity tank and the valve point K.

The propeller shaft sealing system is drained through valve point B.(Complete drainage is possible by use of a suction pump)

Art. no.: 017358

BRUNVOLL AS

6415 MOLDE

NORWAY

IN

F3

BI

STRUCTION FOR FILLING

AND DRAINAGE OF OIL

7C-F45C-F63C-F80C-F100C

>A VV PUMP AGGREGATE

DateCreate

Contr.

22.07.03IH

KA

7762.54

3 of 4

3.3. Drainage of the thruster with the ship afloat.

See notes given in chapter 2.2. In particular note that the shaft seal outer barrier must be keptpressurised during the whole operation.

i. Let the thruster run for aprox. 30 min. to gain temperature and adequate viscosity in oil.ii. Disconnect/close the connection to the A-pipe directly under/ adjacent to the gravity tank

in order to maintain the static header tank pressure on the shaft seal system.iii. Connect PE-port on the pump with PE-port on the thruster (H-pipe), and PF-port on pump

with PF on "Used oil tank"iv. Let the pump run as long as it delivers oil, then stop the pump.

4. AMOUNT OF OIL IN UNITS

The amount of oil is exclusive the piping system.

TYPE

Gear housing/propeller hub

40 litres

F45C

70 litres 170 litres

F80C

390 litres

F100C

>0 litres

loMresPropeller shaftsealing unit

1 litre 4 litres 6 litres

Gravity tank 40 litres 40 litres 90 litres JO litri

Total amountof oil

itres 115 litres 265h%es 485 litres 960 litres

Art.no.: 017358

BRUNVOLL AS

6415 MOLDE

NORWAY

INSTRUCTION FOR FILLING

AND DRAINAGE OF OIL


BPA VV PUMP AGGREGATE

DateCreate

Contr.

22.07.03IH

KA

7762.54

4 of 4

Brunvoll Thruster Units

List of Approved Oil Types to be filled into:

• Hydraulic Power Unit

• Gearhouse System (pipe "E")

« Sealing System (pipe "A")

OIL COMPANY

BP

CASTROL

CHEVRON-TEXACO (FAMM)

CONOCOPHILLIPS

EXXONMOBIL

SHELL

STATOIL

TOTALFlNAELF

MINERAL OILS

ENERGOL GR-XP 68

Alpha SP 68

MEROPA 68 (EP)

Chevron Gear Compounds EPISO 68

PHILGEAR ISO Grade 68

SPARTAN EP 68

MOBILGEAR 626

OMALA 68

LOAD WAY EP 68

ELF EPONA Z68

SYNTHETIC OILS

ALPHASYN T 68

OMALA HD 68

MERETA 68

General Requirements:

a Oil Viscosity Grade according to ISO 3448, ASTM D-2422: ISO VG 68.- Oils with lower viscosity grade must under all circumstances not be used.- Oils with ISO VG 100 may exceptionally be approved provided that the oil's viscosity

index ensures a viscosity comparable to ISO VG 68 at low temperatures (0-10 °C).a The lubricant used shall be an Extreme Pressure - / EP- lubricant.Q The FZG test failure stage according to ISO 14635-1, ASTM D 5182, DIN 51 534

shall be: FZG > 12a The oil shall have good stability in presence of water and good demulsability with rapid

water separation.

NOTE 1: hi case an Oil Filtration Unit is used, it is recommended to use synthetic oil for shipoperation in cold climates (e.g. North Atlantic). Mineral oil may be used if special precautionsare taken (e.g. heating devices) to prevent foam formation in the thruster by the filtration pump.

NOTE 2: Special requirements may apply to the U80 with gear set 11/36 and for the U100 withgear sets 13/51 and 16/58, if rated at their maximum approved DNV rating.

Art. no. : 008872

BRUNVOLL A.S

6415MOLDE

NORWAY

CHART OF LUBRICANTS

OIL TYPES

37-45-63-80-100 SERIES

Date:

Sign.:

04.04.2003

TH/KA

7739.40

1 ofl


1. The servo pump unit should be installed in thruster room, at a level not lower than tunneltop, and as near thruster unit as possible, so that pipes between pump unit and thruster unitare as short as possible.Max. recommended length of each pipe 4-5 m.

All pipes from gravity tank must be installed with "slope down", in order to avoid airlocks. This is of extra importance for pipe "C" to achieve "self-maintaining" ofairbleeding in servo system whenever these are a part off the delivery.(Pipe C: Compensation filling to pump)

All pipe-laying in servo-system should be performed with "hydraulic" tubes and "Ermeto"cut ring fittings. Thread-tape, tow etc. must never be used. It is extremely important thatburrs, scale and corrosion are removed, and that tubes are thoroughly cleaned beforeinstallation.We recommend cleaning the seamless pipes with special spounge-plugs shot through thepipes with compressed air (6-8 Bar). Air pressure forces the plug through the pipesabsorbing dirt and cleaning the pipe inner wall.The plugs are only to be used once, and two shots are recommended. Be sure to usecorrect plug size for the pipes. The pipes are to be cleaned one by one without any fittingsmounted.

2. Oil filling

Fill gravity tank to correct level, middle oil level eye. Use afiltration unit. (Filtration element 3 micron nominal).

3. Start of servo pump

Start servo-pump by service switch on starter cabinet. Run servo-pump and hand operatesolenoid valve(s) for a period to release "all" air from servo system.

Check return oil condition by tapping-off some oil through the V

5. Pressure switch, adjustment (if necessary)

5.1 Adjust pressure switch to approx. 7 - 8 bar.

6. Filler indicator

Check filter indicator (at oil working temperature).

NOTE: At low oil temperature, filter indicator can show "redvalue" without "dirty" filter element.

7. Service work

7.1 Oil change intervals: See maintenance program for thruster unit.

7.2 Gravity tank cleaning

Remove top cover of tank. Use a rubber scraper to clean inside of tank.

IMPORTANT: Never use cotton waste, rags, etc.

1 This applies only when power unit servo unit is part of the delivery.

Art. no. : 17359

BRUNVOLL A.S

6415MOLDE

NORWAY

Prod. Gr. | UK

INSTRUCTION FOR

HYDRAULIC SERVO SYSTEM VV

F 37-45-63-80-100C-SPR-SPA

Dato:

Sign.:

14.01.1998

BM/os

7762.53 C

2 of 2

Pump with pilot-operated pressure regjlator 17, 22, 30, 39, 67 crn3/rev

The stroke ring (T) is held between two control pistons (5) and (3) whose cross—sectionsare in the approximate ratio of 2:1. The smaller of the two pistons is perma-nently subjected to system pressure and, assisted by a spring, it holds thestroke ring in its basic, maximum—displacement position.-System pressure is also admitted to the pressure regulator @ . In the basicposition this 3-way directional control valve unloads the larger control piston.When the pressure attains the setting of the valve spring it is admitted to thelarge control piston and the stroke ring moves to the middle against the resi-stance of the smaller control piston. The delivery is reduced according to theconsumer demand.The characteristics of the pump are shown by the graph. The breakaway part ofof the curve is relatively steep (a.) due to the switching function of the pressureregulator.

FIRST START

Ref. drawings: "Instruction start-up pump aggregate 3PA WR, no. 6758.18".Pressure diagram: No. 7767.39 B

To bleed the air from the hydraulic servo system ir, a smooth andeasy way, use the following prosedure:1. Check oil supply to pump by means of drain/bleed valve located near pump.2 Fully sleeken (CCW) pump pressure adjustment s:-ew.

Deaerating of air from system is most effective ct lowest possible pressure.3. Start and stop pump several times, (at pump rur for short periods.

Bleed and check oil.4. Run pump continuously. Move "propeller pitch" by hand operating the

solenoid valve (large, NG10).Move pitch repeatly backwards and forwards to s-d stop.Check oil (Bleed valve)If necessary, take a break and allow oil/air to ceaerate.

5. When the bleed procedure is satifactorily carried out, adjust pumppressure/pitch speed etc. according to specified values.

Filling the pump bodyThe pump body must be filled with fluid via the crain line beforethe pump is operated for the first time. (Done by Brunvoll)

•Jf Adjustment of stroke-ringscrew and zero position.These adjustments are carried out at thefactory and must not be altered.

(~) Higher pressure{") Lcwer pressurePressure adjustment

cE\

o

Zero-position, fixed

Q,,ai limiting

OReduce(~ Increose p bar

Rev. Forandring/Change Date/Sign.

Instruction for Start Up/ adjustment

Bosch FPV 17-67 Vane pump applied to

Brunvoll BPA WR

Prad.grp.

M3l./Scale:

ART. NO.17817

BRUNVOLL ASBradr. Brunvotl Motorfabrikk AS

Utf.av/Prepared22.03.94 GTSGodkj./Appr.22.03.94 PLTegn./Draw. no

7763.31

Rev.

BRUNVOLLBRUNVOLL A.S. 6101 MOLDE NORWAY

Large control piston w. orifice.

Pressure Compensator.

To clean up orifice inpump "large control piston".

1-. Remove compensator device complete(Close to the pump housing)

2: Pull out piston by means of a M4 screw.

3: Clean orifice in center of piston.(Orifice dia. approx. 01mm)

4: Reassemble.

Spool w. bleeding holesHoles approx. 01mm.

To clean up "Bleeding holes"in pressure Compensator in Pump.

1: Shut pipe valves leeding oil to pump.2: Remove pressure compensator from pump.3: Unscrew plug in bottom end of compensator.

4: "Shock" (Shake off) the compensator againsta wooden piece such that spool moves out.Pull out the spool.

5: Clean holes in spool by pressured air.

6: Reassemble.

When pump is running without load (pitch control valves in neutral), and all is OK,the pressure readed on pressure gauge, will then follow the pump pressure adjusting screw.(up and down).If not, most probable the problem my be caused by blocked "orifices", see above.(Particles/ chips etc. from metal cutting at pipework)Instruction for "To clean Up,", see above.

Pg.: UL Art. no: 20572

BRUNVOLL ASBredr. Brxmvoll Motortobrikk AS

Instruction "To clean up orifices"in pump pressure Compensator/regulator

Bosch variable Vane Pump

05.12.94 OL

7769.74Page 1 of 1

HovedpanelMain control panel

Ekstrapanel (er)Auxiliary control panel (s)

Power supply

I .J

StyreskapCabinet of electronics

Styresignal tildriv motorstarterStart/stopsignal to drivemotor starter

7

Power supply

BRO

BRIDGE

THRUSTER ROOM

Starterskap, pumpeagg.Start cabinet, pump agg.

L_

i LIZ.~Vjy I

Power unit servoI

HydraulikkforbindelserPiping

Elektriske forbindelserCables

WARNING!SHUT OFF valves, marked with *on diagram, must always be openwhen running pump.

TilbakemeldenhetFeedback unit

Rev.High, press, filt.Endring/Modification

11.09.98 01Dat./Sign.

Styring, skjematisk VP-VVRP

Sidepropell, VP-VVRP

Thruster control syst. CP-VVRP (Schematic)

Mat/Scale

ART. NO.20861

BRUNVOLL ASBrisdr. Brunvotl Motorfadrlkk AS

Utfart av/Prepared08.03.95 PLKontr/Checked

Tegn./Draw. no7770.37

Rev.

A

Fyll.niv3Fill Level

GravifasjonsfankGravity tank

Til f, eks tanktoppDrain valves to apoint easilyacessible

Thruster under—vannsseksjon

Thruster subsea section

Pipe A: Oil to shaft sealing systemPipe B: Drain from shaft sealing systemPipe C: Compensation filling to pumpPipe E: Oil to gear housingPipe H: Drain from gear housing (bottom)Pipe L Leak oil, servo-pumpK: Air bleedingPipes S-S: Oil to/ from servo-cylinder

NOTE: The letters marked on drawing arestamped on the units. The units are equipped withErmeto fittings. Steel tube quality ace. to DIN 2391or equivalent standardMax. pipe length between servo-pump unit andthruster unit: Approx. 5m

IMPORTANT!All pipes from gravity tank must be installed with"slope down", min. 10°, in order to ensuretroublefree oil flowNBI Avoid "air locks".

Yard delivery

* WARNINGI SHUT OFF valves, marked withon diagram, must always be open whenrunning pump

Rev.Heigt matrix removed. Item 14 optional 14.02.03 BMForandring/Change

Prodgrp, BL

Mai/Scale:

Date/Sign.

Sm0re-/servosysfem 80 VVR spes,

Lubrication/servo system 80 VVR spec.

F80C F VVR spec, pipe flanges/drain pump

(stand.)ART, NO.

026517

BRUNVOLL ASBredr. Brunvoll Motorfabrlkk AS

Utf.av/Prepared21.03.00 BMGodkj./Appr.

Tegn./Draw. no

7782.47

Rev.

A

'. /-- » "Vur 2 tt W P A R T S L I S T

BRUNVOLL A.S. NO-6415 MOLDE, NORWAY

Product no. Description Draw. no. Sub. dw. no.028901 LUBRICATION SERVO SYSTEM 7782. 47/A

F80 LFWRP30 34/34/34 without drainpump

Quant2

2

2

7

7

2

2

4

4

5

1

6

5

1

1

ST

ST

ST

ST

ST

ST

ST

ST

ST

ST

ST

ST

ST

ST

ST

ST

ST

ST

ST

ST

Pos001

001

002

002

003

003

004

004

005

005

006

007

008

009

010

Oil

012

013

014

015

Art.no026439

026419

02S438

021460

026438

021460

026437

002030

026440

002030

002008

002467

013630

017737

018821

013630

000288

002550

026424

001426

DescriptionFLANGE 18/15-1/2"JIS ISA

O-RING 0 19,60 x 2,40

FLANGE 22-3/4" JIS 20A

O-RING 0 24,00 x 3,00

FLANGE 22-3/4" JIS 20A

O-RING 0 24,00 x 3,00

FLANGE 35-1+1/4" JIS 25A

O-RING 0 29,50 X 3 , 00

FLANGE 28-1" JIS 25A

O-RING 0 29,50 X 3,00

PIPE COUPL STR MALE STOD

PIPE COOTL STR MALE STUD

STRAIGHT STDD ADAPTER

STRAIGHT STDD ADAPTER

STRAIGHT STUD ADP 35-1 1/4

STRAIGHT STOD ADAPTER

PIPE COUPL RED STANDPIPE

PIPE COUPL TEE EQUAL

HAND POMP W/FITTINGS (DREN

PIPE COUPL STR MALE STUD

Printdate: 13. 03. 03 Page; l

Chg. date Responsible140203 MARBAA

Draw.no Seq6777. 2b 1001

2001

6777.24 1002

2002

6777.24 1003

2003

6777.23 1004

2004

6777.29 1005

2005

1006

1007

1008

1009

1010

1011

1012

1013

7782. 48/A 1014

1015

AlexHighlight

66

CO :co I

33

o

Section view A-A

1 1 . 5 43

1 . 8 ±0.05

Detail BScale:2:1

15.03.00 KI

B

12

Section view A-A

Detail BScale:2:1 15.03.00 KI

HilB*to).k/Stilt

^rt. Nr.

026412

026438

Matr.

SS 2348

NVA

liitBriil«/ttaUri«l

FLENS 22-3/4"/JISF7806 20A(027.2)FLANGE

BRUNVOLL ASBrodr. Brunvoll Motorfabrikk AS

N-6415 Molde Norway

6777.24

3.2

Section view A-A

13.5

2.4+0.05

*rt. Nr.

026411

026437

tfatr.

SS 2348

WA

CM

O O

0.2

v

13.5

Section view A-A

2.4 ±0.05

CMO O-I-

3. 2/\*

0.2 + 0 . 10I

Detail BScale: 2:1

21.03.00 OS

Konfircrt/Conftrwl

^rt. Mr.

026420

326440

\flatr.

SS2348

WA

FLENS 28-1"/JIS F7806 25A(034.5)FLANGE

BRUIWOLL ASBrodr. Brunvoll Motorfabrikk AS

N-641S Molde Morway

6777.29

Procedure for determination of header tank height

Fill levelFyllnivl

Header /Gravity tank

T^-

Shaft Immersion [ m ]

The max. and min. heights aredetermined from max, and min,pressure differential, seawafer - oil.The specification of gravity tankheights refers to conditions where thethrusfer is running.For actual heights, see the encloseddrawing entitled;"Determination of Oil Header TankHeight"

Thruster sub sea unit.Thruster undervannseksjon.

Principle sketch Lubrication- /servo system(Exemplified for CP propeller)

Rev. Endring/Modification Dat./Sign, Rev. Forandrlng/Change Date/Sign.

Utfart av/Drawn by01,03,01 BM

Prosess/Process Materiale/Materiat Prod.oppl./info.

Kontr./Checked08.05.01 K.A.

Vekt/Wpight toteranser/Unspecified tolerances

Kfr./Confered MIlestoNk/Scale1:1

BRUNVOLL ASBradr, Brunvoll Motorfabrikk AS

Moide, Norway

Plassering av grav.tank

Location of Header / Gravity tank

Suppl.tegn./draw,' 027631

Tegn./Draw. no

7786.01

Rev.

A

Determination of Oil Header Tank Height

from max. and min. Ship Draught /

Shaft Immersion for Thruster Operation,

EK Mane Bar propeller shaft seal.

3 4 5 6 7 8

Shaft immersion [m]

10

•Min. height — —Max. height

Art. no.: Prod, gr.: Date 04.05.2001

BRUNVOLL AS6415 MOLDENORGE

Determination of Header/Gravity Tank Height

EK Mane Bar propeller shaft seal.

Sign. KA/BM

Contr..

7785.981 of]

CONTENTS

1. REMOVAL OF THE THRUSTER BODY 2

1.1. Generally 21.2. Removal of the coupling half. 21.3. Disassembling the thruster body from the tunnel 2

2. INSPECTION OF SEALS 3

2.1. The seals on propeller blades 32.2. The seals in servo system 32.3. The seals on propeller shaft 32.4. The seals on pinion shaft 4

3. INSPECTION OF BEARINGS AND GEARS 4

3.1. Inspection the crown wheel 43.2. Inspection of the pinion .43.3. Inspection of the bearings on propeller shaft 4

4. REPLACEMENT OF BEARINGS AND GEARS 5

4.1. Generally 54.2. Removal of the pinion 54.3. Removal of the propeller shaft 54.4. Assembly of the propeller shaft 54.5. Assembly of the pinion 5

5. ASSEMBLING THE THRUSTER UNIT 6

5.1. Generally 65.2. Assembly of the thruster body 65.3. Assembling the thruster body into the tunnel 85.4. Fitting the rack gear 95.5. Fitting the coupling half. 9

6. SUPPLEMENTARY INSTRUCTION DRAWINGS 10

Art.no.: 015789

BRUNVOLL AS

6415 MOLDE

NORWAY

1INSTRUCTION FOR SERVICE AND

MAINTENANCE

THRUSTER UNIT UF80TC

DateCreate

Contr.

08.12.00IH

OBH

7758.10

l o f l O

1. REMOVAL OF THE THRUSTER BODY

1.1. Generally

Inspection/replacement of seals in propeller hub, on propeller shaft, and in oil insertionare possible without removing the thruster body from the tunnel. Inspection of thecrown wheel is also possible.

The pinion can be removed, without removing the thruster body from the tunnel. Forremoval of pinion, see item 3.2.

1.2. Removal of the coupling half

For removal of coupling, see instruction drawing no. 7758.05.

Remove the setscrew, which keeps the different parts of the tool together, and fit thetool as shown.

The hydraulic nut is fitted with the piston in its outer position, and the pressure israised. The oil injector is connected to the coupling. The oil pressure on the surfacebetween the conical liner and the coupling is raised, and the coupling will loosen.The pumping is continued while at the same time the pressure in the hydraulic nut isreduced.

The tool is removed, and the screw is fitted again.

1.3. Disassembling the thruster body from the tunnel

For removal of propeller blades mounting tool, article no. 023830 is to be used.See instruction drawing no. 7772.57.

The rack gear is to be removed.

The stay is flame-cut far enough from the gearing housing allowing the thruster bodyto be lowered. The screw connection between the stay and the body can be removed, ifnecessary. The screws between the tunnel and the thruster body are removed, and theunit lowered. See instruction drawing no. 7769.22.

NOTE! Prior to disassembling the crank discs are to be turned anticlock-wise equivalent to full forward pitch. The push rod for the feed-back unit will then be at the lowest and is therefore betterprotected against damage during disassembling and assembling.

Art.no.: | 015789

BRUNVOLL AS

6415 MOLDE

NORWAY

INSTRUCTION FOR SERVICE AND

MAINTENANCE


DateCreate

Contr.

08.12.00IH

OBH

7758.10

2 of 10

2. INSPECTION OF SEALS

(Item nos. refers to drawings of thruster body and pinion sub-assembly)

2.1. The seals on propeller blades

The propeller blades may be removed one by one. The blade-sealing rings (item 40)are exposed when removing the propeller blades. At re-assembling the sealing ringsare to be partly filled up with seawater resistant grease.

NOTE! Great care must be taken when handling the propeller blade, sothat the mating surface for the sealing ring is not damaged.

2.2. The seals in servo system

To gain access to the dynamic seals in the servo system, the cover for the thrusterbody (item 7) is to be removed. The outer cover for the propeller hub (item 14) isremoved by using 2 off hexagon socket setscrews (item 101).

For removal of piston, see instruction drawing no. 7758.03.

Remove the setscrew which keeps the different parts of the tool together, and fit thetools as shown. Raise the pressure in the hydraulic nut until the nut (item 19) can beloosened by use of a pin in the holes provided. After use, the tool is removed, and thescrew is fitted again.

The inner cover (item 13) should be removed. The yoke (item 10) is moved out alongthe piston rod (item 16) until the linkages stop the movement. The screws (item 89)are removed, and the studs (item 20) are pulled out using puller, article no. 020326.

The pivot ami (item 31) and the nut (item 95) are removed, and the bearing housing(item 24) with bearing is pulled off. Hexagon head screw (item 85) is removed and thetube (item 26), which passes through the propeller shaft and piston rod, is pulled out.

There are also dynamic seals between the inner oil insertion (item 15) and the rod(item 23), and between the sleeve (item 35) and the outer oil insertion (item 6).To gain access to the seals, it is necessary to dismantle as follows:The location bolt (item 51), the pipe connection (item 43), the hexagon head screw(item 81) and the outer oil insertion. At last the hexagon head screw (item 83) and theinner oil insertion are removed.

Thus, all dynamic seals are accessible for inspection/replacement.

2.3. The seals on propeller shaft

To gain access to the dynamic seals on the propeller shaft the propeller hub, witch isconnected with an oil shrink connection, must be removed. See instruction drawingno. 7758.04. The bush (item 36) should be removed first.

Art.no.: 015789

BRUNVOLL AS

6415 MOLDE

NORWAY


MAINTENANCE


DateCreate

Contr.

08.12.00IH

OBH

7758.10

3 of 10

2.4.

The hydraulic nut is mounted against the propeller hub with the piston in its outerposition. Pressure is raised in the hydraulic nut. The oil injector is connected to thepropeller shaft, and using the injector, pressure is raised, and the propeller hub willnormally loosen easily. Injection of oil is continued, while at the same time thepressure in the hydraulic nut is re-leased. If the propeller hub does not loosen in thisway, thicker hydraulic oil may be used.

The propeller shaft seal (item 53) is now accessible. To gain access to the lip seals(item 54) on the propeller shaft, the propeller shaft seal is pulled off.

NOTE! Great care must be taken when handling the seal, so that themating surfaces are not damaged.

The housing (item 8) with lip seals is removed with great care in order to avoiddamaging the seals. The lip seals (item 54) should be coated with grease before re-assembling.

The seals on pinion shaft

To gain access to the sealing rings (item 16 on pinion sub-assembly) the bearing housing(item 3) is removed. The sealing rings are coated with grease before re-assembling.

The sleeve (item 5) with O-ring (item 13) is fitted at least.

INSPECTION OF BEARINGS AND GEARS

(Item nos. refers to drawings of thruster body and pinon sub-assembly)

Inspection the crown wheel

When the oil has been drained from the gear housing, the crown wheel may beinspected through the hole at the bottom of the gear housing.A lid (item 34) covers the hole.

Inspection of the pinion

In order to examine the pinion with its bearings, the hexagon head screw (item 79),and pinion (item 1) are to be removed.

If the thruster body is not disassembled from the tunnel, great force may be used topull out the pinion. 3 off hexagon head screws (item 79) are used for pulling out thepinion, after the hexagon head screws (item 11 on pinion sub-assembly) are removed.

3.3. Inspection of the bearings on propeller shaft

The spherical roller bearing on the propeller shaft may be inspected after thedisassembly as described under item 2.3.

3.

3.1.

3.2.

Art.no.: 015789

BRUNVOLL AS

6415 MOLDE

NORWAY

INSTJ

1

RUCTION FOR SERVICE AND

MAINTENANCE

[HRUSTER UNIT UF80TC

DateCreate

Contr.

08.12.00IH

OBH

7758.10

4 of 10

In order to inspect the other bearings on the propeller shaft, the unit must be removedfrom the gear housing. Hexagon head screw (item 76) keeps the unit in place. Whenremoving the propeller shaft from the gearing housing 2 off guide pins, article no.020328 are used. See instruction drawing no. 7769.23.

4. REPLACEMENT OF BEARINGS AND GEARS

(Item nos. refers to drawings of pinion sub assembly and propeller shaft sub-assembly)

4.1. Generally

Replacement of bearings and gears is a skilled job. This should be carried out in aworkshop under the supervision of a Brunvoll service engineer, using the requiredspecialised tooling.

4.2. Removal of the pinion

Removal of pinion from the gearing housing is as described under item 3.2.After the bearing housing (item 3) has been removed, the bearing housing (item 2)with bearings may be pulled off. Retaining ring (item 10) may be removed, and thebearing (item 8) may also be pulled off.

4.3. Removal of the propeller shaft

Propeller hub and seals are removed as described under item 2.3. The propeller shaftshould be removed as described under item 3.3.

The outer bearing housing (item 4) is removed and the spherical roller bearing (item10) is pulled off the propeller shaft. After removing the bearing housing (item 6) withcup, and locking nut (item 11), the bearing housing (item 5) with bearings is pulled offthe propeller shaft.

4.4. Assembly of the propeller shaft

Tightening torque for hexagon socket head screw M24 (item 15): 1080 NmAll screws should be secured with Loctite 243.

If replacement of spherical axial roller bearings (item 9) is necessary, a complete pre-adjusted bearing unit is delivered from Brunvoll.

Locking nut (item 11) should be tightened and secured.

4.5. Assembly of the pinion

Lower bearing (item 8) is fitted followed by ring (item 4) and retaining ring (item 10).The ring acts as a guide for the bearing outer ring during assembly.

Art.no.: 015789

BRUNVOLL AS

6415 MOLDE

NORWAY


MAINTENANCE


DateCreate

Contr.

08.12.00IH

OBH

7758.10

5 of 10

If replacement of spherical axial roller bearings (item 9) is necessary, a complete pre-adjusted bearing unit is delivered from Brunvoll.

All screws and plugs are secured with Loctite 243.

5. ASSEMBLING THE THRUSTER UNIT

(Item nos. refer to drawings of thruster body, thruster unit and rack gear)

5.1. Generally

All O-rings that have been removed must be checked for damage and replaced ifnecessary. Sealing faces against seawater must be thoroughly cleaned, and coated withliquid gasket (for instance Permatex no. 3).

In general all screws are to be secured with Loctite 243. The exception is oil bleedingplugs of VSTI type, and the screws for propeller blades. The propeller blade screwsare to be coated with Molykote.

5.2. Assembly of the thruster body

2 off guide pins, article no. 020328 are used when assembling the propeller shaft intothe gearing housing. See instruction drawing no. 7769.23.

Axial movement of the flange on propeller shaft adjusts the crown wheel.See instruction drawing no. 7758.02.

The pinion is adjusted using an adjustment ring (item 38) between the bearing housingand the gear housing. Tooth mesh between pinion and crown wheel is adjusted asshown on instruction drawing 6731.22.

The backlash could be measured by mounting an arm on the propeller shaft end.Backlash is measured by means of a dial gauge on the arm, 299 mm from the centre,which corresponds, to the mean crown wheel radius.

This measured backlash should be:

2.1122= 11/54Z1/Z2= 11/48Z1/Z2= 11/43Z1/Z2 = 13/46Z1/Z2 = 11/36

0.20 - 0.25 mm0.25 - 0.30 mm0.25 - 0.30 mm0.25 - 0.30 mm0.30 - 0.35 mm

The backlash may also be measured and later checked on the pinion using adjustmenttool article no. 020320 and a dial gauge. The measured backlash is then increased inproportion to the gear ratio.

Art. no.: 015789

BRUNVOLL AS

6415 MOLDE

NORWAY

INST]

1


MAINTENANCE

fHRUSTER UNIT UF80TC

DateCreate

Contr.

08.12.00IH

OBH

7758.10

6 of 10

Z1/Z2 = 11/54 Measured: 0.98 - 1.23 mmZ1/Z2 = 11/48 Measured: 1.09 - 1.31 mmZ1/Z2 = 11/43 Measured: 0.98 - 1.17 mmZ1/Z2 = 13/46 Measured: 0.88 - 1.06 mmZ1/Z2 = 11/36 Measured: 0,98 - 1.14 mm

The cover (item 5) is fitted with oil inlet, marked B, in lowest position.

The thruster body could be delivered with two alternative propeller shaft seals:Mane Bar EK 240 and A8-240 Compact Composite.

Mane Bar EK 240:

Clean the seal, the shaft sleeve and the running surface. Cover the seal's running surfacewith a light film of manufacturer's approved greases and presses the seal against its seat.

Approved grease types for shaft seal type "Mane Bar":

BP : BP Energrease MMEPCASTROL : Burmah Castrol-Spheerol AP GradesSHELL : Shell Alvania EP Grease No. 2TEXACO : Texaco Mulitifax EP 2

A8-240 Compact Composite:

Reference is made to separate service- and maintenance instruction from Deep SeaSeals Limited. For tightening torque, see figures below:

NOTE! When handling the seal, it is essential that the sealing faces beprotected from damage.

For fitting of the propeller hub, see instruction drawing no. 7758.04.

The hydraulic nut, with its piston in retracted position, is mounted against thepropeller hub and the conical liner. The oil injector is connected to the propeller shaft,and the oil pressure on the surface between propeller shaft and conical liner is raised.The pressure is raised simultaneously in pump and injector.When the axial drive-up length has exceeded the piston stroke on the nut, the pressureis to be released so that the oil can be drained from the oil shrink surfaces.Then, remove the pipe between the oil pump and the hydraulic nut, and re-tighten thenut until the piston returns to the retracted position. Again, raise the pressure in bothpump and injector simultaneously, until the hub rests against the sleeve on thepropeller shaft (item 17).

The tool is removed and the locking nut (item 12 on propeller shaft sub-assembly) istightened and secured.

Art. no.: 015789

BRUNVOLL AS

6415 MOLDE

NORWAY


MAINTENANCE


DateCreate

Contr.

08.12.00TH

OBH

7758.10

7 of 10

Fit the bush (item 36).

When the sleeve (item 18) is assembled onto the piston rod (item 16), the radial holesin the sleeve must be in line with the corresponding holes in the rod.

For fitting of the piston, see instruction drawing no. 7758.03.

Remove the setscrew which keeps the different parts of the tool together, and fit thetools as shown. The pressure in the hydraulic nut is raised to specified value, and thenut (item 19) is tightened up using a pin in the holes provided. After use, the tool isremoved, and the screw is fitted again.

Locking nut (item 49) is tightened up and secured.

Tightening torque for screws for units with propeller shaft seal EK240:

Hexagon socket head screwHexagon socket head screwHexagon socket head screwHexagon socket head screw

Hexagon head screwHexagon head screwHexagon head screwHexagon head screwHexagon head screw

M24 (item 75)M20 (item 88)Ml6 (item 89)Ml 0 (item 90)

M20 (item 76 and 78)M20 (item 77)Ml6 (item 79)Ml2 (item 81 and 82)Ml0 (item 83 and 84)

629 Nm309 Nm187Nm37 Nm

309 Nm364 Nm159Nm65 Nm37 Nm

Tightening torque for screws for units with propeller shaft sealA8-240 Compact Composite:

Hexagon socket head screw M8 (DSS supply)

All other screws are tightened as specified for EK 240 above.

8.5 Nm

5.3. Assembling the thruster body into the tunnel

1 off guide pin, art. no. 020328 is used for assembling the thruster body into thetunnel. See item 1.3 and instruction drawing no. 7769.22.

The propeller blades are mounted, the unit is centred in the tunnel, and the screws aretightened up. For fitting of the propeller blades mounting tool, art. no. 023830 shouldbe used. See instruction drawing no. 7758.30 and 1112.51.

Stay ends are bevelled for welding. The surface between stay and thruster body mustbe thoroughly cleaned, and coated with Loctite Master Gasket no. 574.

AiL.no.: 015789

BRUNVOLL AS

6415 MOLDE

NORWAY


MAINTENANCE


DateCreate

Contr.

08.12.00IH

OBH

7758.10

8 of 10

Tightening torque for screws:

Hexagon socket head screw M24 (item 42)Hexagon head screw M24 (item 7)Hexagon head screw M24 (item 8 and 44)

535 Nm629 Nm535 Nm

The screws for propeller blades are secured with acid proof wire (item 24) which isplaced across the screw heads and welded to the same with acid proof steel electrode.

NOTE! The welding apparatus must be earthed to the actual propellerblade where the welding is performed.

The hexagon head screws (item 7) are secured with acid proof wire 06 (item 20) whichis placed across the screw heads and welded to the same with acid proof steelelectrode.

NOTE! The welding apparatus must be earthed to the stay where thewelding is performed.

5.4. Fitting the rack gear

The rack gear (item 21) is fitted.

The purpose of the spring is to prevent backlash in the mechanism by directing adownward point load between the gear wheel (item 4) and the rack (item 6).A suitable pre-load is achieved by moving the propeller blades in 0-pitch, and rotatingthe coupling (item 5) until the rack comes to its lowest position.The spring is pre-loaded by rotating the spring pack (item 7) about 3 turns anti-clockwise, and then locking it with screws (item 15).Do not forget O-rings (item 49 and 50).

5.5. Fitting the coupling half

For fitting of the coupling, see instruction drawing no. 7758.05.

V-ring on coupling should be coated with grease.

Fit the tool as shown.

The hydraulic nut is fitted with the piston in its retracted position. The oil injector isconnected to the coupling. The oil pressure on the surface between the conical linerand the coupling is raised.The pressure is raised simultaneously in the pump and the injector. When the axialdrive-up length exceeds the piston stroke of the nut, the pressure is to be released sothat the oil can be drained from the oil shrink surfaces.Remove the pipe connection between the oil pump and the hydraulic nut, and re-tighten the nut until the piston returns to its retracted position.

Art. no.: 015789

BRUNVOLL AS

6415 MOLDE

NORWAY

INST]

1


MAINTENANCE

PHRUSTER UNIT UF80TC

DateCreate

Contr.

08.12.00IH

OBH

7758.10

9 of 10

Again, raise the pressure in the oil pump and injector simultaneously until the couplingrests against its seat. The piston will touch the end of the conical liner.

The tool is removed.

6. SUPPLEMENTARY INSTRUCTION DRAWINGS

Fitting/removal of coupling 7758.05Fitting/removal of propeller blades 7772.57Fitting/removal of thruster body 7769.22Fitting/removal of piston 7758.03Fitting/removal of propeller hub 775 8.04Fitting/removal of propeller shaft 7769.23Axial movement of crown wheel 7758.02Instructions for assembly of thruster's spiral bevel gear 6731.22Propeller tip clearance limit 7758.30

Art.no.: 015789

BRUNVOLL AS

6415 MOLDE

NORWAY


MAINTENANCE


DateCreate

Contr.

08.12.00IH

OBH

7758.10

10 of 10

VIKTIG! Mo n t e r i n g s v e r k t o e y e t maa vaere m o n t e r t og m u t t e r e nt i l s p e n t foer o l j e t r y k k e t settes paa. Dersom k o b l i n g e n

i k k e er s i k r e t lean den presses av konusen med stor k r a f t

IMPORTANT! The m o u n t i n g t ool has to be i n s t a l l e d and the nut

t i g h t e n e d before t h e o i l pressure i s r a i s e d . I f t h e

c o u p l i n g is not secured it may "push o f f " the c o n i c a l

l i n e r w i t h great force.

Art.no. ; 15824

Art.no. :07812

Ma k s . s I a q / M o x . s t r o k e : 5

01 J e t r y k k / O i 1 pressure:3Q-40 MPa

Art.no.:07807.

Art.no. :20143

01jetrykk/011 pressure:

80-110 MPa

1 ?H T4.

Ar t .no . ;07809

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