US 255_P30 FP Inst Manual - 1

INSTALLATION & ENGINEERING MANUAL

WORK NO.: 514-S267 / S268

Page 1 ( 7 )


ROLLS-ROYCE AZIMUTH THRUSTERS TYPE US 255/P30 FP

Rolls-Royce Work No. Serial Nos.: Hull No.

514-S267 66585 - 66586 NB S 173

514-S268 66589 - 66590 NB S 174

Rev. Date Drawn Checked Approv. Changed pages Description A 27.6.2012 KILA KILA First issue

Rolls-Royce Oy Ab P.O.Box 220, FI-26101 Rauma, Finland Phone: +358 2 83791 Fax: +358 2 8379 4804 Azimuth Thrusters / Propulsion Aftermarket Fax +358 2 8379 4874 Home page: www.rolls-royce.com


WORK NO.: 514-S267 / S268

Page 2 ( 7 )

Copyright 2000 by Rolls-Royce Oy Ab All rights reserved. No part of this publication may be reproduced or copied in any form or by any means without the special permission of the copyright owner.


WORK NO.: 514-S267/S268

Section Heading name Page number

Save Date: 27.06.12 Page 3 ( 7 )

LIST OF HEADINGS

1. GENERAL ........................................... ..................................... 4

2. STORAGE INSTRUCTIONS .................................................... 4

3. MECHANICAL DRAWINGS ............................... ...................... 4

4. HYDRAULIC DRAWINGS ................................ ........................ 5

5. ELECTRICAL INSTRUCTIONS............................ .................... 5

6. INSTRUCTIONS FOR INSTALLATION ONBOARD ............. ... 5

7. AZT AND HYDRAULIC INSTRUMENTATION ................. ........ 6

8. CONTROL SYSTEM COMPONENT DRAWINGS ................. ... 6

9. INTERCONNECTION DIAGRAMS .......................... ................. 7


WORK NO.: 514-S267 / S2687/S268

A = Drawing revision / B = PL drawing number / C = PL revision / D = PL variant / E = PL = Part list / F = Revision of this document

Subsect. Drawing name A B C D E F

Save Date: 27.06.12 Page 4 ( 7 )

TABLE OF CONTENTS

1. GENERAL

1. Guidance for the use of warnings and cautions .. ...................... 6457026 000

2. Safety information ............................. ............................................ 6456930 000

3. Technical Specification 514-S267/S268 .......... ............................ 6465685 000

4. Surface treatment .............................. ............................................ 6450092 000

5. Installation checklist for shipyard ............ ................................... 6456490 000

6. Harbour acceptance test ........................ ...................................... 6456491 000

7. Seatrial acceptance test ....................... ........................................ 6456492 000

8. Code of procedure for bollard pull trials....... .............................. 6458756 000

9. Product disposal and scrapping ................. ................................. 6458097 000

2. STORAGE INSTRUCTIONS

1. Storing of Azimuth Thruster unit ............... .................................. 6452407 001

2. Storing instructions for electric devices....... .............................. 6452404 000

3. MECHANICAL DRAWINGS

1. General Arrangement and intermediate shafting .. ..................... 5161093 000 +PL

2. Watertight penetration ......................... ......................................... 5353189 000

3. Upper gear module .............................. .......................................... 5156920 XXX +PL

4. Hydraulic pump drive ........................... ......................................... 5153422 XXX +PL

5. Transmitter box X2 ............................. ........................................... 5154254 XXX +PL

6. Intermediate assembly .......................... ........................................ 5157180 XXX +PL

7. Lower gear module .............................. ......................................... 5156303 XXX +PL

8. Propeller shaft seal assembly .................. .................................... 5256817 000 +PL

9. Mounting of nozzle ............................. ........................................... 5156892 XXX +PL


WORK NO.: 514-S267 / S2687/S268



Save Date: 27.06.12 Page 5 ( 7 )

10. Gravity tank .................................. .................................................. 5355289 000

11. Earthing of the thruster unit ................. ........................................ 7357979 003 +PL

4. HYDRAULIC DRAWINGS

1. Manufacturing and installation instructions for hydraulic piping .................................. ........................................... 6450868 000

2. Hydraulic diagram, steering and lubrication hydr aulics ........... 8152207 000 +PL

3. Hydraulic piping, steering and lubrication hydra ulics .............. 8252528 000 +PL

4. Pump unit, Steering and Lub. Hydraulics ........ ........................... 8250634 XXX +PL

5. Hydraulic Oil tank ............................. ............................................. 8251722 001 +PL

6. Bracket for hydraulic oil tank ................. ...................................... 5354315 000

7. Hose assembly for hoses between the pump unit an d steering hydraulics oil tank ...................... .................................... 8351255 XXX +PL

5. ELECTRICAL INSTRUCTIONS

1. Terminology .................................... ............................................... 6461005 000

2. General Electrical Specifications .............. ................................... 6461160 001

3. Electric installations ......................... ............................................ 6452403 001

4. Cabling instructions ........................... ........................................... 6460686 000

6. INSTRUCTIONS FOR INSTALLATION ONBOARD

1. Lifting and turning of thruster unit US-types 10 5-305, delivery in one piece ............................. ........................................ 6461370 000

2. Installation of Azimuth Thruster unit and interm ediate shaft line ........................................ ................................................. 6464091 000

3. Casing plate installation instructions ......... ................................ 6350012 000

4. Protection of Azimuth Thruster unit after mounti ng ................. 6454155 000

5. Mounting of bearings ........................... ......................................... 6450072 000

6. Mounting of CARB bearings ...................... .................................. 6454506 000

7. Axial positioning of CARB bearings ............. ............................... 6456487 000


WORK NO.: 514-S267 / S2687/S268



Save Date: 27.06.12 Page 6 ( 7 )

8. Mounting/removing intermediate shaft flange .... ....................... 6454282 000

9. Installation of gravity tank ................... ......................................... 6453693 000

10. Air bleeding of gravity tank line ............. ...................................... 6460640 000

11. Lubrication oil recommendation................. ................................. 6456648 000

12. Hydraulic steering oil recommendation ......... ............................. 6456498 000

13. Gravity line oil recommendation ............... ................................... 6456502 000

14. Tightening torque for screws and nuts ......... .............................. 6451487 000

15. Locking of screws ............................. ............................................ 6452166 000

16. Cardan shaft pointer tools .................... ........................................ 9350077 000

17. Installation and maintenance of cardan shafts . ......................... 6458490 000

7. AZT AND HYDRAULIC INSTRUMENTATION

1. List of alarm points ........................... .................................................. delivered earlier

8. CONTROL SYSTEM COMPONENT DRAWINGS

1. General arrangement of control system, 514-S267 (S 173) ....... delivered earlier

2. General arrangement of control system, 514-S268 (S 174) .......

3. Aquapilot control head, Dimension drawing ...... ........................

4. Thrust Direction Indicator TDI-11, Dimension dra wing .............

5. Azimuth Thruster Control Panel ACP, Dimension dr awing ......

6. Back-up Control Panel BCP004, Dimension drawing ................

7. Bridge Interface Unit BIU, Dimension drawing ... .......................

8. Bridge Interface Unit BIU, Assembly drawing .... ........................

9. Supply Change-over Unit SCU, Assembly drawing .. .................

10. Cable with connector for CANopen equipment in C S ...............

11. CANopen cable with connector for CANopen equipm ent in CS

12. CANopen and HHT connections / X15-1 ........... ..........................

13. Azimuth Thruster Control Unit ACU, Dimension dr awing .........


WORK NO.: 514-S267 / S2687/S268



Save Date: 27.06.12 Page 7 ( 7 )

14. Azimuth Thruster Control Unit ACU, Assembly dra wing ..........

15. Maintenance switch, Assembly drawing........... ..........................

9. INTERCONNECTION DIAGRAMS

1. Cable list...................................... ................................................... delivered earlier

2. Plug connector cables for AZT control panels and AQP ..........

3. Control cables, back-up control ................ ..................................

4. Control cables, thruster room .................. ....................................

5. Control cables, autopilot ...................... ........................................

6. Alarm cables ................................... ...............................................

7. Data cables..................................... ................................................

8. Bus cables...................................... ................................................

9. Power cables, control system power supplies .... ......................

10. Power cables, BIU’s slio and HHT interfaces ... ..........................

6457

026-

C-0

00

Guidance For The Use Of Warnings And Cautions

Rev. Date Drawn Checked Approv. Changed pages Description

0 21.2.2003 KATO JUPE KURT New document.

B 20.6.2005 SEK SEK SEK Added Product Disposal and Scrapping.

C 26.9.2005 KURT KURT KURT Removed Product Disposal and Scrapping to separate instr. 6458097-A-000

Page 1 ( 2 ) 6457026-C-000 U

GUIDANCE FOR THE USE OF WARNINGS AND CAUTIONS

UNDERTAKING ANY WORK ENVISAGED BY THIS DOCUMENT MAY EITHER DIRECTLY OR INDIRECTLY CREATE RISKS TO (1) THE SAFETY AND HEALTH OF THE PERSON UNDERTAKING THE WORK OR (2) THE ULSTEIN AQUAMASTER AZIMUTH THRUSTER AND/OR ITS COMPONENTS WHILST THE WORK IS BEING UNDERTAKEN.

IT IS THE RESPONSIBILITY OF THE USER TO ENSURE THAT APPROPRIATE CONTROLS AND PRECAUTIONS ARE IDENTIFIED AND APPLIED IN RELATION TO THE WORK ENVISAGED BY THIS DOCUMENT IN ACCORDANCE WITH RELEVANT STATUTORY, LEGAL AND INDUSTRY REQUIREMENTS TO PROTECT THE HEALTH AND SAFETY OF THE PERSONS UNDERTAKING THE WORK.

IT IS ALSO THE USER’S RESPONSIBILITY TO ENSURE THAT APPROPRIATE CONTROLS AND PRECAUTIONS ARE IDENTIFIED AND APPLIED IN RELATION TO WORK ENVISAGED BY THIS DOCUMENT TO PROTECT AGAINST RISKS TO THE ULSTEIN AQUAMASTER AZIMUTH THRUSTER AND/OR ITS COMPONENTS WHILST THE WORK IS BEING UNDERTAKEN.

NEITHER THIS DOCUMENT, NOR ITS USE, IN ANY WAY ABSOLVES THE USER FROM THEIR RESPONSIBILITY TO ENSURE THAT THE CONTROLS AND PRECAUTIONS REFERRED TO ABOVE ARE IMPLEMENTED.

IF, WHILST UNDERTAKING ANY WORK ENVISAGED BY THIS DOCUMENT, YOU BECOME AWARE OF ANY ROLLS-ROYCE PRODUCT DESIGN RELATED FEATURE WHICH COULD CREATE RISK TO A PERSON UNDERTAKING WORK OR TO THE ULSTEIN AQUAMASTER AZIMUTH THRUSTER AND/OR ITS COMPONENTS PLEASE CONTACT EMAIL: [email protected], PHONE: +358 2 83791, AFTER OFFICE HOUR NUMBER: +358 40 066 6678 AT ROLLS-ROYCE CFBU AFTERMARKET SERVICE PROPULSION FINLAND, TECHNICAL SUPPORT DEPARTMENT IMMEDIATELY.

6457

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Guidance For The Use Of Warnings And Cautions

Page 2 ( 2 ) 6457026-C-000 U

It is the user’s responsibility to make all relevant hazard identifications and risk assessments of all the activities associated with the use of this document.

It is the user’s responsibility to design and implement safe systems of work and to supply safe equipment (including, without limitation, safety equipment) and training (including, without limitation, health and safety training) to anyone using this document to work on products to which it relates.

A user without the relevant experience of working in accordance with this document or with products, or similar products, to which it relates should seek appropriate advice to enable them to identify the appropriate health and safety controls and precautions and controls and precautions to protect against risks to the Ulstein Aquamaster Azimuth Thruster and/or its components whilst work is being undertaken. Technical assistance can be sought from Rolls-Royce and will be subject to Rolls-Royce’s terms and conditions.

SAFETY INFORMATION

Rev. Date Drawn Checked Approv. Changed pages Description 0 24.9.2003 KATO JUPE KURT Replaces document 6451656.

Page 1 ( 1 ) 6456930-0-000 U

SAFETY INFORMATION

The following signal words are used to identify the level of potential hazard. • Notice • Caution • Warning • Danger

The signal word descriptions of the potential hazard and their layout styles are the following.

NOTICE Notice is used to notify people of installation, operation, or maintenance information which is important but not hazard-related.

CAUTION Caution is used to indicate the presence of a hazard which will or can cause minor injury or property damage if the warning is ignored.

WARNING Warning is used to indicate the presence of a hazard which can cause severe injury, death, or substantial property damage if the warning is ignored.

DANGER Danger is used to indicate the presence of a hazard which will cause severe injury, death, or substantial property damage if the warning is ignored.

Rolls-Royce azimuth thrustersRolls-Royce Oy Ab, Rauma, Finland

TECHNICAL SPECIFICATION 514-P775/P7767/S268

Page 1 ( 20) 6463981-B-000-U

Main Propulsion of a Stern Drive Tugboat Type : Rolls-Royce Azimuth Thruster US 255/P30 FP

Rolls-Royce Project No. : 514-S267 / 514-S268

Shipyard Hull No. : S 173 / S 174

Vessel type : Stern Drive Tug

Number of units : 2 per vessel

Classification : Factory certificate

Definition : Rolls-Royce US 255/P30 FP is a Z-drive azimuth thruster for direct

diesel engine drive, furnished with a fixed pitch propeller running in

a TK -nozzle. The thruster has a “bottom well cover” type stem for

mounting into the vessel. The steering of thruster is controlled by

the Aquapilot control system.

Please note: All the pictures in this document are illustrative examples only.


A 27.06.2012 KILA KILA First issue

Manufacturer:

Rolls-Royce Oy Ab

P.O.Box 220, FI-26101 Rauma, Finland

Phone: +358 2 83791

Fax: +358 2 8379 4804

Azimuth Thrusters / Propulsion

Aftermarket

Fax +358 2 8379 4874

Home page: www.rolls-royce.com


Page 2 ( 20) 6463981-B-000-U

Copyright 2000 by Rolls-Royce Oy Ab All rights reserved. No part of this publication may be reproduced or copied in any form or by any means without the special permission of the copyright owner.

TABLE OF CONTENTS

1. TECHNICAL DATA ................................................................................................ 3

2. SCOPE OF SUPPLY .............................................................................................. 5

3. THRUSTER MECHANICAL CONSTRUCTION ...................................................... 7

4. GENERAL DESIGN FEATURES .......................................................................... 10

5. ALARMS AND INDICATIONS .............................................................................. 14

6. THRUSTER INTERFACES ................................................................................... 15

7. AQUAPILOT CONTROL SYSTEM ....................................................................... 16

8. TESTING............................................................................................................... 20


Page 3 ( 20) 6463981-B-000-U

1. Technical Data

1.1. Rolls-Royce Azimuth Thruster units

Prime mover type ........................................................................................... Diesel engine

Max. power on the input shaft 514-S267 (S 173): .............................................. 2,420 kW

514-S268 (S 174): .............................................. 2,420 kW

Main engine nominal speed 514-S267 (S 173): ............................................. 1,800 rpm

514-S268 (S 174): ............................................. 1,800 rpm

Main engine idling speed ....................................................................................... 600 rpm

Direction of input shaft rotation looked at the input shaft ..................................... Clockwise(1

Gear reduction ratio in unit 514-S267 (S 173): ............................................... 7.516 : 1

514-S268 (S 174): ............................................... 7.516 : 1

Propeller type ..................................................................... Monoblock, fixed pitch propeller

Propeller material ............................................................................................. NiAl-Bronze

Manufacturing standard ................................................................ ISO 484/2 – 1981 class II

Propeller diameter / Number of blades ............................................................ 2,800 mm / 4

Propeller max. revolution 514-S267 (S 173): .......................................... ~ 239.5 rpm

514-S268 (S 174): .......................................... ~ 239.5 rpm

Nozzle type / Material ................... TK ducted / Mild Steel with Stainless Steel inner surface

Direction of propeller rotation looked at ship’s stern (BB) .................................... Clockwise

Direction of propeller rotation looked at ship’s stern (SB) .................................... Clockwise

Stem length(2

...................................................................................................... 3,800 mm

Clutch type ..................................................... Built-in, hydraulically operated clutch (on/off)

Steering gear .................................................................................... Hydraulically operated

Steering speed (3 ..................................................................................................... ~ 2 rpm

Steering/lubrication pump drive ...................................................... Mechanical V-belt drive

1) I.e. the engine is running Counter-clockwise when looking at the flywheel.

2) The vertical distance between the input shaft and the prop. shaft.

3) At engine speed of 33...100 % of the nominal input speed rpm.

1.2. Steering hydraulics, cooler data / unit

Type of cooling water ........................................................................................Fresh water

Max. temperature of inlet water ................................................................................. +32ºC

Demand of cooling water ................................................................................... ~ 1.6 m³ / h

Pressure difference ............................................................................................. ~ 0.05 bar

Heat dissipation ........................................................................................................ ~ 8 kW

All values are per one unit.


Page 4 ( 20) 6463981-B-000-U

1.3. Lubrication oil unit, cooler data / unit

Type of cooling water ........................................................................................Fresh water

Max. temperature of inlet water ................................................................................. +32ºC

Demand of cooling water ................................................................................... ~ 7.7 m³ / h

Pressure difference ............................................................................................. ~ 0.05 bar

Heat dissipation ...................................................................................................... ~ 61 kW


1.4. Pressurization of the main seal system

Propeller shaft seal & Steering tube seal ...................................................... By gravity tank

1.5. Lubricant capacities / types

Lubricating Oil volume in the Thruster unit ...................................................... ~ 2,000 liters

Seal Oil (Gravity) Tank ......................................................................................... ~ 38 liters

Steering Hydraulic Oil Tank ................................................................................ ~ 150 liters


1.6. Weights

Thruster unit ...................................................................................................... ~ 26,000 kg

Steering hydraulics oil tank .....................................................................................~ 250 kg

Intermediate shaft lines ....................................................................................... ~ 2,200 kg

Seal Oil (Gravity) Tank ............................................................................................ ~ 31 kg

Control system .......................................................................................................~ 150 kg

All values are dry weight per one unit.

1.7. Control system voltage supply

Reserve supply for SCU (from ship’s sources) ...............................24 VDC (battery supply)

Power consumption ........................................................................................... Max.300 W


SUP = DC Power Supply Unit SCU = Supply Change-over Unit


Page 5 ( 20) 6463981-B-000-U

2. Scope of supply

2.1. Azimuth thruster units

2 PCs Azimuth thruster, including following equipment per thruster:

2.1.1. Built-on equipment

- Built-in clutch

- Nozzled propeller

- Hydraulic steering machinery

- Lubrication hydraulic system

- V-belt drive for steering and lubrication hydraulic systems

- Alarm sensors

- Zinc anodes

2.1.2. Separately delivered equipment

- Oil tank for steering hydraulics

- Gravity tank for main seals

- Set of flexible hoses

2.1.3. Intermediate shaft line

- Shaft line with two cardan shafts and solid steel shafts, see section 3.7

2.2. Control system

2.2.1. Wheelhouse control equipment as „drop-in‟ modules for one control station and per each thruster

- 2 PC Aquapilot Control Lever (AQP)

- 2 PC Thrust Direction Indicator (TDI)

- 2 PC Azimuth Thruster Control Panel (ACP)

- 1 PC Back-up Control Panel (BCP)

2.2.2. Other equipment for Wheelhouse control console, for each thruster

- 1 PC Bridge Interface Unit (BIU)

- 1 PC Connection Box for CanOpen & HHT (CSC)

2.2.3. ECR control equipment as „drop-in‟ modules, for each thruster

- NA

2.2.4. Thruster room control equipment, for each thruster

- 1 PC Azimuth Thruster Control unit (ACU)

- 1 PC Supply Change-over Unit (SCU)

2.2.5. Thruster room control equipment, for ship set

- 1 PC Maintenance Switch (AMS)

- 1 PC Hand Held Terminal (HHT)

2.3. Miscellaneous items

2.3.1. Spare parts

- Commissioning parts, 1 set per ship


Page 6 ( 20) 6463981-B-000-U

2.3.2. Documents, for ship set

- Engineering documents for shipyard in English

- Manuals in English, 3 sets

Service Manual for Mechanical and Hydraulic Equipment

Service Manual for Control System

User‟s Guide

2.3.3. Certificates

- No classification

2.4. Exclusions

The following items are not included in the Rolls-Royce supply unless otherwise agreed:

- Installation onboard.

- Prime movers (diesel engines).

- Flexible couplings with torsional vibration calculations, or any other auxiliaries for the prime

movers, if not specified.

- 220 VAC electric supply for control equipment.

- 24 VDC battery supply for control equipment.

- Water supply for the heat exchangers.

- Electric cabling.

- External piping.

- Autopilot system

- Central alarm system.

- Model test, cavitation test.

- Training of the crew or shipyard personnel.

- Oil fillings.

- Spare parts and tools other than specified.


Page 7 ( 20) 6463981-B-000-U

3. Thruster mechanical construction

3.1. Main components in the upper part

- Upper gear housing - Planetary gears with hydraulic driven motors - Mechanical azimuth angle indicator

3.2. Main components in the upper power line

- Horizontal input shaft - Built-in clutch - Upper bevel gear pair - Vertical shaft with tooth coupling - Bearing arrangement

3.3. Main components in the intermediate part

- Large diameter slewing ring - Steering tube - Support bearing - Stem tube with a “bottom well cover” type hull fitting module (to be bolted into the ship)


Page 8 ( 20) 6463981-B-000-U

3.4. Main components in the intermediate power line

- Vertical shaft with tooth couplings

3.5. Main components in the lower part

- Lower gear housing - Fixed pitch propeller - High performance TK-Nozzle

3.6. Main components in the lower power line

- Vertical shaft with tooth coupling - Lower bevel gear pair - Propeller shaft - Bearing arrangement


Page 9 ( 20) 6463981-B-000-U

3.7. Intermediate shaft line

3.7.1. Components of intermediate shaft line (length ca. 8 meters)

- Two cardan shafts. - Solid shafting in needed length with grease lubricated roller bearings, bearing housings, shaft

flanges and fixing bolts. The bearings and flanges are pre-assembled on the shafts. - One watertight bulkhead sealing of standard Rolls-Royce type, pre-assembled on the shaft. - One stub shaft in roller bearings, with a flange for connection to cardan shaft and a key-way

end for connection to the flexible coupling on the main engine; the bearings and flange are pre-assembled on the shafts.

Flexible coupling with torsional vibration calculations is not included in the R-R scope of supply.

NOTE! Torsional vibration calculations of flexible coupling have to be accepted always by Rolls-Royce Oy Ab.

3.7.2. Arrangement principle of the shaft line


Page 10 ( 20) 6463981-B-000-U

4. General design features

4.1. Body parts, stem tube and steering tube

The upper housing, stem tube and steering tube are fabricated of primed steel or steel tube by welding. Lower housing is either a cast or welded steel construction. The welding stresses are removed by annealing before machining.

4.2. Propeller

Manufacturing of propeller shall be done according to document 6455969.

Manufacturing tolerance is according to standard ISO 484/1–1981 for propellers with diameter greater than 2.5 m and ISO 484/2–1981 for propellers with diameter 2.5 m or less.

Propeller class II is to be obeyed, but with exceptions so that pitch, blade edge finishing and balancing will be done according to class I. By this way we ensure that propellers will have performance according to class I, and so the cavitation risks are minimal.

4.3. Gear wheels in the upper and lower gear

- Cyclo-palloid wheels with arched teeth. - Surface hardened and HPG –machined. - Material: Steel 17 Cr Ni Mo 6. - Designed for continuous operation with max. torque.

4.4. Shafts

The internal shafts of thrusters are made of high tensile steel.

The vertical shaft is split into two sections. The sections are connected with tooth coupling for easy installation of the lower assembly and to avoid alignment problems. The tooth coupling is also a safety feature to accommodate the shear-off of the lower assembly in case of severe accident. Shaft and shaft joints are designed for continuous operation with maximum torque.

All the shaft joints are one of the following types: - bolted flange joint. - cylindrical shrink fit joint. - conical shrink fit joint.

4.5. Bearings of the power transmission

All of the bearings are of roller type. Only the highest available bearing quality is assembled. The calculated lifetime complies with the classification society requirements.

4.6. Main seals

- The seal between the stem tube and the steering tube (between seawater and oil) is a pair of double lip seals. The oil pressure by gravity tank exists between the seals preventing the water from seeping in.

- Propeller shaft seal system:

Dirt barrier and two lip seals between water and gravity oil.

The oil pressure by gravity tank prevails in between two seal systems.

One lip seal between gravity oil and gearbox oil.

Rope guard with net knife protects the propeller shaft seal system.


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4.7. Gravity oil tank

The oil in the gravity tank line maintains the internal static pressure against water for the propeller shaft and steering tube seal cavities. If any of these seals starts leaking the oil level in the gravity tank drops which indicates to the crew that there may be something wrong with the seals. If the oil level in the gravity tank goes below the minimum level an alarm is triggered.

The gravity tank is to be mounted near the propulsion unit at the given height range measured from the propeller shaft line and loaded water line. Piping between thruster and gravity tank has to be continually rising, min. rising angle is 5 degrees.

(T = distance between the propeller shaft line and loaded water line.)

The installation and piping work is shipyards duty.

4.8. Anodes

The thrusters are equipped with sacrificing zinc anodes against electrolytic corrosion.

4.9. Lubrication system

4.9.1. General

The lubrication system perform the following functions: - Lubrication, cooling and filtering. - Clutch control.

4.9.2. Lubrication

The lubrication of the thruster is a self-sustained, built-in arrangement.

The lubricated objects are either immersed or sprayed with oil. The oil circulation is arranged with internal boosters.

Lubrication oil is cooled with an external cooler. The cooler is of tube type and is suitable for either freshwater or seawater use.


Page 12 ( 20) 6463981-B-000-U

4.10. Clutch control

The clutch is engaged with lubrication oil pressure and disengaged with springs. The operation of the clutch is to be performed at idle speed of the engine. The clutch control valve is electrically controlled, but also a manual control is available. The valve is designed to maintain its position in the case of loss of control signal. If the hydraulic pressure is lost the clutch disengages but it can be locked manually to „engaged‟ position.

4.11. Hydraulically operated steering gear

The steering hydraulics is a complete system with pumps, motors, valves, filters and an oil cooler. The steering hydraulic system has a separate oil tank, and is thus entirely separated from the lubrication system.

The oil flow, produced by a variable displacement axial piston pump is led directly into the hydraulic motors connected to the steering gear. The hydraulic motors rotate the slewing ring fixed on the intermediate part and so carry out the turning of the intermediate and lower part of the thruster.

Steering oil is cooled with an external cooler. The cooler is of tube type and is suitable for either fresh water or seawater use.

Maintenance / local steering methods: - Manual local control on the main hydraulic pump without a tool (in case of electric control

system failure). - By maintenance/local control switch to turn the unit locally in propulsion room during

maintenance. - Manual crank/ratchet (in case of main hydraulic pump failure).

4.11.1. “Black out” situation

Steering hydraulic pump is driven by V-belts from the thruster input shaft. When the main engine is running and thruster input shaft is rotating, there is always power available for steering.

In case of complete “black-out” including back-up batteries, the thrusters can be steered by manually at main hydraulic pump.

1. There is a possibility for local steering of the thruster unit by actuating the steering pump solenoid valve manually.

2. Before carrying out the manual steering from the hydraulic pump the main engine must be running at idle speed.

3. There are push buttons on both sides of the steering hydraulic pump; thruster steering can be done by pressing these push buttons (see the picture).

Steering hydraulic pump:


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4.12. Mounting / installation

4.12.1. Bottom well cover type mounting


Page 14 ( 20) 6463981-B-000-U

5. Alarms and Indications

Alarm transducers are separate from control and monitoring sensors. Alarm display units in the Wheelhouse and Engine Control Room are included in the delivery.

5.1. Control system alarms

- System warning from ACU control unit ................................................ Breaking contact

- Failure from ACU control unit .............................................................. Breaking contact

More detailed reason for these alarms (warning, failure) can be read by Hand Held Terminal (HHT) from the unit (ACU) where the alarm occurs. The Hand-Held terminal is included in the standard tool set.

5.2. Lubrication system alarms

- Lubrication oil level low ........................................................................ Breaking contact

- Lubrication oil temperature high ........................................................... Breaking contact

- Clutch control oil pressure low ............................................................. Breaking contact

- Oil filter 1 clogged ................................................................................ Breaking contact

- Oil filter 2 clogged ................................................................................ Breaking contact

5.3. Steering hydraulic alarms

- Booster pressure low ........................................................................... Breaking contact

- Hydraulic oil tank level low ................................................................... Breaking contact

- Hydraulic oil tank temperature high ..................................................... Breaking contact

- Hydraulic oil filter 1 clogged ................................................................. Breaking contact

- Hydraulic oil filter 2 clogged ................................................................. Breaking contact

5.4. Gravity oil tank alarms

- Gravity oil tank oil level low .................................................................. Breaking contact


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6. Thruster Interfaces

6.1. Prime mover interface

6.1.1. From thruster to prime mover

Prime mover rpm control, main ............................................................................ 4…20mA

Prime mover starting allowed ...................................................................... Making contact

6.1.2. Prime mover starting allowed

Azimuth thrusters are supplied with Fixed Pitch propellers (FP). This means, that when the propeller is rotating, it gives a certain thrust. To avoid this thrust in a start-up situation, the rpm set value from the Aquapilot Control head has to be idle.

Azimuth Thruster Control Unit (ACU) has an interlocking contact at the idle speed (rpm) position.

This relay contact has to be connected to the prime mover‟s start-up circuit (contact closed in start-

up situation).

6.1.3. Prime mover warming-up

The bridge control panel is provided with a “clutch engage prevent” push button. By pushing this button you can prevent the thruster built-in clutch from engaging, and warm-up the prime mover at higher main engine speed than idle speed.

There is also a “clutch engage prevent” input (signal from external system), which prevents the

clutch from engaging. This system is mainly intended for service and maintenance purposes.

6.2. Autopilot Interface

6.2.1. From thruster to Autopilot

Autopilot selection ....................................................................................... Making contact

- The selection contact will activate the autopilot

In a typical installation autopilot does not receive any feedback signal from the thruster.

6.2.2. From Autopilot to thruster

Control signal ....................................................................................................... 4…20mA

Aquapilot control system is closed loop system. When the autopilot mode is selected system reads its set point from the autopilot. Autopilot gives an angle set value (4…20 mA) to the Aquapilot system‟s built-in control loop. Signal values correspond thrust angles -45°…0…+45°.

(4 mA -45 deg., 12 mA 0 deg., 20 mA +45 deg.)

Prime mover rpm control is through the Aquapilot control lever.


Page 16 ( 20) 6463981-B-000-U

7. Aquapilot control system

The Aquapilot is an independent follow-up control system with integral time dependent back-up controls for one azimuth thruster unit. This means that each thruster has an independent control system, and so failure of one thruster does not affect the control system of the other one.

7.1. Design features for Aquapilot control system

7.1.1. Supply to be provided for control system

Main voltage ................................................................................ 110 VAC, 60 Hz, 1-phase

Reserve voltage ....................................................................................... 24 VDC batteries

7.1.2. Contact specifications

Voltage .................................................................................................................... 30 VDC

Current ........................................................................................................................... 2 A

Power .......................................................................................................................... 60 W

7.1.3. Ambient temperature recommendation

Machinery room ..................................................................................................... 0…50°C

Steering and control room ...................................................................................... 0…50°C

7.1.4. Control units

Installation ................................................................................................... Wall installation

Enclosure .................................................................................................... Painted cabinet

Cable entrance .......................................Through cable glands at the bottom of the cabinet

Cable connectors ................................................ Cable glands at the bottom of the cabinet

Grounding connection .............................................................. At the bottom of the cabinet

Painting ................................................................................................ RAL 7035 light grey

Protection class .............................................................................................. IP 22 or IP 44

7.1.5. Electronic modules, panels, displays

Installation ............................................................................................... ‘Drop-in’ modules’

Protection class (above) ...................................................................... IP 22, IP 44 or IP 56

Cable connection ................................................................. Row terminal with 1.5 m cable

Grounding connection ............................................................................. Below the module

Painting .......................................................................................................................Black

7.1.6. Control voltage

System and distribution ......................................................... Insulated double-wire system

Protection .............................. Double-pole automatic circuit breakers with an alarm contact

Voltage drop for system cabling calculation ................................................... Max. 2.5 VDC


Page 17 ( 20) 6463981-B-000-U

Minimum voltage for each control system module ................................................ 19.2 VDC

7.2. Main components in the system

7.2.1. Aquapilot control head (AQP)

Functions:

- Steering (by 360° horizontal rotation).

- Prime mover RPM (by tilting the lever 0°…+90°).

- Clutch engagement/disengagement (by tilting the lever 5° from upper position, including a sensing point).

Steering scale includes feeling points in

every 90 .

Lever friction is adjustable (both tilting and steering).

Starting of prime mover is possible only when the lever is in upright position.

7.2.2. Thrust direction indicator (TDI-11)

Thrust Direction Indicator (TDI) is electrically independent from the control system. TDI is hardwired to the propulsion unit. Display consist of red LED‟s and dimming is controlled by + / - buttons on bottom of display. Glare shield is delivered loose.

TDI includes following indications:

- Thrust direction quick reading indication with 15° steps.

- Thrust direction accurate reading indication with 1° steps.

- Propeller rpm indication 0...999 rpm.

- Propeller thrust indication (0…100%).

7.2.3. Azimuth Thruster Control Panel (ACP)

All selections are controlled by the wheelhouse panels. Panels include push buttons with informative text label and indication light symbol (with dimmer control). Following functions are controlled by Azimuth Thruster Control Panel (ACP):

- Clutch engagement prevention.

- Dimmer & lamp test.

- Autopilot mode selection:

Autopilot gives angle order for thrusters (+-45 degrees), rpm control stays Aquapilot. Each thruster can be selected for Autopilot mode separately. Following modes are available for autopilot operation. Only one of these modes is available at the same time, the selection to be done during the commissioning.

Mode “One by One”: Autopilot drives only one thruster at a time, Port or Stbd.

Mode “Symmetric”: Turns both thrusters with equal azimuth angles.


Page 18 ( 20) 6463981-B-000-U

Mode “Asymmetric”: Initially the thruster on the same side as the turning curve operates (usually

outer thruster). For hard turns the other (usually inner thruster) units joins operation automatically.

7.2.4. Back-up control panel (BCP)

Back-up control is an independent time-dependent control mode for azimuth thrusters. Back-up control panel is hardwired directly to Azimuth Thruster Control Unit (ACU). Turning is controlled with push buttons and prime mover rpm is controlled by potentiometer.

7.2.5. Alarm unit M1000 (HACB) NOT APPLICABLE

7.2.6. Bridge interface unit (BIU)

Bridge interface unit (BIU) is to be located in the Bridge console. BIU is an I/O interface point to other systems at bridge also distributes control signals to different control stations.

7.2.7. CANopen and HHT Connection Box (X15-1)

The delivery includes the CANopen cables with connectors for the main control console in the wheelhouse.

7.2.8. Engine Room Control Board (ERCB) NOT APPLICABLE


Page 19 ( 20) 6463981-B-000-U

7.2.9. Azimuth Thruster Control Unit (ACU)

Each thruster has independent control electronics. Control electronics are located in the control units. The main unit is Azimuth Thruster Control Unit (ACU), located in the vicinity of the thruster. ACU controls and monitors all functions of its azimuth thruster.

ACU includes:

- Control voltage maintenance/service switch.

- Filtration unit for control voltage supply.

- Fuse breakers with signal contacts for alarm.

- Control electronics.

7.2.10. Supply change-over unit (SCU)

If the voltage in main supply drops below 22 volts, the voltage-sensing relay will connect the system to use reserve supply. Change-over actions cause an alarm in the central alarm system.

When the voltage in the main supply rises up to about 23 V, the voltage relay makes a change-over action and control system uses the main supply again.

7.2.11. Maintenance switch (AMS08)

The scope of supply includes a non-follow up (NFU) time-dependent Azimuth Thruster maintenance switch (AMS), for maintenance and local control purpose. The selection switch for local control and the connection point for AMS is inside the ACU. There is one AMS per shipset.


Page 20 ( 20) 6463981-B-000-U

8. Testing

The Rolls-Royce quality assurance policy includes the testing of each thruster unit.

The tests are performed under the supervision of the classification society when applicable. Also the customers or their representatives are welcome to observe the trials.

The test program comprises:

- Adjusting and testing of the steering system. - Adjusting and testing of the lubrication system. - Adjusting and testing of the alarm and the indication transducers. - Pressure test of the hydraulic system. - Adjusting and testing of the control system. - Functional test. - Full torque test. - Checking of tooth contact. - Full rpm test. - Steering/rotation test. - Gravity line shaft sealing test.

SURFACE TREATMENT

Rev. Date Drawn Checked Approv. Changed pages Description C 21.5.2002 KaTo SeK SeK New layout. D 12.8.2003 KaTo J-PV J-PV 1 Paint brands updated E 01.06.2005 PASA J-PV J-PV Paint brands updated

Page 1 ( 1 ) 6450092-E-000 U

SURFACE TREATMENT

Surface treatment is done according to painting standard of Aquamaster as follows.

1. Surface Treatment During Manufacturing

Sand blasting Sa 2 1/2 - SIS 055900.

1.1. Underwater parts 1 Epoxy primer Teknoplast primer 3 50 µm, white.

2 Epoxy coating Teknoplast HS150 TM5877/ 05 250 µm, black

1.2. Other outer surfaces 1 Epoxy primer Teknoplast primer 3 50 µm, white.

2 PU top coat Teknodur Combi 0550-09 40 µm, blue. RAL 5012.

1.3. Inner surfaces in contact with oil 1 Epoxy primer Teknoplast primer 3 50 µm, white.

2. Repair Painting

A broken part in painting is carefully cleaned of dirt and rust by steel-wire-bruchs of sand washing. The painting is done as specified above.

INSTALLATION CHECK LIST FOR THE SHIPYARD

Rev. Date Drawn Checked Approv. Changed pages Description 0 24 Jan 03 MIJU KaTo JPV New document. B 13 Nov 06 MLeh New layout.

Page 1 ( 4 ) 6456490-B-000 U


APPLIES FOR: ULSTEIN AQUAMASTER AZIMUTH THRUSTER

WORK NO.: ….………………………………………

SERIAL NO.: ………………………………………...

NOTE!: FILL THIS LIST FOR EACH THRUSTER UNIT


Page 2 ( 4 ) 6456490-B-000 U

Attention! See service manual for drawings and instructions. In case of any ambiguous matter please contact Rolls-Royce representative.

Note! Following actions need to be done before Rolls-Royce commission work.

Checked Sign./date 1. BEFORE INSTALLATION 1.1 Welding of casing plate or welded unit - Flatness readings recorded ……………… Measured max. value: ____________________ mm 2 BEFORE LAUNCHING 2.1 Installation of bottom well cover

- Installing the locating pins to cover flange ………………

2.2 Installation of pipes - Cooling water pipes with flow control valves - Hydraulic unit pipes (if installed) - Check cleanness of all pipes installed by shipyar d

flush and record ……………… Max. particle size: __________________ mm 2.3 Gravity tank installation

- Inspection of pipeline - Supply air (if installed) ………………

2.4 Oil filling

Note. Use external filter (10 micron) when filling - Lubrication oil oil maker / type - Steering oil (if separate steering hydraulic) oil maker / type - Gravity oil oil maker / type - Steering gear brake oil (if installed) oil maker /type ………………

2.5 System venting

- Propeller shaft seal - Gravity tank line ………………


Page 3 ( 4 ) 6456490-B-000 U

Checked Sign./date

2.6 CP - system venting (if installed)

Note. Rolls-Royce representative recommended - CP-hub venting - Propeller pitch movement - Propeller rotation - Inspection of lifting hole plug in blades

not installed - ………………

2.7 Inspections of underwater parts - Leakage - Zinc anodes - Inspection of all seals and plugs for leakage ………………

2.8 UL-alignment (if installed)

Note. Rolls-Royce representative recommended Requires lifting / lowering system start up and venting

- Lub oil filling the system - Retractable movement alignment recorded

0º FWD 180º AFT 90º PORT 270º STB Lower position A Middle position B Upper position C

- Grease packing (tallow packing) after alignment

not installed - ……………… 3 AFTER LAUNCHING 3.1 Intermediate shaft line

- Alignment checked and recorded (table should atta ched) - Check axial positioning of Carb bearing - Check grease filling of bearings ………………

3.2 Installation of flexible coupling (if inst alled)

- Alignment checked and recorded (table should atta ched) not installed - ………………

3.3 Filling of grease to gear couplings (if ins talled)

- Grease maker and type: not installed - ………………


Page 4 ( 4 ) 6456490-B-000 U

Checked Sign./date 4 CONTROL SYSTEM 4.1 Installation of all electronic equipments ……………… 4.2 Check that power supply system is build according to requirement ………………

4.3 Installation of all cables acc. to diagram and instructions

- Check data cable type and size Type: __________________________________________ …………….…

4.4 Verify all cabling connections according to the diagrams ………….…… 5 REMARKS

DATE AND PLACE: …………………………………………………………………… SHIPYARD REPRESENTATIVE : …………………………………………………… SHIPYARD ACTION: Return this filled installation ch ecklist to Rolls-Royce representative together with commission order. ROLLS-ROYCE REPRESENTATIVE ACTION: Scan and store t his Installation check list for the shipyard to The Installed Product Data base (IPDb).

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HAT – HARBOUR ACCEPTANCE TEST


0 24 Jan 03 MIJU KaTo JPV New document.

B 13 Nov 06 MLeh New layout.

Page 1 ( 4 ) 6456491-B-000 U



WORK NO.: ….………………………………………

SERIAL NO.: ………………………………………...


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Page 2 ( 4 ) 6456491-B-000 U

Attention! See service manual for drawings and instructions.

Checked Sign./date

1. FIRST INSPECTION 1.1 Installation checklist

- Verify that the items in the “installation checklist” are carried out and that the form is filled in and signed …………

1.2 Visual inspection

- Check that all items of the delivery are undamaged and are correctly installed (according to the installation descriptions) ………….

1.3 Power supplies

- Check power supplies …………. 1.4 Earth fault test

- Check the main supply earth faults ………….

2 FIRST TIME START UP 2.1 First time start up

- Oil filling of the pumps and the steering motors before first start up - Hydraulic system air venting during running - Check pressures during running - Check all oil levels before and after start - Check temperatures of the bearings ……………

3. FUNCTION TEST

Verify all the functions according the service manual 3.1 Steering

- Main - Back-up ……………

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Page 3 ( 4 ) 6456491-B-000 U

Checked Sign./date

3.2 Indicators - Azimuth - Propeller RPM - Pitch angle (if installed) ……………

3.3 PM / RPM control - Output signal - RPM regulator (if installed) ……………

3.4 Local control

- Turning - Clutch (if installed) - Pitch (if installed) - Lifting / lowering (if installed) ……………

3.5 Alarms - Check all alarms points ……………

3.6 Pitch control (if installed) - Main - Back-up - Load control not installed - ……………

3.7 Lifting / lowering control (if installed)

- Main - Local not installed - ……………

3.8 Clutch control (if installed)

-Check function not installed - ……………

3.9 Electrical shaft (if installed)

- Check adjustments not installed - ……………

3.10 Control change over (if installed)

- Verify functions between stations not installed - ……………

3.11 Interface of external systems (if installed)

- Check adjustments not installed - ……………

3.12 Micropilot (if installed)

- Check functions not installed - ……………

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Checked Sign./date 4 HAND HELD TERMINAL TRAINING Train chief engineering to use hand held terminal (HHT) to read LOG-files in a case of failure not installed - ……………

5 REMARKS

Chapter 5 mentioned remarks and recommendations are informed to the shipyard. DATE / SIGN.:……………………………………………………. SHIPYARD REPRESENTATIVE

DATE AND PLACE: …………………………………………………………………………. ROLLS-ROYCE / REPRESENTATIVE : …………………………………………………… ROLLS-ROYCE REPRESENTATIVE ACTION: Scan and store this HAT Harbour acceptance test document to the Installed Product Database (IPDb)

SAT – SEATRIAL ACCEPTANCE TEST

Rev. Date Drawn Checked Approv. Changed pages Description 0 24 Jan 03 MIJU KaTo JPV New document. B 16 Nov 06 MLeh New layout. C 14 Mar 11 VELA SISA LASA Changed E-mail addresses for points 4.3 and 4.4

Page 1 ( 4 ) 6456492-C-000 U



WORK NO.: ….………………………………………

SERIAL NO.: ………………………………………...



Page 2 ( 4 ) 6456492-C-000 U

Attention! See service manual for drawings and instructions.

Checked Sign./ date 1. INSPECTIONS BEFORE SEATRIAL 1.1 HAT- harbour acceptance test

- Verify that the items in the “harbour acceptance test” document are carried out and the form is filled i n and signed ……………….

2 INSPECTIONS DURING SEATRIAL

2.1 Check and observe oil levels before and d uring sea trial - Lubrication oil - Steering oil - Gravity oil ……………….

2.2 Check and observe pressures

- Lubrication oil - Steering oil - Gravity ……………….

2.3 Check and observe temperatures after load test

- Lubrication oil _______ ºC - Steering oil _______ ºC - Bearings: No1 __________ºC No2 __________ºC No3 __________ºC No4 __________ºC No5 __________ºC No6 __________ºC - Shaft line components ……………….

2.4 Check intermediate shaft line vibrations - Check and record vibrations in whole R PM range ………………. 2.5 Check and observe oil leaks

- Lubrication - Steering system - Gravity line ……………….

2.6 Measure and recors heat exchange function after load test

- Temperature difference of cooling water _______ºC - Temperature difference of oil _______ºC ……………….


Page 3 ( 4 ) 6456492-C-000 U

Checked Sign./ date 3. ADJUSTMENTS DURING SEATRIAL 3.1 PM / RPM control

- Nominal - Idle ……………….

3.2 Speed modulating clutch RPM (if installed) - Rated RPM - Idle RPM not installed - ……………….

3.3 Load control (if installed)

- Check load curve not installed - ……………….

3.4 Pitch control (if installed) - Check control modes not installed - ……………….

3.5 Micropilot (if installed)

- Check adjustments - Check function not installed - ……………….

4. ACTIONS AFTER SEATRIAL 4.1 Oil sampling recommended for owner

(especially water content) ……………….

4.2 Send dump files and CMSP (*.CCN) datafile (if installed) with E-mail to [email protected] ……………….

4.3 Send CPP-parameters (if installed) with E- mail to [email protected] ……………….

4.4 Send data file (if frequency converters ar e mounted) of electric turning gear (ATU) with E-mail to

[email protected] ……………….


Page 4 ( 4 ) 6456492-C-000 U

4.6 Remarks to the shipyard

Chapter 4.6 mentioned remarks and recommendations a re informed to the shipyard. DATE / SIGN. : ……………………………………………………. SHIPYARD REPRESENTATIVE

DATE AND PLACE: …………………………………………………………………………. ROLLS-ROYCE / REPRESENTATIVE : …………………………………………………… ROLLS-ROYCE REPRESENTATIVE ACTION: Scan and store this SAT Seatrial acceptance test document to The Installed Product D atabase (IPDb)

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00 CODE OF PROCEDURE FOR BOLLARD PULL TRIALS

Rev. Date Drawn Checked Approv. Changed pages Description A 4 Jul. 06 TAKO

Page 1 ( 8 ) 6458756-A-000 U

CODE OF PROCEDURE FOR BOLLARD PULL TRIALS OF TUGS WITH AQUAMASTER

PROPULSION UNITS

CONTENTS

1. DEFINITION...................................................................................................................2

2. TEST CONDITIONS ......................................................................................................2 2.1. General ......................................................................................................................................2 2.2. Length of Towline .....................................................................................................................3 2.3. Water Depth...............................................................................................................................4 2.4. Current.......................................................................................................................................4 2.5. Wind Speed ...............................................................................................................................5 2.6. Trim............................................................................................................................................5

3. TRIAL PROCEDURES ..................................................................................................5 3.1. Trial Site ....................................................................................................................................5 3.2. Preparations..............................................................................................................................6 3.3. Readings ...................................................................................................................................6 3.4. Recording of the Readings.......................................................................................................7 3.5. Bollard Pull................................................................................................................................7

Sustained bollard pull ..................................................................................................................7 Maximum static bollard pull .........................................................................................................7

4. CORRECTIONS ............................................................................................................8 4.1. Correction Factor ......................................................................................................................8

.

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The purpose of this code is to standardise, as far as practicable, the procedure for carrying out bollard pull trials, so that trial results carried out on different occasions correctly reflects the comparative performance of the tugs concerned.

This code is based on the following codes:

BSRA: Code of Procedure for Bollard Trials of Tugs (1961) DNV: Bollard Pull Testing procedure (1994) BV: Bollard Pull Measurement and Certification (1990)

1. Definition

A bollard pull trial is a test, conducted for the purpose of determining the static pull that a tug is capable of exerting under practical operating conditions.

2. Test conditions

2.1. General

In order to minimise the effect of environmental conditions, the trials should not be conducted in severe weather conditions. The site for the trials should be chosen with care to fulfil the following requirements:

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2.2. Length of Towline

Bollard trials are often carried out in the sheltered waters of a harbour basin. In order to avoid the influence of dock walls a towline as long as possible should be used. The length of the towline, measured between the stern of the vessel and the shoreline shall not be less than given by equation (1), or as taken from figure 1.

LT = 3 P0.6 - 0.03 * P [m](1)

where P is the total propulsive power in kilowatts.

MINIMUM TOWLINE LENGTH

0

50

100

150

200

250

300

350

400

0 1000 2000 3000 4000 5000

TOTAL PROPULSIVE POWER [kW]

Tow

line

leng

th [m

]

Figure 1. Minimum towline length to be used in bollard pull trials

LT

d 0

Figure 2. Towline length and water depth

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2.3. Water Depth

The water depth at the test location shall not be less than 20 meters within a radius of 100 meters of the vessel. For vessels with high power, the recommended minimum water depth beneath the keel or thruster is given by equation (2), or taken from figure 3.

d0 = 0.06 * LT + 3 [m] (2)

MINIMUM WATER DEPTH

0

5

10

15

20

25

0 1000 2000 3000 4000 5000

TOTAL PROPULSIVE POWER [kW]

Min

imum

wat

er d

epth

(b

enea

th th

e ke

el)

[m]

Figure 3. Minimum water depth, beneath the keel or thruster, in bollard pull trials

2.4. Current

The tests should be carried out in waters without current, wherever possible. In areas with tidal current, the tests should be timed to the hours of slack water.

The current should in any case not exceed 1 knot, from any direction.

The build-up of circulation should be monitored during the trial. The speed of the water surface should not exceed 0.5 m/s.

A certain amount of circulation will inevitably build up as the trial proceeds. Thus the maximum pull should be obtained early in the bollard test. That's why the pull at the highest power must be taken during the first 5 minute period since the pull in the static condition is obtained.

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2.5. Wind Speed

The trial shall be performed with a wind speed not exceeding 5 m/sec. If there is any violent yaw during the course of a test, the readings should be repeated. The angles of yaw should be recorded.

2.6. Trim

The vessel shall be trimmed at even keel or at a trim not exceeding 1 % of the length of the vessel by the stern, if the propulsion units are at the stern of the vessel, or by the bow in the case of tractor tugs.

3. Trial procedures

3.1. Trial Site

The position chosen for the trials should be such that the tug is well clear of any walls and it is advisable to choose a place where the wall astern recedes on either side of the bollard so as to give a clear run for the propeller race, as shown at in fig. 4 and fig. 5.

Not good position

Good position Best position

Figure 4. Positioning of the tug for bollard pull trials

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Good position

Not good position

Figure 5. Positioning of the tug for bollard pull trials

The water depth on the trial site should comply with the requirements in 2.3.

3.2. Preparations

The main engines have, of course, to be warmed up before starting the trials. As often a series of pulls at different engine settings are taken in succession, steps should be taken to prevent circulation to become established. As a part of this, the engines should be warmed up, and all preliminary adjustments carried out before the tug is brought into position for the bollard pull trials.

Where the trials are to cover a range of propeller revolutions, the bollard pull at the maximum revs should be carried out first, while the water is still undisturbed.

In the test the hull and thrusters to be clean.

3.3. Readings

The conditions of bollard pull trials are such that it is unlikely that completely steady readings will be obtained and mean values therefore will be used in the analysis.

Either an electric strain cell or a mechanical load gauge is suitable for the bollard pull measurements, the first being preferable. The gauge should be calibrated, preferably both before and after the trials, and it is advisable that the calibration should be carried out with the gauge in the horizontal position in which it is used. The accuracy of the strain cell or the load gauge shall be better than ±1 %.

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The pull shall be taken on the tug's ordinary towing hook, towing winch or towing bit. The gauge shall generally be fitted

• between the eye of the towing wire and the bollard ashore

or where this is not practicable

• between the eye of the towing wire and the hook.

With the gauge ashore, provision should be made to allow it to swing freely about the bollard so as to align itself with the towline. If the gauge is connected to the towing hook, measures should be taken to prevent the friction of the cable in the towing house or on the bulwark at the stern to reduce the bollard pull readings.

If the load gauge is arranged ashore, some means should be provided for maintaining communication between the vessel and the shore.

3.4. Recording of the Readings

It is recommended that the bollard pull is continuously recorded either by a data logger or by a graphic recorder.

If this is not possible, the load gauge should be monitored continuously and the readings should be recorded at 30 seconds' intervals for at least the 5 minutes' run.

A tug can normally not be maintained in position at the bollard, without application of steering. Steering action will, however, affect the pull and should thus be kept to a minimum. It should also be possible to synchronise the influence of steering with the other readings. Thus, in practice, the steering angles should be recorded at 30 seconds' intervals.

3.5. Bollard Pull

Sustained bollard pull

The sustained bollard pull is the mean value of the recorded readings during the 5 minutes' run.

Maximum static bollard pull

The maximum static bollard pull is the mean of the readings during 30 seconds. If readings are not continuous, the mean is obtained from the two maximum noted value (interval 30 seconds)

When it is desired to relate the recorded pulls to the shaft horsepower actually developed, a torsion meter should be fitted. In many cases, however, it is considered sufficient to relate the pull to the engine revolutions. Power estimates according to shop test data are not accepted as reliable.

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4. Corrections

4.1. Correction Factor

If the towline and/or the depth of water is not according to the requirements in 2.2. and 2.3., the measured bollard pull should be corrected, using the correction factors presented in figure 6.

LENGTH OF TOWLINE, REQUIRED = LT

LENGTH OF TOWLINE, USED = L DEPTH OF WATER BELOW KEEL/THRUSTER, REQUIRED = d0

DEPTH OF WATER BELOW KEEL/THRUSTER, USED = d

BOLLARD PULL, NOMINAL FB = k * FBm

FBm = MEASURED BOLLARD PULL

Correction Factor

1,00

1,02

1,04

1,06

1,08

1,10

1,12

1,14

1,16

0 0,1 0,2 0,3 0,4 0,5 0,6 0,7 0,8 0,9 1 1,1

d/d0

Cor

rect

ion

Fact

or, k

L/Lt

= 1

.0

L/Lt

= 0

.8

L/Lt

= 0

.6

L/Lt

= 0

.5

L/Lt

= 0

.4

Figure 6. Correction factors for shallow water and short towline

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PRODUCT DISPOSAL AND SCRAPPING


A 27.9.2005 KURT KURT KURT New document.

Page 1 ( 1 ) 6458097-A-000 U

PRODUCT DISPOSAL AND SCRAPPING

Dismantle the machine, separating the parts following the instructions given in this manual.

You must group the parts according to the materials they are made of: iron, stainless steel, aluminium, copper, bronze, plastic and rubber.

The parts must be disposed of by the relative centres in full compliance with the laws in force on the matter of dismantling and demolishing industrial waste.

Waste oil: to dispose of waste oil abide by the laws for protecting the environment and the laws in force in the Country where the machine is used.

STORAGE OF PROPULSION UNIT

Rev. Date Drawn Checked Approv. Changed pages Description A 5.6.2002 KaTo SeK SeK New layout. B 8.12.2011 KaTo JuPe JuPe Protection oil Cortec M-529 added

Page 1 ( 1 ) 6452407-B-001 U

STORAGE OF PROPULSION UNIT

The best place for storage is a dry place indoors. If this is not possible, storage outdoors is also possible. In this case the unit has to be covered with a proper cover if possible, stored under a roof. When the storage period is over 2 years, only storage indoors is recommended.

A propulsion unit delivered from the manufacturer is possible to be stored in good condition (in a warm and dry place indoors) a short time (2-3 months) without special protective measures.

The following protective measures have to be taken when the propulsion unit is stored in a dry place indoors over 3 months, in a moist place indoors or outdoors and also between installation on board and taking into use.

• The propulsion unit has to be stored in either a vertical or horizontal position, with the driving flange downwards

• If the hydraulic steering aggregate or the tank is fastened to the propulsion unit, e.g. onto the bottom well cover, the unit has to be stored in the vertical position.

• The propulsion unit must be totally filled with oil for the storage period. If the storage time exceeds two years, it is recommended that a special protection oil, e.g. ESSO RUST BAN 623 or CORTEC M-529 or corresponding, is used. When the storage period is less than two years, lubrication oils recommended in the service manual can be used. These oils can be left into the unit when it is taken into use. Where protection oil is used, it must absolutely be replaced by a recommended lubrication oil when taking the unit into use.

• Also the hydraulic steering aggregate and the tank (if there is anyone) must be filled with recommended hydraulic oil for the storage period. Before taking the unit into use, this oil has to be changed.

• Oil coolers and the cooling water piping are drained of water by means of e.g. compressed air.

• When storage the unit in a horizontal position, the unit's oil filling plug must be sealed oil-tight. If the unit cannot be raised into vertical position for the filling, the filling is performed through the uppermost flange on the upper body. During the filling, the unit shall be in a tilted position with the upper body lifted up.

• All the unit's unpainted steel parts, such as driving flange, are protected with appropriate protective grease. When storing the unit outdoors, it is also advisable to protect the hydraulic hose joints.

These protective measures shall be taken also when a propulsion unit onboard is out of use for over three months.

STORAGE INSTRUCTIONS

Rev. Date Drawn Checked Approv. Changed pages Description 0 17 Sep. 96 AKN New document. B 15 Feb. 06 Mleh KaTo JuPe New layout. C 29 May 07 IiLi JaJa JPV Changed Document D 27.Feb 08 IILI MARS AASU 2, 3 Added use of silica gel bags E 13 Jul 10 HeTo JuPe JuPe 2 Material code updated Page 1 ( 4 ) 6452404-E-001 U


TRANSPORT CONDITIONS...............................................................................................2

GENERAL ...........................................................................................................................2

STORE AIR .........................................................................................................................2

STORAGE PLACE..............................................................................................................2

TEMPERATURE .................................................................................................................2

MEANS OF STORAGE .......................................................................................................3

LONG TERM STORAGE.....................................................................................................3

ELECTRIC MOTORS ..........................................................................................................3

STORAGE ENDING ............................................................................................................3

LIFTINGS ............................................................................................................................4


Page 2 ( 4 ) 6452404-E-001 U

Transport conditions Components are packed according to the order specifications. All electric units are protected according to the following specification:

• Drop-in panels/ boxes from outside are protected by a protective coat, made by Kendall K1 RP-5000 protection oil.

• Other electric units and connectors are protected with Kendall CML protection oil.

• The transport package has also siligacel bags. Silicagel bags are also inside of transmitter box.

• The sealing bushings/ cable glands of the connection boxes, starters etc. are closed.

General Dry, ventilated indoor isothermal storage have to be arranged. Short term storage in rain proof packing is possible. If stored out doors, possible heating must be switched on and working. Storage on the ground surface is not allowed, there have to be separate platform or like, and protection against rain must be arranged over the packages. Oil heating e.g. cannot be switched on without filling the oil.

Store air Air is to be dust free ,without corrosive gases (chlorine, sulphur compounds etc.. Relative humidity max. 75 %. If relative humidity is constantly more than 75% then Rolls-Royce Oy Ab should be contacted for further assistance regarding storing.

Also silica gel bags are to be used inside the control cabinets to prevent forming of humidity inside the cabinets if constant relative humidity exceeds 75%.

There is not allowed to be any substances causing the corrosive attack.

Storage place There must not be ventilation tubes or windows near the storage place. Electric instruments must be stored at least one (1) meter from the floor level. Electronic devices must be stored on level, dry base, over one (1) meter from the floor level and higher. Starters, controls desks are stored at floor level or higher with a separate base (platform or like).

Temperature Have to be over 10° C and fast variations in temperature have to be avoided.


Page 3 ( 4 ) 6452404-E-001 U

Means of storage Stored on a level, dry base supported by fastenings or package supports. If instruments are stored in their transport packages the air inside them as well as dryness of instrument, must be taken care of by e.g. silicagel bags. It is especially important to ensure that motors, brakes and heaters etc. connection boxes are kept dry. Instruments must not be stored one upon another. Broken or detached packaging must be repaired and it must be ensured that humidity or impurities have not penetrated the instruments. It is recommended that instruments are stored only in one place.

Long term storage If electric instruments are stored over six months special attention must be paid to the conditions of their storage place. The following inspections and services must be made every three months:

• check if humidity has been condensed inside package • dry and add silicagel, if needed • if it has package to be opened, dryad and recovered • repair package if it is broken

Electric motors Insulation resistance in coils must be checked before use. This resistance must not be lower than one Mega Ohm. If values are below this, attempts must be made to dry the motor by switching standby heating on for a while. The motor can also be dried in an electric repair shop.

Brushes of direct current machines must not be touch commutator during storage, but they must be lifted up or separated from the commutator with a insulating sheet which is not hygroscopic or corrosive.

If motor has cylinder bearing, you must stop the rotor turning by transport support in order to protect the bearing against vibration damage. Motors equipped with vibration absorbers should also be stored according to above instructions. When taking into use a motor that has been stored over a year, remove the outer bearing plates and check the bearings for any signs of corrosion. If such are found change the bearings as smallest corrosion damage can significantly shorten the lifespan of bearings. Undamaged bearings must be relubricated.

Storage ending Instruments must be stored in their own packages as long as possible. Packages are removed only when installation begins. Also silica gel bags are to be removed when installation begins.


Page 4 ( 4 ) 6452404-E-001 U

Liftings When lifted up use only marked lift points and officially accepted and inspected lifting devices.

.

APPROVALDATE:2012-04-26

KILA

KILA


KILA

KILA

Page 1 of 1

Rolls-Royce Oy Ab PART LIST 14.05.2012 /PAVA P

Work No. 514-s267-308 -02

Drawing No. : T 5161093-A-000 MAIN ASSEMBLY US 255/3800 P30 FP Customer : Harley Marine Servic

PARTNo:

CODE/DRW NAME UN PCS/DWR

1 K 5156920-H-C18 UPPER GEAR PCS 12 K 5153422-E-R18 HYDRAULIC PUMP DRIVE PCS 13 K 5157180-k-002 INTERMEDIATE ASSEMBLY PCS 14 K 5259475-A-000 BOTTOM WELL COVER ASSEMBLY PCS 15 K 5156303-G-004 LOWER GEAR PCS 16 K 5156892-A-002 MOUNTING OF NOZZLE PCS 17 K 5257530-C-001 GRAVITY TANK PCS 18 A 5251678---000 INPUT FLANGE PCS 19 K 7357979-B-003 EARTHING OF THE THRUSTER UN PCS 110 D 8258025 NOZZLE PROPELLER PCS 111 A 5153765---016 CASING PLATE PCS 112 A 6358550 O-RING BAND MM 113 A 4877740 CONICAL PIN PCS 214 A 4121845 HEXAGON SCREW PCS 6015 A 4514092 HEXAGON NUT PCS 12017 A 5257395---000 TRANSPORT SUPPORT PCS 119 A 5161093---000 INTERMEDIATE SHAFTING PCS 120 E 5257176-A-000 INTERMEDIATE SHAFT PCS 121 E 5257177-A-000 INTERMEDIATE SHAFT PCS 122 A 6419685 CARDAN SHAFT PCS 223 A 1644240 KEY STEEL MM 124 K 5353189-0-000 WATERTIGHT PENETRATION PCS 125 A 5350423---000 FLANGE FOR INTERM. SHAFT PCS 326 A 5450835---000 FIXING FLANGE PCS 328 A 6191463 BEARING HOUSING PCS 529 A 6147171 SPHERICAL ROLLER BEARING PCS 230 A 6272257 SLEEVE PCS 231 A 6147241 CARB -BEARING PCS 332 A 6275063 SLEEVE PCS 333 A 6271918 GUIDE RING PCS 1034 A 6275067 SEAL PCS 1035 A 6648103 GREASE NIPPLE PCS 538 A 4877710 CONICAL PIN PCS 1039 A 4514057 HEXAGON NUT PCS 3241 A 4128676 HEX SCREW TOT.THREAD SHANK PCS 3243 A 4120720 HEX SCREW TOT.THREAD SHANK PCS 1244 A 4128682 HEXAGON SCREW PCS 1045 A 4711182 WASHER PCS 1046 A 4514092 HEXAGON NUT PCS 20

Page 1 of 2

Rolls-Royce Oy Ab PART LIST

Work No. 514-s267

Drawing No. : K 5156920-H-C18 UPPER GEAR 255 P30 FP/75/BS Customer : Harley Marine Servic

PARTNo:


0 D 5150696-G-000 SCREW LOCKING PCS 10 D 6463686-A-000 DIRECTIONS FOR ... PCS 11 K 5156923-E-C18 UPPER GEARS PCS 12 K 5153412-G-000 INPUT SHAFT ASSEMBLY PCS 13 K 5154254-C-119 TRANSMITTER BOX PCS 14 K 5256780-C-000 GEAR FOR TRANSMITTER BOX PCS 15 E 5159091-D-000 UPPER HOUSING, MACHINING PCS 16 K 5156112-A-000 OIL TANK ASSEMBLY PCS 19 K 5353774-A-000 FILLING PIPE PCS 110 A 5352210---000 OIL PIPE PCS 111 A 5352517---000 OIL PIPE PCS 112 A 5254950---000 OIL PIPE PCS 113 A 5451539---000 LOCKING RING PCS 114 K 5355435-B-001 ÖLJYN ALARAJAHÄLYTYS PCS 116 K 5353453-0-000 MANUAL STEERING DEVICE PCS 117 E 5353713-C-000 SUPPORT PCS 120 A 5450007---01 SAMPLER PIN PCS 122 E 5450944-B-000 FLANGE PCS 124 K 5355368-A-001 KÄÄNTÖVAIHDE PCS 225 A 6619922 LAMELLA CLUTCH PCS 128 A 5352538---000 DIP STICK PCS 130 A 7427202 TEMPERATURE SWITCH PCS 131 A 5451935---000 MAKER'S ID LABEL PCS 132 A 3693136 HYDR. LABEL PCS 133 A 3693100 LABEL PCS 134 A 5352708---000 FLANGE PCS 135 A 5153404---000 BEARING HOUSING PCS 139 A 6354960 O-RING PCS 140 A 6358037 O-RING PCS 241 E 5352710-B-000 FLANGE PCS 242 A 5353152---000 COVER PCS 243 A 4740503 HARDENED WASHER PCS 444 A 5353765---000 SEALING PCS 145 A 5267551 PLUG PCS 246 E 5351180-0-000 COVER PCS 149 A 4740501 HARDENED WASHER PCS 850 A 4711100 WASHER PCS 451 A 4740551 FITTING WASHER PCS 2053 E 8451288-A-000 HYDRAULIC PIPE PCS 154 E 8451287-A-000 HYDRAULIC PIPE PCS 155 E 8451286-B-000 HYDRAULIC PIPE PCS 157 E 8451300-C-000 HYDRAULIC PIPE PCS 158 A 1763618 PRECISION STEEL TUBE M 159 A 4210183 ALLEN BOLT PCS 660 A 4210184 ALLEN BOLT PCS 2861 A 4210182 ALLEN BOLT PCS 662 A 4218172 ALLEN BOLT PCS 3665 A 4211604 ALLEN BOLT PCS 866 A 4210171 ALLEN BOLT PCS 267 A 4210151 ALLEN BOLT PCS 2068 A 4210155 ALLEN BOLT PCS 1069 A 4210193 ALLEN BOLT PCS 270 A 4210133 ALLEN BOLT PCS 8

Page 2 of 2


Work No. 514-s267

Drawing No. : K 5156920-H-C18 UPPER GEAR 255 P30 FP/75/BS Customer : Harley Marine Servic

PARTNo:


71 A 4210130 ALLEN BOLT PCS 472 A 4274932 STOP SCREW PCS 273 A 4696180 CHARGE SCREW PCS 1074 A 5170168 MALE STUD FITTING PCS 375 A 5170242 ELBOW FITTING PCS 376 A 5170239 ELBOW FITTING PCS 177 A 5164323 ELBOW FITTING 45DEG PCS 178 A 5170235 ELBOW FITTING PCS 179 A 5170156 MALE STUD FITTING PCS 181 A 5170234 ELBOW FITTING PCS 183 A 5170426 COVER NUT PCS 284 A 5170423 COVER NUT PCS 186 A 5170438 SLEEVE PCS 287 A 5170435 SLEEVE PCS 188 A 4210153 ALLEN BOLT PCS 1289 A 4210173 ALLEN BOLT PCS 2891 A 6358099 O-RING PCS 192 A 6358130 O-RING PCS 193 A 4741403 HARDENED WASHER PCS 3694 A 6376187 USIT SEAL PCS 1296 A 4210154 ALLEN BOLT PCS 497 A 4210131 ALLEN BOLT PCS 498 A 6355721 O-RING PCS 199 A 6356110 O-RING PCS 1100 A 6358090 O-RING PCS 1112 A 5170300 THREADED COUPLING 90DEG PCS 1120 A 5353801---000 PLUG PCS 1121 A 5453240---000 WASHER PCS 1122 A 6352948 O-RING PCS 1123 A 4210153 ALLEN BOLT PCS 1124 A 4210136 ALLEN BOLT PCS 4125 A 5267407 PLUG PCS 2

PRELIMINARY

Page 1 of 1


Work No. 514-s267

Drawing No. : K 5153422-E-R18 HYDRAULIC PUMP DRIVE 205-255/69-/75- Customer : Harley Marine Servic

PARTNo:


1 E 5251944-H-000 V-BELT PULLEY PCS 12 E 5254859-C-000 V-BELT PULLEY PCS 13 E 5153050-D-000 SUPPORT PCS 14 E 5351101-E-000 BEARING HOUSING PCS 15 E 5254860-A-000 FLANGE PCS 16 A 5351926---000 SPLINED BUSH PCS 17 A 6445324 V-BELT PCS 68 A 6112071 DEEP GROOVE BALL BEARING PCS 29 A 5153051---000 BELT SHIELD PCS 110 A 5452446---000 FLANGE PCS 411 A 5451847---000 FLANGE PCS 112 A 4496205 THREAD BAR M 313 A 4496205 THREAD BAR M 414 A 6255992 RETAINING RING FOR BORE PCS 115 A 4120980 HEX SCREW TOT.THREAD SHANK PCS 416 A 4210183 ALLEN BOLT PCS 817 A 4123781 HEX SCREW TOT.THREAD SHANK PCS 418 A 4210168 ALLEN BOLT PCS 219 A 4210161 ALLEN BOLT PCS 820 A 4210154 ALLEN BOLT PCS 821 A 4210142 ALLEN BOLT PCS 822 A 4514038 HEXAGON NUT PCS 2023 A 4514056 HEXAGON NUT PCS 424 A 4711146 WASHER PCS 825 A 5267597 PLUG PCS 126 A 4210172 ALLEN BOLT PCS 427 A 4740520 FITTING WASHER PCS 2

Page 1 of 2


Work No. 514-s267

Drawing No. : K 5154254-C-119 TRANSMITTER BOX AQM Customer : Harley Marine Servic

PARTNo:


1 A 7040739 ASSEMBLY PLATE PCS 12 A 7040097 COVER PCS 13 A 7040081 ASSEMBLY PLATE PCS 14 A 7040085 ASSEMBLY PLATE PCS 15 A 7040084 ASSEMBLY PLATE PCS 17 A 7040043 GEAR PCS 38 A 4275390 STOP SCREW PCS 69 A 7040740 SHAFT PCS 110 A 7040108 PLATE PCS 111 A 7040036 SCALE PCS 112 A 7040020 BOLT PCS 313 A 7040040 WINDOW PCS 114 A 7040032 SPRING WASHER PCS 614 A 7040231 HEXAGON NUT PCS 615 A 7040021 BOLT PCS 216 A 7040201 SUPPORT PCS 217 A 7040180 SLOT-HEADED BOLT,CYL.HEAD PCS 619 A 7350920---001 ANGLE SENSOR PCS 220 A 7040181 SLOT-HEADED BOLT,CYL.HEAD PCS 621 A 7040168 FINGER SCREW PCS 422 A 7040190 U-SEAL PCS 423 A 7040185 O-RING PCS 424 A 7040741 SCREW PCS 625 A 7040742 SEALING RING PCS 126 A 7040160 CYLINDER HEXAGONAL SCREW PCS 227 A 7040028 WASHER PCS 428 A 7040172 FLATHEAD CAP SCREW PCS 629 A 7040161 CYLINDER HEXAGONAL SCREW PCS 1030 A 7040028 WASHER PCS 1031 A 7040162 CYLINDER HEXAGONAL SCREW PCS 432 A 7040028 WASHER PCS 433 A 7040022 BOLT PCS 234 A 7040023 BOLT PCS 234 A 7040202 BOLT PCS 135 A 7944006 WIRE RESISTOR PCS 139 A 7040046 GEAR PCS 140 A 7040007 BEARING PIN PCS 141 A 7040172 FLATHEAD CAP SCREW PCS 242 A 7040121 LOCKING RING FOR SHAFT PCS 143 A 7428811 MICRO SWITCH PCS 144 A 7040060 SLEEVE PCS 246 A 7040178 SLOT-HEADED BOLT,CYL.HEAD PCS 247 A 7040025 WASHER PCS 248 A 7040029 SPRING WASHER PCS 249 A 7040229 SLOT-HEADED BOLT,CYL.HEAD PCS 150 A 7040031 SPRING WASHER PCS 251 A 7040037 SCALE PCS 152 A 7356473 CABLE GLAND PCS 152 A 7356591 CAP PLUG PCS 252 A 7356593 CAP PLUG PCS 252 A 7356599 CABLE GLAND PCS 352 A 7356639 CABLE GLAND PCS 253 A 7587150 BREATHER PCS 2

Page 2 of 2


Work No. 514-s267

Drawing No. : K 5154254-C-119 TRANSMITTER BOX AQM Customer : Harley Marine Servic

PARTNo:


54 A 7581202 mounting rail M 154 A 7587105 TERMINAL BLOCK PCS 2354 A 7587112 TEST PLUG ADAPTER PCS 254 A 7587123 END PLATE PCS 254 A 7587179 TERMINAL BLOCK PCS 155 A 7040214 SLOT-HEADED BOLT,CYL.HEAD PCS 256 A 7040024 WASHER PCS 2U2 W 7356296-0-XXX TRANSMITTER BOX PCS 1dwg W 7357311-C-001 TRANSMITTER BOX PCS 1dwg K 7452040-A-001 TRANSMITTER BOX PCS 11.syys A 7040139 HOUSING PCS 12.syys A 7040743 NUT PCS 13.syys A 7040744 PLATE PCS 24.syys A 7040068 PLATE SPRING PCS 45.syys A 7040122 LOCKING RING FOR SHAFT PCS 26.syys A 7040004 SHAFT PCS 17.syys A 7040137 PROGRAM PLATE PCS 28.syys A 7040110 ADAPTER PLATE PCS 29.syys A 7040103 FLANGE PCS 110.syys A 7040745 PLATE SPRING PCS 111.syys A 7040075 BALL BEARING PCS 212.syys A 7040123 LOCKING RING FOR SHAFT PCS 113.syys A 7040126 LOCKING RING FOR HOLE PCS 114.syys A 7040199 INTERMEDIATE RING PCS 1temper A 7015027 TEMPERATURE INDICATOR PCS 2


ARTA

ARTA


ARTA

ARTA

Page 1 of 2


Work No. 514-s267

Drawing No. : K 5157180-k-002 INTERMEDIATE ASSEMBLY 255 P30 FP/GS Customer : Harley Marine Servic

PARTNo:


0 D 5150696-G-000 SCREW LOCKING PCS 10 D 5452743-0-000 INTERMEDIATE PART PIPING PCS 10 D 6458232-A-000 GENERAL INSTRUCTION PCS 11 E 5157080-J-002 STEM TUBE PCS 12 E 5157183-G-002 STEERING TUBE PCS 13 E 5157121-C-000 STEERING TUBE FLANGE PCS 14 E 5157179-E-000 INTERMEDIATE FLANGE PCS 15 E 5254586-L-002 VERTICAL SHAFT PCS 16 E 5452418-B-000 FLANGE PCS 17 E 5352633-C-000 LOCKING RING PCS 18 E 5154681-B-000 SEALING HOUSING PCS 19 A 5251786---000 COVER PCS 110 A 5255602---000 COVER PCS 111 A 5255760---000 SEALING RING PCS 112 A 6414116 GEAR COUPLING OUTER PART PCS 214 A 6180308 SLEWING RING PCS 115 E 5452568-B-000 SUPPORT PCS 316 A 6132480 CYLINDRICAL BEARING PCS 117 A 6328140 SHAFT SEAL X-TYPE PCS 118 A 6328141 SHAFT SEAL X-TYPE PCS 119 A 6358450 O-RING PCS 120 A 6358355 O-RING PCS 221 A 6359537 O-RING PCS 222 A 6358340 O-RING PCS 223 A 6358280 O-RING PCS 424 A 6356695 O-RING PCS 225 A 6351635 O-RING PCS 426 A 4218163 ALLEN BOLT PCS 327 A 4210242 ALLEN BOLT PCS 5428 A 4121907 HEXAGON SCREW PCS 3229 A 4210207 ALLEN BOLT PCS 430 A 4210203 ALLEN BOLT PCS 4832 A 4218153 ALLEN BOLT PCS 1633 A 4210183 ALLEN BOLT PCS 5634 A 4210406 ALLEN BOLT PCS 1635 A 4210160 ALLEN BOLT PCS 336 A 4210155 ALLEN BOLT PCS 337 A 4213933 ALLEN BOLT PCS 1639 A 4449388 STUD BOLT PCS 1341 A 4514092 HEXAGON NUT PCS 1342 A 4275403 STOP SCREW PCS 343 A 5170009 STRAIGHT FITTING PCS 244 A 5170168 MALE STUD FITTING PCS 345 A 5164322 ELBOW FITTING PCS 146 A 5170428 COVER NUT PCS 847 A 5170440 SLEEVE PCS 848 A 1763622 PRECISION STEEL TUBE M 149 A 5170171 MALE STUD FITTING PCS 250 A 5170429 COVER NUT PCS 451 A 5170441 SLEEVE PCS 452 A 1763627 PRECISION STEEL TUBE M 153 A 5267413 PLUG PCS 154 A 5267407 PLUG PCS 1

Page 2 of 2


Work No. 514-s267

Drawing No. : K 5157180-k-002 INTERMEDIATE ASSEMBLY 255 P30 FP/GS Customer : Harley Marine Servic

PARTNo:


55 A 5170010 STRAIGHT FITTING PCS 156 A 5210957 FAST COUPLING PCS 157 A 4443460 STUD BOLT PCS 3258 A 4525725 CAP NUT PCS 3259 A 1946300 STEEL WIRE MM 160 A 1946300 STEEL WIRE MM 1

Page 1 of 1


Work No. 514-s267

Drawing No. : K 5156303-G-004 LOWER GEAR 255 P30 FP/PL/TK Customer : Harley Marine Servic

PARTNo:


0 D 5150696-G-000 SCREW LOCKING PCS 10 D 6463686-A-000 DIRECTIONS FOR ... PCS 11 K 5156266-D-004 LOWER GEARS PCS 12 K 5256817-B-000 PROPELLER SHAFT SEALING PCS 14 E 5156322-F-002 LOWER HOUSING, MACHINING PCS 15 E 5150095-C-000 PROTECTIVE CAP PCS 16 A 5250191---000 PROPELLER CUP PCS 17 E 5350107-B-000 FIXING FLANGE PCS 18 E 5156318-A-000 ROPE GUARD PCS 19 A 4740551 FITTING WASHER PCS 2410 A 4740551 FITTING WASHER PCS 611 A 5453417---000 LOCK PIN PCS 112 A 5453138---000 CHECK VALVE PCS 115 A 5355467---001 Anode PCS 116 A 6581865 SPRING PCS 217 A 6359354 O-RING PCS 118 A 6359353 O-RING PCS 119 A 6357990 O-RING PCS 120 A 4218057 ALLEN BOLT PCS 1221 A 4210445 ALLEN BOLT PCS 1222 A 4210184 ALLEN BOLT PCS 2423 A 4210183 ALLEN BOLT PCS 624 A 4218059 ALLEN BOLT PCS 1625 A 4218059 ALLEN BOLT PCS 626 A 4175040 HEX SCREW TOT.THREAD SHANK PCS 327 A 4121006 HEXAGON SCREW PCS 328 A 4740503 HARDENED WASHER PCS 2431 A 5268025 PLUG PCS 132 A 5267407 PLUG PCS 133 A 6601573 CHECK VALVE PCS 134 K 8252429-A-001 HYDRAULIC PIPING PCS 135 A 1946300 STEEL WIRE MM 1

Page 1 of 1


Work No. 514-s267

Drawing No. : K 5256817-B-000 PROPELLER SHAFT SEALING 255 FP P30 IHC300 Customer : Harley Marine Servic

PARTNo:


0 D 5156317-B-000 PROPELLER HUB PCS 11 A 6375982 PROPELLER SHAFT SEAL PCS 1

Page 1 of 1


Work No. 514-s267

Drawing No. : K 5156892-A-002 MOUNTING OF NOZZLE 255 P30 TK025/D2800 Customer : Harley Marine Servic

PARTNo:


1 E 5155495-B-000 NOZZLE PCS 13 K 5156238-A-000 FIN WELDING ASSY PCS 24 K 5353608-0-000 MOUNTING OF ZINC ANODES 10, PCS 10

Page 1 of 1


Work No. 514-s267

Drawing No. : K 7357979-B-003 EARTHING OF THE THRUSTER UN US/FP, Thruster unit bolt fixing Customer : Harley Marine Servic

PARTNo:


1 A 4123637 HEX SCREW TOT.THREAD SHANK PCS 32 A 4720715 SPRING BASE PCS 33 A 4711128 WASHER PCS 34 A 4514038 HEXAGON NUT PCS 15 A 7243891 INSULATED WIRE M 26 A 7369302 CABLE SHOE PCS 47 A 4513994 HEXAGON NUT PCS 18 A 4720671 SPRING BASE PCS 19 A 4711084 WASHER PCS 110 A 4123219 HEX SCREW TOT.THREAD SHANK PCS 111 A 7452498---001 EARTH BAR PCS 112 A 7243964 INSULATED WIRE M 113 A 7369303 CABLE SHOE PCS 1

MANUFACTURING OF HYDRAULIC PIPING

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

Page 1 ( 4 ) 6450868-D-000 U


CONTENTS

1. PIPE MATERIAL ...........................................................................................................2

2. SUCTION PIPES ...........................................................................................................2

3. HIGH PRESSURE PIPES..............................................................................................3

4. RETURN LINES AQUAMASTER UNIT BODY .............................................................3

5. HYDRAULIC HOSES ....................................................................................................3

6. FIXING OF PIPES .........................................................................................................4

7. PRESSURE TEST OF PIPES .......................................................................................4



Page 2 ( 4 ) 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



Page 3 ( 4 ) 6450868-D-000 U

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

4. Return lines 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



Page 4 ( 4 ) 6450868-D-000 U

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.


Page 1 of 1


Work No. 514-s267

Drawing No. : KHD 8152207-A-000 HYDRAULIC SCHEME STEERING AND LUB.HYDRAULICS Customer : Harley Marine Servic

PARTNo:


1 K 8250634-F-XXX PUMP UNIT PCS 12 A 8250004---000 HYDRAULIC SUBPLATE PCS 13 A 6659861 FILTER ELEMENT PCS 23 A 6659922 PRESSURE FILTER PCS 24 A 6749149 VALVE UNIT PCS 17 A 6750022 BALL VALVE PCS 110 A 6749181 VALVE UNIT PCS 111 A 7429766 PRESSURE SWITCH PCS 112 A 6779079 COOLER PCS 114 A 6685525 PRESSURE GAUGE PCS 117 A 7429766 PRESSURE SWITCH PCS 118 A 7733019 THERMOMETER PCS 121 A 6679077 HYDRAULIC MOTOR PCS 222 A 6749093 VALVE UNIT PCS 123 A 6690002 CHECK VALVE PCS 124 A 8151151---000 HYDRAULIC OIL TANK PCS 125 A 6659858 FILTER ELEMENT PCS 225 A 6659928 PRESSURE FILTER PCS 227 A 6779078 COOLER PCS 128 A 7427002 LEVEL SWITCH PCS 129 A 7429824 TEMPERATURE SWITCH PCS 130 A 7429766 PRESSURE SWITCH PCS 131 A 6680005 PRESSURE GAUGE PCS 132 A 7731002 THERMOMETER PCS 133 A 8451013---000 DIP STICK PCS 134 A 6654739 BREATHER-FILLER STRAINER PCS 135 A 6750033 BALL VALVE PCS 145 A 6639211 MEASURING CONNECTOR PCS 5


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