INSTRUCTION HANDBOOK CONTROLLABLE PITCH PROPELLER INSTALLATION PART 1 LIPS ORDER NR. H04062 YARD N.B. NR. 1176

Transcription

1 John Crane-Lips INSTRUCTION HANDBOOK CONTROLLABLE PITCH PROPELLER INSTALLATION PART 1 LIPS ORDER NR. H04062 YARD N.B. NR The information made available in this handbook is believed to be amply sufficient for the purpose of assembly on board, and operation and maintenance of the equipment. In case more information or assistance by LIPS personnel is required, or spare parts need to be ordered, please contact: LIPS BV P.O.BOX BB DRUNEN Ll PSSTRAA T RP DRUNEN THE NETHERLANDS - (C) Copyright LIPS B.V. Global Specialised Enging /:rtx / CPP > MECHANICAL

2 John Crane-Lips INSTRUCTION HANDBOOK CONTROLLABLE PITCH PROPELLER INSTALLATION PART 1 LIPS ORDER NR. H04071 YARD N.B. NR The information made available in this handbook is believed to be amply sufficient for the purpose of assembly on board, and operation and maintenance of the equipment. In case more information or assistance by LIPS personnel is required, or spare parts need to be ordered, please contact: LIPS BV P.O. BOX BB DRUNEN LIPSSTRAAT RP DRUNEN THE NETHERLANDS (C)' Copyright LIPS B.V. Global Specialised Engineen"ng

3 John Crane-lips 3 CONTENTS Part 1 A, GENERAL and FIRST-HAND INFORMATION 1 MAIN PARTICULARS 2 SCOPE OF SUPPLY 3 TOOLS 4 SPARE PARTS 5 NUMERICAL INFORMATION 6 PREPARATIONS, COMMISSIONING AND TESTING Part 1 B, SHAFT LINE and HYDRAULIC SYSTEM 1 SYSTEM DESCRIPTION 2 ASSEMBLY and DISASSEMBLY of the SHAFT LINE 3 HYDRAULIC SYSTEM 4 MAINTENANCE 5 ITEMS and EOUIPMENTS 6 DRAWINGS REMOTE CONTROL This part of the total system is described in Part 2 EMERGENCY PROCEDURES: See: Part 1 B, chapter 3.6 Notes LIPS B.V. does not accept responsibility for mistakes or typing errors in this Instruction Handbook. Wherever this book or drawings refer to 'owner', 'purchaser' or 'yard' in connection with responsibility, work to be carried out or goods to be supplied, these words are to be read as 'contracting party'. In case work, which is not fully described in this Instruction Handbook is carried out without the supervision of LIPS service personnel, LIPS' guarantee lapses. Global Specialised Engineen'ng

4 John Crane-Lips 4 PART 1A, GENERAL and FIRST-HAND INFORMATION 1 MAIN PARTICULARS 1.1 General 1.2 Arrangement 1.3 Units 1.4 Ship specification 1.5 Basis of LIPS design and lay-out 2 SCOPE OF SUPPLY 2.1 Propeller with blades 2.2 Shaft line 2.3 Shaft line accessories 2.4 Pitch servo unit 2.5 Hydraulic power equipment 2.6 Miscellaneous items 3 TOOLS 4 SPARE PARTS 5 NUMERICAL INFORMATION 5.1 Shaft line and hydraulic system 5.2 Types of hydraulic oil 6 PREPARATIONS, COMMISSIONING AND TESTING 6.1 Preparations to be made by the yard before receipt of hardware 6.2 Commissioning and testing Notes: The make of all items and parts in this specification is in accordance with LIPS standards unless stated otherwise. The information given on parts lists or drawings is correct in case this specification deviates from same. Global Spea"o!ised Engineering

5 John Crane-Lips 5 1 MAIN PARTICULARS 1. 1 General Yard J.J. Sietas KG Newbuilding number 1176/ Arrangement The LIPS controllable pitch propeller installation consists of: - Propeller hub with blades - Shaft line - Pitch servo unit at the forward end of the gear wheel shaft - Hydraulic power equipment 1.3 Units The International System of Units (S.I) is used with a few exceptions, e.g. knots (1 knot= 0,51444 m/s) and revolutions per minute. 1.4 Ship specification The undermentioned data, provided by the purchaser, or estimated by LIPS on behalf of the purchaser, have been taken into account for the design of the equipment Type of vessel Bulk Carrier (Sietas Typ 167) Classification - Classification Society - Class notation -Ice class Germanischer Lloyd MC AUT + SBG no 1.5 Basis of LIPS design and lay-out Design and lay-out of the equipment have been based on the information of section 1.4 and of this section Propeller strength calculations have been based on: - Engine power, MCR 7300 kw - Propeller speed 152,0 rpm -Ship speed 15,45 knots Globa/Speeialised Engineering

6 1.5.2 Propeller hydrodynamic design has been based on: Delivered power at propeller 5927 kw Propeller speed 152,0 rpm Ship speed 14,5 knots Prime mover configuration: John Crane=Lips One engine, make, type power, MCR engine speed at MCR power, CSR engine speed at CSR Gearbox with clutch - make, type - lay-out of shafts reduction ratio - flexible coupling MaK, 8M kw 500,0 rpm (nominal) 5927 kw 500,0 rpm : ASUG, GVE 950x3,29-51 Ox0,27 : offset 3,2895 : 1 : yes Power supply available for E-motors 450 V /60 Hz/3 phase for controls 230 V /60 Hz/1 phase for emergency conditions 24 VDC floating battery back-up - quality: to Classification Society requirements Global Spttcialiser:l Engineering

7 John Crane=Lips 7 2 SCOPE OF SUPPLY 2.1 Propeller with blades Propeller propeller diameter hub type/diameter number of blades direction of rotation 4800 mm C/1300 mm 4 counterclockwise Material and workmanship of propeller material of blades material of hub blade manufacturing accuracy blade surface finish NiAI bronze NiAI bronze ISO 484 (1981) class 1 class Shaft line The shaft line consists of, from aft to forward: Propeller shaft length 9051 mm outside diameter aft/fwd 404/360 mm bore 130 mm material C45E aft end solid flange fwd end hydraulically fitted flange coupling Moving oil pipes Moving oil pipes inside the shafts, with blocking valve One set of coupling bolts flange holes and bolts finished machined Results of shaft line calculations (for information of the yard only) - elastic line - gap and sag 2.3 Shaft line accessories (no shaftline acessories) C/aba!Specia!ised EngineWng

8 John Crane.. Lips Pitch servo unit The pitch servo unit mainly consists of an oil distribution (00) box and a stub shaft Oil distribution (00) box Type Location Fitted to type VL 90-C forward end of gearbox gear wheel shaft Accessories - One set of flexible hoses to connect the 00 box with the pipes to the hydraulic power equipment 2.5 Hydraulic power equipment The hydraulic equipment consists of a power pack as specified below Power pack tank, capacity 400 dm 3, provided with welding nipples for external connections, combined respiration device and filling connection, drain plug and dip stick; and furthermore with built-on equipments and accessories as follows: Two electrically driven pumpsets, each consisting of: hydraulic pump, make LIPS standard type gear pump nominal speed 1800 rpm pitch adjusting time 32 s, full ahead-ballard astern at nominal speed electromotor, make LIPS standard type, class cage rotor, IP54, class F power 13 kw 2.5.1:2 Oil cooler for fresh water system material of plates heat dissipation plate type 40 C inlet temperature stainless steel 7,5 kw Hydraulic parts: - main distribution proportional valve for electric pitch control, with manual control - load sensing circuit - duplex return filter with change-over valve - pressure safety valve - pressure switch, 'pressure available' - pressure gauge, working pressure - temperature gauge, oil temperature (i) Global Specialised Engineering

9 John Crane.. Lips Alarm signals Sensors, switches or transmitters as follows pressure switch, low oil pressure alarm - low oil level switch in power pack tank - clogged oil filter pressure failure in hub spare pump on (yard delivery) Hub pressure pump Flow 0,4 dm 3 /min and furthermore: - pressure switch, low oil pressure alarm - pressure safety valve 2.6 Miscellaneous items Packing The equipment is sufficiently packed for storage during 6 months in a dry ventilated TICroup G!aba/Speda!ised Engineering

10 John Crane.. Lips 10 3 TOOLS The tools supplied with the ship set under this contract are listed in Part 1 B, Chapter 5.3. For further identification refer to Part 1 B of this handbook using the figure number-item number combination or the W-number. 4 SPARE PARTS The spare parts supplied with the ship set under this contract are listed in Part 1 B, Section 5.4. For further identification refer to Part 1 B of this handbook using the figure number-item number combination or thew-number. To order new spares, see Chapter 4.3 in Part 1 Global Speda/iscd Engineering

11 John Crane-Lips NUMERICAL INFORMATION 5.1 Shaftline and hydraulic system For main data, see Chapter 2, Scope of supply, as well as the drawings of the blade and the shaft line in Part 1 B Propeller material of blade bolts material of yoke X17CrNi16 2 GGG-40.3 Pitch values (given for the section at 0, 7R) design pitch ahead 19,17 ballard pitch ahead 15,17 ballard pitch astern -14,87 After assembly, three pitch values have been marked on the hub and the blades based on measurements with a clinometer: zero pitch maximal ahead pitch maximal astern pitch 0 0, with respect to the middle position of hub 22,50, with push-buttons -17,50, with push-buttons Emergency conditions: maximal pitch ahead for emergency start and operation according to the engine maker, as indicated on the scale:... to be determined during test of emergency procedure. (see chapter 3.6, Part 1 B) Shaft line oil content of shaft line Hydraulic system pump capacity operating pressure safety valve pressure pressure switch, setting stand-by pump 'in' pressure switch, setting low pressure alarm relay TR1 (yard delivery) time delay setting stand-by pump thermal switch TS1, setting included in total, see next section 71,4 dm 3 /min 74 bar 89 bar 8 bar 6 bar 5 s 65 C T/Group Global Specialised Engineering

12 John Crane... lips Oil capacity of all LIPS components and pipes, including shaft line but excluding that of all supplies by yard and third parties: 12 oil capacity of power pack tank oil capacity of the shaft bore oil capacity of the pitch servo unit oil capacity of the hub container (drum) for emergency pump pipe outside diameter x wall thickness in mm see the hydraulic diagram. Global Spea"a/ised Engineering

13 John Crane-Lips Types of hydraulic oil Types of oil for hydraulic system The following types of oil may be used in the hydraulic system and the gear type pumps. The oil has to have anti-wear additives. Oil Trade name Pour Viscosity in est company point Viscosity index oc 40 C 50 C AGIP oso Arnica ARAL Vitam GF Vitam HF BP Energol SHF Bartran HV CASTROL Hyspin AWS Hyspin AWH CHEVRON Mechanism LPS ELF Visga Hydrelf ESSO Nuto H Univis HP FINA Hydran Hydran HV KUWAIT Gulf Harmony AW MOBIL DTE 15M SHELL Tellus Tellus T TEXACO Rando Oil HD TOTAL Azolla Equivis Global Spaeialist:d Engin8eting

14 John Crane-Lips 14 6 PREPARATIONS, COMMISSIONING AND TESTING 6. 1 Preparations to be made by the yard before receipt of hardware The following preparations have to be made: Arrangement of hydraulic pipes. For pipe layout, flanged and welded connections to the hydraulic components, instructions for mounting of pipes and flushing see Part 1 B, Chapter 3 and Chapter 6, fig 5.1 "Hydraulic diagram". Flushing of piping and system components installed by the yard by means of special flushing pumps and filters of the yard. For flushing instructions see Part 1 B, Chapter 3.4. For layout, connection and minimum bending radius of the flexible hoses for the oil distribution unit see Part 1 B, Chapter 6, fig 4.1 "Arrangement of pitch servo unit". Precautions to be made for correct location and placement of components. For the interface between gearbox housing and OD-unit see drawing "Dimensions of shaft end of gearbox" which is separately sent to the gearbox manufacturer or the yard. This drawing is not part of this manual. For the location of hydraulic powerpack see Part 1 B, Chapter 6, fig 5.1 "Hydraulic diagram". For space required and the corresponding foundation bolt pattern see Part 1 B, Chapter 6, fig 5.2 "Hydraulic powerpack" and fig. 5.3 "Assembly oiltank" For the location of a shaft blocking device, a shaft brake, a speed-pickup, a shaft earthening device or a turning device see (if part of the scope of supply) Part 1 B, Chapter 6, fig 2.1 "Arrangement of Shaftline". For the corresponding foundation bolt pattern see Part 1 B, Chapter 6. Preparation of hoisting facilities. Hoisting instructions and equipment for the propeller shaft and intermediate shafts (if supplied) see Part 1 B, Chapter 6 "Transport and hoisting tools for shaft" For hoisting instructions of the propeller blades see Part 1 B, Chapter 2.9 For hoisting all necessary equipment is delivered. Preparation for storing facilities. The propeller installation is adequately packed and conserved for a period of 6 months. Global Speda!ised Engineering

15 John Crane.. Lips 15 When a longer period of storage of the propeller installation is needed LIPS has to be contacted Cathodic Protection Though bronze propellers are inherently resistent to corrosion by seawater, galvanic processes may give rise to electro-chemical corrosion. Prevention of this corrosion can be achieved by: installation of zinc or aluminium anodes or an impressed current system. short circuiting the tailshaft to the hull by means of an earthening device (slip ring). This earthening device is not part of the LIPS supply. The device must also be equipped with a monitoring feature (mvolt instrument) so operators can actually witness proper functioning daily. LIPS strongly advises to install above mentioned earthening device. For a good protection it is also necessary to take care of the following: Use only anodes which can be welded to the hull. Paint only the welded areas of the anodes. Attach sufficient anodes near the stern of the ship to protect the propeller. This protection must be regarded as additional to the protection system of the ship. (See also figure 1 of this paragraph) Attach no anodes where they are likely to cause cavitation on the propeller. (See shading in figure 1 of this paragraph) Locate the earthening device on the propeller shaft or at least as much as possible aft on the shaftline. Every shaftconnection where the protective current has to pass will cause significant reduction of the effect of the earthening device. Periodically check and replace the Global Spedalised Engi'neering

16 John Crane... Lips I INSTRUCTION SHEET CATHODIC PROTECTION FOR PROPELLER ARRANGEMENT OF ANODES ON STERNFRAME AND RUDDER I I I I I : : +2xD! Total area of anodes: ' Sacrificial current density for propeller: Normal trade, RO-RO, Passenger : Is = 0, 7 A/m 2 Tugs, Dredgers, Fishery vessels : Is = 1,0 A/m 2.. Ice breakers : Is = 1,4 A/m 2 ClJrrent capacity of zinc : lz = 11,5 A/m 2 Current capacity of aluminium : See data supplier j TOTAL AREA OF ZINC = AREA OF PROPELLER x Is! a! Notes: For gqod cathodic protection of the propeller and other rotating parts in! the shaftline, an earthening device must be applied. For propeller running in extremely polluted water a higher value must be applied. Area of anodes is for propeller protection only and is additional to protection system of the hull. l (i) Global Sp«lalised Engineering

17 John Crane-Lips Commissioning and testing First activities When the propeller installation arrives at the yard, the yard installs it on board according to LIPS drawings and instructions. During installation, the following must be carried out by the yard: 1. Insertion of the propeller shaft. 2. Mounting of blades (if not already mounted by LIPS). 3. Filling hub with oil or grease while deaerating (if not already done by LIPS). 4. Alignment of shafting (not responsibility of LIPS). 5. Coupling of shafts and pipes and oil distribution unit(s). 6. Completions of pipe connections for hydraulic systems. Pipes must be cleaned thoroughly. Afterwards, the hydraulic system must be filled with the required type of oil. 7. Control components must be placed and connected (electric cables or pneumatic pipes) according to LIPS instruction drawings and/or diagrams. LIPS strongly advises having a LIPS engineer present for some of this work, being; Action 2. Action 5. mounting of blades coupling of shafts and pipes and oil distribution unit(s). When all this is completed, commissioning by LIPS engineering staff can begin. The following commissioning works have to be carried out for each installation At the yard 1. Adjustment and testing of the mechanical/hydraulic system. 2. Commissioning of the total remote control system: a) checking all cable connections. b) pump switch function (if 2 pumps are supplied). c) checking of alarms, signals and illumination. d) pitch/rpm adjustment for various control stands. e) checking of load control function/load sharing function. f) checking of electrical shaft system (if supplied) At sea The following control values must be determined and adjusted: 1. The full load pitch position freesailing and under ballard-conditions; and for one or two engines. 2. Full load running with engine(s) for adjusting load control and load sharing (when supplied). (@) Global Spedalised Engineen'ng

18 John Crane-Lips 3. Checking and, if necessary, re-adjustment of running up and down times for pitch actuation. 4. Checking of pitch/rpm combination (if supplied). 5. Measuring of actuating pressures while actuating from Full Ahead to Full Astern and back with pitch changes of about 5 degrees, under full RPM. 6. Checking of RPM control system and re-adjusting if necessary. 7. Re-adjustment of safety valves in hydraulic system if necessary Measurements The official final results of the following measurements will be highly appreciated by LIPS B.V. for their own development program: 1. Results of speed trials as a function of power and propeller RPM/pitch. 2. Results of crash stop tests (stopping time and distance). 3. Results of ballard pull tests. 4. Results of torsion, vibration and axial vibration measurements of shaft line. 5. These data to be completed with: -draft fore and aft. - windforce/direction - loading conditions - other interesting factors/conditions (@) GlobatSpecialised Engineering

19 !IS PART 1 B, SHAFT LINE and HYDRAULIC SYSTEM John Crane-Lips 19 Chapter Chapter Chapter Chapter Chapter Chapter SYSTEM DESCRIPTION Introduction General Propeller hub with blades Shaft line Pitch servo unit Hydraulic power equipment ASSEMBLY and DISASSEMBLY of the SHAFT LINE Receipt of hardware Warnings and instructions Propeller shaft with hub Shaft line components Pitch servo unit Shaft alignment First time assembly Inspection and withdrawal of propeller shaft Mounting and demounting of propeller blades HYDRAULIC SYSTEM Receipt of hardware Warnings and instructions Mounting Filling, flushing, draining and oil sampling Operational checks Emergency pitch setting Interfaces MAINTENANCE Inspection and maintenance Faultfinding and remedies How to order spare parts ITEMS and EOUIPMENTS Items, general Items, hydraulic power equipment Tools and equipment Spare parts Sub-suppliers manuals DRAWINGS Alignment instruction sheets System drawings Glabo/Spqa"afised Enginllf!ring

20 John Crane-Lips 20 1 SYSTEM DESCRIPTION 1.1 Introduction The descriptions given in this chapter explain the working principles of the shaft line and hydraulic system and of the relative subsystems. It may be hard to avoid that items not being part of the LIPS scope of supply are mentioned to elucidate such explanations. It is therefore to be noted that the specification in Part 1 A, Chapter 2, Scope of Supply, is the only valid enumeration of the items that are supplied under this contract General HUB. The blades are operated by an actuating yoke and a hydraulic pistoncylinder combination in the hub. The axial movement of the yoke is transformed into a rotation of the propeller blades. SHAFT LINE. The oil to change the position of the hydraulic piston is pumped through the inside or along the outside of the moving oil pipe in the shaft line. HYDRAULIC POWER EQUIPMENT. The energy, required to adjust the position of the blades (the pitch) is generated by a hydraulic pump which supplies the oil through the oil distribution box into the running shaft. The oil is directed either to the inside or to the outside of the moving oil pipe and thereby to the aft side or the forward side of the actuating cylinder. During the time that the pitch is not changed, the hydraulic oil in the shaft line is trapped by a blocking valve in the moving oil pipe. In all descriptions, reference is made to drawings and relative parts lists by the 'figure' numbers. Parts are indicated by their part number from time to time in combination with the figure number, e.g. (2.1-1) means: fig. 2.1, part nr. 1 (propeller shaft). Figure numbers not mentioned have not been used, see Part 1 B, Chapter 6 for list of drawings. All assemblies and parts have a LIPS reference number, i.e. a capital letter 'W' or 'M' followed by 9 digits. These numbers are listed on the parts lists in Chapter 6 of Part 1 B. All partnumbers are included in the LIPS data base and used for identification and ordering of spares. For ordering of spare parts see also Part 1 B, Chapter Propeller hub with blades (type 4C, Part 1 B, Chapter 6, fig. 1.2) The LIPS type 4C controllable pitch propeller has the following features: The hub body (1.2-25) is cast in one piece with large bearing collars, to absorb the loads exerted by the blades and by the crank-slot Clobol Specialised Engineering

21 John Crane... Lips Each blade is connected to its blade carrier ( ) by means of bolts ( ) and dowels ( ). The bolts have heads for a hexagonal spanner and underneath the bolt heads are 0-rings for sealing. The bolts must be tightened with a dynamometric wrench. For the tightening torque see Part 1 B, Chapter 6, fig 1.2. The bolts are locked with welded-on stainless steel strips. Rotation of blades and carriers is effected by the axially moving cylinder-yoke ( ) through the crank-slot mechanism. The slots are located in the cylinder-yoke. The crank pins are integral with the blade carriers; they are located on the same side as the leading edge of the blades. The pins are provided with high-strength bronze sliding blocks ( 1.2-2). The cylinder-yoke moves axially across two pistons. The forward piston forms an integral part with the propeller shaft, the aft piston is part of the hub cover ( ). When oil is pumped through the inner oil pipe to the aft side of the cylinderyoke, it moves forward causing blade rotation to increase pitch. The aft piston is sealed with a high-pressure seal ( ), consisting of an 0-ring and a sealing ring. In the same way oil can be pumped through the outer oil pipe to the forward side of the cylinder-yoke, resulting in blade rotation towards astern pitch. A meehanite piston ring ( ) acts as a seal between forward piston and cylinder. The pitch of the propeller blades is fed back to the control system by means of the inner oil pipe which is connected to the moving yoke. The hydraulic pressure to change the pitch depends on the characteristics of the pitch actuating (blade spindle) torque which in turn depends on the hydrodynamic design of the blade and the friction in the hub mechanism. The propeller blades (Part 1 B, Chapter 6, fig. 1.1) have been designed especially for this ship based on the data specified in Part 1 A, Chapter 1. A hydrodynamic blade design made by LIPS for a C-type hub is made such that the blade spindle torque always acts to astern direction. In consequence the pressure to adjust the blades to the ahead direction will always be greater than while adjusting to astern. lri the inner oil pipe a blocking valve is incorporated. When the pitch is not adjusted, or during a hydraulic failure, this blocking valve automatically closes. Because of the tendency of the blades to move to astern the pitch will be kept on the closed oil volume in the aft cylinder. (see also Chapter 1.4 shaftline and Chapter 1.6 hydraulic installation) It should be noted that both pressure compartments of the cylinder-yoke are surrounded by compartments with low-pressure oil. The mechanism inside the hub is oil-lubricated. The hub cavity is connected with the 00 box via the oil channel between the outer stationary pipe and the inside of the shaft bore. By means of a hub pressure system connected to the 00-box, static pressure is maintained in the hub cavity. By means of a small leakage path from front cylinder to the hub lubrication cavity a continuous Global Specialised Engineering 21

22 John Crane-Lips circulation of lubrication oil over the highly loaded parts of the hub mechanism is guaranteed. By means of plug (1.2-44) a provision is made to de-aerate the hub cavity. The blade seals ( ) are synthetic rubber endless cord 0-rings mounted under the blade flange. The sealing-rings and grooves are dimensioned in such a way that the tolerance in the blade bearing dimensions can be easily absorbed while retaining the proper compression rate required for the sealing action. Each groove is serrated to avoid peripheral movement of the sealing-ring. The blade seals are subjected to only hub pressure system oil pressure. They are relieved from varying actuating pressures. During shutdown of the hydraulic system, the blade seals remain under a head that exceeds the pressure of the surrounding water, since the hub pressure system runs continuously. For numerical information of the controllable pitch propeller see Part 1 A, Chapter For required torque and locking instructions of bolt connections see Part 1 B, Chapter 6, figure 1..2 "Assembly of the hub" Shaft line (Part 1 B, Chapter 6, fig. 2.1) The shaft line of the controllable pitch propeller installation consists of, from aft to forward: hub with blades, see Section 1. 3 propeller shaft, with hydraulically fitted flange coupling (gear wheel shaft), pitch servo unit VL 90-C, See Section 1.5 The hub is connected to the propeller shaft flange with bolts and dowels. These are protected by a flange cover fitted with sealing rings and filled with mineral grease. The shafts are hollow to contain the hydraulic pipe insert. This pipe insert consists of two co-axial pipes. The inner moving pipe connects the cylinderyoke in the hub with the feedback mechanism in the pitch servo unit. It transmits the position of the cylinder-yoke and thereby the blade position. It also transmits high pressure oil to the aft side of the cylinder-yoke to maintain the blade position or to adjust the pitch in the ahead direction. The outer stationary pipe is fitted in the shaft bore and transmits pressurized oil to the forward side of the cylinder-yoke to adjust the pitch in the astern direction. A third channel is available between the stationary pipe and the inside of the shafts. This channel connects the hub with the oil tank and contains hydraulic oil for hub lubrication. The inner pipe has, where necessary, sleeves with longitudinal flats to keep the unsupported length within required limits. The outer oil pipe has welded-on longitudinal strips for the same purpose. The inner pipe is provided with a built-in blocking valve. It holds the pitch during the time when no changes are required, and also in emergency conditions. It is a non-return valve, pilot-operated and pressure actuated:. Global Speeialised fngineedng

23 John Crane-Lips 23 directly by oil pressure inside the pipe or with a pilot piston by oil pressure outside the pipe, depending on the direction of oil flow required. 1.5 Pitch servo unit (type VL-C, Part 1 B, Chapter 6, fig. 4.2) The OD box is used to transfer hydraulic oil into the rotating shaft. The indication of oil channels is as shown on the hydraulic diagram with list of symbols. Besides this function, the OD box is used to transfer the pitch feed back signal from the inner moving and rotating oil pipe to the stationary world. In the main, the pitch servo unit consists of a guide bush (4.2-18) fitted to the gear wheel shaft. There is no direct connection to the gearbox housing. The guide bush also supports the outer oil pipe. The stationary oil distribution (OD) box runs on the guide bush guided by ball bearings (4.2-29). A torque stay (4.2-21) connected with the ship is required. An insert (4.2-7) with two high-pressure ring-shaped oil distribution chambers is fitted into the OD box housing (4.2-5). The guide bush is running inside the insert with proper clearances maintained by the roller bearings. The gap between the guide bush and the insert acts as a seal. The clearance is set to a minimum in order to reduce the leakage as much as possible. In the forward ring chamber, oil is pumped which is led to the stationary outer oil pipe resulting in an pitch change to astern. In the aft ring chamber, oil is pumped to the inner moving oil pipe resulting in a pitch change to ahead. At the aft end of the insert a low pressure oil seal (4.2-22) is fitted. The housing of the OD box is utilized to collect leakage oil from the high-pressure ring chambers and the channel between the stationary pipe and the shaft. The OD box is connected with the pipe lines to the hydraulic power pack by.flexible hoses, see Part 1 B, Chapter 6, figure 4.1, "Arrangement oil supply unit" Emergency pitch setting can be effected if the hydraulic power is down or the hydraulic control system is out of order. The plug ( ) is replaced with an insert with a self-closing quick-release coupling ( ). The insert closes the connection with the proportional valve and thus with the power pack tank. The hose end of the emergency pump can be put into the coupling in order to pump oil through the insert to the hub. For normal operation the original situation has to be restored again, i.e. the special plug has to be removed and to be replaced with the original plug. The procedure is described in Section 3.6. A transmitter box (see also Part 1 B, Chapter 6, fig. 4.4) is attached to the OD box housing. By means of a slip ring (4.2-24) which is attached to the moving oil pipe and a sliding block (4.2-37) attached to a feed back lever (4.2-35), the pitch feed back signal is transferred to a spindle (4.2-30). This spindle tranf.ifers T/Group Global Specialised Engineering

24 John Crane-Lips the achieved pitch position to the pointer (4.2-34) and to the transmitter box. This box houses two potentiometers, one for feedback of the achieved pitch and one for the pitch indicating/monitoring system Hydraulic power equipment General The hydraulic installation consists of: piston-cylinder-yoke arrangement inside the hub in-shaft pipes with blocking valve in the moving oil pipe pitch servo unit (VL-C) with OD box which has a built-on mechanical pitch indicator and pitch transmitter box as well as an emergency pitch setting connection hydraulic power pack with power pack tank The parts of the hydraulic installation inside the hub, the shaft and the pitch servo unit have been outlined in the respective systems descriptions in the previous paragraphs. The description of the hydraulic power equipment is given below. The hydraulic diagram and hydraulic arrangement is shown in Part 1 B, Chapter 6, fig. 5.1, with a list of symbols attached Power pack mounted hydraulic pitch control equipment for pitch servo unit VL-C The hydraulic power pack mainly consists of an oil tank with built onto the top two electrically driven pumps, duplex return filter and the valve for hydraulic pitch control. One pump is acting as main pump, the other one as stand-by pump, as directed from the engine room. Pressure switch PRS1 provides the signal 'oil pressure available'. _In case of a main pump failure, pressure switch PRS1 A or PRS1 B provides the signal to switch on the stand-by pump and switch off the main pump. A continuing low pressure condition will trigger an alarm by pressure switch PRS2. PRS1 and PRS2 can be adjusted. When a pitch change is required, the pitch control valve is electrically operated. One of the pumps will supply oil to the appropriate ring-shaped chamber in the OD box via this valve. Consequently, the oil is pumped through the moving oil pipe or via the cavity outside this pipe to the intended side of the piston in the hub to change pitch. Return oil from the piston is flowing to the OD box and, together with OD box leakage oil, to the power pack tank. The pitch control valve is a 4-way, pilot-operated, proportional valve (4WVPROP). The extent of the opening of the main valve (4WVPROP) is regulated by a built-on pilot valve. The pilot valve pressurizes the main valve. The pressure generated by this pilot valve is proportional to the variable electric Globa/Spea alised Engin8enilg

25 John Crane-Lips 25 input signal from the remote control system, regulating the constant rate of pitch change. The hydraulic system comprises a load sensing system which reduces the pumppressure to the minimum needed. Furthermore the load.sensing system adjusts a required constant pressure drop across the proportional valve in order to provide for a stable control behaviour. The load sensing system consist of a shuttle valve SV and load sensing valve PSV4. The load sensing system is acting directly on pressure relief valve PSV1. From the pressure relief valve PSV1 a small quantity of oil constantly flows via PSV4 and the shuttle valve to either the ahead (C1) or astern (C2) feed line to the propeller. The shuttle valve SV connects to the line with the highest pressure. The load sensing valve PSV4 is adjusted to approx 6 bar. The highest pressure in one of the feed lines to the propeller plus the pressure adjusted at PSV4 will operate the main pressure relief valve PSV1. Consequently the pitch actuating pressure is the pressure in the load sensing line + the equivalent pressure to compensate for the spring tension in PSV1 (about 5 bar) + the pressure drop over the non return valve NRV3, the filter and the oil cooler (about 6 bar). Now three situations can be distinguished: The system is at rest. The proportional valve is not operated and is in its middle position. The: pressure in the C 1 and C2 lines is relieved because the A and B port of the proportional valve are connected to the T (tank) connection. The yoke in the hub is kept in its required position by the blocking valve (BV).The pressure relief valve PSV1 is bypassing the complete pump flow and the pump pressure is the pressure drop over (PSV4 + spring PSV1 + NRV3 + oilcooler + filter). Depending on the pump flow and the degree of pollution of the filter the pump pressure will be about bar. Thermal losses are minimized during this condition. The system is changing the pitch. The proportional valve is operated and one of the ports A or B is connected with the pump. The rest pressure ( bar, see previous part) will be sensed immediately in the feed line C1 or C2. Consequently the pressure relief valve PSV1 will close by the load sensing line. The pump pressure will increase until the cylinder yoke in the propeller is moving. Because of the adjusted pressure drop at PSV4 and the spring compensation in PSV1, the pump pressure will always be kept higher than the system pressure in the C 1 or C2 feedline and consequently the pressure drop over the proportional valve will be kept at a constant level of about 11 bar regardless of the flow through the valve. The safety pressure is reached. When the pressure in the C1 or C2 feedline has become extremely high, for example when the hub is at the end of its stroke, the loadsensing pressure becomes higher as the spring setting of PSV2. PSV2 opens and pressure in the load sensing line is relieved and consequently PSV1 opens. Glaba! Specialised Engineering

26 John Crane-Lips 26 An oil cooler is built on which is to be connected with the cooling water system, see Part 1 A, Chapter 2. The hydraulic oil is used for hub lubrication. The space between the stationary oil pipe and the shaft is filled with oil and connects the hub cavity with the OD box. The hydraulic system is kept under static pressure by the hub pressure system. The hub pressure system replaces the normally used headertank system. (See also hydraulic diagram Part 1 B, Section 6, Figure 5.1). When electric motor (EM 1) or (EM2) is running (normal operation) the hub pressure will be kept by means off leakage oil within the oil distribution box. When the E-motors (EM 1 and EM2) are switched off, the hub is kept at a pressure slightly higher than that of the surrounding seawater by the electric motor (EM3) and pressure relief valve (PSV6). The hub pressure system is fitted with a pressure safety valve (PSV6) which sets the right pressure for the hub, and a low pressure switch (PRS6) for low pressure alarm as well a shut off valve (SOV9) for maintenance. This valve can be closed when service operations have to be carried out on the pitch servo unit or in case of casualties. Caution: During normal operations this valve has to be open at all times to ensure proper functioning of the installation. (@> Global Specialised Engineering

27 John Crane.. Lips 27 2 ASSEMBLY AND DISASSEMBLY OF THE SHAFT LINE 2.1 Receipt of hardware On receipt of hardware shipped by LIPS or by a third party under this contract, the following must be done: check the integrity of the packing, check the goods for completeness against the packing lists provided, check the goods for damage. Missing parts or visible damage must be reported immediately to the effect that it is possible to establish the reason for same,i.e. how, where and when. The goods have been sufficiently packed for storage during 6 months in a dry place under shelter. If storage is to be continued for a longer period of time, LIPS is to be informed well before expiration. 2.2 Warnings and instructions All parts fitted for temporary protection, such as covers, caps and plates, have to be left in place as long as possible and are only to be removed for immediate connection to opposite parts. All pipe ends, 0-rings and 0-ring grooves have to be inspected for damage before mounting. All temporarily unprotected parts have to be kept scrupulously clean. The sequence of steps to be taken for shaft line assembly and disassembly have to be adhered to; LIPS BV is to be informed about deviations on beforehand. The special tools and regular tools to be used are listed in Part 1 B, Chapter 5.3 for identification and application description. The torque required to fix the various bolts, screws and nuts is listed on the relevant drawings in Part 1 B, Chapter 6; these values have to be adhered to meticulously; neither overtorque nor undertorque is acceptable. Further numerical information, such as dimensions, weights and oil quantities, is provided in Part 1 A, Chapter 5. If the procedures and instructions, given in this chapter, are not strictly followed, LIPS BV reserves the right to deny any claim with respect to any damage done to the equipment supplied as well as with respect to operational hazards. Global Speo atised Engin«edng

28 John Crane.. Lips Propeller shaft with hub type C Blades, hub and shaft are supplied in assembled condition. The center of gravity of the assembly is indicated on the drawing. Lifting can be done with slings while locally protecting the shaft, see Part 1 B, Chapter 6, fig In the transport condition, on first delivery, the moving oil pipe is set in the full forward position; the protruding end of the oil pipe is protected by a cover. Caution: This cover has to be removed before the ship is launched because the blades will tend to move during launching. The moving oil pipe has to be in the full forward position for assembly and locking of the oilpipes in the shaft. If for some reason, the oil pipe is not in this position, it has to be adjusted. In order to do so the recommended procedure is described in the next section Pitch adjustment during assembly In order to change the pitch to the desired position the moving oilpipe has to be coupled temporarily with the pipe in the gearbox. In order to do so the recommended procedure is described in chapter 2. 7 "first time assembly". The pitch servo-unit has to be fitted already. A tool for emergency setting (sheet ) is supplied that can be fitted on the pitch servo-unit. See also Part 1 B, Chapter 6, fig 4.1. Oil can be pumped into the shaft with the air-driven low-pressure pump (see sheet ). The air pressure (6-8 bar) of the on-board supply must be enough to enable pitch changes. The proper position of the inner oil pipe can then be achieved. An adapter for the pump connection has been supplied with the tool. Pitch adjustment to change the position of the oil pipe may be carried out on the yard's premises. To this end, or to mount the blades, hub and shaft are to be properly supported. GlobtJ/ Specialised Engineering

29 John Crane-Lips Hydraulically fitted flange coupling In general, the coupling supplied under this contract, consists of two sleeves of high quality steel, a flanged inner sleeve and an outer sleeve. The outer surface of the inner sleeve is tapered and the bore of the outer sleeve has a corresponding taper. The cylindrical inner sleeve bore has a loose fit on the shaft in order to allow sliding over the shaft with ease. The outer sleeve is hydraulically driven up the tapered inner sleeve in order to compress the inner sleeve on the shaft. To allow this drive-up, the friction of the mating tapered surfaces is to be overcome by injecting oil at high pressure between the tapers, where it forms a load-carrying oil film separating the two components. When the outer sleeve has reached its correct position, the injection pressure is released and the oil film is drained off, restoring normal friction between the sleeves. Demounting the coupling is affected by working the other way around. The special tools (Lips supply) required are listed in Part 1 B, 5.3 for further documentation. The following documentation sheets are listed for reference: Hydraulic pump, air-driven: /1. - Ratio 1':50 Pump set for airdriven pump: /2. Oil injector Assembly data Reference is made to the drawing "Assembly coupling flange", Part 1 B, Chapter 6.2 fig Numerical information required is listed in the datasheet of this section. Note: Information in this data sheet indicating oil pressures required for the drive-up process is for information only. The required increase of outer diameter of the outer sleeve of the coupling as listed on the data sheet is the parameter determining the final ability of the coupling to transmit the torque with sufficient safety. Receipt of Hardware The coupling is assembled and ready for use. The hydraulic nut is securely locked already. For normal (dis) mounting it is not necesary to disassemble the coupling. G/obo/Spea atised Engineedng

30 John Crane... Lips 30 Mounting procedure Caution: never mount the coupling when the flange bolts are already mounted. 1. Check the following points first the shaft end on which the coupling is to be mounted, or parked temporarily, and the inner sleeve bore must be thoroughly cleaned and degreased with white spirit. ensure that no burrs whatsoever appear on the shaft end or inner sleeve bore. air pressure of 6 to 7 bar to be available; alternatively nitrogen in cylinder can be used, reduced to the same pressure mineral oil to be available for oil injector(s) and hydraulic pump. Any mineral oil may be used. For type of oil: see data sheet in this section. oil injector(s) and airdriven high pressure hydraulic pump to fit in connection holes. micrometer of suitable size to measure the increase in diameter of the outer sleeve of the coupling during the drive-up proces. A "pi-tape" can be used as well. (only necessary for first time Global Specialised Englneen'ng

31 John Crane... lips Note: For first time assembly all mentioned steps are applicable. Furthermore it is assumed that the ship is in drydock or still at its building berth. For mounting of the coupling when, for example, shaft survey has to be carried out, only steps 9 to 16 are applicable To put the coupling into its position on the shaft, the shaft has to be slid aftwards. (Vessel in dry dock) This will enable the coupling to pass through the space obtained in between the shaft end face and the counter flange. Position the coupling by means of hoisting tools with the injector holes in the top position. It is recommended to pull the coupling upwards to compensate for its weight when sliding the coupling over the shaft. 3. Slide the shaft forward into the coupling while carefully guiding the coupling to prevent it from becoming misaligned causing possible damages. Proceed until the face of the shaft emerges out of the coupling. 4. Position the coupling at its temporarely axial location on the shaft as indicated in Chapter 6.1 "Alignment instruction sheets, Open shaft showing intended situation before coupling the shafts with gap&sag values". 5. Mount the coupling temporarily to allow for a fixed flange to secure the shaft during launching of the vessel. Furthermore gap & sag measurements has to be carried out on a mounted coupling flange. The stepwise mounting procedure is described in step Because it is a temporarily mounting, a drive-up resulting in a diameter increase of the outer sleeve of about 50 % of the indicated value will suffice. 6. Now the (propeller) shaft can be temporarily tightened with the flange of the coupling to the hull of the vessel. Check the correct axial position of the shaftline. Now the ship can be launched. The adjacent shaft or gearbox is aligned with the gap&sag method as described in chapter 2.6 "shaft alignment". Global Spedalised Engineenflg

32 John Crane-lips With a temporary jack the shaft has to be vertically positioned to the gearbox flange to get a zero sag value. Couple and lock the oil pipes. 8. Release the coupling as described in the section "demounting procedure". 9. Check if the shaft is still at its final axial position. Note: The distance between the shaft end and the gearbox flange should be as indicated in Chapter 6, 2.1 "Arrangement of Shafting". This distance has to be thoroughly checked against the value given on the indicated drawing. It is advised to axially fix the shaft in its final position before sliding and mounting the coupling. Marking the shafts position before mounting and checking after mounting will suffice as well. Warning: Deviations beyond the tolerance for axial position of the shaft will cause extensive damage Put 0-ring ( ) in its place. Apply some mineral grease on the 0-ring. Slide the coupling forward along the shaft until the flange of the coupling and the flange of the gearbox are in contact. f I I I 11. When mounting the coupling, measure the outside diameter of the outer sleeve accurately at an axial position located at a distance from the forward (flange) side of the outer sleeve which equals half the shaft diameter at the coupling. see also the datasheet in this section. 12. Connect the air driven pump at the hydraulic cylinder of the coupling (connection 1) and only slacken the vent hole screw on the outer sleeve adjacent to the pump connection hole (do not connect the vent hole with the oil drum). Connect the injectors (connection 2) and inject oil between the coupling sleeves until oil emerges at the flange side of the outer sleeve. 13. Then pump oil into the hydraulic cylinder of the coupling until air-free oil escapes through the vent hole. After closing the hole, continue to pump oil, thus driving up the outer sleeve. During the entire drive-up process the injection of oil between the sleeves should also be continued in order to maintain the oil film. A proper oil film is assured when oil is bleeding in between the outer and inner sleeve. Caution: Global Sp«io!ised Engk1eerfng

33 John Crane-Lips 33 When it is hard to proceed the drive-up proces, always intensify the pumping on the injectors to restore or increase the oil film. Increasing pressure on the airdrivenpump may be dangerous in such situations. Drive-up is complete when the diameter of the outer sleeve has increased by the dimension o. In the data sheet the allowable tolerances are given for the diametrical increase. It is advisable to proceed with the drive-up until the diametrical increase has reached the maximum allowable value. Because of the release of oil pressure, the diameter of the outer sleeve will reduce again. Release oil pressure on the oil injectors before finally measuring o. The increase in diameter of the coupling has to be checked on the same axial position as where the diameter was measured before. At the end of the drive-up process the minimum o must equal at least the indicated value. To facilitate re-mounting in future, record distance between aft face of flange and forward face of outer sleeve. If, after the first drive-up, a record is made of the exact final position of the outer sleeve, it will be unnecessary to measure dimension o subsequently. 14. After the pressure has been released on the oil injector it takes about 10 minutes before the oil film pressure between the two sleeves has vanished. The oil pressure in the hydraulic cylinder must not be reduced until this has occured. Disconnect the injectors and the pump, but let the oil remain in the hydraulic cylinder. Seal the oil ducts with the appropriate plugs ( , 9). Leave the oil chamber filled with oil. 15. Fit the coupling bolts. 16. Coat the exposed parts of the coupling seatings and the inner sleeve with rust preventive; this will also prevent moisture from penetrating underneath the coupling inner sleeve. Sealing between the nut and the outer sleeve and shaft can be obtained by tape (not Lips C/ubu/ Spedu/ised Engineen'ng

34 John Crane-Lips 34 Demounting procedure Caution: never demount the coupling when the flange bolts are still mounted. 1. Turn the shaft in order to locate the plugs of the coupling in top position. Remove the coupling bolts and all plugs ( , 9). 2. Connect the airdriven high pressure pump on connection 1 and the injectors on connection 2. Connect the return pipe to the vent hole as well. Locate a dial gauge against the outer coupling sleeve. This dial gauge will indicate the first small movements when the coupling loosens. Adjust the oil pressure in the hydraulic unit to the indicated pressure for demounting (see data sheet in this section). 3. Using the injectors, force oil between the coupling sleeves until it emerges all around the periphery at the forward end of the outer sleeve. This may take minutes. 4. Small movements and consequently loosening of the outer sleeve will be indicated by the dial gauge. When no movement is noticed after the oil has started to bleed out from the front side, wait for about 15 minutes. Periodically pump some extra oil with the radial injector(s) to fully built up the oil film. Repeat this sequence until the dial gauge indicates a small movement. Because of the pressure in the hydraulic cylinder this movement will be towards the flange. Caution: never open the return valve on the hydraulic cylinder when no signs of loosening has been observed. Damage could occur to the coupling when doing so. 5. Slowly open the return valve on the pump and on the return pipe just enough to allow the outer sleeve to slide slowly down the inner sleeve. 6. Clean the shaft adjacent to the coupling and slide the coupling completely on to the shaft. The pump connection hole and the vent hole must be closed whilst the coupling is being moved; the oil in the hydraulic unit will then transmit the externally applied forces and the sealing rings will not be damaged. Disassembly of the coupling The Hydraulic coupling flange is a unit which should normally not be disassembled. However, should it become necessary to do so for a good reason, the nut must be removed first. It is locked by four bolts. During disassembly the mating cone surfaces of the inner and outer sleeve has to be treated with care to avoid any damage. When the coupling sleeves have been reassembled, new sealing rings has to be applied. Global Spcdalised Engineenng

35 John Crrane... Lips The mating cone surfaces of the inner and outer sleeve has to be thoroughly cleaned and a thin layer of oil has to be applied. The nut must be screwed on the inner sleeve over the full length of the thread until it blocks. 35 (@) Global Speda!ised Engineen'ng

36 John Crane-Lips MOUNTING DATA HYDRAULIC COUPLING FLANGE 36 Order number: H H04071 (stamped) HCF-type (shaft dia. at the position of HCF) [mm]: HCF 360 Shaft bore at the position of HCF [mm]: 130 Increase of outerdia. of the outer sleeve (8.) [mm]: (stamped) Tolerance on 8. [mm]: GUIDELINES Drive-up: Cone pressure [bar]: 1450 Nut pressure [bar]: 125 Ratio cone/nut pressure: Drive-up length, approximately [mm]: 52 Drive-off: Cone pressure [bar]: 1550 Nut pressure [bar]: 135 Ratio cone/nut pressure: Maximums allowed: Cone pressure [bar]: 1575 Nut pressure [bar]: 150 IMPORTANT: 1. The outer diameter of the outer sleeve has to be measured at position A, see figure below, A=% D. 2. The above mentioned value of delta (8.) and its tolerance has to be achieved (measured) AFTER the pressure on the cone has been released and a time span of at least 20 minutes has expired to allow the oil film to be drained from the cone. T/Group G/obol Spedali'sed Engfneerfng

37 John Crane-Lips Fitting and mounting of coupling bolts Reference is made to Part 1 B, Chapter 6, Figure 2.1.1, coupling bolt and figure 2.1, Arrangement of shaftline. For the flange connection between gearbox or main engine the coupling bolts are supplied by Lips with oversize. The boltholes of both flanges has to be honed to equal diameters by the yard. The bolts have to be finish machined by the yard to the final measured hole diameter with the appropriate tolerance. (see figure ) The bolt diameter = the measured diameter of the belonging hole + indicated tolerance. Caution: All bolts and belonging holes have to be numbered in pairs. The bolts have to be finish machined to not less than 1.6 mjl. It is recommended not to freeze bolts for mounting because rust will built up. Dismounting of the bolt will be more difficult How to connect/disconnect the moving (inner) oil pipes Note: The instructions for connecting/disconnecting the moving (inner) oil pipe are for general purpose. More specific information is found in the related sections like the mounting procedure for the pitch servo unit. The following is to be observed: 1. Oil pipes project out of one of the shafts forward over a distance as indicated on the drawing in Part 1 B, Chapter 6, fig If not, follow the procedure as described in the related sections. An appropriate distance is left in between the shafts. (see the related sections) 2. The moving oil pipe in the propeller shaft can rotate with respect to the cylinder-yoke in the hub. 3. To carry out the operation, use a spanner on the pipe coupling and hold the opposite moving oil pipe with a spanner as soon as the flats on the latter are protruding. 4. Make sure that there is a firm contact between the pipe coupling and the moving oil pipe applying the required torque. 5. Lock the pipe coupling and the moving oil pipe with the set screw. This is to be done as follows: - a hole has been drilled and tapped in the pipe coupling; use a hand tool to drill a hole in the pipe as indicated on the drawing "Arrangement of shafting", Part 1 B, Chapter 6, fig if necessary, retap the hole in the pipe coupling, Global Specialised Engineerfng

38 John Crane-Lips make absolutely sure that no metal particles whatsoever end up inside the shaft, - apply the set screw, using Loctite 243 and secure with hand punch in 2 locations. 6. The operation is to be carried out with great care for reasons of integrity and calibration. 38 ClobaiSpedalised Engineedng

39 John Crane-Lips Pitch servo unit VL-C (Part 1 B, Chapter 6, figs. 4.1, 4.2) Note: For service purposes the pitch servo unit itself and the transmitter box have to be accessible; The same holds for emergency conditions. It is supposed that the shaft line is fully assembled, that the guide bush (4.2-18) and the oil supply pipe (4.2-17) are already fitted, and that all connections are tightened and secured (See First time assembly). Mounting and demounting of the OD box can best be achieved with the oil pipe in the aftermost position, because of the mounting space required. During first time assembly this can be achieved by applying the tool shown on fig , Part 1 B, Chapter 5. The OD box can be mounted and demounted in accordance with the instructions below and figure 1 of this paragraph. Mounting procedure 1. Slide the OD box over the oil supply pipe. 2. Fit the screws (4.2-3). 3. Lock these bolts with Loc-tite nr Fit the screws (4.2-28). 5. Lock these screws with Loc-tite nr Mount cover (4.2-16) with screws (4.2-8). 7. Lock these screws with Loc-tite nr Connect the pipes and electric cables. 9. Fit the drain plug (4.2-14). Global SpeeialisN Engineering

40 John Crane.. Lips 40 Demounting procedure 1. Put the inner oil pipe in the aftermost position. 2. Shut down the hub pressure system, see Part 1 B, Chapter 1, Hydraulic power equipment. 3. Drain the hydraulic oil by removing plug (4.2-14). 4. Disconnect the pipes and electric cables. 5. Remove cover (4.2-16) with screws (4.2-8). 6. Remove screws (4.2-28). 7. Remove screws (4.2-3). 8. Now the OD box can slide forward and be removed. Global Spsdalised Engineering

41 John Crane.. Lips 41 LIPS part code : W INSTRUCTION SHEET VL 70 MOUNTING/DEMOUNTING VL 80 SEQUENCE OD-BOX VL 80-C Date I mod.: I Type: VL 90-C A B LD c VL VL 80/80-C VL 90-C ! Figure 1. ' = G/aba/Spedalised Engineen"ng

42 John Crane.. Lips Shaft alignment The results of the shaft alignment calculations prepared by LIPS are given in this section. These calculations are made based upon the agreement with the purchaser. They do not necessarily cover all preliminary work to install the shaft line properly Introduction This section describes the procedure for assembling the shaft line in such a way that the correct alignment is achieved. This procedure is intended as a general guidance for shipyards using the Gap & Sag method for shaft alignment. The shipyard however will always remain responsible for the execution and final performance of the shafting system. Reference is made to Part 1 B, chapter 6.1: Figure 1 Figure 2 Nominal alignment of shaftline (coupled situation), MCR-power (condition free sailing ahead), warm, working temperature. Open shaft showing the intended situation before coupling the shafts with Gap & sag values. Cold condition Thermal expansion influencing the alignment of the gearbox To achieve the prescribed alignment in the hot operating condition, the gear case should be set low by an amount equal to the thermal rise. The thermal expansion of the gearbox was taken to be 0,166 mm at a temperature rise from 20 C to 60 C (cold and warm condition). Note: When the temperature of the gearbox differs from the assumption the correct Sag value can be obtained by interpolation of the thermal rise of the gearbox. The difference in offset for the existing temperature and the assumed temperature can be added to the Sag value. The Gap value remains the same for the whole temperature range. Global Specialised Enginesring

43 John Crane-Lips Guidelines for installation of propeller shafts in newbuilding vessels according the Gap and Sag method. Stage 1 The aft and forward sternboss should be bored concentric to a datum line. After this the stern bearings can be mounted. Note: The mentioned datum line is the line passing through the center of the bores of the aft and forward stern bearings. The shaft centerline as referenced in this report is not the same as the datum line as it is offset below the datum-line by half the bearing clearance. All bearings will be set to offset from the shaft centerline. Stage 2 After installation of the complete propeller shaft (including the shaft coupling) the shaft is positioned in the correct axial position. The coupling is temporarily mounted on the propeller shaft. Apartial drive-up, resulting in a diameter increase of the outer sleeve of about 50% of the value indicated in section will suffice. The distance between the gearbox flange and the flange of the coupling has to be 306 mm. The distance from the propellerhub protection cap to sterntube is binding reference. The gearbox should be placed on adjusting blocks and parallel to the shaft center line. tage 3 At this stage the ship is afloat. The yard can now proceed to position and align the gearbox to the propeller shaft until the calculated Gap and Sag values have been reached. It is assumed that the gearbox is in cold condition (20 C). The Gap and Sag dimension are to be measured very accurately by clock gauges n 0,01 mm. It is most advisable to rigidly mount one radial- and one axial rotary dial gauge to the flange of the gearbox output flange and rotate the gearbox output shaft slowly and record the deflection on top, bottom, port and starboard side. The location, where the dial gauge reading is taken must be clearly marked so the measurement can be re-taken at exactly the same position. The measured radially deflection (the average of the top and bottom measurements) shows the radial offset (Sag), whereas the recorded values on port and starboard must be equal. (See figure for the current situation showing the open shaft and Gap & Sag values) Clabo! Spedalised Engineen'ng

44 John Crane-Lips 44 Notes: The Gap value is the difference between the distance of the top and bottom side of the flanges. A positive Sag value indicates that the gearbox is offset above the propeller shaft flange. A positive Gap value means that the distance between the gearbox and propeller flange on bottom side is larger than on topside. Stage 4 At this stage the gearbox will be at its final position according to the Gap & Sag values at the flanges. Now the coupling and the bolts can be placed according to the instructions in the Instruction Handbook. In this situation the flanges are not parallel. If this should cause problems while inserting the fitbolts the following procedure is recommended: Locate four dial gauges at every far edge of the gearbox foundation. Put all dial gauges to zero. Jack the shaft flange over a distance equal to the Sag value. Now the Sag between the propeller shaft flange and gearbox flange is zero. Position the gearbox in such a way that both flanges are parallel. Now the gearbox offset deviates from the final alignment. Place the coupling and fit the bolts. Re-adjust the gearbox to its initial offsets in such a way that all dia gauges are at zero again. Stage 5 At this stage the gearbox is properly aligned and the shafts have been coupled. The gearbox is ready to be chocked in its final position. It is possible that the vertical position of the gearbox will have to be corrected to compensate for compression of the cast chocking when the foundation bolts have been tightened at the correct torque. The typical value is 0,01 mm compression for each 10 mm of chocking height. So for 30 mm of chocking the gearbox should be moved 0,03 mm C!aba/Speda/ised Engineenilg

45 John Crane=Lips First time assembly The sequence of steps to be taken is shown below. For information about handling and securing the various parts, reference is made to the previous sections of this chapter Actions to be carried out before launching of the ship: Put the aft sterntube seal assembly on the propeller shaft. Put the propeller shaft with hub in the proper position in the vessel. When the gearbox is already put in place at this stage, it is to be advised that the hydraulic flange coupling is parked in its position in order to slide the propeller shaft directly into the coupling. Put the forward sterntube seal assembly onto the propeller shaft. Mount forward & aft seal assemblies to the sterntube. Do not fix the forward seal with dowels in thsi stage. Fill the sterntube system with the required type of oil. Remove the protecting cap of the moving oil pipe at the forward end of the propellers haft. Temporarily fix the hydraulically fitted flange coupling onto the propeller shaft. Temporarily tighten the propellershaft radially and axially before launching the vessel by means of the bolt pattern of the coupling. IMPORTANT: During launching and part of the fitting period, the axial position of the propellershaft must remain blocked to prevent accidental movement aftwards causing damage to the seal assemblies, loss of oil and ingress of water. It is to be strongly advised to insert the oil pipes and blocking valve into the hollow bore of the gearbox shaft before placing the gearbox into the ship or before placing the engine in front of the gearbox. Ensure that all pipe connections are locked Actions to be carried out after launching of the ship: If not already carried out; Insert the moving oil pipes and the blocking valve in the bore of the gearbox secondary shaft. Ensure that all pipe connections are locked. G!abul Spcda/ised Englnoon'ng

46 John Crane-Lips Slide the guiding bush of the pitch servo unit (Part 1 B, Chapter 6, fig. 4.2) over the inner moving oil pipe (4.2-17) and connect the guiding bush (4.2-18) to the gearbox. Align the gearbox. Connect the moving oil pipes 46 Mount the hydraulic flange coupling on its final position and connect the flanges. 2.8 Inspection and withdrawal of propeller shaft in drvdock Important: Before draining the system the propeller blades should be positioned at the correct position as described in the foregoing chapters. For information on handling and securing the various parts, reference is made to the previous sections of this chapter. e Drain the oil from the shaft line via the pitch servo unit. Remove all blades in case of complete shaft withdrawal. Support the shaft line where necessary and prepare for rectilinear displacement. Remove the coupling bolts of the hydraulic flange coupling. Demount the coupling and slide the coupling aftwards to its parking position. Caution: never demount the coupling when the flange bolts are still mounted. 6. Disconnect the moving pipes. 7. Pull the propeller shaft in the aft direction. 8. Assembly of the shaft line is carried out the other way around. 9. Always de-aerate the hub-lubrication cavity. (see also Part 1B, Chapter 2.3) 2.9 Demounting of blades, C-hub For mounting tools, see Part 1 B, Chapter 5.3. Sufficient hoisting facilities to be arranged for, (see Part 1 A, Chapter 6) For hoisting instructions see figure 1 in this paragraph. Global Spedafised Engineering

47 John Crane-Lips 47 Some oil will be spilled and should be caught during the operation. 1. Shut down the hub pressure system, see Part 1 B, Chapter 3, Hydraulic System. If the hub has to be drained: remove the plugs (1.2-44) and drain. 2. Turn the propeller shaft to bring the blade that is to be exchanged into the 12 o'clock position. 3. Remove the locking strips that are welded on the heads of the blade bolts by careful grinding. 4. Loosen blade bolts with socket wrench and ring spanner (see Part 1 A, Chapter 3, for tools) and remove bolts. 5. Apply the hoisting clamp, the two eye bolts, chains, turn buckles and bow shackles (see for tool identification, sheet , Part 1 B, Chapter 5). To avoid damage to the blade an aluminum plate must be placed between the jaws and the blade. 6. Create the same tension in both chains by tightening the turn buckles. Place a bow shackle in the centre hole of the hoisting bracket and hoist the blade by this. A deviation from the horizontal position of the bladefoot can be corrected by placing the bow shackle in one of the extreme holes. 7. Take the blade off the hub Mounting of bladesl C-hub For mounting tools, see Part 1 B, Chapter 5.3. Sufficient hoisting facilities to be arranged for, (see Part 1 A, Chapter 6) For hoisting instructions see figure 1 in this paragraph. Note: Where oil is to be used for mounting of the blades, reference is made to Part 1 A, Chapter 5.2, types of oil to be used for the hydraulic system. In case the vessel is already in service some oil will be spilled and should be collected during the operation. 1. Turn the propeller shaft to bring the bladefoot opening into the 12 o'clock position. 2. Apply mounting tools on the blade for hoisting as described in the previuos section. 3. Visually check the 0-ring of the blade sealing (Part 1 B, Chapter 6, ) on damages possibly occured by storage or transportation, and remove the quality lead seal, if present. Secure some hydraulic oil. 4. Clean the 0-ring grooves in the hub body. TICroup C/oba/Spedalised Engineering

48 John Crane-Lips Make sure that the flange of the new blade, the side that is to be fitted against the hub and especially on 0-ring running area, is absolutely clean. Remove any wear and corrosion with emery cloth no. 80 and 240. Maximum surface roughness (CLA) Ra = 0,8 pm. 6. Rub complete 0-ring surface with oil. 7. Place the 0-ring on the 0-ring groove. Push the 0-ring gently in the groove on opposite positions of the 0-ring circumference. Avoid torsion of the 0- ring. 8. Generously apply oil to the running surface of 0-ring and adjacent surfaces of the hub body. g_ Apply oil to the running surface of the blade foot. 10. Put the propeller blade into position on the hub. 11. Rub 0-rings under the blade bolt heads (Part 1 B, Chapter 6, fig ) with oil. 12. Grease the blade bolt head contact surface and thread section with copaslip (part 1 B, Chapter 6, fig ). 13. Mount the bolts handtight with a socket wrench and ring spanner (for tool identification see sheet and , Part 1 B, Chapter 5.3). 14. Remove the hoisting tools. 15. Tightening of the blade bolts, see figure 2 of this paragraph. Note:The procedure given in this section is for reference only. Alternative methods like the use of a hydraulic torquing device is allowed as well. The bolts can be easily tightened by means of a hoisting arrangement attached to the aft body of the vessel. Use the socket wrench and ring spanner, but lengthen it to 1 meter. (lengthening is yard supply). First the aftmost bladebolts have to be tightened. Pull by means of a chain block and dynamometer or unster (all yard supply) over 60 - goo angle until correct tightening torque is reached. See fig. 1.2, Part 1 B, Chapter 6 for the applicable blade bolt tightening torque. Pull preferably in one (slow) pull. Do not pull intermittently. Note 1: Correct tightening torque has to be read when angle a between wrench and dynamometer is ± goo. Note 2: When the length of the wrench differs from 1 meter the required pulling force read from the dynamometer has to be changed according! Globof Spea"alised Engineering

49 John Crane... Lips 49 Torque (Nm) = kg * m * 9,81 or N * m. 16. Turn the propeller shaft 180 to tighten the foremost blade bolts, at portside using the forward hoisting eye. Suggestion: Before turning the propeller shaft tighten the foremost blade bolts of the opposite propeller blade. This reduces the number of turnings. 17. Lock the bolts by welding strips onto the heads, see Part 1 B, Chapter 6, fig Caution: Be sure the blades are sufficiently earthed during welding to avoid damage to the blade seals. 18. Turn the vent hole (Part 1 B, Chapter 6, fig , plug) in the hub to the top position and supply oil from the tank; make sure that the hub is fully filled up with oil. 19. Make sure that the plugs are inserted and tightened with the torque required (see Part 1 B, Chapter 6, figure 1.2) and that the static head remains fully available to the hub. (@) Global Spedaliscd Engineen{lg

50 John Crane-Lips 50 INSTRUCTION SHEET HOISTING OF PROPELLER BLADE BLADE HOISTING CLAHP HAS TO BE POSITIONED ABOVE CENTER OF GRAVITY OF BLADE.. 1 CENTER OF GRAVITY I / CAN BE APPROXIHATELY FOUND ON A LINE BETWEEN THE EYE BOLTS. I : i IHPORTANT, i THE BOLT ON THE.. : HOISTING CLAMP HAS : FOR HORIZONTAL POSITIONING OF BLADE, ALWAYS CONNECT CHAINBLOCK AS INDICATED. TO BE TORQUED BEFORE HOISTING THE BLADE. FOR TORQUE VALUES SEE TOOL IDENTIFICATION SHEET : ALWAYS APPLY PROTECTION PLATES TO AVOID DAHAGE. NECESSARY TOOLS 1 - EYEBOLTS 2x flips SUPPLY} SEE HOISTING CLAHP 1x (LIPS SUPPLY} SEE BOW SHACKLE 5x {YARD SUPPLY} 4 - ALUHINIUH OR SOFT BRASS PLATE 1x (YARD SUPPLY} 5 - ENDLESS HOISTING SUNG 1x (YARD SUPPLY} i Figure 1 : ,.-.-,., ,,.,.n,..., ,,.-,,,,,-..-., : Global Specialised Enginrren"ng

51 J hr CrrmeLips 51 Lips part code W Date I mod.: I INSTRUCTION SHEET TIGHTENING OF BLADE BOLTS Type: HUIS TING EYES WEL BED To THE SI-I/P TOTAL 4 PCS FOR MOUNTING AND BEMOUNTING (YARD SUPPLY) 1/2 B/A. HUB OUT OF 1I DYNAMOMETER OR UNS TER TO READ kg. OR N. (YARD SUPPLY) HUB SEEN FROM TI-fE STARBOARD S/DE WRENCH 1000 LENGTHEMNG PIPE (THICK WALLED) (YARD SUPPLY) Figure 2 of part 1B, chapter 2 TI Group GIoISpi,fi,,d Eginth,g

52 John Crane-Lips 52 3 HYDRAULIC SYSTEM 3.1 Receipt of hardware On receipt of hardware shipped by LIPS or by a third party under this contract, the following must be done: check the integrity of the packing, check the goods for completeness against the packing lists provided, check the goods for damage. Missing parts or visible damage must be reported immediately to the effect that it is possible to establish the reason for same,i.e. how, where and when. If the goods have to be stored for a short period of time, this is to be done in a dry place under shelter. Storage for long periods is to be done in accordance with separate LIPS instructions which will be sent on request. 3.2 Warnings and instructions All assemblies, sub-assemblies and parts of the hydraulic system have to be mounted in the ship in such a way, that they are free from harmful vibrations originating from other equipment. If harmful vibrations are to be expected from such equipment, the yard has to take care that the LIPS equipment is flexibly mounted and connected to pipes with flexible hoses. All parts that are fitted for temporary protection, such as covers and caps, have to be left in place as long as possible and are only to be removed for immediate connection to opposite parts. All pipes supplied by the yard have to be flushed prior to fitting onto the LIPS equipment. All pipe ends, 0-rings and 0-ring grooves have to be inspected for damage before mounting. All temporarily unprotected parts have to be kept scrupulously clean and utmost care to be taken that no foreign matter whatsoever enter pumps and other components. Numerical information, such as dimensions, weights, types of oil to be used and oil quantities, is given in Part 1A, Chapter 5. Requirements regarding maximal pipe lengths and maximal number of bends are shown on the hydraulic diagram. The pipe work supplied and fitted by the yard has to comply with the requirements of the Classification Society and the instructions as listed in this section. Before starting first time operation, the system has to be flushed thoroughly. C/obtll Spedalised Engineering

53 John Crane.. L.ips 53 If the procedures and instructions, given in this chapter, are not strictly followed, LIPS BV reserves the right to deny any claim with respect to any damage done to the equipment supplied as well as with respect to operational hazards. 3.3 Mounting The hydraulic parts are mounted into sub-assemblies as indicated on the hydraulic diagram by dot-and-dash lines. The sub-assemblies and parts have to be connected as shown on the diagram. For the tank(s) a certain vertical position is required as shown on the diagram in order to ensure sufficient head. The installation of the hydraulic sub-assemblies and pipe lines has to comply with the following requirements: the pipe lines have to be mounted in such a way that no vibrations and stresses are transmitted to the parts and sub-assemblies they connect the lines have to be adequately supported in order to prevent transmission of vibrations elbows and manifolds to be provided with buttweld flanges to allow for inspection and cleaning of the inside piping pipes that have been heated for any reason must subsequently be immersed in an acid solution and be rinsed thoroughly and oiled thereafter. 3.4 Filling, flushing, draining and oil sampling Flushinq of piping and system components installed by the yard. Before operating the hydraulic system, all piping must be flushed to ensure that the power pack operates with a clean system. A hydraulic system which is not clean can cause failure of the hydraulic pump and the valves on the power pack. The hydraulic components of the LIPS delivery are already cleaned at the makers work shop. Before connecting the hydraulic piping always make sure to work with flushed clean pipes and couplings to prevent any ingress of dirt in the hydraulic system. The piping connecting the hydraulic components must be demounted in order to create a flushing arrangement. Using temporary piping all separate pieces are connected in a closed loop with the flushing unit. Flushing is done with a special flushing unit, the pump unit of the hydraulic power pack can not be used for flushing because the flow of this pump is much too small. In general the flow of the flushing pump should be enough to give a flushing velocity of at least 7 m/s. When the prescribed pipe diameters are used (see hydraulic diagram) following flows are required: Global Spedalised Engineering

54 John Crane-Lips I PIPE SIZE I MIN. PUMP FLOW I PIPE SIZE I MIN. PUMP FLOW I 28 X 3,5 145 dm 3 /min. 48 X dm 3 /min. 35 X dm 3 /min. 60 X dm 3 /min. 42 X dm 3 /min. 60 X dm 3 /min. 42 X dm 3 /min. 76,1 X 2, dm 3 /min. 48 X dm 3 /min. 88,9 X 3, dm 3 /min. 54 It is possible to flush with one of the recommended oils of the list but a special flushing fluid with lower viscosity is preferred. Always use clean oil. The flushing oil must be heated to 60 C. Minimum flushing duration for each flushing loop is 2.5 hours. Each hour of flushing is to be interrupted by a 5 minute rest. If possible revert the direction of the flow a few times. Light hammering on the hydraulic piping will accelerate the loosening of the dirt particles. Check filter(s) of the flushing unit regularly. If necessary, replace filter cartridge(s). The flushing has to be continued until filter(s) remain(s) clean. When the piping has been flushed properly, drain all piping and blow out the remaining flushing fluid with dry air, remove the temporary piping and re-install all piping in its original position Filling The following stepwize procedure has to be followed for first time filling of the hydraulic system and when the system is (partly) drained during maintenance in dry dock: Always use one of the recommended types of oil as listed in Part A, chapter 5. Use clean oil. The maximum contamination level is 17/14 ace. ISO 4406, equivalent to 8 ace. NAS 1638). Make sure that all material used for filling is cleaned before filling takes place. Filling must be done through a filter. All internal SOVs have to be open. When in dry dock, the bleed plugs of the hub ( ) have to be set in the twelve-a' clock position and removed while filling, the bleed hole has to be observed during the entire filling operation and closed immediately on the appearance of oil using the proper torque to the plug. The bleed plug of the oil distribution box has to be removed, observed during the entire filling operation and closed on the appearance of oil with the proper torque applied to the plug. Open the external connection to the power pack tank and start filling via the combined respiration device and filling connection (AB 1-FILL) with clean oil until the tank is up to the maximal allowable Global Specialised Engineering

55 John Crane-Lips Start-up of flushed and filled hydraulic system Prime the pumps one by one and check the direction of rotation of the electro motor. Start one pump. Check the oil level in the power pack tank with the dipstick and make sure that it does not fall below the allowable minimum after the air has escaped; supply oil when necessary up to the maximal allowable level. Check the return filter regularly; if necessary replace filter elements; the flushing has to continue until the filter remains clean. Check the proper operation of the oil cooler by fully opening the water feed. Remove the air entrapped in the shaft line by locally changing the pitch regularly from full forward to full astern; this procedure has to be repeated during dock trials and later on during sea trials; it will eventually lead to removal of all air Draining In case work has to be done on hydraulic parts in the shaft line, the valve of the hub pressure system SOV9, has to be closed. The hub can be drained by using the bleed screws in the hub body. The pitch servo unit has a bleed screw and a drain plug Oil sampling instruction The good results of the analysis of an oil sample and the related interpretation and diagnosis are depending on the following: General: Take the sample always from the same place, in the same condition and in accordance with this instruction. Always use clean sampling tools, check that the bottle had never been opened and/or used before. Take sample in good hygienic environment. The system should be at operating temperature. If possible the installation has to be in operation (propeller running) during the sampling, if not, take sample not more than 30 min. after propeller stop; pump of hydraulic system must be in operation. Note all data on the sticker of the sampling bottle. Send sample always to the same laboratory. Clobo/Spedalised Englnflering

56 John Crane=Lips 56 Hydraulic System: Remove the pressure gauge (5.2-96) from its minimess connection. Clean the sampling point with paraffin and connect the sampling hose. Let ± 2 liter of hydr. fluid flow away into a bucket or can. This removes all the dirt out of the minimess connection and hose. Screw the cover of the sampling bottle open and prick the tube through the cellophane. Fill the bottle up to ± 80%. Disconnect the sampling hose and let it drain in the bucket or can. Screw the cover back on the bottle. Replace the pressure gauge on the minimess connection Operational checks Pitch adjusting time (VL, RT-L, VL-C) Warning: It is strictly forbidden to run with two pumps simultaneously in order to reduce pitch adjusting time. The equipment has not been designed and selected for such purpose. This would lead to damage. Adjustment of pitch adjusting time: Since the capacity of the active pump is constant and always fully utilized, the fastest pitch changes are achieved with the 4-way proportional valve (4WVPROP) in fully open position. The suitable pitch adjusting time is achieved by properly energizing 4WVPROP. This one-time setting is done with the control system during trials only, see Part Safety valve (VL, RT-L, VL-C) Put the propeller blades in the maximum ahead position with the ahead push-button of the 4-way proportional valve (4WVPROP). The safety valve PSV2 is now set at the safety pressure, see list attached to the hydraulic diagram. The safety pressure is the maximum calculated pressure with an extra margin of 15 bar. Note: During the first trials of the ship the required pressure might be somewhat higher due to "running in" phenomena. In order to keep full controllability the safety pressure has to be temporary adjusted to a higher level. It is of importance to check the maximum req.ed. Cloba!Specialised Engineering

57 John Crane-Lips 57 pressure after some time and decrease the setting of the safety valve as much as possible. Check the pressure on the pressure gauge and correct if necessary by adjusting PSV Local manual control (VL, RT-L, VL-C) The 4-way proportional valve 4WVPROP can also be actuated with the pushbuttons on either end Switch-over system of the pumps Make sure that the local manual starters of both pumps are in position 'AUTO'. On the ECR/ER panel, select pump 1 as the main pump with the pump select knob. Stop the running of pump 1 by switching the local manual starter in position 'OFF'. Check whether the low-pressure alarm is activated. Check whether the stand-by pump is automatically started. Now check the system the other way around by switching the local manual starters of both pumps to 'AUTO' again and on the ECR/ER panel selecting pump 2 as the main pump. Stop the running of pump 2 by switching the local manual starter in position 'OFF'. Check whether the low-pressure alarm is activated and the stand-by pump automatically started. Switch the starters of both pumps to 'AUTO' again. Cloba/Spedalised Engineering

58 John Crane-Lips Emergency pitch setting In case of an emergency in the hydraulic system, it may not be possible to restore the proper operation of the controllable pitch propeller within the time span available. In such a condition, the propeller blades may be adjusted to a suitable ahead position with the emergency equipment. Pressurized air must be available to operate the emergency pump delivered under this contract. Emergency pitch setting operation has to be carried out with the shaft stopped. The blades can be moved to and blocked in a ahead position in which the propeller installation can be driven like a fixed pitch system. The suitable pitch for starting and running of a fixed pitch propeller system is depending on the main engine and clutch (if available) characteristics. It is of importance to carry out a test during trails to determine a suitable pitch setting in which the engine can be started and the clutch engaged with fixed pitch. Furthermore all necessary tools and equipment must be checked and tested on proper functioning. Notes: When it is necessary to sustain emergency pitch setting during a longer period it might be necessary to repeat the pitch setting procedure because some small leakage is to be expected. In order not to lose time in emergency conditions, it is recommended to locate the container (drum) with hydraulic oil and the emergency pump in the vicinity of the OD box, ready for use. During emergency pitch setting operation, the pitch can be read locally from the scale and mechanically driven pointer on the pitch control unit. The blocking valve in the shaft line will secure the pitch in that position and block the tendency of the blades to change pitch in the astern direction. The procedure is as follows (VL, VL-C, see fig. 4.1, "Arrangement of oil supply unit" and Chapter 5.3 for tools and equipment) Remove the plug (4.1-11) and fit the insert assembly ( , , , , , ) with female part for the quick-release coupling ( , ). Connect the hose of the low-pressure air-driven hydraulic pump with quick-release coupling to the insert ( ). Pump oil into the shaft until the pitch is in the suitable ahead position. Plug and pump can be left in place until normal operation with the hydraulic system is restored. Disconnect the pump, remove the insert and, fit plug (4.1-11) and seal ( ) when the hydraulic system is working again. Global Specialised Engineen'ng

59 John Crane-Lips Interfaces The electrical power available for the hydraulic system is mentioned in Part 1 A, Chapter 1. The starters for the electric pumps are not supplied by LIPS. The hydraulic pump logic is not supplied by LIPS. Global Spedalised Englneen"ng

60 John Crane.. Lips 60 4 MAINTENANCE 4.1 Inspection and Maintenance The following instructions for inspection and maintenance have to be carried out during each and every drydocking, regardless of the period of time since the last docking. Reference is made to: Part 1 A, Chapter 5, for numerical and adjustment data Part 1 B, Chapter 2, for the Shaft line Part 1 B, Chapter 3, for Hydraulic system Part 2, for system descriptions and other information of control system General During all maintenance and repair operations, especially on the hydraulic system, the utmost care and cleanliness is essential. Impurities can always cause dangerous malfunctions in the hydraulic system At docking During every docking the following items have to be inspected and the following actions have to be taken: Visual check of blades; pitting and surface deterioration should be repaired; it is advisable to have the blade surfaces professionally reconditioned in order to achieve efficient operating conditions. Visual check of all external bolts, locking strips and wire. Sample the hub oil to check that there has been no water ingress; follow the procedures as given in Part 1 B, Chapter 2; the hub to be refilled with the appropriate oil and the cap screws to be fitted with the torque required, see Part 1 B, Chapter 6 for the appropriate drawings. The part of the hull and the appendages around the propeller require cathodic protection; check the anodes and carry out replacements where necessary to sustain another period till going into dry dock again, see fig. 1 in paragraph of part 1 A "Zinc Protection for Propeller". Renew the blade seals every four years. (see Part 1 B, Chapter 2.9) It is to be advised to check the condition of the blade seals whenever the vessel enters dry dock. After removal of the rope guard the tightness of the sterntube seals is to be checked, preferable after the vessel has been in dock for at least 12 hours. Glaba!Spsa"a/isMI Engineen"ng

61 John Crane.. Lips 61 Note: all rubber seals are to be renewed each time after disassembly. Global Spedalised Engineering

62 John Crane-Lips Maintenance Schedule General: For fault finding and remedies see part 1 B, Chapter 4.2 Before entering a harbour check the response of the pitch actuating system. Every 50 hours: filter cartridges are to be checked on the visual indication of clogged filter. After each oil renewal and when the clogging indicator of the filter gives an alarm, the filters have to be renewed. check oil level in the tank(s). check oil temperature on the tank. observe abnormal noise of pumps. check oil pressures of hydraulic system and compare with adjustment data and previous made notes. Every week: Inspection and cleaning of the shaft-to-mass slip ring assembly. It is recommended to clean the slipring because a moisture of grease can significantly affect the resistance of the brushes. With the ship underway regularly check the potential difference between the shaft and the ships hull. If the potential difference is more than 60 mv, reconditioning of the brushes and slip-rings is necessary. check the functioning and condition of the cooler. Every Month: The oil in the sterntube is to be checked. Stop the running pump. Check if the stand-by pump is starting. When the switch-over is working properly, stop the stand-by pump and check if the low-pressure alarm is triggered. Restore normal operation. Change running pump and stand-by pump function. Every Global Specialised Engineeti'ng

63 John Crane-Lips 63 Pitch servo unit, checks to be carried out: pipe connections clearances between OD box and shaft connections of all sealing rings, all other outside bolt and screw connections testing of oil samples, using oil company's facilities. For sampling instructions see Part 1 B, Chapter 3. cleaning of tank(s) and renewal of oil, every one or two years depending on the number of operating hours and the oil condition. check of all pipe and flange connections. test of safety valve, back-pressure valve and pressure switch setting. -- Global Spedalised Engineering

64 John Crane.. Lips Adjustment data and service journals This table has to be filled in by the LIPS service engineer during seatrials for future references. Adjustments data Order no.: Max. operating pressure: when actuating to ahead. Engineer: I Date: Min. operating pressure: When not actuating. I I Actuating time: full ahead to full astern with push-buttons Actuating time: full astern to full ahead with push-buttons Standby function pump 1 (To be checked) Standby function pump 2 (To be checked) Oil type Oil temperature during service: GlabaiSpedalis«< Engineering

65 John Creune... Lips 65 AFSTELGEGEVENS /ADJUSTMENT DATA C I VL-C NAAF I HUB TYPE: ORDERNR. I -NO.: 4C13 H H04071 Penexcentriciteit in naaf I pin excentricity in hub: E1 = mm Middenstand naaf - 0 gr. spoed (0, 7R) I mid. position hub- 0 degr. pitch (0,7R): H1 = 0.00 gr./degr. S1 = 0.00 mm Berekende max. spoed vooruit I calculated max. pitch ahead: H4 = gr./degr. S4 = mm Berekende max. spoed achteruit I calculated max. pitch astern: H5 = gr./degr. S5 = mm Max. spoed vooruit vanaf middenstand naaf tot aanslag I max. pitch ahead from mid. position hub to piston stop: H6 = gr./degr. S6 = mm Max. spoed achteruit vanaf middenstand naaf tot aanslag I max. pitch astern from mid. position hub to piston stop: H7 = gr.ldegr. S7 = mm Middenstand olietoevoereenheid - 0 gr. spoed naaf I mid. position oil supply unit - 0 degr. pitch hub: S10 = mm LIJST NR. I LIST NO.: W Global Specialised Engineen"ng

66 John Crane=Lips 66 I This table can be used by the ships personnel to register disturbances in the propeller system. This records can be of importance for fault finding and maintenance. Date I Engineer I I SERVICE JOURNAL I Mal function I Measures taken I I I I I I I I I I Global Spw"olised Engineering

67 John Crane-Lips Faultfinding and remedies System malfunctions No pitch change Phenomenon : no response to command signal to change pitch or a too slow response Reason : various Action/check : simultaneous low-pressure or low-level alarm, if so, see below, push-button operation as instructed in Part 2, working order of the hydraulic system by hand operation of the solenoids on the 4-way valve; watch the mechanical pitch indicator and the pressure gauge; also watch the pitch adjusting time, whether the hydraulic pump is running, and if so, check the oil temperature, the pressure relief valve -(PSV) for hanging at a level too low to change pitch or too high to trigger the alarm. the response at a lower rpm level. Low-pressure alarm Phenomenon : low-pressure alarm, stand-by pump switched on Reason : various Action/check : simultaneous low-level alarm, if so, see below, whether the pump is running, and at the proper speed, if so, check the oil temperature, if not, check the electrical connections, the pressure relief valve (PSV); should this valve be in open position, no pressure build up will result, filter(s); clogged filter indication/alarm the lines for leakage Low-level alarm Phenomenon : low-level alarm Reason : low level in the lowest tank Action/check : the level in the lowest oil tank, the lines for leakage. High temperature of svstem Phenomenon : high temperature of system Global Specialised Engineering

68 John Crane-Lips Reason : various Action/check : the working temperature indicated on the thermometer; should not be over the maximum temperature of 65 C. working order of the hydraulic system by hand operation of the solenoids on the 4-way valve; watch the mechanical pitch indicator and the pressure gauge; also watch the pitch adjusting time, the working order of the oil cooler and the water inlet and outlet temperatures with a contact thermometer, the thermometer on the power pack tank, the temperature of the following parts by hand: OD box pressure safety valve (PSV) 68 Noisy system Phenomenon : system becomes gradually noisy Reason : cavitation Action/check : switch over to other pump and observe noise change, if so check obstruction or leakage of the suction line of pump, viscosity and temperature of the oil; too high viscosity or too cold oil can cause this phenomenon; if persistent, check the oil quality against the data given in Part 1 A, Chapter 5. the de-aeration of the system. switch over to other pump and observe noise change Foam in system Phenomenon : system shows foam generation Reason : air. Action/check : the pipe connections at the suction side of the pumps, other elements at the suction side, such as the shaft seal of the pump, the oil quality against the data given in Part 1 A, Chapter 5. Oil filter alarm Phenomenon : clogged oil filter. Reason : filter elements far too dirty Action : change filter. Gfoba/Spodalised Engineen'ng

69 John Crane... Lips Item/equipment failure Oil pump Phenomenon - Wrong direction of rotation, quickly leading to irreparable damage - Insufficient oil supply Possible cause - wrongly connected at terminal - air in suction line Remedy - change only 2 wires - check oil level - check for leakages in suction line connections - by-passing oil through safety valve - check correct setting - disassemble valve as necessary - worn or damaged pump - replace complete pump gear - Pump is noisy - air in pump housing and/or suction line - de-aerate (bleed) - check oil level - check for leakages in suction line connections - insufficient oil flow to - check suction line to be pump open - Shaft seal leaks oil worn or damaged pump gears - worn or damaged seals replace complete pump - replace seal assembly 4-Way valve Phenomenon (4WVPROP, proportional type) - No reaction when energizing solenoid Possible cause - Failure remote control system or bad solenoid Remedy - Check manual control of valve if ok repair remote control or change valve. C/oba/Spedalised Engineen"ng

70 John Crane.. Lips 70 Oil cooler Phenomenon Temperature rise of outlet oil and/or increasing pressure drop High temperature of outlet oil but normal pressure drop Oil leakage to water side Insufficient oil flow through the cooler - Water in the oil Possible cause dirt or other insulating layer at plates (oil side) mud and/or scale at inside (water side) leaking plates leakage anywhere in the system air in the system leaking cooler while oil pressure in cooler is below water pressure Remedy clean cooler with an approved detergent soft scale and mud to be removed with brush hard scale to be removed with an approved detergent replace plate trace oil leakage and suppress same trace air leakage and suppress same; attention to suction lines check oil level in tank to be above the suction line connection de-aerate (bleed) air from the system check water pressure, to be ::::;; 3 bar repair leaking plates as mentioned above T/Group Global Sperialised Engineeri'ng

71 fb fj.awrr.. ' fi 0 ' 4.3 How to order spare parts John Crane.. Lips 71 To order spare parts from LIPS B.V., the address and phone, fax and telex numbers on the cover page of this Instruction Handbook are to be used. Communication by telephone should be confirmed by letter, fax or telex. The following details must be quoted in all communication regarding parts of an installation: LIPS order number Shaft line and hydraulic system Item number and Designation, as these appear on the parts list Number of the assembly drawing on which the part appears Example: H09999, item nr 17, blade bolt, W(9 digits) Control system How to order spare parts for the control system, see Part 2. With the information in this section, possible malfunctions in the hydraulic system can be located. Remedies are given, but obvious remedies are not specified. If nevertheless LIPS' service is needed, the malfunction should be reported as detailed as possible for successful communication: what, when, where and under which Clobo/ Spedalised Engin(!(lring

72 5 ITEMS AND EQUIPMENTS, SUPPLIED UNDER THIS CONTRACT 5.1 Items, general John Crane-Lips 72 Item F/Pnr. Q lnr Section F/Pnr = Q = lnr = Section = Figure number/part number Quantity LIPS Identification number Section to find sub-suppliers manuals in this book; see top right of each sheet: section/reference/page number Global Specialised Engineering

73 John Crane-Lips Items, hydraulic_12ower equipment Item Symbol F/Pnr Q lnr Rnr - low level switch LLS1 - thermometer TM - air breader & filling filter AB1 +FILL - return filter element - return filter alarm RFA - Visual pollution indicator - electric motor EM1-2 - shaft coupling - oil pump P1-2 - pressure safety valve PSV1,2 - non return valve NRV3 - non return valve NRV5 - shuttle valve sv - 4/3-way prop. valve 4WVPROP - oil cooler oc - pressure gauge PG1 - low pressure switch PRS W / W / W / W / W / W / W / W / W / W / W / W / W / W / W / W / W /017 F/Pnr = Figure number/part number Q = Quantity lnr = LIPS Identification number Rnr = Reference number to find the sheet in this book; see top right of each sheet: section/reference/page number Clobo/ Speelalised Engineedng

74 John Crane-Lips , Oesctiption: Level switch Identification picture Symbol of fig.5.1 Description : Magnetic operated level switch for high or low fluid level detection. Technical data : General data : Medium Max. pressure at 120 C Max. operating temperature Max. ambient temperature Min.specific gravity Electrical data : : mineral oil : 25 : 330 : 110 : 0.75 bar oc oc Voltage Max. current : 24 V DC : 0.5(0.25)A/250VDC Dimensions : A B : 180 :50 mm mm Spare parts : Float Micro switch W W Main particulars : Mass approx. Overall dimensions lxbxh :2 : 250x350x1 00 kg mm Clabo/ Specialised Engineering

75 Jou CraneLips Lips part code W Description: Date/mod.: I Thermometer Reference no.: 5.2/2 Drwg. fig, no. - Part no.: E. Identification code : Diagram code: TiA Identification picture Symbol of fig.5.1 Description Thermometer for oil temperature indication. Technical data Temperature range :0-120 DC Spare parts Complete thermometer W Main particulars Mass approx. : 0,4 kg Connection : 1/2 BSP Case diameter x Ienght : 63 x 1 30 mm TI Group C/b,/Spdithd E,,Im,ñ,ig

76 ....,.. Identification picture Oesctiption: Air breather and filling filter John Crane-Lips 5.2/3 I Symbol of.5. ; :: ----) Description : Air breather for filtering in and outcoming air for the hydraulic tank. Technical data : General data: Medium Separation air : mineral oil : 10 micron Spare parts : Filter element : W Main particulars : Mass approx. Connection Overall dimensions dia.x h :0,5 :50 : 117x177 kg mm mm Clabat Specialited Engineen"ng

77 ... John Crane.. Lips l:}=:r=wm--m ::::: ' ::::: Return filter element :::; s.2-o37 :::r illii ;;;;;;; ; ;l lilll lilil i ; illl :::-mw' Description : Element for return filter. Technical data : General data: Medium Filter mess Filter material Max. pressure drop : mineral oil : 10 pm nom. : organic paper : 10 bar Spare parts : Return filter element W Main particulars : Mass approx. Overall dimensions lxbxh :0,3 :... x... x... kg mm Global Speeialiscd Engineering

78 - 1 John Crane.. Lips lips part code : W Description: Pressure switch t::::--=g-% : :: : ): t l ; l I ' I = [ l : I. r '=:-:-:-... : Description : Pressure switch for clogged return filter. Technical data : General data: Medium Pressure range Adjustable pressure range Max. shock resistance Electrical data: Voltage Max. current Electrical connection Isolating class Adjusting and connections: : mineral oil : 0-80 : 0,5-8 : 15 : 24 :5 : Pg 11 : IP 65 bar bar g v A Wire connections are 1 and 2 for open contact when pressure is increased. When adjusting alarm setting of pressure switch loosen the locking screw at the switch top and adjust the pressure turning the adjusting screw in the center of the switch top. Spare parts : Complete pressure switch W Main particulars : Mass approx. Connection Overall dimensions lxbxh : 0,2 kg : 1/4 inch BSP female : 75x30x74 Global Speeiulised Enginsen"ng

79 John Crane-Lips iii! Lipswo7;13ooso Description: Visual pollution indicator : Identification picture Function : Visual indication of clogged filter. Technical data : Hydraulics data : Pressure range Medium Case dia. Connection : 0-6 : mineral oil :40 : 1/8 BSP male bar mm Main particulars : Mass approx. Dimensions Case diameter :0,2 : 1/4 BSP :40 kg mm Cloba/Specia/ised Engi'neering

80 John Crane-Lips Iii Lip;;;8:a25844 Description: I Electric motor EM i Identification picture j Symbol of fig.5.1 :,. =,. : :,.,. : :: :, :,.,. Description : Three phase squirrel cage induction motor for hydraulic pumps. Technical data : Connection Dimensions according Ambient temperature Output S1 Rated current Output S6 S6 current Voltage Frequency Rotation frequency at S 1 Protection class Insulation class Mounting Construction : PG 29 : IEC 72 I DIN :55 C : 13 kw : 22,5 A : 18 kw : 31,5 A :450 v : 60 Hz : 1800 min 1 : IP 54 : F (temperature limit 155 C) : V 1 with cap on vane : ace. to rules Clasification Spare parts : Bearing set W Main particulars : Mass approx. Overall dimensions lxbxh : 102 : 589x31 Ox383 kg mm Global SpedaftSed Englneen"ng

81 John Crane... Lips Ups part code : Description: Reference no.: W /8 Date I mod.: I Shaft coupling Drwg. fig. no. Part no.: Identification code : B N3 Diagram code: Identification picture Description : Teethed flexible coupling for E-motors ace. to I.E.C. norm DIN and hydraulic pump. Technicai data : Bores ace. to ISO fitting H7 Keys ace. to DIN 6885 sheet 1 Moment of inertia J Nom. torque Tkn Max. torque Tk Materials: Nave Coupling bush : : 100 : 200 : steel : polyamide 6.6 kgm 2 Nm Nm Fitting instructions: During fitting of the coupling take care that the gape between the two naves is 4 mm and the coupling bush can easily moved in axial direction. Max. deflections: Axial : ± 1 mm Radial : ± 0,4 mm Arc a: ± 1 Spare parts : Coupling bush W Main particulars : Mass approx. Overall dimensions : 1,49 : DIA.92 x L=88 kg mm j) GlobaiSpeda/ised Engineen"ng

82 John Crane.. Lips / Lips part code : WOO GO Description: , Oil pump 5.2/9 Identification picture Symbol of fig.s. 1 Description: Fixed displacement gear pump supplying oil under pressure to the hydraulic system. Technical data : Hydraulics data : Medium Min. pressure suction side Max. pressure suction side Max. working pressure Flow at min 1 Direction of rotation Rotation frequency Efficiency at max. press. : mineral oils HLP,HV(DIN 51524) : 0, 7 bar absolute : 1, 5 bar absolute : 250 bar : 44 dm 3 /min : right handed : min 1 : '7vol 0,94 and '1tot 0,89 Spare parts : Repair set W Main particulars : Mass approx. Dimensions I x b x h : 2,7 : 150x113x90 kg mm < ) Global Sptldalised Engineen"ng

83 John Crane.. Lips Lips part code : W I Identification code : RVGA-LAN NG20 :: :: ::: Description: :.::'::.:: : : Safety valve adjustable.. ::. :::::. :: ::: :;:.:: : : :::: ::::: : Reference no.: 5.2/10 Drwg. fig. no. part no.: Diagram code: PSV1-2 Identification picture Symbol of fig ; PSV 1 )r(!'!. i ' ' i, )!( ; '-r;: PSV2 Description: Adjustable safety valve setting max. pressure. Technical data : Hydraulics data : Medium Max. pressure Max. input flow Adjustable pressure range : mineral oil : : bar dm 3 bar Spare parts : Complete valve : W Main particulars : Mass approx. Dimensions dia. x I : 0,5 : 40 X 130 kg mm Global Speda5sed Engtneen"ng

84 1 John CraneLips ""Wii07i7104 Non return valve ::::: Dtwg.fig. no. -Part no.: :'::. llll i;-:-----,lli /! NRV3 ( I Identification picture j Symbol of fig.5.1 i.(»>'x«-:>»»».... I t='"' ccc"4 i rj:r: --. i \ A I L ' --' ' <\V>...,... Y' IL t: -:-t : v ' :- Description : Non-return valve for return line. Technical data : General data: Medium Cracking pressure : mineral oil : 2 bar Spare parts : Complete valve : W Main particulars : Mass approx. Overall dimensions L 1,6 114 kg mm Globa!Spscialised Engineering

85 John Crane-Lips H Ups pan code : t W Description: 5.2/12 Non return valve Identification picture Symbol of fig.5.1 : : : :.:.: : : : lh'i'!.,.,. : : : : ;._...L... m O- ;,_ -t : <Vi! ,, l. v ' : l. '' :' ""-., ,...w...-.,..._..,...,...,.y,o,....._._,., -t :...,.. : -'-- /\ :...: Description : Non-return valve in return line. Technical data : General data: Medium Cracking pressure : mineral oil :2 bar Spare parts : Complete valve : W Main particulars : Mass approx. Overall dimensions L :0,2 : 19 X 49 kg mm Global Spea"olis Engineering

86 John Crane.. Lips Description: 5.2/13 Shuttle valve ! Symbol of fig.5.1 lldootffiootloo plotu" I! I I I -o,_..,r-> : Description: Shuttle valve sensing highes pressure in C1 or C2 and connects this pressure with main safety valve PSV1. Technical data : Hydraulics data : Medium Max. pressure Max. input flow : mineral oil : 350 : 20 bar dm 3 Spare parts : Seal set : W Main particulars : Mass approx. Dimensions dia x I : 0,012 : 13 X 23 kg mm Clobo/ Spedatised Engi'neenflg

87 John Crane-Lips.:.. Lips part code : Description: Reference no.: W /14 Date I mod.: I 4/3 Way proportional valve Drwg. fig. no. Part no.: Identification code : 4WRZ1 OW50/NEZ4M :.:: :=:=::=:== :. = = : ::.. Diagram code.: 4WVPROP. :::=:::.::-::: :--: :. =. :- : :;: :::=: Identification picture Symbol of fig ::1A).--,,--.! (.K18) ' I ' [] - s J a #-...L ! : -Lo , I '......: Description : Two stages pilot operated proportional valve with pressure reducing valve between pilot and main valve. Technical data : Hydraulics data : Connections Medium Max. pressure Flow at b.p 5 bar : conform I.S.O AB-03-4A : mineral oil (HL-HLP) to DIN : P-A-8-T 315 bar : 21 dm 3 /min Electrical data : Connections Voltage Max. current Coil resistance AT 20 C Operating rate Isolating class. : conform I.S.O PG 11 : 24 v : 700 ma : 19,5 Q : 100 % : IP 65 Spare parts : Repair set Seal set W W Main particulars : Mass approx. Dimensions : 7,8 : 280x176x70 kg Global SpecialiJed Englneenitg

88 Description: / Oil Cooler Identification code : M3-FM/14,.;. John Crane.. Lips : ::::. Reference no.: 5.2/15 Drwg. fig. no. - Part no.: :;:; Diagram code.: oc Identification picture :: Symbol of fig.5.1 li 4= "I/ I ; :... ; ' Description : Oil cooler plate type for cooling the hydraulic oil in the C.P.P. installation. Technical data : General data: Heat tranfer Medium 1 Flow 1 Medium 2 Flow 2 : 7,4 : mineral oil :4,3 : fresh water : 2,5 kw Spare parts : Complete cooler W Main particulars : Mass approx. Overall dimensions lxbxh Global Specialised Engineering

89 John Crane... Lips Lips part code : Reference no.: W Description: 5.2/16 Date I mod I Identification code : Pressure gauge Drwg. fig. no. part no.: Diagram code: PG... ::: : :;. :.;..,.=:: :,: :... ::; Identification picture Symbol of fig ;... Function : Indication of working pressure. Technical data : Hydraulics data Pressure range Medium : : mineral oil bar Main particulars : Mass approx. Dimensions Case diameter :0,2 : 1/4 BSP : 63 kg mm (@) Global Specialised Engi'neering

90 John CranemLips Lips part code : Description: Reference no.: W /17 Date I mod.: I Low pressure switch Identification code : Drwg. fig. no. Part no.: Diagram code: PRS :=:.=...: = :::... :... :..:=. =: : Identification picture Symbol of fig Description : Pressure switch for standby and low alarm. Technical data : General data: Medium Pressure range Adjustable pressure range Max. shock resistance Electrical data: Voltage Max. current Electrical connection Isolating c"lass Adjusting and connections: : mineral oil : : 5-70 : 10 : 24 : 1 : Pg 13,5 : IP 54 bar bar g v A Wire connections are 1 and 2 for open contact when pressure is increased. When adjusting alarm setting of pressure switch loosen the locking screw at the switch top and adjust the pressure turning the adjusting screw in the center of the switch top. Spare parts : Complete pressure switch W Main particulars : Mass approx. Connection Overall dimensions lxbxh : 0,2 kg : 1/4 inch BSP female : 72,5x33x125 mm Global Spea'olised Engi'neen"ng

91 John Crane... Lips Tools and equipment The tools supplied with the ship set are listed below. For further identification refer to the identification sheet where all parts are listed seperately with the belonging LIPS identification number. Item Hub (type C or D) Q Rnr. - Socket adapter; for blade bolts and flange bolts - Ring spanner - Hoisting tools for propeller blade Eye bolt Hoisting clamp Shaft line. - Transport tools for the propeller shaft - Hydraulic pump, high-pressure airdriven, for the shaft coupling. (and for emergency pitch setting) - Pumpset, tools for high-pressure pump / /2 Pitch servo unit - Tool for pitch adjustment - Tool for emergency pitch adjustment Fitted flange coupling - Oil injector SKF Hydraulic airdriven pump: see shaftline Q = Quantity Rnr = Reference number to find the sheet in this book; see top right of each sheet: section/reference/page number Globol Speda/Ued Engineedng

92 John Crane-Lips Socket adapter [ Identification picture ' u IS} : ' : A L B ::...: Description : Socket adapter for blade bolts and flange bolts. Technical data : Lips identification no. A[mm] W W W W W W W W W W W W woo W W W / W W W W W W W W W W B [mml C [mml L [mml , II t..,.ffl...,_

93 John Crane-Lips Lips part code : Description: Reference no.: Date I mod.: I Slugging ring wrench Drwg. fig. no. -Part no.: Identification code : Diagram code: Identification picture aj <( L :...: Description : Slugging ring wrench for blade bolts and flange bolts. Technical data : Lips identification no. A[mm] W W W W W W W W W W / W W W L [mm] B [mm] Mass [kg] 0,50 0,68 0,80 1,03 1 '16 1,50 1,58 2,30 2,50 3,54 3,90 7,20 6, :- _... _. -: _:.J.DELIVERED ITEM.... :.... -: Global SpedaliJed Engi'neering 5_3 006A.ENG

94 John Crane-Lips : Identification picture : A Description : Hoisting tool for propeller blade. Technical data : Drawing number Size A Size B Max. allowed blade mass [kg] W M W M W M W M I W M30 V M WQ M W M <@> Globol SpedalisRd Engi'needng 5_3-013.ENG

95 .;.;-;:... :.....::.:;., '.-::;.-.:.:- John Crane-Lips Lips part code : Description: Reference no.: Date I mod.: I Hoisting clamp Orwg. fig. no. Part no.: Identification code : Diagram code: = =: = j Identification picture == I REQUIRED TORQUE SEE TABLEJ...: Description : Clamp for hoisting of blade. Technical data : Max. blade mass [kg] Lips identification no. Item 1 Item W W I 3000 W W A[mm] B [mm] Mass [kg] ,1 Required torque item 2 [Nm] 187,260 Global SpedafiJed Engi'nS'efing 5_3 015C.ENG

96 -::. John Crane-Lips..-:-:::. :.:::::.::-:. ::::::::..: :. :: ::=:::::.:-...::::...::.::: : -=:::=::::.::: : Lips part code : Description: Reference no.: Date I mod.: I :;:;;... Identification code : Transport tools for propeller shaft liii : =::::::' ::: :::.:.: :... : : Identification picture 2 Description : Tools for transportation of the propeller shaft. Technical data : Size Lips identification no. Item 1 Item 2 NW 13 W W NW 16 W W NW 25 W W NW 30 W W NW40 W W NW 50 W W NW / NW 30 SPECIAL W W A[mm] Global Spedo/Ued Engineering 5_3 01 6A.ENG

97 John Crane-Lips. ::: : :::::::.. : :.::. = :: ::=.::: :. Lips part code : Description: Reference no.: Date I mod.: I Tool for pitch adjustment Identification code : :.: Drwg. fig. no. -Part no.:!i!::... ;-;;;;. ;... ::::: Identification picture f- 5 w a: f w VJ f- <1: :c w u a: <1: ::l ::.: VJ ::l VJ a: w 0 a: w Cl... :J...J 00 0 f- <1: w 5 :c a: <1: 0 w 0 a: > ::l VJ VJ w a: Cl......J 0 Description : Tool for pitch adjustment Technical data : Lips identification no.'s 1-- I--./ Item 1 W Item 2 Item 3 W A2 W W A2 W A2 Item 4 M M M Glabal Spedali'sed Engi'neen"ng 5_3-027A.ENG

98 John Crane-Lips Lips part code : W Date I mod.: I...;:;:: Identification code : = : 9650 Description: High pressure airdriven pump Figure no.: Drwg. fig. no. - Part no.: Diagram code.: EPPS Identification picture Symbol of fig.5.1 / l...: Description/Application : Pneumatic driven high pressure pump for mounting and demounting of hydraulic fitted coupling and for emergency pitch setting. If no separated pump for emergency pitch setting is delivered. CAUTION in case of emergency pitch setting max. air supply pressure is 2 bar. Technical data : Hydraulics data : Medium Pressl!re ratio : mineral oil :50 : 1 Connections : Air inlet Oil outlet : 1/4" NPTF : 3/8" NPTF Spare parts : Complete pump W Main particulars : Mass approx. Dimensions dia. x I :8,2 : 150 X 930 kg mm Global SpedatiJed Engineen"ng

99 John Crane-Lips Description: T High pressure airdriven pump set ; l: : Identification picture, ' r--, I I ' I r -+- f-rl -@- 0 t ; 0 ',. :: '... 0 :... : Air driven high pressure pump set Item Ont- Description 1 1 High pressure pump Hexagon double nipple 1 /4"x1 /4" NPT (male/male) Air-regulator/gauge/filter-1 /4" (female) Hexagon double nipple, high pressure 3/8" NPT (male/male) Hexagon double nipple, high pressure 3/8" NPT (male/male) Tee, high pressure 3/8" NPT High pressure ball valve, 3/8" PT (female) 8 Recirculating hose, L= 1000 mm, 1 /2" I. D. with 3/8" PT connector (male) 9 High pressure hose, L = 2000 mm, 1 /4" I. D. with 3/8" NPT (male) and 1 /2"-27 (female) connections Rotating swivel, high pressure, 1/4" PT x 1/2"-27 (male/male) Union, high pressure, 3/8 NPT (male/female) NB: High pressure pumpsets are marked with "HP" under the pump name-plate for easy identification. Packed in wooden box lxbxh Mass approx. incl.box : 1220x220x220 : 15 mm kg Global Specialised Engineedng

100 _ -- r John Cirane... Lips f Mounting for emergency pitch setting procedure FIG. 2 Fig 1 normal situation FIG.1 Fig 2 remove plug fig 3 fit emergency pitch setting tool Fig 4 plug in quick connecting coupling nipple of pneumatic operated pump Restoring normal operation Remove nipple of pneumatic operated pump Fig 4 Remove emergency pitch setting tool Fig 3 Mount plug fig 2 Normal situation is restored Fig 1 FIG. 3 FIG.4?) Global Spedo!iJed Englneering

101 Description: John Crane-Lips -::::::::: : :.. ::: ::::: ::::::: :::.: = =::.... :::::::::::::::: Reference no.: I :: = Oilinjector Orwg. fig. no. -Part no.:....:= } Identification code : Diagram code.: Identification picture Symbol of fig Description : Handpump for mounting and demounting of hydraulic fitted coupling. Technical data : Hydraulics data : Medium Max. pressure : mineral oil :3000 bar Spare parts : Complete pump W Main particulars : Mass approx. Dimensions kg Global Spea"ofiJcd Engineeting

102 John Crane.. Lips 5.4 Spare parts The spare parts supplied with the ship set are listed below. For further identification refer to figure number - part number combination and the LIPS identification number. Item F/Pnr Q lnr. Hvdraulic power equipment Return filter element Two for commissioning, one spare Bearing for E-motor of pump set unit E-motor for hub pressure system Pump for hub pressure system W W W W F/Pnr = Q = lnr = Figure number/part number Quantity LIPS Identification number (@) G/aba/ Speda/Ued Engineering

103 John Crane-Lips 6 DRAWINGS 6.1 Alignment instruction sheets The instruction sheets used in Part 1 B, paragraph 2.6 Alignment of shaftline, have been listed below: 1 Nominal alignment of shaftline (coupled situation), MCR-power (condition free sailing ahead), warm, working temperature. 2 Open shaft showing the intended situation before coupling the shafts with Gap & sag values. Cold condition. Clobol SpeclaliJed Engineenitg

104 r---, , ,r---r , r I. " PROJECT: 1176, (H04062FS. OAT) CLIENT: J.J. SIETAS KG F!? E.S/1/L/!Vc; ALIGNMENT deflection Lips warm condition w CD w CD en z Offset:.00 4 cold condition Offset:.- U1 0.!>. CD z ".00.!>. CD CD en.- w -" z z w CD 0 w w CD CD 0 0 -I 2 w w en en 0 0 -I U1 Etill ld 0.!>. U1 * w.!>.w.!>. U1A"U f Jl 3 4

105 PROJECT: 1176, (H04062GS. OAT) CLIENT: J.J. SIETAS KG ALIGNMENT open shaft Lips SAG mm Offset:.-.!>..!>. 1\J CD en z.00 cold condition.00!voiy..30b w 0 U1 0 1\J z f- X !3 - I 0.!>. I /\ Bear ing 1 w 0 CD.!>. 0 l - w w w ld CD CD en r-n 1\ u 2 w.!>..!>.w.l>. U1 U1A"U1 I I 3.11

106 John Crane-Lips 6.2 System drawings The drawings that are used in this Instruction Handbook, Part 1 A and B are listed below with figure number, title and LIPS identification number. Figure numbers missing have not been used. For remote control drawings/diagrams see Part 2. Fig. Title lnr. 1 PROPELLER AND ACCESSORIES 1.1 Propeller/Blade 1.2 Assembly of hub 2 GENERAL ARRANGEMENT 2.1 Arrangement of shaft line Coupling Bolt Assembly of coupling flange 4 PITCH SERVO UNIT 4. 1 Arrangement oil supply unit 4. 2 Assembly oil supply unit 4. 3 Assembly auxilary tool for pitch adjustment 4.4 Assembly feed back box 5 HYDRAULIC POWER EQUIPMENT 5.1 Hydraulic diagram and hydraulic arrangement 5.2 Hydraulic power pack 5.3 Connection diagram W A 1 W A 1 W A 1 W A3 W A2 W A 1 W A 1 W A2 W A2 W A2 W A 1 W A3 6 ARRANGEMENTS FOR TRANSPORT AND HOISTING OF EQUIPMENT 6.1 Hoisting tools for propeller blades W A Arrangement transport tools for propeller shaft W A3 Global Speda!iJed Engineen"ng

107 Title: Propeller.blade Page: 1 of 1 Type: Drawing: List: H Ordemo: H04062 fig.m.: 1.1 ltemno. N a m e 001 Propeller.blade Art.tzo. W Quantity 4,0 Notes: -Item numbers not listed have not been used in this install. - The quantities an partnumbers shown on the parts list are believed to be correct, the quantities shown on the drawing are for illustration only. END OFLIST

108 MRX. RRDIUS RRKE THICKNESS CLERRRNCE CURVE CONSTRUCT ION PITCH DISTRIBUTION EXPRNOEO OUTLINE PROJECTED OUTLINE R/R BLRDE SECT IONS ======::::;:====== sli!:qi.0 901' -=====================================r=-0.9 SSI.Q Q,.... c::l '00'1 I R PROPELLER ORTR OIRMETER 4BOO MM HUB 0 IRMETER I300 MM HUB TYPE 4C13 PITCH.""'" 3230 MM NUMBER OF BLRDES 4 DIRECTION OF RDTRTION LEFT-HRNOEO!ORRWN RIGHT HRNOEDl EXPRNOEO BLRDE RRER RRTIO O.S7B SKEWRNGLE 3B.B DEGR MRSS OF ONE BLROE ''' IS60 KG FOR BLROEFLRNGE OETRILS SEE OWG. WOB4BIDBS3 MRSS MOM. ENGINE OUTPUT OF INERTIR PROP. IN RIR IISI4 KGM' 7300 KW OETRIL BLRDE ROOT FILLETS!NOT TO SCRLEl I OETRIL RNTI SINGING EDGE RT T.E. FROM O.SR TO TIP. FULL RT O.SSR!NOT TO SCRLEl OETRIL BLRDE TIP!SCRLE I e.0) RROIUS PITCH!MMl S 0.9S B O.BS 34B6 O.BO 3S BO o.so S B 0.2B3 2B21 MERN 3492 PITCH FOR MRX. POWER PROPELLER REVOLUTIONS CLRSSIFICRT ION 1S2.00 RPM PITCH SELECTED FOR S927 KW RT PROPELLER 1S2.00 RPM.. TRIRL CONDITION. BLRDE FINISHING TDLERRNCES IN RCCORORNCE WITH ISO CLRSS I THE DESIGN SHOWN ON THIS ORRUING 16 THE ABSOLUTE PROPERTY OF -LIPS PROPELLER WORKS IT t1ry NOT BE COPIED OR REPROOUCEO. IT MAY NOT BE EXEOJTED BY. USED FOR OR SHQI.IN TO THIRD PARTIES WITHOUT THE WRITTEN CONSENT OF THE m4ner. GL r m r r N ro.,. ro 0 :I HYDRODYNAMIC DESIGN DEPARTMENT /IO.O

109 e Title: Assembly of the hub Page: 1 of 2 Type: 4C13-3AOX Drawing: W List: H Order no: H04062 fig.nr.: 1.2 ltemno. Name Art.tw. Quantity 002 Sliding block W ,0 004 Plug W ,0 011 Locking.wire W ,9 012 Hub cover bolt W ,0 013 Seamless a-ring seal M ,0 014 Seamless a-ring seal W , ring for blade foot W ,0 016 Strip W ,0 017 Blade bolt W ,0 018 Seamless a-ring seal M ,0 019B Blade carrier W ,0 020D Moving cylinder yoke W ,0 021 Piston ring with clip W ,0 022 Dowel W ,0 025 Hub body W ,0 026 Dowel W ,0 027 Cord ring with vulcanized joint W ,0 028 Flange cover W ,0 029 Dubo retaining ring M ,0 031 Hexagon screw M ,0 037 Connecting piece W ,0 038 Hex. socket set screw with full dog point M ,0 039 Hub cover W ,0 040 Hex. socket head cap screw M ,0 042 Ring in two pieces W ,0 043 Dubo retaining ring M ,0 044 Hex. socket head cap screw M ,0 045 Bush W ,0 046 l?eamless a-ring seal W ,0 048 Flange bolt W ,0 049 Hex.socket set screw w.cup point M ,0 050 Plug W ,0 052 Seamless a-ring seal M ,0 067 Hexagon socket pipe plug W ,0 068 Heavy type cyl. spring dowel M ,0 069 Piston seal W ,0 070 Hex. socket head cap screw M ,0 lii.. 2.iif.-i,,,fmi,,fffif.SK!!'If::;w.J.c'O:Smt;:"stiWZ2SZZ':!:ii.t!Z::mw;!tl'Zl.'S;:s:\mm'tmi<-s

110 Title: Type: List: Assembly of the hub 4C13-3AOX H Page: 2 of2 Drawing: W Orderno: H04062 fig.llr.: 1.2 ltemno. N a m e Art.llO. Quantity Notes: -Item numbers not listed have llot beell used ill this install. - The quantities an partnumbers shown Oil the parts list are believed to be correct, the qualltities shown Oil the drawing are for illustration Ollly. END OF LIST

111 ., T.!G.. LNT 309LHF!DIN 8556, Sli X2CrN B.H.B.E.. AVES7:4 PS T.lG.. LNT 309LHF!DIN 8556, Sli X2CrNi SHIELDED H 7:4( ARC WELDING. AVESJll PS.,,';f:.. ' DOORSNEDE SECTION : B- B f I 1 AANZICHT P VIEW P o 1 c. c.. ' DE NAAF IS RECHTSDRAAIEND GETEKEND THE HUB HAS BEEN ORA WN FOR A RIGHTHANDED PROPELLER T.lG.. LNT Ni[ro /DIN 1736: SG NiCr20Nbt B.H.B.E. AVES7:4 PS T.t.G. LNT NiCro /DIN 17]6, Sli N'tCr20Nbt SHIELDED HE7:4L ARC WELDING. AVES7:4 P AANHAALHOHENT REQUIRED TORQUE IN Nm POST. NR. ITE!1 NO. BOUT EN DRAADGAT DROO{j- EN SCHOON BOU AND THREADHOLE DRY AND CLEAN BOUT EN DRAADGAT BEHANOELEN MET COPASLIP BOLT AND THREADHOLE TREATED WITH COPASLIP VOOR HET HONTEREN N DE BESCHERHKAP DE FLENS EN Df GATEN BEHANDELEN HET VET I SHELL RHOOINA 2 OF GEUJKWAARDIG I BEFORE FtmNG THE FLANGECOVER THE SHAFTFLANGE AND HOLES HAVE TO BE TREATED WITH MiNERAL GREASE I SHELL RHODINA 2 DR EQIJILENT I ALLE POSTNIJHHERS GEHERKT HET BORGEN HET l.oct!te NR. 243 ITEH NO'S HARKED WITH HUST BE LOCKED WITH LOCT!TE NO. 243

112 Title: Arrangement shafting Page: 1 of 1 Type: 4C13-3AONL90-C Drawing: W List: H Orderno: H04062 fig.nr.: 2.1 ltemno. Name Art. no. 001 Propeller shaft W Reinforcing sleeve W Fit bolt W Hexagon nut W Split pin M Oil supply pipe W Oil supply pipe W Oil supply pipe W Oil supply pipe W Sleeve W Sleeve W Sleeve W Supporting sleeve W Supporting sleeve W Hex. socket set screw with full dog point M Seamless a-ring seal M Seamless a-ring seal M Assembly blocking valve -W Assembly Couplingflange H Sleeve W Sleeve W Hex.socket set screw with full dog point M Quantity 1,0 1,0 12,0 12,0 12,0 2,0 2,0 1,0 1,0 1,0 1,0 1,0 10,0 2,0 4,0 8,0 2,0 1,0 1,0 1,0 1,0 4,0 Notes: - Item numbers not listed have not been used in this install. - The quantities an partnumbers shown on the parts list are believed to be correct, the quantities shown on the tjrawing are for illustration only. END OFLIST

113 HIIR Rl ADF SHAFTFI ANfiF Oil HASS, S 268 = lrg J, lrgm' lin air) ( \ I...,., '""'' ROPE GUARD YARD SUPPLY... \ I AFT SFAI 19S / YARD SUPPLY HAKE 8LOHH VOSS TYPE, SIHPLEX COHPACT SC28 SIZE 4SO _AEI BfABJ/'/[ UFRNT/JRF I YARD SUPPLY YARD SUPPLY HAKE, 8LDHH VOSS 1/ " l I -,. \5. '& '& '& '& ' I= I I I v I I I '//// r- - - t VJV '& I '& i//// i;:j I _1 \ a: \!\ F v v r\j \ Ztfi..S.ff. Gf.IAO..g \ ZIEISEE DETAIL 8 I 2 Kl I 670 I sos 14SO 30SO 364 I FWD RFAR/Nfi YARD SUPPLY HAKE, BLOHH VOSS PROPF/1 FR SHAFT IEXO SHAFT 1LANGEJ Oil PIPFS OIL HASS, S 127 = 7018 lrg J, lrgm' 187 HASS, 920 lrg J, lrgm' 1/ j COUPLING flamj _ HCF 360 SPECIAL FWD <;FA/ YARD SUPPLY HAKE BLOHH VOSS TYPE SIHPLEX COHPACT SC2Z SIZE HOI F 0/A. 60!nom ON P r 40 COUPLING BOLTS IPRE-HACHINEOJ LIPS SUPPLY.._ "' '& "' '& - GEARBOX.c:: 130 '& ---- == -.._ I.c:: -- - If r t--. t t-- '& I t r- '& t== I -y h lie/see DETAil c/ 306 8SO I 244S I = 70 --,-,-::- -, - 11t 211 nil TYPE VL90-C HASS, 85 lrg \5 98 '\_ RflY ZIEISEE DETAIL J 9051 I I I I I I I I I s 6 l FRAHE SPACING 100 I DETAIL A DETAIL C I 179 I 244 A = I I I I I I I I I LIPS SUPPLY WITH 2 mm OVERSIZE FINISH HACHINEO AT THE YARD CORRECT 0/HENSION = HEASUREO 0/A. OF HOLE :; SEE ORWG. NO;. W A3 DETAIL D DETAIL M H DETAIL N HAX VOORU!TIAHEAO 'IMlJ : 11 Siefas KG N.B. : JJ UPS C11WIMJ., HIJ4062 IIIJ40lt VOORU!T I HAX AHEAD POSITION [ CEN.S HAlE BEEN fra WN N HAX. AIEAD POSITJ:N i'easi.re /JiiNj ASSElfiY CN BOARD ebfleel1. B n..., min'' ROTATION...., COUNTER-CLOCKWISE ILEFTHANOEOI ffjiifmj5} HAKE....., HaK TYPE....., 8H43 POWER..., 7300 lrw I SOO min'' UWlBIJX HAKE....., ASUG TYPE..., GVE 950 x S10 x 0.28 REDUCTION..., , 1 +

114 ' ( 36 J w ;r-- v.ii k---\1 - II! '0...;t "" 1\ ::::::::::J=f=j i ==Jct:===t======---...J li---l ij1) ===}!j==1.6p1v. 23 VOORDRAAIEN OP 62 PRE-MACHINE 62 NADRAAIEN ( NIET SLIJPEN OF SCHUREN J OP OPGEMETEN DIA. GAT _;: MACHINE ( DO NOT GRIND J TO MEASURED DIA. HOLE_;: Hateriaa/naam: Haten"al name: Hateriaa/kode Haterialcode 34CrNit1o6, quenched and tempered Norm: EN Standard SEW 550 R f. " R A.., %. 1 min. ) z o/ { n ) min. Impact Energy, J P o,or po.l /o, ""'. KV { 150-V I Nlmm2 Langs Tangent Dwars Langs Tangent Dwars Langs Tangent Dwars Temp. 0 Long. Tang. Trans. Long. Tang. Trans. Long. Tang. Trans. [ YARD MASSA CA kg MASS APPROX. N.B. 1.6 LIPS ORDERNO. : 1fcW w 3 #) CLASS lie/see SPEC HATE1IIAAL AF1 TNB( OPf'ERKNifN I HATE1I1AL I I afi{5j(ns I I 1/fHARKS I ::t!lff:=mw= ( ISO ) pj BOVEN Ill!2 AFiflPWI I OVER Q() QOO r.norm r r--+-r r r-- :u: 1 UP TO AID NJ.IDli B/1 VERSPAIEJIE JEWERI(HBI TaERANTE I FU/ HAOHli fffiiatlm I lo;; I TaERAICE I B/1 le OVER«IJEWfl//(IW( 5 - I FU/ AU OTifR fffiiatlm I LIPS Drunen. The Netherlands Z0,1 Z0,1 z0,2 1T1B. I NA/' I z0.5 z Q() t 10.3 z0.5 zo.b z{5 zz5 z4 PASBOUT FIT BOLT SOIAAL I SCALE I 1 : 1.5 z{2 z2 z6 z8 OAM1 I OATf I z3 z4 z5 z6 z8 %10 z12 z12 TYF I TYF I LD II Specificah"e/Specificatioh: j Opm./Remarks: _I Gelijk aan/equal to : ( Dia. 100 ) W A3 zit frlern.hfr I ORlEliNIHJER I

115 Title: Assembly Couplingflange Page: 1 of 1 Type: HCF360 SPECIAL Drawing: W List: H Ordemo: H04062 fig.nr.: Itemno. Name Art. no. 001 Bush. flanged W Box. coupling W Piston W Round nut W Piston seal W Seamless a-ring seal M Ring.collar. toothed W Plug.screw.hexagon head W Plug.screw.hexagon head W Hex. socket set screw with full dog point M ring W Quantity 1,0 1,0 1,0 1,0 1,0 1,0 1,0 2,0 2,0 2,0 1,0 Notes: - Item numbers not listed have not been used in this install. - The quantities an partnumbers shown on the parts list are believed to be correct, the quantities shown on the drawing are for illustration only. END OF LIST

116 GEGEVENS VOOR OPPERSEN INSLAAN OP KOPPELBUS STAHP DATA FOR FITTING ON COUPLING BUSH [ DOORSNEDE : A - A SECTION S:: :...->--'--1 <::> '0 'Q X+--+..,.-.,..... :::::....c::: <::> :1" '0 I _j 'Q 'Q 8 YARD, 11 Sief<JS KG N.B. ' LIPS OROERNO., H04062 HOt.011 CLASS, u.l. SBG HC AUT , /YJO DETAIL 8 SCHAAL/SCALE 1 : BOREN 8/J HONTAGE 2x DRILL AT ASSEHBLY ALLE POSTNUHHERS GEHERKT HET BORGEN HET LOCTITE NR. 243 ALL ITEHNUHBERS HARKED WITH LOCK WITH LOCTITE NO. 243 GEBRUIK VOOR HET OPPERSEN VAN DE KOPPELFLENS DE GEGEVENS VOLGENS DE INSTRUKTIE EN ZOALS INGESLAGEN IS IN DE KOPPELBUS USE FOR FITTING THE COUPLING FLANGE THE DATA FROH THE INSTRUCTION AND AS STAHPED ON THE COUPLING BUSH ma UW ZOOO SAN KOPPELFLENS Drunen, The Netherlands ASS. COUPLING FLANGE CJAII.If(DIQfJ / w SO<AALISCIJ f _d._ - ( ACE RrlOIESS ( fi NSDiS fefjilhj ( CRAWN J. I <.::..:::] 'NJ!kNIIDI NIOll 1ER/ M.SCHREURS W Tt1f(T'I HCF SPEC.

117 Title: Arrangement oil supply unit Page: 1 of 1 Type: VL 90-C Drawing: W List: H Orderno: H04062 fig.m.: 4.1 Itemno. Name Art. no. 001 Sealing. ring.metal and rubber. bonded s M Hex. socket head cap screw M Welding nipple for sae-flange W Single coil square section spring washer M Sealing. ring.metal and rubber. bonded s M Intermediate flange W Reducing socket nipple M Hexagon head screw plug M Hose coupling compl..self closing W Hex. socket head cap screw M Flange half W Nipple W Seamless a-ring seal M Quantity 5,0 12,0 3,0 16,0 1,0 1,0 1,0 1,0 1,0 4,0 6,0 1,0 1,0 Notes: -Item numbers not listed have not been used in this install. - The quantities an partnumbers shown on the parts list are believed to be correct, the quantities shown on the drawing are for illustration only. END OF LIST

118 A... ; ( NAAFIHUB TYPE 'D'.. r r trfax VOORIJIT 0" SPOED!1AX ACHTERUIT!1AX AHEAD.. ZERO PITCH. 1'1AX ASTERN I s 4 s 5 I.-----=---..:._----l-+---_-=-= r 1 I ONTLUCHTtNGSSCHROEF BLEED SCREW --ffih--t r- I (.._, ;s::::5 --- ::_S4: --.- II!1AX ACHTERU/T I 0 SPOED I!1AX VOORIJIT. ) \!1AX ASTERN ZERO PITCH!1AX AHEAD ' , NAA,FIHUELD:Pf '[' I \ AfTERNATIEVE!10NTA6E POSITIE AIJERNATlVE ASSERBlY POSITION TER/J6/'1ELDKAS FEED BACK BOX AFTAP PLU6 DRAIN Pt.U6 6/BSP V2' 98 MNSLIJITIN6 NQODSPOEDVERSTELUNft Cf)NNECTION E!1ER6ENCY PITCH SEmN6.- AANZICHT P VIEW P I / ($) " OLIEDRUK ACHTERUIT OIL PRESSURE ASTERN [2 C1 3 NK OLIEDRUK VOORUIT OIL PRESSURE AHEAD

119 -I Title: \ Assembly oil supply unit Page: 1 of 2 Type: VL 90C Drawing: W List: H Orderno: H04062 fig.m.: 4.2 Itemllo. Name Art. no. Quantity 001 Seamless a-ring seal M ,0 002 Hex. socket head cap screw M ,0 003 Hex. socket head cap screw M ,0 004 Hex. socket head cap screw M ,0 006 Seamless a-ring seal M ,0 007 Sealing ring W ,0 008 Hex. socket head cap screw M ,0 009 Copper sealing ring M ,0 010 Bleed screw W ,0 011 Hex. socket head cap screw M ,0 012 Cover W ,0 013 Sealing. ring.metal and rubber. bonded s M ,0 014 Reducing socket nipple M ,0 015 Oil supply housing W ,0 016 Cover W ,0 017 Oil supply pipe W ,0 018 Guiding bush W ,0 019 Supporting ring W ,0 020 Hexagon screw M ,0 021 Connection. flange W ,0 022 Oil seal W ,0 023 Unhardened parallel pin M ,0 024 Slip ring W ,0 Seamless a-ring seal M ,0 026 Seamless a-ring seal M ,0 027 Ring W ,0 028 Hex. socket head cap screw M ,0 029 Hexagon head screw plug M , haft W ,0 031 Hexagon socket pipe plug W ,0 032 Oil seal W ,0 033 Distance. ring W ,0 034 Pointer W ,0 035 F eed-back.lever W ,0 036 Retaining ring for shaft M ,0 037 Sliding block W ,0 038 Unhardened parallel pin M ,0 039 Hexagon socket pipe plug W ,0 '\-1;mJ.\\',s>m-'!Gotil?..mi7/.t\'ltt',.".'l\lm,.,.,.Sk,.,.)>'H,,Mk.l:.::o/f.';'.f'::'mY.;m..m:;;;zr,.m,

120 Title: Assembly oil supply unit Page: 2 of 2 Type: VL 90-C Drawing: W List: H Orderno: H04062 fig.nr.: 4.2 ltemno. N a m e Art. no. 040 Hardened cyl. pin W Ring W Sealing. ring.metal and rubber. bonded s M ring M Measuring coupling W Quantity 2,0 1,0 8,0 1,0 1,0 Notes: -Item numbers not listed llave not been used in tllis install. - Tile quantities an partnumbers sllown on tile parts list are believed to be correct, tile quantities sllown on tile drawing are for illustration only. END OFLIST

121 OOORSNEDf SECTION 'A - A " VERlRAAJO CLTCKDIJ Slr) HJSIRAWN OOORSNEDf SECTION '8-8 I I r-t- 1ANJW/E!AS lien/ '<MEL SHAFT II II J I I AANiAAJ.I'CHNT RfQU!RfD TCRtltL ALL POSTIUffRS ti 1 1/KT let Bt:R«N 1 1 LOCTJTE 1R. 241 ALL ltfl'ftufjers HARKED WITH LCVC WITH LICTITE J 1 I [2 aienltk ACHT 1/UJT OIL PII SSLIIE ASTEIIN Crt aiett an PII SSL/IE AJEAD

122 Title: Auxiliary tool for pitch adjustment Page: 1 of 1 Type: VL90-C Drawing: W List: H Orderno: H04062 fig.nr.: 4.3 Itemno. N a m e Art. no. 001 Pressure gauge coupling W Straight fitting w.progressive ring W Bush W Seamless a-ring seal M Quantity 2,0 2,0 1,0 3,0 Notes: - Item numbers not listed have not been used in this install - The quantities an partnumbers shown on the parts list are believed to be correct, the quantities shown on the drawing are for illustration only. END OF LIST

123 OL/EDRUK ACHTERUIT OIL PRESSURE ASTERN [2 I DOORSNEDE : SECT/OM.. A - A GIBSP 114' GELEIDINGSBUS IN VL GUIOINGBUSH IN VL 1 OL!ETOEVOERPIJP IN VL OIL SUPPLY PIPE IN VL B 'il - -. '- 13S o VERORAAIO GETEKENO 13S o MISORA WN OLIEDRUK VOORUIT. OIL PRESSURE AHEAD [1.... v ';. ; -. '...:.... :--..._:..:_:.t:r... I;IULPGERf![JSCHAP MONTEREN ALS OL!ETOEVOERHUIS GE.OEI10NTEERO.IS MOUNT AUXILIARY TOOL WHEN OIL SUPPLY HOUSING IS Olst10VNTEO,_.

124 Title: Assembly. transmitting. box Page: 1 of 1 Type: VL-2P Drawing: W List: H Orderno: H04062 fig.nr.: 4.4 Itemno. Name Art. no. 001 Segment. toothed W Hex.socket set screw w.cup point M Gearwheel W Hex.socket set screw w.cup point M Box W lnsert.screw thread. heli-coil M Cover W Packing W Slotted cheese head screw M Rail W Cover W Packing W Oil seal W Hex. socket head cap screw M Sheet W Plain washer M Hex. socket head cap screw M Synchro. clamp W Clip W Support. end W Hexagon socket pipe plug W Quantity 1,0 2,0 2,0 2,0 1,0 12,0 1,0 1,0 2,0 0,1 1,0 1,0 1,0 4,0 1,0 4,0 12,0 6,0 8,0 2,0 4,0 Notes: - Item numbers not listed /rave not been used in tlris install. - Tire quantities an partnumbers s/row tire parts list are believed to be correct, tire quantities s/rown on tire drawing are for illustration 011ly. END OF LIST

125 .,.. _;. - _.,- :.: _... _... '1!.:::'\:ik,,,..,_::_ T:/2_i111'{/IL :i. -.:;;- < -_,. fir_$.. _..,. ;. '; T#HINRL NR.S.... -, ;...:-.:-;, :....J...\ '../ '._.:'.... : ;,.. ;...' ' \... )...

126 c HYORAIJU[ LNTS WILL BE SIRPUEIJ WITH SA 3000 PSI fi.an{jfs AMJ Wf/.0 ftttlmis IACC.IRWG. W J2 AO,! Bl.ll/0 WELO/Nli F1.A111ES HAVE TO BE ORilliiJ BY THE l!!ra PIPES HAVE TO BE SEA!1LESS STEEL P/PfS. WE AOVTSf PflfC/S/UN PIPfS AIT. TO ON 2391 HATfRIAL Sf J5 (jfjk Cil MJK PA(jf 2 ILLOYOSI. /THOSE PIPES ARE CLfA}EJ) NSIOfJ. fl.80ws AMJ I1ANIFOJ..OS HUST BE PROVUJEIJ WITH BUTT Wf/.0 FlAMifS TO ALLOW ClEANMi AMJ INSPECT/aol CF PIP/Nii I r = 350 Nlmm 1 I. NOT SI.I'PUEIJ BY LIPS BV. HYCJRAIJI..tr LINES /fjst BE HDUIITEIJ IN SWf A I1AfllfR THAT NO STRESSES ARE TRANSHTTEIJ TO THE SIB- ASSE1181JfS OR ajhi'oients WHICH THEY lffil(. HOREIJVER THEY HUST BE AOEQUA!El.Y SlPPORTEIJ TO PREVENT THE TRANSMISSION Of VllJRA11JNS. PIPES WHICH HAVE BEEN lffateij for ANY RfASfX>I IWElJl//'(j OR HAKlMi CF Bf}8}SL /fjst Sl.BSEOWITLY BE llffrsfo IN AN ACifJ SOLUTION AND AFTfJIWA!IDS THOF/OIJfRY fl.usi 0 T/IIOUiiH. Fl/JER ElfJfNTS SHa.Ul BE 0/AN[jf[] IN PRMIPLE AFTfJI fl.ushng THROIEH THE SYST&I AFTfJI TRAI/.5 AND AFTfJI 500 RfN'IMj HOURS f»' N1N{j ON CINJTIONS Of flfheiits. J REPLAtfHENT flfhfiits WILL BE SI.I'Pl.IEIJ. J 2 I I 4WVPROP 2,.._, 'l I sv 1 L-(}-.-)-.J Q [_PSV4 [2 [1 H6 1- A LIST CF SYHBOI.S AMJ 1NfiJIII1ATI(1-I HAS BEEN ATTAO IJ TO 7HS HYCJRAIJU[ IJAURAH. COIJ WITIIN RfffR TO ELC. /JAGRAH. PRS2 PRS1 R3...,... R2, R1...,... r-, PSV1 I ( I l L-f-_f"" -:!....J I I I I NRVS 8 YARD : 11. Sietas KG N.B. : LIPS ORDERNO. : H H04C ll._.:. : aass : 6.L HI PIPE OD. x /D. = 35x21 (JxJ ABV1 ) ( TAl 400 dm 1 <D Tt1. \L Ps_j DRAIN FEMALE I \::DRAIN r BSP HYDRAULIC POWERPACK I FEMALE 1'BSP SEf DETAIL Et1ERIIENCY PITCH SETTING r-= DETAIL I I 1 EMERGENCY PITCH SETTING 1 1 [1 SOV'3 ECB [1 I I H[ BV ---, I I I TR+FBB (R11+R21 ODB I 1..!..1 I I R PROCEDURE SEE MANUAL_j L l-i am L 1 P s Drunen, The Netherlands ODB HYDRAULIC DIAGRAM OA1lH f DAif I mrrn _,_ W

127 Title: Hydraulic power pack Page: 1 of 2 Type: HPP Drawing: W List: H Orderno: H04062 fig.nr.: 5.2 Itemno. Name Art. no. Quantity 001 Name plate W ,0 002 Name plate W ,0 004 Tank. oil W ,0 010 Sheet W ,0 011 Packing W ,0 014 Absorber W ,0 021 Dip stick W ,0 023 Level switch W ,0 026 Thermometer W ,0 032 Air filter W ,0 033 Filter cartridge W ,0 036 Return.filter W ,0 037 Return filter cartridge W ,0 038 Pressure.switch W ,0 039 Indicator W ,0 049 Flange W , phase E-motor with squirrelcage W ,0 052 Lantern piece W ,0 053 Packing W ,0 054 Flexible.coupling W ,0 055 Gear pump W ,0 057 Flange W ,0 058 Absorber W ,0 062 Non return valve W ,0 063 Manifold block W ,0 064 Safety valve W ,0 066 Valve W ,0 067 Shuttle valve W ,0 068 ry1anifold block W ,0 069 Valve. four-way W ,0 075 Non return valve W ,0 076 Non return valve W ,0 091 Assembly of oil cooler W ,0 096 Pressure gauge W ,0 098 Pressure. switch W ,0 106 Measuring coupling W ,0 108 Pressure gauge coupling W ,0 109 Pressure gauge coupling W ,0 t:mt:=r.:'z;;.:'lsf-w;;!.'!mm.,...'i4jif.jo,w;:;m;;,n,,)hl>&i,.j:%zilffifuiimj.;%m!w;'itrd.t;<\!!!.utl'ii'? l

128 Title: Hydraulic power pack Page: 2 of2 Type: HPP Drawing: W List: H Orderno: H04062 jig.nr.: 5.2.e Item no. Name Art. no. 111 Welding nipple for sae-flange W Welding nipple for sae-flange W Flange. blind W Hydraulic hose W Flange. blind W Arrangement of hydraulic power pack W Measuring coupling W Ball. tap W Valve W Pressure. switch W Gear pump W phase E-motor with squirrelcage W Flexible.coupling W Quantity 2,0 1,0 1,0 1,0 1,0 1,0 1,0 1,0 1,0 1,0 1,0 1,0 1,0 Notes: -Item numbers not listed have not been used in this install - Tile quantities an partnumbers shown on tile parts list are believed to be correct, tile quantities shown on tile drawing are for illustration only. END OF LIST

129 AB1+FILL LLS1 RFA RF1-2 oc 91 DETAIL 1 (H5,6,7) II 3/4" SAE I "' "-1 s_ am 0 EM , 2 d l \1 V7EW PUMPSET P sv Bar PSV1,2 69 <8 t\ eo, ' "'"' s=a'--; 66 PSV4 Minimum to remove t-motor DS1 4WVPROP SOV9..'+'. :r =1 32 EM3 NRV1-2 rfrr Pk 8 S2 PG1 C1+C2 I \ ALL DIMENSIONAL TOLERANCES ACC. : DIN 7168/1 ALL MENTIONED VALUES ARE NOMINAL Functional Connections -, , ral ---r- : NRV5 C1+C2-97o HYDRAULIC: C1 SAE 3/4" Psi Pipe OD x ID : 35 x 27 C2 SAE 3/4" Psi Pipe OD x ID : 35 x 27 T SAE 3/4" Psi Pipe OD x ID : 35 x 27 COOLING-WATER : CW-IN CW-OUT Welding nipple Pipe OD x ID : 33.4 x 26.6 Welding nipple Pipe OD x ID : x Reservoir Caoacitv! I DRAIN 1" PN16 DIN 2566 J, -... k lf==ai,_ 112 I t2o8 112 I 1584 I J CW-IN I I CW-OUT 8x Slot fpr_ M16 '"' I J:b I 1\ I r:b ltj Ll I 292 r 228 Cit). 0>.:::: t; 9_25 I N "' u I CW-IN+ cw...,ou J i 23 <:> a::> FILL I YARD : J.J. Sietas K.G. N.B. : i UPS ORIJCRNO H04062 < /f04071 ' CLASS : G.L. + SQG + MC AUT

130 John Crane-Lips Version :4.1 0 ORDERNR. H HOAGtoo-o8-o7 Sub-assembly Drwg.no. Hydraulic diagram W A2 Assembly oiltank Hydraulic power pack W A 1 Dim. sheet power pack W A3 Connection diagram W A3 Mod. A Page 1. Description Classification Operation pressure: Safety pressure: Test pressure high: Test pressure low: Data GL + SBG + MC AUT 74 bar 89 bar 177 bar 15 bar Component. 4WVPROP With pilot valve AB1-FILL ABV1,2 BV C1 C2 DRAIN DS1 ECB EM1 EM2 EMl EPPS FBB H5,6,7 HC LLS 1 NRV1,2 NRVl NRVS. oc ODB P1 SELECTION TABLE HYDRAULIC COMPONENTS Description 4-way proportional valve Air breather and filling filter Air breathing valve Blocking valve Line to OD box (ahead) Line to OD box (astern) Drain Dip stick Emergency connection block Electric motor Electric motor Electric motor Hub pressure system Emergency pitch setting Feedback box Flexible hoses Hydraulic cylinder Low-level switch Non-return valve Non-return valve Non-return valve Oil plate cooler Oil distribution box Hydraulic pump Data NW 10 See data EM2 13 kw min V - 60 Hz - 3 ph S6-25% 18 kw- needed 13,5 kw 0,12 kw min V - 60 Hz - 3 ph Potentiometer adjusted pitch Standard make: BESTA Cracking-pressure: 0,5 bar Cracking-pressure: 2 bar Cracking-pressure: 3 ba.r Q water 40 C: 4,2 mj/h Heat transfer: 7,4 kw 1750 min- 1-71,4 dmj/min T/Group C!cbal Specialisf!d Enr;inecring

131 e Version :4.10 ' John Crane-Lips ORDERNR. H HOA012too-oa-o7 Mod. A Page 2. SELECTION TABLE HYDRAULIC COMPONENTS Component Description Data P2 Hydraulic pump 1750 min" - 71,4 dm--;,-/min Pl Hydraulic pump 1750 min 1-0,4 dm;:j/min Hub pressure system PG1 Pressure gauge bar PRS1 Pressure switch Adjusted at: 8 bar Stand-by pump in Make: Herion Type: 80. PRS2 Pressure switch Adjusted at: 6 bar Low pressure alarm Make: Herion Type: 80 PRS6 Pressure switch Adjusted at: 1,5 bar Low pressure alarm Hub pressure system PSV1,2 Pressure safety valve Adjusted at: 89 bar PSV4 Pressure safety valve b.p approx. 10 bar PSV6 Pressure safety valve Adjusted at: 2 bar R1,2,3 Restrictor RF1,2 Return filter RFA Return filter alarm SOV1,2,3,9 Shut off valve SOV13 Self sealing coupling. sv Shuttle valve T Leakage oil OD box to power pack tank TA1 Power pack tank Volume oil: 400 dmj Thermometer TP1 Test point TR Transmitter box Potentiometer achieved pitch Remark: 0 code for purchasing department. e Mod. A: Remark about flanges for fill and drain added!> T/Group Clabo/ SpecJoli!tld fnginrr.ting

132 HYDRAULIC POWER PACK E/11 E/12 E/13 8!... "t "t ; 1il _, _, "t "t _, ::5 ;!:5 "t I'::... _, :lt :lt <::) <:::> _, <:::> _, c:j TO Ca/TROL SYSTEM I TO ALARH 1 TO cavma 1 TO ALARH SYSTEM SYSTEM SYSTEM 1 TO cavma 1 TO RW CONTRa. SYSTEM 1 TO t:rmra. 1 SYSTEM SYSTEM TO ALARM AMJ f'dit(rn6 SYSTEM lml 1 lmlll lmlll TO E-HJTfR STARTER I TO E-HJTOR STARTER I TO E-HJTOR STARTER I PITCH FEED BACK BOX TO crntrol SYSTEM EE LIPS TTifL I NA/' I REMARKS: ALARH CONTACTS OPENED IN ALARH COND!TlON DRAWN CONDITION IS PRESSURELESS (TANK EHPTYJ CONNECTION DIAGRAM i Drunen. The Netherlands HYDRAI.lJC system AND SHAFTlH 1--l---1--i-=n AJo RKAANSE FfiO.E1(1E I =t:'!6/ AFI TlaN SOl4AL I SCALE I OA!tH I OOf I I NERCAN PRO.ECT/(lo/ I WAARII" /[LA/ N lid "if IN I'I1I TER --- I SIHACE RrXmESS o/ I t:# NSDIS f.:(f1fj( }1}=1 CIIA;:;;;:-;;WN::-: l -c:::.:j 'IJ!J/frxUfLAJ,.,,. 1 IN I'I1I TER 1 R. van Bruggen TYFf I TYFf I II ilt H04062 H04071 auriufer I aamutjlr I W AJ

133 Title: Tool.lifting. for blade.propeller Page: 1 of 1 Type: Drawing: W List: H Orderno: H04062 fig.nr.: 6.1 Itemno. N a m e Art. no. 001 Bracket. hoisting. for blade.propeller W Protection plate W Hexagon screw W Eye.lifting W Hoisting.bracket W Quantity 1,0 2,0 2,0 2,0 2,0 Notes: - Item numbers not listed /rave not been used in tlris install. - Tire quantities an partnumbers sir own on tire parts list are believed to be correct, tire quantities slwwn on tire drawing are for illustration only. END OF LIST 24-ll-00

134 I I I I HOISTING AND t10unting OF BLADES VOOR MONTAGE HIJSBEUGEL BLADOPPERVLAK GOED SCHOONMAKEN BEFORE MOUNTING THE HOISTING CLAMP THOROUGHLY CLEAN THE BLADE SURFACE GEBRUIK HARPSLUITING VOOR STABIL/TEIT EN GELEIDING VAN HUSBAND USE SHACKLES FOR STABILITY AND GUIDANCE OF HOISTING STRAPS 8 I..1 I I. I I. \ I I \. \ \ BENODIGD AANHAALMOMENT 280 Nm REQUIRED TORQUE 280 Nm II GEBRUIK SPANBANDEN TEGEN HE VERSCHUIVEN VAN DE HIJSBEUGEL USE STRAPS TO AVOID MOVEMENT OF THE HOISTING CLAMP 2_1 POST- I QUANTTTY I 'tmft!uf1er a«h1jjvnj 1 CESCW'Tm I i - - _, "S! i ""..:-! f ii cf - R ;:! - "" tr I1ATf1IIAAI.. IHiilERIALI f ISO J AF1 11aN 8IJVfN 1 OVER I II'EN5DIS I rot EN I T I UP ro ANJ ICLI.fNi I {)0( 811 VERSPAIENE BEWfR(IWI TaD/ANT I FrR f'1ach#lj U'ERAIKIIS I I Ta.EIIAICE I BU CE OVEJia BEWfRKNBI I FrR All OTI R CFfRAlriiS I -- c0.5 of EE LIPS TTTEl I NAJ I CEZE Tf1(fJNj IS EHND1 IAN LPS B. V. EN HAG ZrNBI SCHIFTWN TrE51EJHlj fb((i(t1d.. [RI CER EW/AfiESSf /'ET W RDI VERf J6iVI.UBJ llxh 1-mi' CERWi wrren WJIUa I [J [J(f[J I tt AAN CEll»/ TfR NZA wrrcen VEIIS11Ifi(T THS ljiaioni F81ANi Tl PRCFfRTY tt LPS B. V. AIIJ HAl' WfTill/T WII1TTEN Pf1HSSDI tt Tl OWfER IIJT BE I'UJFIJEIJ BE USED FrR THRO PARTES r:r BE t1ven ro THRO PARTES FOR PERUSAl. I AFTHNi I feparwent I SAMENST. HIJSGEREEDSCHAP BLADEN ASSEMBLY HOISTING TOOLS BLADES I%ZIEN I APPROVED I ONll1 I OATf I W TYPE I TYPE I MAX 3000 kg. AFrBID IIIN TEKEJNj I C116NA1ES FRa1 ljiamii:i' I A A3

135 Title: Transport tool for propeller shaft Page: 1 of 1 Type: C-VL NW40-2/NW30-2 Drawing: W List: H Orderno: H04062 jig.nr.: 6.2 Itemno. N a m e 001 Piece.retaining 002 Hexagon bolt Art. no. W W Quantity 1;0 1,0 Notes: - Item numbers not listed have not been used in this install. - The quantities an partnumbers shown on the parts list are believed to be correct, the quantities shown on the drawing are for illustration only. END OF LIST

136 2 1 ZWAARTEPUNT VAN SCHROEFBLAD CENTRE OF GRAVITY OF PROPELLER BLADE ZWAARTEPUNT MET BLADEN CENTRE OF GRAVITY WITH BLADES ; ZWAARTEPUNT ZONDER BLADEN CENTRE OF GRAVITY WITHOUT BLADES - - -# I lie/see DETAIL A DETAIL A 225 MASSA MET BLADEN : kg MASS WITH BLADES MASSA ZONDER BLADEN : MASS WITHOUT BLADES kg A TTTB. I NAJ I TRANSPORTGEREEDSCHAP V. SCHROEFAS TRANSPORT TOOLS FOR PROPELLERSHAFi 180 WOB

137 PARTNUMBER- PARTLIST CROSS-REFERENCE H04062 This list can be used to find the locati9n of a certain partnumber and as such can be used durbtg maintenance, repair and overhaul. Part number Item catchword Partlist number Drawing figure Partlist catchword lt(!m Need UM Class ---- H Assembly Couplingftange H W Arrangement shafting ST M Reducing socket nipple H Arrangement oil supply unit ST M Reducing socket nipple H Assembly oil supply unit ST M Hexagon head screw plug H Assembly oil supply unit ST M Hexagon head screw plug H Arrangement oil supply unit ST M Slotted cheese head screw H Assembly.transmitting.box ST M Hex. socket head cap screw H Assembly.transmitting.box ST M Hex. socket head cap screw H Assembly oil supply unit ST M Hex. socket head cap screw H Assembly oil supply unit ST M Hex. socket head cap screw H Assembly. transmitting. box ST M Hex. socket head cap screw H Assembly oil supply unit ST M Hex. socket head cap screw H Arrangement oil supply unit ST M Hex. socket head cap screw H Assembly oil supply unit ST M Hex. socket head cap screw H Assembly of the hub ST M Hex. socket head cap screw H Assembly oil supply unit ST M Hex. socket head cap screw H Assembly of the hub ST M Hex. socket head cap screw H Assembly of the hub ST M Hex. socket head cap screw H Assembly oil supply unit ST M Hex. socket head cap screw H Arrangement oil supply unit ST ' Page 1 of11

138 Part number Item catchword Partlist number Drawing figure Partlist catchword Item Need UM Class M Hex. socket set screw w.cup point H Assembly.transmitting.box ST M Hex.socket set screw w.cup point H Assembly.transmitting.box ST M Hex. socket set screw w.cup point H Assembly of the hub ST M Hex. socket set screw with full dog point H Arrangement shafting ST M Hex. socket set screw with full dog point H Assembly of the hub ST M Hex. socket set screw with full dog point H Arrangement shafting ST M Hex. socket set screw with full dog point H Assembly Couplingflange ST M Hexagon screw H Assembly oil supply unit ST M Hexagon screw H Assembly of the hub ST M lnsert.screw thread. heli-coil H Assembly.transmitting.box ST M Plain washer H Assembly.transmitting.box ST M Single coil square section spring H Arrangement oil supply unit ST.,,.;-,,.. M Dubo retaining ring H Assembly of the hub ST M Dubo retaining ring H Assembly of the hub ST M Unhardened parallel pin H Assembly oil supply unit ST M Unhardened parallel pin H Assembly oil supply unit ST M Split pin H Arrangement shafting ST M Heavy type cyl. spring dowel H Assembly of the hub ST M Retaining ring for shaft H Assembly oil supply unit ST M Seamless a-ring seal H Arrangement oil supply unit ST M ring H Assembly oil supply unit ST M Seamless a-ring seal H Assembly oil supply unit ST sr- --- M Seamless a-ring seal H Assembly oil supply unit Page 2 of 11

139 Part number Item catchword Partlist number Drawing figure Partlist catchword Item Need UM Class M Seamless o-ring seal H Arrangement shafting ST M Seamless o-ring seal H Arrangement shafting ST M Seamless o-ring seal H Assembly oil supply unit ST ' M Seamless o-ring seal H Assembly oil supply unit ST M Seamless o-ring seal H Assembly of the hub ST M Seamless o-ring seal H Assembly of the hub ST M Seamless o-ring seal H Auxiliary tool for pitch adjustment ST M Seamless o-ring seal H Assembly Couplingflange ST M Seamless o-ring seal H Assembly of the hub ST M Copper sealing ring H Assembly oil supply unit ST M Sealing. ring.metal and rubber. bonded H Arrangement oil supply unit ST M Sealing. ring.metal and rubber. bonded H Assembly oil supply unit ST M Sealing. ring.metal and rubber. bonded H Assembly oil supply unit ST M Sealing. ring.metal and rubber. bonded H Arrangement oil supply unit ST W Oil supply pipe H W Assembly oil supply unit ST -- W Assembly blocking valve H W Arrangement shafting ST --- W Part.spare H Part ST W Unit. handle H Assembly panel.house.wheel ST W Unit. handle H Assembly panel.wing ST W Unit.handle H Assembly panel.room.control.engine ST W Unit. handle H Assembly panel.wing ST W Shaft H W Assembly oil supply unit ST W Ring in two pieces H W Assembly of the hub ST ' Pflge 3 of 11

140 Part number Item catchword Partlist number Drawing figure Partlist catchword Item Need UM Class W Flexible.coupling H Hydraulic power pack ST W Gearwheel H !W Assembly. transmitting.box ST W Segment.toothed H !W Assembly.transmitting.box ST W Moving cylinder yoke H W Assembly of the hub ST W Blade carrier H !W Assembly of the hub ST. W Feed-back.lever H W Assembly oil supply unit ST W Connecting piece H W Assembly of the hub ST W Piston ring with clip H !W Assembly of the hub ST W Hub body H W Assembly of the hub ST. W Oil supply housing H W Assembly oil supply unit ST W Hub cover H W Assembly of the hub ST W Cover H W Assembly.transmitting.box ST W Cover H W Assembly.transmitting.box ST W Cover H !W Assembly oil supply unit ST W Cover H W Assembly oil supply unit ST W Sliding block H W Assembly oil supply unit ST W Sliding block H W Assembly of the hub ST W Supporting sleeve H W Arrangement shafting ST ---- W Supporting sleeve H W Arrangement shafting ST W Manifold block H Hydraulic power pack ST W Manifold block H Hydraulic power pack ST W Supporting ring H W Assembly oil supply unit ST - W Slip ring H W Assembly oil supply unit ST Page 4 of 11

141 Part number Item catchword Partlist number Drawing figure Partlist catchword Item Need UM Class W Distance.ring H W Assembly oil supply unit ST W Ring H W Assembly oil supply unit ST W Ring H W Assembly oil supply unit ST W Sealing ring H W Assembly oil supply unit ST W Guiding bush H W Assembly oil supply unit ST W Bush H Woo Assembly of the hub ST W Bush H IW Auxiliary tool for pitch adjustment ST W Lantern piece H Hydraulic power pack ST W Box H W Assembly.transmitting.box ST W Sheet H W o 4.4 Assembly.transmitting.box ST W Sheet H Hydraulic power pack ST W Name plate H Hydraulic power pack ST W Name plate H W Hydraulic power pack ST W phase E-motor with squirrelcage H Hydraulic power pack ST W Absorber H Hydraulic power pack ST W Gear pump H Hydraulic power pack ST W Pump.plunger H Tool for shafting ST W Gear pump H Hydraulic power pack ST W Hand pump H Tool for shafting ST W Air filter H Hydraulic power pack ST W Filter cartridge H Hydraulic power pack ST W Return filter cartridge H Hydraulic power pack ST W Indicator H Hydraulic power pack ST Page 5 of 11

142 Part number Item catchword Partlist number Drawing figure Partlist catchword Item Need UM Class W Pressure.switch H Hydraulic power pack ST W Measuring coupling H Assembly oil supply unit ST W Straight fitting w.progressive ring H Auxiliary tool for pitch adjustment ST W Measuring coupling H Hydraulic power pack ST W Pressure gauge coupling H Auxiliary tool for pitch adjustment ST W Pressure gauge coupling H Hydraulic power pack ST W Pressure gauge coupling H Hydraulic power pack ST W Sleeve H W Arrangement shafting ST W Sleeve H W Arrangement shafting ST W Sleeve H W Arrangement shafting ST W Flange H Hydraulic power pack ST W Flange H Hydraulic power pack ST W Intermediate flange H W Arrangement oil supply unit ST W Flange half H Arrangement oil supply unit ST W Flange.blind H Hydraulic power pack ST W Hose coupling compl..self closing H Arrangement oil supply unit ST W Connection.flange H Assembly oil supply unit ST W Nipple H Arrangement oil supply unit ST W Welding nipple for sae-flange H V\ Arrangement oil supply unit ST W Welding nipple for sae-flange H Hydraulic power pack ST W Welding nipple for sae-flange H Hydraulic power pack ST W Plug.screw.hexagon head H Assembly Couplingflange ST W Plug.screw.hexagon head H Assembly Couplingflange ST Page 6 of 11

143 Part number Item catcltword Partlist number Drawing figure Partlist catchword Item Need UM Class W Plug H Assembly of the hub ST W Plug H W Assembly of the hub ST W Hexagon socket pipe plug H Assembly oil supply unit ST W Hexagon socket pipe plug H Assembly of the hub ST 1-- W Hexagon socket pipe plug H Assembly oil supply unit ST W Hexagon socket pipe plug H Assembly.transmitting.box ST W Safety valve H Hydraulic power pack ST W Non return valve H Hydraulic power pack ST W Non return valve H Hydraulic power pack ST W Non return valve H Hydraulic power pack ST -- W Valve H Hydraulic power pack ST W Shuttle valve H Hydraulic power pack ST 1--- W Valve H Hydraulic power pack ST W Pressure gauge H Hydraulic power pack ST W Dip stick H Hydraulic power pack ST W Level switch H Hydraulic power pack ST W Pressure.switch H Hydraulic power pack ST W Thermometer H FIG. 681 K 5.2 Hydraulic power pack ST -- f- W Pointer H W Assembly oil supply unit ST W Indicator H Assembly panel.house.wheel ST W Indicator H Assembly panel.room.control.engine ST W Indicator H Box. indicator ST W Indicator H Assembly panel.wing ST Page 7 of/1

144 Part number Item catchword Partlist number Drawing figure Partlist catchword Item Need UM Class W Indicator H Assembly panel.wing ST W Synchro clamp. H Assembly.transmitting.box ST W Potentiometer H Assembly panel.room.control.engine ST W Strip H Assembly of the hub ST W Rail H Assembly.transmitting.box MT W Support.end H Assembly. transmitting.box ST W Clip H Assembly. transmitting.box ST W Card.print H W Control cabinet ST W Indicator H Assembly panel.room.control.engine ST W Component. control H Assembly panel.room.control.engine ST W Card.print H W Control cabinet ST W Card.print H W Control cabinet ST W Card.print H W Control cabinet ST W Card.print H W Control cabinet ST W Cord ring with vulcanized joint H Assembly of the hub ST W Seamless o-ring seal H Assembly of the hub ST W Seamless o-ring seal H Assembly of the hub ST W ring H Assembly Couplingflange ST W Oil seal H Assembly oil supply unit ST W Oil seal H Assembly oil supply unit ST W Oil seal H Assembly.transmitting.box ST W Packing H W Assembly. transmitting.box ST W Packing H W Assembly.transmitting.box ST Page 8 of 11

145 Part number Item catchword Partlist number Drawing figure Partlist catchword Item Need UM Class W Packing H Hydraulic power pack ST W Packing H Hydraulic power pack ST W Eye.lifting H Tool.lifting. for blade.propeller 004B 2 ST W Flange bolt H Assembly of the hub ST. W Hub cover bolt H Assembly of the hub ST W Hexagon bolt H Transport tool for propeller shaft ST W Bleed screw H !W Assembly oil supply unit ST W Hexagon nut H Arrangement shafting ST W Dowel H fw Assembly of the hub ST. W Dowel H Assembly of the hub ST W Locking.wire H Assembly of the hub MT W Hardened cyl. pin H Assembly oil supply unit ST W Piston seal H Assembly of the hub ST W Piston seal H Assembly Couplingflange ST W Slugging ring wrench H Tool for hub ST W Socket wrench H W Tool for hub ST --- W Absorber H Hydraulic power pack ST W Blade bolt H W Assembly of the hub ST. W Ball.tap H Hydraulic power pack ST W Flexible.coupling H Hydraulic power pack ST W Measuring coupling H Hydraulic power pack ST W Valve. four-way H Hydraulic power pack ST W Sleeve H W Arrangement shafting ST Page 9 of 11

146 Part number Item catchword Partlist number Drawing figure Partlist catchword Item Need UM Class W Sleeve H !Wo Arrangement shafting ST W Pressure.switch H Hydraulic power pack ST W Return.filter H Hydraulic power pack ST W Hexagon screw H Tool. lifting. for blade.propeller ST W Box. coupling H W Assembly Couplingflange ST. W Piston H W Assembly Couplingflange ST W Round nut H W Assembly Couplingflange ST W Ring.collar.toothed H Assembly Couplingflange ST W Reinforcing sleeve H Arrangement shafting ST W Bracket. hoisting. for blade.propeller H W Tool.lifting. for blade.propeller ST W Protection plate H W Tool. lifting. for blade.propeller ST W Flange.blind H W Hydraulic power pack ST W phase E-motor with squirrelcage H Hydraulic power pack ST W Hydraulic hose H Hydraulic power pack ST W Tank. oil H Hydraulic power pack ST W ring for blade foot H Assembly of the hub ST W Hoisting.bracket H W Tool.lifting. for blade. propeller ST W Propeller. blade H W Propeller. blade ST W Flange cover H W Assembly of the hub ST W Bush.flanged H W Assembly Couplingflange ST W Shaft H W Order parts-list ST W Propeller shaft H W Arrangement shafting ST. W Manual. instruction H Manual. instruction ST Page loof 11