PSS INSTALLATION INSTRUCTIONS Imprtant - Read Befre Starting! Befre starting yur installatin carefully read the fllwing warnings and instructins. Failure t prperly fllw the warnings and instructins culd lead t persnal injury r even death, r physical, envirnmental r prperty damage. The PSS Shaft Seal yu are preparing t install is a thrugh-hull fitting that prtects against water frm entering the bat where the shaft enters the hull, when prperly installed and maintained. Make sure that yu r yur designated installer is a qualified prfessinal, knwledgeable and skilled t install the PSS crrectly, and that yu have all the required tls and additinal equipment n hand befre beginning installatin. If remving the engine transmissin fr repair r if launching the bat withut a transmissin installed, then the shaft must be kept in place with a device that will secure the shaft with the PSS belw in its nrmal "cmpressed mde". Install the PSS ONLY with the bat ut f the water. DO NOT USE il, grease (petrleum prducts) r silicne prducts at any time during the installatin. Use sap and water t lubricate the -rings f the rtr when sliding it dwn the shaft. Clean the seal area f yur bat s yu d nt cntaminate the seal surface with dirt, il r ther freign matter. D nt damage r scratch the face f the carbn r the face f the stainless steel rtr during unpacking r while handling r installing the PSS. There shuld be a ttal f fur (4) set screws in the tw hles f the rtr (tw sets screws in each hle). If yu must mve the stainless steel rtr, make sure t remve the tp set screws in rder t access the bttm tw set screws. D nt re-use the supplied cupped pinted set screws. If multiple tightening has flattened the cupped-pint set screw, replace the affected screw with a new ne. There shuld be a ttal f fur (4) hse clams securing the bellws ends. These clamps shuld be replaced if they shw any sign f crrsin. D nt slide the aft bellw cuff t far dwn ver the stern tube. The leading edge f the stern tube culd cause damage t the inner ribs f the bellw and imprperly limit the bellw mvement and travel. If fitting a vent line (bats under 12 knts), d nt run a lp at the tp end f the hse as this culd prmte a siphn. If the bat sits idle fr a lng perid f time (generally 3 mnths r mre), it is necessary t mve the carbn face back t allw a small amunt f water t enter the bat.
As with any hse under the waterline, the PSS bellws must be inspected n a regular basis (i.e., n less than at least every 6 mnths under mst circumstances) and checked fr any signs f deteriratin (cracks, splits, tears, brittleness, r ther signs). Upn any sign f deteriratin the bellw must be replaced. As preventive maintenance the bellw shuld be replaced n less than every six (6) years, regardless f its apparent cnditin. D nt allw any petrleum-based liquid r crrsive material t cme in cntact with the PSS. Take care t ensure that this des nt ccur, fr example, when perfrming any general maintenance, r winterizing the engine. The shaft shuld be near centered and run parallel t the shaft lg. D nt use an zne generatr (e.g., air cleaner) in r arund yur bat. The extra zne will speed up the deteriratin f any rubber prduct, including the PSS bellw. The bellws will need mre frequent inspectin and replacement in an envirnment where nnsealed batteries emit sulfuric acid vaprs. Sulfuric acid vaprs will accelerate deteriratin f any rubber materials including the PSS bellws. D nt use sealant t fit the bellw t the stern tube r the hse t hse barb. D nt run dry. D nt use the PSS SEAL n a submarine vehicle. Cmpnents List Stainless steel hse clamps - 4qty Nitrile bellw - 1qty Carbn graphite flange - 1qty Stainless steel rtr - 1qty Stainless steel set screws - 4qty (1 spare als included) Nitrile -rings - 2qty (2 spares als included) Stainless steel hse barb fitting - 1qty Hse barb insert & washers - 1qty Clamp Jackets - 4qty The PSS Shaft Seal is a mechanical face seal that is created between the flat surfaces f the rtating stainless steel rtr and the statinary carbn flange. The statinary carbn flange is attached t the vessels stern tube with hse clamps and the carbn flange is attached t the frnt side f the bellws with hse clamps. The stainless steel rtr is fit n the shaft in frnt f the carbn flange. The stainless steel rtr is used t cmpress the bellws befre the cllar is secured t the shaft with set-screws. This cmpressin (pre-lad) maintains cntact between the faces and allws the PSS t cmpensate fr the thrust frm the prpeller. The carbn flange is bred larger than the shaft diameter allwing it t flat arund the shaft and thus cmpensate fr mst misalignment and vibratin prblems. The stainless steel cllar is sealed t the shaft by tw -rings that are recessed int the bre f the cllar. These -rings rtate with the shaft and stainless steel rtr and d nt experience wear during peratin. Bellw Cmpressin Shaft Diameter: 3/4" t 1-3/8" (20mm t 35mm) = 3/4" (20mm) f cmpressin
Shaft Diameter: 1-1/2" t 3-3/4" (38mm t 95mm) = 1" (25mm) f cmpressin Installatin Instructins In all cases, the bat must be ut f the water t perfrm this installatin. 1. Unblt the shaft cupling frm the transmissin cupling. 2. Remve the shaft cupling frm the shaft. Cupling styles will vary by manufacturer. Sme cuplings use set screws t keep the cupling in place, while thers use a rll pin and thers use a nut (always use the apprpriate tls and prcedures fr yur particular applicatin). 3. Remve the ld stuffing bx and packing material. There are three types f packing glands that can be fund n mst bats: "Classic", "Blt On" and "Threaded". 4. Clean the entire expsed prtin f the shaft with very fine sand paper (#400 r #600 grit) in rder t remve any debris r rugh edges. Pay particular attentin t the keyway lcated at the frward end f the shaft, where the stainless steel rtr will pass. The shaft and keyway must NOT have any sharp edges that culd damage the -rings upn installatin. 5. Slide the pen end f the bellw and its hse clamps dwn the shaft and nt the bare stern tube and make sure the bellw has a prper fit ver the shaft lg. Once in place the bellw shuld verlap the stern tube by the same amunt as the bellw cuff s the hse clamps will prperly tighten the bellw t the shaft lg. WARNING: D nt slide the bellw cuff t far dwn and ver the stern tube. If the bellw is slid t far nt the stern tube the frward edge f the stern tube culd damage the inner ribs f the bellw and imprperly limit the bellw s travel. Tighten the hse clamps t secure the bellw t the stern tube and fit the black clamp prtectr t the tail f the hse clamps. 6. Make sure the carbn flange is in place n the frward end f the bellw and that the tw hse clamps prperly secure it. Als cnfirm that the carbn is free f any defects r imperfectins n its plished face. 7. Remve the stainless steel rtr frm the prtective puch. Verify that there are tw (2) -rings placed int the -ring grves inside the bre f the rtr. Cnfirm that the mating face f the rtr is free f any defects r imperfectins. Take 2 (tw) set screws frm the plastic bag, apply a drp f thread-lck (blue tube) t the thread f each set screw, and thread them. WARNING: Tw mre set screws will need be installed at step 14. Thread ne screw int each hle, stpping just shrt f the screw prtruding int the inside bre f the rtr. 8. Lubricate the shaft and -rings f the rtr, and slide the stainless steel rtr dwn the shaft. Use a petrleum free liquid (e.g., a dish sap / water slutin wrks well) as the lubricant. CAUTION: DO NOT USE OIL, GREASE OR SILICONE AS THE LUBRICANT. 9. Re-attach the shaft cupling t the shaft and make sure that all the safety devices prvided and recmmended by the cupling manufacturer are in place. 10. Re-attach the shaft cupling t the transmissin making sure that it is installed t the manufacturer specificatins and tlerances. Make sure all the safety devices prvided and recmmended by the cupling manufacturer are in place. 11. Nw that the shaft is in place, verify that the carbn is centered n the shaft (nte the carbn ring is bred at a larger diameter than the shaft), verify that the bellw cuff is prperly placed n the stern tube and verify that the shaft is near center in the shaft lg. Adjust s the PSS runs true with the shaft. Tighten all the hse clamps arund the stern tube and the carbn.
12. Slide the stainless steel rtr dwn the shaft until it just TOUCHES the carbn. Mark this psitin n the shaft as the "neutral" psitin with a marker r a piece f tape n the shaft just in frnt f the rtr. 13. Sliding the stainless steel rtr aft, cmpress the bellw by the amunt indicated n the bellw cmpressin chart, using the "neutral" mark as a reference pint. While keeping the bellw in the "cmpressed" psitin, tighten the tw (2) set screws against the shaft with the prvided allen wrench (Use apprximately 6 ft punds f trque fr shafts 3/4" t 1-3/8" and 8 ft punds f trque fr shafts 1-1/2" t 3-3/4". If yu need t insert the lng arm f the allen wrench int the hle, a vice-grip, fr example, may be fitted n the shrt arm t help prvide the required trque. 14. Remve frm the plastic bag tw (2) additinal set screws, apply a drp f thread-lck (blue tube) t the thread f each set screw, and thread ne int each hle. This will act as a lcking device fr the first set screws. D nt re-use cupped pint set screws. 15. Plumbing the system: Nte: Sailbats r displacement pwerbats with a pwering speed belw 12 knts can use either methd A r B. Hwever, displacement bats with a bearing in the shaft lg must plumb water t the seal. Lw speed bats: (Under 12 knts f bat speed under pwer and n bearing in the shaft lg). Using a 3/8" (8 r 9mm) I.D. "underwater rated" hse (nt prvided with the PSS), cnnect the hse t the hse barb fitting installed n the carbn and secure the hse with tw (2) hse clamps. Run the hse t a pint in the bat at least tw (2) feet abve the waterline, making sure that the hse des nt apply any lad n the carbn part f the seal. Keep the hse as clse as pssible t the centerline f the vessel s the tp f the vent hse is never belw the waterline, even if the bat heels. Secure the hse in place with the necessary fittings that insure it will nt pull free and drp. This hse is nw a venting hse that will help ensure that n air is trapped in the seal. WARNING: D nt run a lp at the tp end f the vent hse as it culd start a siphn actin in sme extreme cnditins. Als, make sure the vent hse is prperly secured frm falling belw the waterline. If the vent hse were t fall dwn belw the waterline, water wuld cme in the bat. Als, d nt plug r blck the end f the vent hse, as this wuld prevent the line frm venting. High-speed bats: (Over 12 knts f bat speed under pwer). Nte: Bats that can exceed 12 knts n a single engine must run a crssver line between seals t ensure bth seals maintain water flw, while running n nly ne engine. Fr high-speed vessels it is required that a water supply be plumbed t the PSS fr the purpse f cling and lubricating the seal faces (i.e., at ver apprximately 12 knts f speed a vacuum is created in the stern tube and water is drawn away frm the PSS resulting in a lss f cling water that may cause the carbn t ver heat). There are multiple surces f water fr the supply. The fllwing are a few nn-exhaustive examples. These are examples nly and they may r may nt apply t yur particular bat.
Maximum water pressure shuld nt exceed 10 PSI. T-ff the engine raw water-cling line. (Nte:T-kits are available separately frm PYI Inc. fr internal hse 3/4", 1", 1-1/4", 1-1/2") Thread a barb fitting int the drain plug f the heat exchanger if applicable. Thread barb fitting int the drain plug f the exhaust manifld if the manifld is raw water-cled. Add a small scp under water fr keel-cled bats r T-ff anther water pick up. (Nte: A valve must be installed t regulate the water flw as t high water flw may ver pressurize the PSS seal). Use an apprpriate "underwater rated" hse frm the fittings n the bat and the fitting n the PSS and secure them with tw (2) hse clamps at each end. NOTICE: All plumbing must fllw the standards and practices f prper bat plumbing. Fr example, if the pick-up n the engine is lcated under the waterline, an anti-siphn fitting must be installed, in additin t ther standards and practices. Testing: When launching the bat, inspect the PSS and make sure the PSS is prperly in place. Water shuld nt be entering the bat frm the PSS seal area. Run the engine in gear as in a nrmal peratin. It is nrmal at this time t ntice a very fine spray r mist cming frm the seal and sme carbn dust, as the PSS requires a break in perid (see belw). The PSS shuld nt be leaking at rest and shuld never spray mre than just a fine spray r mist.