7364M Main Propeller Installation Manual 2019 09-11-040022

Installation Manual
MPP – Marine Propulsion Propeller
Caterpillar: Confidential Green

INSTALLATION MANUAL
MPP HDX
MPP620 1 Receipt and Storage
Installation Manual 2 Main Unit
Order No 7364M 3 Hydraulic System

Yard Detroit Brasil
NB No. C416
Technical support and spare parts: 4 Remote Control System
Contact your local CAT dealer.
5 Technical Data
6 Accessories
7 Alarm System
8 Appendix – Drawings
9 Appendix – Oil Requirements
10 Appendix – Pre-commissioning
Report
Document Version: 1 Date: September 11, 2019

INSTALLATION MANUAL
MPP HDX
TABLE OF CONTENTS
1. RECEIPT AND STORAGE
1.1. INTRODUCTION
1.2. SAFETY
1.3. GENERAL HAZARD INFORMATION
1.4. PRESSURIZED AIR AND WATER
1.5. FLUID PENETRATION
1.6. CONTAINING FLUID SPILLAGE
1.7. LINES, TUBES AND HOSES
1.8. ASBESTOS INFORMATION
1.9. DISPOSE OF WASTE PROPERLY
1.10. BURN PREVENTION
1.11. OILS
1.12. BATTERIES
1.13. FIRE PREVENTION AND EXPLOSION PREVENTION
1.14. FIRE EXTINGUISHER
1.15. LINES, TUBES, AND HOSES
1.16. CRUSHING PREVENTION AND CUTTING PREVENTION
1.17. MOUNTING AND DISMOUNTING
1.18. BEFORE STARTING THE PROPULSION EQUIPMENT
1.19. STARTING THE PROPULSION EQUIPMENT
1.20. STOPPING THE PROPULSION EQUIPMENT
1.21. ELECTRICAL SYSTEM
1.22. GROUNDING PRACTICES
1.23. PRESERVATION BY THE VENDOR
1.24. CONSIGNEE'S/SHIPYARD'S QUALITY PROTECTION
1.25. CORROSION PROTECTION
1.26. PROPELLER VS HULL – NOBLE POTENTIAL AND CORROSION
1.26.1. SHAFT GROUNDING TO PROTECT AGAINST STRAY CURRENT CORROSION
1.27. MAINTENANCE OF PROPELLER SYSTEMS TAKEN OUT OF OPERATION
1.28. LIST OF INSTALLATION RESPONSIBILITIES
1.29. NAMES AND LABELS IN DRAWINGS
1.30. RULES FOR THE CONSIGNEE/SHIPYARD
1.31. SEALING COMPOUND
1.32. PREPARATIONS FOR TECHNICAL TEST RUN
1.33. PRE-COMMISSIONING ACTIVITIES - YARD
1.33.1. BEFORE THE VESSEL IS LAUNCHED
1.33.2. ANY TIME BEFORE THE FIRST SERVICE ENGINEER VISIT
1.34. PRE-COMMISSIONING ACTIVITIES TO BE PERFORMED UNDER THE SUPERVISION
OF A CATERPILLAR SERVICE ENGINEER
1.34.1. BEFORE SYSTEM STARTUP
1.34.2. AT QUAY
1.34.3. AT SEA TRIAL
1.35. LAY-UP REQUIREMENTS
2. MAIN UNIT
2.1. GENERAL
2.2. MPP PROPULSION SYSTEM OVERVIEW
2.3. TYPE OF DELIVERY
2.4. DISMOUNTING
2.5. GENERAL TORQUE DATA
2.6. LIFTING THE PROPELLER AND SHAFT
2.6.1. PREPARATIONS
2.6.2. LIFTING PROCEDURE
2.7. PROPELLER BLADES AND SHAFTS
2.7.1. LIFTING A BLADE
2.7.2. INSTALLING THE BLADES

INSTALLATION MANUAL
MPP HDX
2.7.3. DISMOUNTING A PROPELLER BLADE IN A NOZZLE

2.7.4. MOUNTING A PROPELLER BLADE IN A NOZZLE
2.7.5. CHECKING A USED BOLT
2.7.6. TIGHTENING BLADE AND HUB BOLTS
2.7.7. NET CUTTERS (IF INCLUDED)
2.7.8. LEAK TESTING
2.7.9. PRESSURE TESTING
2.7.10. INSTALLING THE PROPELLER SHAFT
2.7.11. GUARDS AROUND THE PROPELLER SHAFT
2.7.12. FILLING THE HUB WITH OIL
2.7.13. LOCKING BOLTS AND PLUGS BEFORE LAUNCHING
2.7.14. VERIFY CORRECT MOUNTING OF THE BLADES
2.7.15. MOUNTING A FLANGE JOINT
2.7.16. OIL MOUNTED COUPLING - OMC
2.7.17. SCOPE OF SUPPLY
MOUNTING THE OMC COUPLING
2.7.18. DISMOUNTING INSTRUCTIONS
2.8. OIL PIPES
2.8.1. GENERAL
2.8.2. OIL CHANNELS
2.8.3. INSTALLING MALE COUPLINGS INTO THE PIPE ASSEMBLY
2.8.4. INSTALLING THE GEAR SHAFT PIPES
2.8.5. MOUNTING THE PROPELLER SHAFT
2.9. OD BOX
2.9.1. PIPE CONNECTIONS
2.9.2. INSTALLATION BY THE YARD
2.9.3. BEFORE INITIAL STARTUP
3. HYDRAULIC SYSTEM
3.1. INTRODUCTION
3.1.1. HYDRAULIC POWER UNIT (HPU) OVERVIEW
3.2. INSTALLATION
3.2.1. PLACING THE HYDRAULIC AND HEADER TANKS
3.2.2. PIPE WORK
3.2.3. FLUSHING THE OIL PIPES
3.2.4. LENGTH OF PIPING
3.2.5. ELBOWS AND BENDS
3.2.6. INSTALLATION AND SETTING TO WORK
3.2.7. ADJUSTMENT OF WORKING PRESSURE
3.2.8. OIL DRAINAGE OF THE HUB
3.3. SYSTEM CLEANLINESS
4. REMOTE CONTROL SYSTEM
4.1. GENERAL
5. TECHNICAL DATA
5.1. OVERVIEW
6. ACCESSORIES
6.1. STERN TUBE ASSEMBLY
6.2. SHAFT SEAL (MAPROM)
6.3. SHAFT BRAKE SYSTEM (DELLNER SKD 65)
6.4. NOZZLE (DMC)
6.5. GEARBOX (REINTJES)
6.6. SHAFT EARTHING DEVICE
6.7. NET CUTTER
7. ALARM SYSTEM
8. APPENDIX - DRAWINGS

INSTALLATION MANUAL
MPP HDX
8.1. MECHANICS
8.2. HYDRAULICS
8.3. REMOTE CONTROL SYSTEM
8.4. MECHANICAL DRAWINGS
9. APPENDIX – MPP OIL REQUIREMENTS
9.1. GENERAL INFORMATION
9.2. OIL REQUIREMENTS, MINERAL OIL
10. APPENDIX – PRE-COMMISSIONING REPORT
10.1. PRE-COMMISSIONING CHECK LIST

INSTALLATION MANUAL
MPP HDX
1. RECEIPT AND STORAGE

1.1. INTRODUCTION
This description includes the Caterpillar regulations for products produced/supplied by Caterpillar. The
object of the storage regulations is to prevent quality deterioration during transport, storage and
installation.
The contents of this manual are not fully order-specific, which means that minor deviations may exist
as to text and images.
Caterpillar endeavors to ensure that all information in this document is correct and fairly stated, but
does not accept liability for any errors or omissions.
The insertion of drawings and accessory manuals into this main document means that the pagination
in the footer may be broken.
1.2. SAFETY
The equipment to which this manual applies must only be used for the purpose for which it was
designed. Improper use or maintenance may cause damage to the equipment and/or injury to
personnel. The user must be familiar with the contents of the appropriate manual before attempting to
operate or work on the equipment.
The user is responsible for ensuring that proper actions, in accordance with the relevant statutory,
legal, and industry requirements, are taken to protect against risks to personal health and safety in
relation to the work described in this manual. Neither this manual, nor its use, in any way absolves the
users from their responsibility to ensure that such proper actions and precautions are taken.
Caterpillar disclaims any responsibility for damages or injury caused by improper installation,
use or maintenance of the equipment.
WARNING: Do not operate or work on this equipment unless you have

read and understand the instructions and warnings in the Operation and
Maintenance Manual(s). Failure to follow the instructions or heed the
warnings could result in serious injury or death.

INSTALLATION MANUAL
MPP HDX
1.3. GENERAL HAZARD INFORMATION

Attach a “Do Not Operate” warning tag to the controls before the propulsion system is serviced or
repaired. These warning tags (Special Instruction, SEHS7332) are available from your Cat dealer.
Attach the warning tags to the propulsion equipment and to each operator control station. When
appropriate, disconnect the starting controls.
Figure 1. Cat warning tag.

Do not allow unauthorized personnel on or around the propulsion equipment, when the equipment is
being serviced.
Cautiously remove the following parts:
• Filler caps
• Grease fittings (if applicable)
• Pressure taps
• Breathers
• Drain plugs
To help prevent spraying or splashing of pressurized fluids, hold a rag over the part that is being
removed.
Use caution when cover plates are removed. Gradually loosen, but do not remove the last two bolts or
nuts that are at opposite ends of the cover plate or the device. Before removing the last two bolts or
nuts, pry the cover loose to relieve any spring pressure or other pressure.
Figure 2. Personal Protective Equipment (PPE).

• Wear a hard hat, protective glasses, and other protective equipment, as required.
• When work is performed around propulsion equipment that is operating, wear protective devices
for ears to help prevent damage to hearing.
• Do not wear loose clothing or jewelry that can snag on controls or on other parts of the propulsion
equipment.
• Ensure that all protective guards and all covers are secured in place on the propulsion equipment.
• Never put maintenance fluids into glass containers. Glass containers can break.
• Use all cleaning solutions with care.
• Report all necessary repairs.

INSTALLATION MANUAL
MPP HDX
Unless other instructions are provided, perform the maintenance under the following conditions:
• The engine is stopped. Ensure that the engine cannot be started.
• The protective locks or the controls are in the applied position.
• Disconnect the batteries (if applicable) and power supply, when maintenance is performed or
when the electrical system is serviced. Disconnect the battery ground leads (if applicable). Tape
the leads to help prevent sparks.
• Do not attempt any repairs that are not understood. Use the proper tools. Replace any equipment
that is damaged or repair the equipment.
• Power supplies switch off and locked.
1.4. PRESSURIZED AIR AND WATER

Pressurized air and/or water can cause debris and/or hot water to be blown out which could result in
personal injury.
The maximum air pressure for cleaning purposes must be reduced to 205 kPa (30 psi) when the air
nozzle is deadheaded and used with effective chip guarding (if applicable) and personal protective
equipment. The maximum water pressure for cleaning purposes must be below 275 kPa (40 psi).
When pressurized air and/or pressurized water is used for cleaning, wear protective clothing,
protective shoes, and eye protection. Eye protection includes goggles or a protective face shield.
Always wear eye protection for cleaning the hydraulic system.
Avoid direct spraying of water on electrical connectors, connections, and components. When using air
for cleaning, allow the machine to cool to reduce the possibility of fine debris igniting when redeposited
on hot surfaces.
1.5. FLUID PENETRATION

Always use a board or cardboard when you check for a leak. Leaking fluid that is under pressure can
penetrate body tissue. Fluid penetration can cause serious injury and possible death. A pin hole leak
can cause severe injury. If fluid is injected into your skin, you must get treatment immediately. Seek
treatment from a doctor that is familiar with this type of injury.
1.6. CONTAINING FLUID SPILLAGE

Care must be taken to ensure that fluids are contained during performance of inspection,
maintenance, testing, adjusting, and repair of the product. Be prepared to collect the fluid with suitable
containers before opening any compartment or disassembling any component containing fluids. Refer
to Special Publication, NENG2500, “Cat Dealer Service Tool Catalog” or refer to Special Publication,
PECJ0003, “Cat Shop Supplies and Tools Catalog” for tools and supplies suitable to collect and
contain fluids on Cat products. Dispose of all fluids according to local regulations and mandates.
1.7. LINES, TUBES AND HOSES

Do not bend or strike high-pressure lines. Do not install lines, tubes, or hoses that are damaged.
Repair or replace any hydraulic lines, tubes, or hoses that are loose or damaged. Leaks can cause
fires. Inspect all lines, tubes, and hoses carefully. Do not use bare hands to check for leaks. Always
use a board or cardboard for checking engine components for leaks. Tighten all connections to the
recommended torque.
Check for the following conditions:
• End fittings that are damaged or leaking.
• Outer covering that is chafed or cut.
• Wire that is exposed in reinforced hose.
• Outer covering that is ballooning locally.
• Flexible part of the hose that is kinked or crushed.
• Armoring that is embedded in the outer covering.

INSTALLATION MANUAL
MPP HDX
Ensure that all the clamps, the guards, and the heat shields are installed correctly. Correct installation
of these components will help to prevent these effects: vibration, rubbing against other parts and
excessive heat during operation.
1.8. ASBESTOS INFORMATION

Cat equipment and replacement parts that are shipped from Caterpillar are asbestos free. Caterpillar
recommends the use of only genuine Cat replacement parts. Use the following guidelines when you
handle any replacement parts that contain asbestos or when you handle asbestos debris. Use caution.
Avoid inhaling dust that might be generated when you handle components that contain asbestos
fibers. Inhaling this dust can be hazardous to your health. The components that may contain asbestos
fibers are brake pads, brake bands, lining material, clutch plates, and some gaskets. The asbestos
that is used in these components is bound in a resin or sealed in some way. Normal handling is not
hazardous unless airborne dust that contains asbestos is generated. If dust that may contain asbestos
is present, there are several guidelines that should be followed:
• Never use compressed air for cleaning
• Avoid brushing materials that contain asbestos
• Avoid grinding materials that contain asbestos
• Use a wet method to clean up asbestos materials
• A vacuum cleaner that is equipped with a high efficiency particulate air filter (HEPA) can also be
used
• Use exhaust ventilation on permanent machining jobs
• Wear an approved respirator if there is no other way to control the dust
• Comply with applicable rules and regulations for the work place. In the United States, use
Occupational Safety and Health Administration (OSHA) requirements. These OSHA requirements
can be found in “29 CFR 1910.1001”
• Obey environmental regulations for the disposal of asbestos
• Stay away from areas that might have asbestos particles in the air
1.9. DISPOSE OF WASTE PROPERLY
Figure 3. Proper waste disposal.

Improperly disposing of waste can threaten the environment. Potentially harmful fluids should be
disposed of according to local regulations. Always use leakproof containers when you drain fluids. Do
not pour waste onto the ground, down a drain, or into any source of water.
For additional information, please refer to the Caterpillar EHS Assurance Manual.

INSTALLATION MANUAL
MPP HDX
1.10. BURN PREVENTION

Do not touch any part of an operating propulsion equipment. Allow the equipment to cool before any
maintenance is performed on the engine. Relieve all pressure in the air system, in the hydraulic
system, in the lubrication system, in the fuel system, or in the cooling system before any lines, fittings
or related items are disconnected.
1.11. OILS
Hot oil and hot lubricating components can cause personal injury. Do not allow hot oil to contact the
skin. Also, do not allow hot components to contact the skin.
1.12. BATTERIES
Electrolyte is an acid. Electrolyte can cause personal injury. Do not allow electrolyte to contact the skin
or the eyes. Always wear protective glasses for servicing batteries. Wash hands after touching the
batteries and connectors. Use of gloves is recommended.
1.13. FIRE PREVENTION AND EXPLOSION PREVENTION

Use of personal protection equipment (PPE) may be needed. All fuels, most lubricants, and some
coolant mixtures are flammable. Always perform a Walk-Around Inspection, which may help you
identify a fire hazard. Do not operate a product when a fire hazard exists. Contact your Cat dealer for
service. Flammable fluids that are leaking or spilled onto hot surfaces or onto electrical components
can cause a fire. Fire may cause personal injury and property damage.
If the application involves the presence of combustible gases, consult your Cat dealer for additional
information about suitable protection devices.
Remove all flammable materials such as fuel, oil, and debris from the propulsion equipment. Do not
allow any flammable materials to accumulate on the propulsion equipment.
All fluids that are captured in fluid spill containment basins should be cleaned up immediately. Failure
to clean up spilled fluids can cause a fire. Fire may cause personal injury and property damage.
Store fuels and lubricants in properly marked containers away from unauthorized persons. Store oily
rags and any flammable materials in protective containers. Do not smoke in areas that are used for
storing flammable materials.
Do not expose the propulsion equipment to any flame.
Do not weld on lines or tanks that contain flammable fluids. Do not use flame to cut lines or tanks that
contain flammable fluid. Clean any such lines or tanks thoroughly with a nonflammable solvent prior to
welding or flame cutting.
Wiring must be kept in good condition. Properly route and attach all electrical wires. Check all
electrical wires daily. Repair any wires that are loose or frayed before you operate the propulsion
equipment. Clean all electrical connections and tighten all electrical connections.
Eliminate all wiring that is unattached or unnecessary. Do not use any wires or cables that are smaller
than the recommended gauge. Do not bypass any fuses and/or circuit breakers.
Arcing or sparking could cause a fire. Secure connections, recommended wiring, and properly
maintained battery cables will help to prevent arcing or sparking.
Inspect all lines and hoses for wear or for deterioration. Properly route all hoses. The lines and hoses
must have adequate support and secure clamps. Tighten all connections to the recommended torque.
Leaks can cause fires. Properly install all oil filters. The filter housings must be tightened to the proper
torque.
Gases from a battery can explode. Keep any open flames or sparks away from the top of a battery. Do
not smoke in battery charging areas.
Never check the battery charge by placing a metal object across the terminal posts. Use a voltmeter or
a hydrometer.

INSTALLATION MANUAL
MPP HDX
Improper jumper cable connections can cause an explosion that can result in injury. Refer to your
battery manual for specific instructions.
Do not charge a frozen battery. Charging a frozen battery may result in an explosion.
The batteries must be kept clean. The covers (if equipped) must be kept on the cells. Use the
recommended cables, connections, and battery box covers when the propulsion equipment or battery
is operated.
1.14. FIRE EXTINGUISHER

Make sure that a fire extinguisher is available. Be familiar with the operation of the fire extinguisher.
Inspect the fire extinguisher and service the fire extinguisher regularly. Obey the recommendations on
the instruction plate.
1.15. LINES, TUBES, AND HOSES

Do not bend high-pressure lines. Do not strike high pressure lines. Do not install any lines that are
bent or damaged.
Repair any lines that are loose or damaged. Leaks can cause fires. Consult your Cat dealer for repair
or for replacement parts.
Check lines, tubes, and hoses carefully. Do not use your bare hand to check for leaks. Use a board or
cardboard to check for leaks. Tighten all connections to the recommended torque.
Replace the parts if any of the following conditions are present:
• End fittings are damaged or leaking.
• Outer coverings are chafed or cut.
• Wires are exposed.
• Outer coverings are ballooning.
• Flexible parts of the hoses are kinked.
• Outer covers have embedded armoring.
• End fittings are displaced.
Make sure that all clamps, guards, and heat shields are installed correctly to prevent vibration, rubbing
against other parts, and excessive heat.
1.16. CRUSHING PREVENTION AND CUTTING PREVENTION

Support the component properly when work beneath the component is performed. Unless other
maintenance instructions are provided, never attempt adjustments while the propulsion equipment is
running.
Stay clear of all rotating parts and of all moving parts. Leave the guards in place until maintenance is
performed. After the maintenance is performed, reinstall the guards.
Keep objects away from moving fan blades. The fan blades will throw objects or cut objects.
When objects are struck, wear protective glasses in order to avoid injury to the eyes.
Chips or other debris may fly off objects when objects are struck. Before objects are struck, ensure
that no one will be injured by flying debris.
1.17. MOUNTING AND DISMOUNTING

Inspect the steps, the handholds, and the work area before mounting the propulsion equipment. Keep
these items clean and keep these items in good repair.
Mount the propulsion equipment and dismount the propulsion equipment only at locations that have
steps and/or handholds. Do not climb on the propulsion equipment, and do not jump off the propulsion
equipment.
Face the propulsion equipment in order to mount the propulsion equipment or dismount the propulsion
equipment. Maintain a three-point contact with the steps and handholds. Use two feet and one hand or
use one foot and two hands. Do not use any controls as handholds.

INSTALLATION MANUAL
MPP HDX
Do not stand on components which cannot support your weight. Use an adequate ladder or use a
work platform. Secure the climbing equipment so that the equipment will not move.
Do not carry tools or supplies when you mount the propulsion equipment or when you dismount the
propulsion equipment. Use a hand line to raise and lower tools or supplies.
1.18. BEFORE STARTING THE PROPULSION EQUIPMENT

Inspect the propulsion equipment for potential hazards.
Do not start the engine and the propulsion equipment or move any of the controls if there is a “DO
NOT OPERATE” warning tag or similar warning tag attached to the start switch or to the controls.
Before starting the propulsion equipment, ensure that no one is on, underneath, or close to the
propulsion equipment. Ensure that the area is free of personnel.
All protective guards and all protective covers must be installed if the propulsion equipment must be
started in order to perform service procedures. To help prevent an accident that is caused by parts in
rotation, work around the parts carefully.
Do not bypass the automatic shutoff circuits. Do not disable the automatic shutoff circuits. The circuits
are provided in order to help prevent personal injury. The circuits are also provided in order to help
prevent propulsion equipment damage.
1.19. STARTING THE PROPULSION EQUIPMENT

If a warning tag is attached to the engine start switch or to the controls, DO NOT start the engine and
propulsion equipment, or move the controls. Consult with the person that attached the warning tag
before the engine is started.
All protective guards and all protective covers must be installed if the engine must be started in order
to perform service procedures. To help prevent an accident that is caused by parts in rotation, work
around the parts carefully.
Start the propulsion equipment from the operator compartment or from the engine control room panel.
Always start the propulsion equipment according to the procedure that is described in this Operation
and Maintenance Manual, (Operation Section).
Knowing the correct procedure will help to prevent major damage to the propulsion equipment
components. Knowing the procedure will also help to prevent personal injury. Ensure that the electrical
motor heaters (if equipped) are working properly.
Engine exhaust contains products of combustion that can be harmful to your health. Always start the
engine and operate the engine in a ventilated area. If the engine is started in an enclosed area, vent
the engine exhaust to the outside.
1.20. STOPPING THE PROPULSION EQUIPMENT

To avoid accelerated wear of propulsion equipment components, stop the propulsion equipment
according to this Operation and Maintenance Manual, (Operation Section).
Use the Emergency Stop Button (if equipped) ONLY in an emergency situation. DO NOT use the
Emergency Stop Button for normal engine stopping.
After an emergency stop, DO NOT start the engine until the problem that caused the emergency stop
has been corrected.
1.21. ELECTRICAL SYSTEM

Never disconnect any charging unit circuit or battery circuit cable from the battery when the charging
unit is operating. A spark can cause the combustible gases that are produced by some batteries to
ignite.
Check the electrical wires daily for wires that are loose or frayed. Tighten all loose electrical wires
before the propulsion equipment is operated. Repair all frayed electrical wires before the propulsion
equipment is started.

INSTALLATION MANUAL
MPP HDX
1.22. GROUNDING PRACTICES

Proper grounding is necessary for optimum propulsion equipment performance and reliability.
Improper grounding will result in uncontrolled electrical circuit paths and in unreliable electrical circuit
paths.
Uncontrolled electrical circuit paths can result in damage to bearings, to bearing journal surfaces, shaft
surfaces and to aluminum components.
Uncontrolled electrical circuit paths can also cause electrical activity that may degrade the propulsion
equipment electronics and communications.
Ensure that all grounds are secure and free of corrosion.
If rubber couplings connect the steel piping of the cooling system and the radiator, the piping and the
radiator can be electrically isolated. Ensure that the piping and the radiator are continuously grounded.
Use ground straps that bypass the rubber couplings.
1.23. PRESERVATION BY THE VENDOR

Products supplied by Caterpillar have been preserved against corrosion during transport and
associated temporary storage. The packaging is designed to provide protection during transport.
1.24. CONSIGNEE'S/SHIPYARD'S QUALITY PROTECTION

The consignee/shipyard must take the necessary steps to ensure that the quality of the Caterpillar
products does not deteriorate during storage and installation. This requires careful handling and
protection against corrosion, sand and dirt. The consignee/shipyard is responsible for ensuring that the
storage regulations are followed. Caterpillar does not accept responsibility for corrosion damage
and/or other quality deterioration after the propeller unit and equipment have been delivered.

INSTALLATION MANUAL
MPP HDX
1.25. CORROSION PROTECTION

The hub cylinder is drained of oil after tests in the factory. The remaining oil film serves as corrosion-
protection.
The static part of the propeller (the hub, excluding the piston and hydraulic cylinder, including the
hollow bore in the propeller shaft + the outside of the pipe assembly, see the image below) is not
protected against corrosion in that way.
If the propeller is stored for a short time, this is not a problem. But when storing for a long time (>12
months on shore or if you suspect that it will be kept for >2 months and launched with the propeller
system not fully mounted so that it can’t be filled with oil), the shipyard/owner must perform the actions
described in this section.
If the vessel is already launched when it becomes evident that it will be kept for > 2 months before
system startup, corrosion protection can be filled through the D-connection, and the air will then be
evacuated from the L-connection.
Before launching, fill the static part of the hub with a minor volume of corrosion protection, VpCl -322
Oil Concentrate or equivalent. For VpCl -322 Oil Concentrate, 1 liter per 1.1 m3 applies. If an
equivalent product is used, fill the volume recommended by the supplier.
Blades Time for first corrosion protection refill Subsequent corrosion protection refills
After >12 months on land Every 24 months
Blades mounted
After >2 months in water Every 12 months
Blades not After >6 months on land Every 6 months
mounted*
*Wooden covers are mounted in the hub.
Figure 4. Wooden covers.

INSTALLATION MANUAL
MPP HDX
The volume of the static part is specified in the hub assembly drawing:
Figure 5. The arrow points at the volume of the static part of the hub. (Example drawing)
Fill the corrosion protection in the plug hole in the static part of the hub:
Figure 6. Plug hole.

If the vessel has already been launched, the corrosion protection can be filled using pressurized air in
the D or L connection.
If the propeller is delivered with the blades mounted on the hub, the space is tight and will contain the
corrosion protection. Otherwise, the corrosion protection can leak out to some extent but it will still
provide a certain protection.
The hollow bore of the propeller shaft is also protected due to the fact that the corrosion protection
evaporates within the space.

INSTALLATION MANUAL
MPP HDX
1.26. PROPELLER VS HULL – NOBLE POTENTIAL AND CORROSION

Due to the noble potential of certain metals in a propeller system (copper and nickel), the hull in
practice works as a sacrificial anode.
Order of corrosion (platinum is least corrosive in this table):
Metal Voltage
Platinum +0.47
Titanium +0.37
Silver +0.30
Copper (propeller) +0.04
Nickel (propeller) -0.03
Lead -0.27
Iron (hull) -0.40
Aluminium (propeller) -0.53
Zinc -0.76
This means that the hull must be properly protected using paint and anodes. Also, a shaft grounding
device is required.

INSTALLATION MANUAL
MPP HDX
1.26.1. SHAFT GROUNDING TO PROTECT AGAINST STRAY CURRENT CORROSION

Stray current occurs if the propeller shaft has a higher potential than the hull. This can happen
because of isolating oil film in the propeller shaft bearing (#1 below). Voltage can also be induced
because of badly grounded equipment (#2), for example shafts in engines or generators, i.e.
resistance to earth occurs. The potential is then transmitted to the propeller shaft.
In this way, if the propeller shaft obtains higher potential than the hull the current goes out from the
propeller via the saltwater to the hull (#3), and the propeller will be damaged (#4).
To protect the propeller system against such damage, Caterpillar strongly recommends that a
propeller shaft grounding system (5) is installed.
However, if welding is done on a vessel using land-based current and a ground fault occurs, a shaft
grounding system will not prevent against stray current corrosion. The same applies if the vessel is
connected to a source of power supply on shore that is badly grounded, or if a neighboring vessel is
badly grounded.

INSTALLATION MANUAL
MPP HDX
1.27. MAINTENANCE OF PROPELLER SYSTEMS TAKEN OUT OF

OPERATION
Caterpillar assumes that the temperature in the engine room is constant, in order to avoid
condensation when the vessel is out of operation for more than a month. The electronics for the
propeller should not be turned off, as they generate some heat which can also prevent condensation.
The equipment should be tested every month according to the procedure below, so that the oil in the
hub will circulate:
• Rotate the propeller using the main engine.
• Run the pumps for approximately 1 hour.
• Operate the pitch.
• Test run all the control panels (operate fully ahead and astern, about ten times).
Finally, normal maintenance is recommended, whether the vessel is in operation or not.

INSTALLATION MANUAL
MPP HDX
1.28. LIST OF INSTALLATION RESPONSIBILITIES

PART 1
It is the responsibility of the project manager at the shipyard to ensure that this form is filled out. The
completed form must be handed over to Caterpillar’s service engineer before the vessel is launched.
INSTALLATION PERFORMED RESPONSIBILITY CATERPILLAR
PROCEDURE SERVICE
ENGINEER
ATTENDING
Mount the stern tube Yard No
and bearings according
Company:
to the SHAFTING
ARRANGEMENT and
STERN TUBE drawings …………………………..
+ the corresponding
manuals in the
Accessories chapter. Name:
…………………………..
Signature:
…………………………..
Mount the stern tube Yard No
seals according to the
Company:
seal manufacturer’s
manual.
…………………………..
Fill out the protocols
from the manufacturer
and present them to
Caterpillar’s service Name:
engineer.
. …………………………..
Signature:
…………………………..
Insert the propeller shaft Yard No
according to chapter 2
Company:
in the Installation
Manual and the
SHAFTING …………………………..
ARRANGEMENT
drawing.
Name:
…………………………..
Signature:
…………………………..

INSTALLATION MANUAL
MPP HDX

PROCEDURE SERVICE
ENGINEER
ATTENDING
Connect the hydraulic Yard If requested
coupling according to
Company:
chapter 2 in the
Installation Manual and
the SHAFTING …………………………..
ARRANGEMENT
drawing.
Name:
…………………………..
Signature:
…………………………..
Mount the intermediate Yard No
shafts according to
Company:
chapter 2 in the
the SHAFTING …………………………..
ARRANGEMENT
drawing.
Name:
…………………………..
Signature:
…………………………..
Mount the propeller Yard If requested
blades according to
Company:
chapter 2 in the
Installation Manual.
…………………………..
Name:
…………………………..
Signature:
…………………………..

INSTALLATION MANUAL
MPP HDX

PROCEDURE SERVICE
ENGINEER
ATTENDING
If the propeller blades Yard If requested
are mounted at the
Company:
shipyard, perform a
leakage test according
to chapter 2 in the …………………………..
Installation Manual.
Name:
…………………………..
Signature:
…………………………..
Align the shafts Yard No
according to the gap
Company:
and sag calculations.
…………………………..
Name:
…………………………..
Signature:
…………………………..
Permanently mount the Caterpillar Yes
OD box according to
Company:
chapter 2 in the
the OD BOX drawing. …………………………..
Measure run-out and
note it in the service
report. Name:
…………………………..
Signature:
…………………………..

INSTALLATION MANUAL
MPP HDX

PROCEDURE SERVICE
ENGINEER
ATTENDING
Mount the shaft line Yard No
accessories according
Company:
to each supplier’s
manual and the
SHAFTING …………………………..
ARRANGEMENT
drawing.
Name:
…………………………..
Signature:
…………………………..
Install the hydraulic Yard No
power unit according to
Company:
chapter 3 in the
the HYDRAULIC …………………………..
ARRANGEMENT and
HYDRAULIC SYSTEM
drawings. Name:
…………………………..
Signature:
…………………………..
Complete all piping Yard No
according to the
Company:
HYDRAULIC
ARRANGEMENT and
LUBRICATION …………………………..
SYSTEM drawings.
Name:
…………………………..
Signature:
…………………………..

INSTALLATION MANUAL
MPP HDX

PROCEDURE SERVICE
ENGINEER
ATTENDING
Flush clean the piping Yard No
drawn by the shipyard
Company:
according to chapter 3
in the Installation
Manual. …………………………..
A copy of the oil
analysis must be
handed over to the Name:
Caterpillar service
engineer. …………………………..
Signature:
…………………………..
Fill the system with oil Yard No
according to the oil
Company:
recommendations
appendix in the
Installation Manual. …………………………..
Name:
…………………………..
Signature:
…………………………..

PROCEDURE SERVICE
ENGINEER
ATTENDING
Install the control boxes: Yard No
Company:
a) Central unit
(CENTRAL UNIT …………………………..
drawing)
b) Local unit (LOCAL Name:
CONTROL CABINET
drawing)
…………………………..
Signature:
…………………………..

INSTALLATION MANUAL
MPP HDX

PROCEDURE SERVICE
ENGINEER
ATTENDING
Install all cabling so that Yard No
all power supply to
Company:
Caterpillar System is
ready to power “on”
according to the …………………………..
LAYOUT AND CABLE
PLAN drawing.
Name:
…………………………..
Signature:
…………………………..
Install the frames for the Yard No
control panels according
Company:
to the CONTROL
PANEL drawing.
…………………………..
Name:
…………………………..
Signature:
…………………………..
Fill out the pre- Yard No
commissioning check list
Company:
at the end of this manual
and send it to the
Caterpillar contract …………………………..
engineer.
Name:
…………………………..
Signature:
…………………………..

INSTALLATION MANUAL
MPP HDX
Project Manager
Name:
……………………………………………………………………………………………………………
Signature:
……………………………………………………………………………………………………………
Date:
……………………………………………………………………………………………………………

INSTALLATION MANUAL
MPP HDX
PART 2
It is the responsibility of the project manager at the shipyard to ensure that this form is filled out. When
the sea trial is completed, the list is handed over to Caterpillar’s service engineer.
PROCEDURE SERVICE
ENGINEER
ATTENDING
Install the control panels Caterpillar Yes
according to the
Company:
CONTROL PANEL
drawing.
…………………………..
Name:
…………………………..
Signature:
…………………………..
Start-up Caterpillar Yes
Company:
…………………………..
Name:
…………………………..
Signature:
…………………………..
Sea trial Yard/Caterpillar Yes
Company:
…………………………..
Name:
…………………………..
Signature:
…………………………..

INSTALLATION MANUAL
MPP HDX
Project Manager
Name:
……………………………………………………………………………………………………………
Signature:
……………………………………………………………………………………………………………
Date:
……………………………………………………………………………………………………………

INSTALLATION MANUAL
MPP HDX
1.29. NAMES AND LABELS IN DRAWINGS

If you fail to locate a specific drawing mentioned in this manual, it might have a new name. If so,
please refer to this list:
OLD DRAWING NAME NEW DRAWING NAME

OD BOX DISTRIBUTOR GP–SHAFT
PROPELLER HUB ASSEMBLY HUB GP–PROPELLER
OD BOX ASSEMBLY DISTRIBUTOR GP–SHAFT
FEEDBACK ASSEMBLY GEAR GP–FEEDBACK
1.30. RULES FOR THE CONSIGNEE/SHIPYARD

RECEIPT OF GOODS
The consignee/shipyard must inspect the Caterpillar products immediately on arrival.
This involves the inspection of:
• Product units with reference to transport documents.
• Any damage to packaging or product units.
• Any damage to preservative coating.
• Any rust/corrosion damage.
If no special time limit has been agreed in the contract terms, observed shortages and damage are to
be reported to Caterpillar within 10 days of receipt of the goods.
STORAGE
The Caterpillar products must be stored under protective conditions.
The equipment should be stored indoors under dry conditions. When storing outdoors, use applicable
waterproof covering, protecting against direct sunlight too, and keep the humidity at the lowest
possible level.
All hydraulic equipment must be stored indoors under dry conditions. This applies to the remote
control system as well.
TRANSPORT IN THE SHIPYARD

All units must be transported with care.
INSTALLATION
All products must be protected during the installation period. The following rules apply:
• The equipment must be carefully protected against sand, dust, and damaging moisture.
• Control panels and indicators shall be protected against impact after installation in the vessel.
1.31. SEALING COMPOUND

All sealing compound mentioned in this manual is yard supply.
1.32. PREPARATIONS FOR TECHNICAL TEST RUN

Only service personnel from Caterpillar or personnel authorized by Caterpillar must start up the plant
and test it in the ship, unless other arrangement has been agreed upon.
In connection to this, Caterpillar service personnel must check that the storage regulations have been
followed by the shipbuilder.

INSTALLATION MANUAL
MPP HDX
1.33. PRE-COMMISSIONING ACTIVITIES - YARD

Fill out the Pre-commissioning Report attached at the end of this manual and send it to Caterpillar
before Caterpillar service is sent to the yard for supervision of the remaining commissioning activities.
Study the items below extra carefully.
1.33.1. BEFORE THE VESSEL IS LAUNCHED

Minimum requirements:
• All plugs in the hub must be mounted and locked before launching.
• The propeller shaft must be in a position where the propeller shaft seal is tight.
• Lock the shaft so that it doesn’t move axially.
1.33.2. ANY TIME BEFORE THE FIRST SERVICE ENGINEER VISIT

• Ensure that the hydraulic tank is clean and then fill it. Record the oil type and quantity.
• Mount and align the shaft line and coupling. The aligning requirements are stated in the
instructions from the coupling manufacturer.
• Connect the gravity tank before filling. Flushing must be carried out according to Caterpillar
instructions. All piping must meet the cleanliness requirements before filling.
• Install the auxiliary systems to a state where the hydraulic and remote control systems can be
tested.

INSTALLATION MANUAL
MPP HDX
1.34. PRE-COMMISSIONING ACTIVITIES TO BE PERFORMED UNDER

THE SUPERVISION OF A CATERPILLAR SERVICE ENGINEER
1.34.1. BEFORE SYSTEM STARTUP

• Check the installation work (mechanical, hydraulic and electric) done by the shipyard.
The physical and practical alignment of the high speed shaft is the exclusive responsibility of the
shipyard. If the shipyard needs support from Caterpillar in this respect, this has to be clearly
agreed upon in advance.
• Start up the hydraulic pumps and adjust the pressure settings.
• Install and adjust the pitch feedback system.
• Test the local operation of the pitch maneuvering.
• Start up the remote control system and perform the initial adjustments.
• Check the pressure and temperature sensors and interlock functions.
1.34.2. AT QUAY
• Check for any external leakage.
• Check pressures and temperatures.
• Adjust the zero pitch position.
• Adjust full pitch and engine load.
• Test the functions of the remote control system and make the necessary adjustments.
• Fill out the Caterpillar sea trial report.
1.34.3. AT SEA TRIAL

Testing and acceptance of tunnel thruster installation can be completed at quay. The activities listed
below can be performed under the supervision of a Caterpillar service engineer at sea trial in
connection with the main propulsion system trials. The pitch setting function and control must be
adjusted and fully tested before the sea trials can be carried out.
• Observe oil levels, pressures, filters, temperatures, and leakage; make the necessary
adjustments.
• Test the functions of the remote control system and make the necessary adjustments.
• Perform the maneuvering test according to classification society.
• Perform the maneuvering test for completion of the Caterpillar sea trial report.
• Accept the installation.

INSTALLATION MANUAL
MPP HDX
1.35. LAY-UP REQUIREMENTS

If the propeller has been in use and maintained according to the instructions in the MPP Operation
and Maintenance manual, it is already filled with oil and no other preservation procedures are
required. However, depending on the climate, if the propulsion system includes a cooler, it must be
prepared to avoid freezing according to the instructions from the cooler manufacturer.
During the lay-up period, ensure that the relative humidity in the engine room is at a normal level for
the vessel. (Unprotected steel does not rust below 70% relative humidity). If the blades are removed,
this restriction also applies to the propeller itself.
When the propeller is started up again after the lay-up period, the ambient temperature must be
normal and specifically above 0˚ C. The blade seals must be checked and replaced if needed, based
on the age of the seals and the experience from the operation history of the vessel.
Start up the hydraulic system and exercise it by going from full pitch ahead to full pitch astern 10
times. Check the moisture of the oil to ensure that it is at a normal level for the vessel.

INSTALLATION MANUAL
MPP HDX
2. MAIN UNIT
2.1. GENERAL
This manual describes how to install a Caterpillar MPP propeller with an HDX type Oil Distribution Box
(OD box).
WARNING: To carry out the installation and mounting instructions in this

manual, you must have the required qualifications. In case of uncertainty,
please contact your local Cat dealer.

INSTALLATION MANUAL
MPP HDX
2.2. MPP PROPULSION SYSTEM OVERVIEW
Figure 7. MPP propulsion system.
Ref. Name Description

1 Main unit
2 Stern tube Sleeve containing shaft bearings and lubrication fluid.
3 Propeller shaft
4 Intermediate shaft
5 Shaft generator/PTO Eliminates the need for independently driven generators, utilizing main engine
rotation.
6 Hydraulic power pack The hydraulic tank with pumps generating the system pressure, as well as filters
and sensors for alarm functionality and other functions.
7 High speed shaft Connection between the main engine and the gearbox in applications where the
gearbox is not installed immediately behind the main engine. Rotates at the same
rpm as the main engine. The gearbox then gears down to a lower rpm for the
propeller shaft.
8 Main engine
9 Shaft seal Dynamic (rotating) seal that seals between the hub flange cover and the stern
tube. There is water on the outside and lubrication oil, or water, on the inside.
10 Forward seal Dynamic seal that seals between the engine room and the stern tube. There is air
on the outside and lubrication oil or water inside. If the propeller shaft is water-
lubricated, the system can include a forward seal only.
11 Oil Mounted Coupling (OMC) A hydraulic-mounted flange coupling with tapered inside diameter which is
mounted on the tapered shaft end. Attached to a flange on the intermediate shaft
or the gear box.
12 Sleeve coupling A cylindrical sleeve coupling. Connects two straight shaft ends. No bolt
connection required.
13 Gear box

INSTALLATION MANUAL
MPP HDX
14 HDX gear mounted OD box Distributes the hydraulic oil, enabling rotating shaft pitch setting. It also works as a
feedback unit. The actual pitch position is sent to the remote control system, but is
also visually displayed on a mechanical scale.

INSTALLATION MANUAL
MPP HDX
2.3. TYPE OF DELIVERY

The propeller hub is delivered assembled and mounted on the tail shaft. The piston rod, piston rod
head, blocks and blade mounts are in place. If it is possible, with respect to transport, the blades are
already mounted on the propeller hub. If the blades are not mounted on the hub before installation,
please refer to section 2.7.2.
2.4. DISMOUNTING
To dismount the unit, you generally perform the mounting steps in reverse order. However, if there are
necessary deviations from the direct reverse procedure, a note indicates the exception.See example
below.
Example Dismounting Note:
Dismounting Note: Instead of performing step x above, connect the pump to

the threaded hole (#1 in Figure y) and pump up the oil pressure, then pull off
the crown wheel.

INSTALLATION MANUAL
MPP HDX
2.5. GENERAL TORQUE DATA

The following table contains the general torque data that should be used for mounting. However,
please note that if torque data in a drawing diverges from the data below, torque data in the drawing
takes precedence. This table applies to standard supplied screws only.
Thread Property Class

8.8 A4-80
M6 9.8 9.3
M8 24 22
M10 47 44
M12 81 76
M16 197 187
M20 385 364
M24 665 629
M30 1310 1240
M36 2280 2160
M39 2930 2770
M42 3640 -
M48 5450 -
Table 1. General torque data.
Nominal mounting torque expressed in Nm for steel screws for rough, greased steel screw joint
reinforcement. 1Nm = 0.737 foot pounds.

INSTALLATION MANUAL
MPP HDX
2.6. LIFTING THE PROPELLER AND SHAFT
2.6.1. PREPARATIONS
Thoroughly clean the tail shaft and stern tube, and carry out a complete inspection for any damage
that might have occurred during transportation.
Use soft slings to protect the bearing surfaces. Ensure that the lifting equipment is approved for lifting
the stated weight.
Lubricate and protect all parts using grease or thick oil in preparation for installation.
Note: Care must be taken not to damage the surfaces during lifting
operations.
Mount the outer (aft) stern tube seal on the shaft in accordance with the instructions from the
manufacturer.
When freely lifting the propeller with the propeller shaft, position the lifting points symmetrically around
the center of gravity, and along the shaft. See the image below as to the proportions:
Figure 8. Lifting points

For exact dimensions, please refer to the CENTER OF GRAVITY ASSEMBLY, PROPELLER SHAFT
AND HUB drawing.
If the seal is not split, the astern seal box is mounted on the shaft. If possible, lift in the propeller with
the blades mounted on the hub.

INSTALLATION MANUAL
MPP HDX
2.6.2. LIFTING PROCEDURE

When mounting the propeller and the shaft in the hull, perform the following schematic steps:
Figure 9. Lifting at mounting.
Note: Weld two lifting eyes to the hull if this hasn’t already been done.
Also, some yards may provide a cart to roll in the shaft.
Furthermore, if the stern tube stretches a long distance into the hull, you
have to lift and push simultaneously from inside the hull. This not to scratch
the stern tube bearings.

INSTALLATION MANUAL
MPP HDX
In analogy with mounting, dismount in accordance with the schematic figure below:
Figure 10. Lifting at dismounting.

INSTALLATION MANUAL
MPP HDX
2.7. PROPELLER BLADES AND SHAFTS
2.7.1. LIFTING A BLADE

Preparations
Arrange a flat bar iron (yard supply) around the blade and lift it with a pulley block:
Figure 11. Lifting arrangement.

INSTALLATION MANUAL
MPP HDX
2.7.2. INSTALLING THE BLADES
General
The following procedure applies if the blades have been delivered unmounted.
Perform the following steps for each blade:

1. Make sure that the identifiers punched on the blade and on the hub match. Correct component
location is essential.
Installation Identifier Description

Single Screw 1-4 Blade 1-4
Twin Screw P1-P4 Port propeller, blade 1-4
Twin Screw SB5-SB8 Starboard propeller, blade 5-8
Figure 12. Identifier locations.
Ref. Description
1 Punched blade identifier.
2 Punched hub identifier.

INSTALLATION MANUAL
MPP HDX
2. Check that the dowel (#1 in Figure 13) is inserted into the unthreaded hole in the blade mount:
Figure 13.Installing the blades.
Ref. Description
1 Dowel
2 Blade seal
3 Bolts with O-rings
3. Make sure that the grove is clean and dry.

4. Apply a light and even coat of lubricant on the blade seal using multi-silicone grease OKS 11-10,
or equivalent. Make sure there is no excess grease in the groove UNDER the seal.
Figure 14. Blade seal in grove.
Note! If the blade seal is lubricated incorrectly, that is too much grease
and/or unevenly applied, the seal may be damaged thus requiring
mandatory replacement.
5. Attach the blade seal (#2 in Figure 13) in the groove in the hub body.
6. Fasten the blade to the blade mount. Ensure that each screw has an O-ring correctly positioned in
its groove (#3 in Figure 13).

INSTALLATION MANUAL
MPP HDX
7. Tighten all bolts in accordance with the main drawing. Use rotation measurement described in
section 2.7.6.
8. Weld-lock the screws on the side of the head. The locks must be placed along the periphery of the
screws (not towards the bottom of the screw head):
Note: When welding, be very careful not to damage the O-ring under each
bolt head.
Figure 15. Weld-lock the bolts.
Note: After the final tightening of the blade bolts, the hub must be tested,
using low pressure air for example, to ensure that there is no leakage at
blade bolts, blade seals and oil plugs. Please refer to section 2.7.8 below.

INSTALLATION MANUAL
MPP HDX
2.7.3. DISMOUNTING A PROPELLER BLADE IN A NOZZLE
WARNING: The main engine must be shut down and all pumps must be
shut off before dismounting the blade. Place warning signs wherever
necessary to ensure that the engine and pumps are not started before
finishing the blade dismounting/mounting.
Perform the following steps:

1. Weld four lifting eyes to the hull.
2. Adjust the blades to zero pitch position.
3. Remove the weld locking on the blade bolts by grinding carefully.
4. Drain the hub.
5. Using the Caterpillar-supplied power socket tool, loosen the blade bolts until the tightening torque
is just gone but keep the bolts fixed.
6. Turn the blade to 6 o’clock position.
7. Insert a wedge under the blade and secure the blade so that it does not turn over without the
support of the hoisting belts.
8. Remove the blade bolts using the power socket tool.
9. Apply four hoisting belts around the blade flange and fasten them to the welded lifting eyes in the
hull:
Figure 16. Apply four hoisting belts around the blade flange.
10. Lower the blade and take it out of the nozzle.

11. Ensure that the hole in the hub is covered.
Repeat the steps above for the remaining blades.

INSTALLATION MANUAL
MPP HDX
2.7.4. MOUNTING A PROPELLER BLADE IN A NOZZLE
WARNING: The main engine must be shut down and all pumps must be
shut off before mounting the blade. Place warning signs wherever
necessary to ensure that the engine and pumps are not started before
finishing the blade dismounting/mounting.

1. Weld four lifting eyes to the hull.
2. Adjust the blades to zero pitch position.
3. Turn the hub so that the opening for the blade flange points at 6 o’clock:
Figure 17. The opening for the blade points at 6 o’clock.
4. Apply four hoisting belts around the blade flange and fasten them to the welded lifting eyes in the
hull.
5. From aft, position the blade just under the opening:

INSTALLATION MANUAL
MPP HDX
Figure 18. From aft, position the hoisted blade under the hub opening.
6. Insert a wedge under the blade and secure the blade so that it does not turn over when the
hoisting belts are removed in the next step.
7. Remove the hoisting belts.
8. Fasten the blade bolts in accordance with chapter 2.7.2.
Repeat the steps above for the remaining blades.

INSTALLATION MANUAL
MPP HDX
2.7.5. CHECKING A USED BOLT
Check the following:

1. Ensure that there are no visible damages.
2. Ensure that the threads are undamaged and that the bolt threads easily into its hole. Minor
protruding burrs may be adjusted in a professional way using a deburring tool.
3. Examine the shaded area in Figure 19 for cracks using dye penetrant inspection. If any cracks are
found, the bolt must be discarded.
Figure 19. Checking a used bolt for cracks.
2.7.6. TIGHTENING BLADE AND HUB BOLTS
General
In the factory, OKS530 dry lubricant and OKS 250 all-round paste are applied on bolts. This should be
done at the yard as well. However, to obtain a correct tightening that is not affected by such factors the
method below should be used:
Figure 20. Tightening steps.

The image above serves as an example! Please refer to the corresponding drawing for exact figures.
Perform the following steps

1. Pre-tighten one of the outer bolts (#1 in Figure 21) just so that there is contact between the bolts
and the protective guard/blade flange.
2. To achieve a more well-defined starting angle, tighten the first bolt to 20% of the full tightening
torque (please refer to the PROPELLER HUB drawing). This way, grease, burr, hair and other
disturbing factors are eliminated or minimized.

INSTALLATION MANUAL
MPP HDX
3. Mark the position of the screw head at a suitable point (#1 in Figure 20) on the outer diameter of
the screw.
4. Mark the tightening chord distance on the protective guard in accordance with the PROPELLER
HUB ASSEMBLY drawing (#2 in Figure 20) +- 5%.
5. Tighten the bolt to the prescribed torque in the PROPELLER HUB ASSEMBLY drawing.
6. Perform the steps above for the other outer bolts (#1 in Figure 21) on each side of the blade. After
that, check that the two contact surfaces are perfectly tight using a 0.05 mm feeler gauge in the
remaining two center holes (#2 in Figure 21).
Figure 21. Outer bolts (1) and holes for measuring tightness (2).
7. Perform steps 1 - 5 for the remaining two center bolts in the empty holes.

INSTALLATION MANUAL
MPP HDX
2.7.7. NET CUTTERS (IF INCLUDED)
A Caterpillar Net Cutter Delivery Comprises:

• Knives
• Bracket for welding
• Screws
• Locking washers
To mount the net cutters on the rope guard, perform the following steps:
1. Mark the position of the net cutter hole in relation to the protection cover:
Figure 22. Net cutter position
2. With the rope guard separated from the hub, cut out the hole (the hole is best made a bit extra
long).
3. Ensure that the distance between the knife and the protection cover (1 in Figure 23) is correct in
accordance with the CUTTER GROUP drawing:

INSTALLATION MANUAL
MPP HDX
Figure 23. Net cutter parts.
Ref. Description
1 Knife position
2 Sides for welding
3 Bracket
4 Knife
4. On three sides (2, dotted line in Figure 23), weld the bracket (3 in Figure 23) in the hole.
5. Using the screws and washers, adjust and fasten the knife (4 in Figure 23) to the bracket.

INSTALLATION MANUAL
MPP HDX
2.7.8. LEAK TESTING

GENERAL
If the hub, propeller shaft, and propeller blades are delivered assembled, a leakage test has been
performed at the factory.
However, if the hub, propeller shaft, and propeller blades are not delivered assembled, but assembled
at the shipyard, the equipment must be tested for leakage after mounting. To do this, perform the
steps in this instruction.
Cover
Mount the cover at the end of the shaft, using the O-ring and screws:
Figure 24. Cover.
Hub
Pressurize to 1 bar. Use the air pressure tool assembly when you test the hub for leakage (1):
Figure 25. Air-pressure tool assembly for testing the hub.
When testing the hub for leakage, the air leakage tool must be mounted and all connections must be
plugged. (The tool is delivered with quick-couplings that are automatically leak-proof when the male
end is not connected.) Use leak detection spray when testing and ensure that the manometer still
shows 1 bar after 30 minutes of pressurizing.

INSTALLATION MANUAL
MPP HDX
WARNING: Do NOT over-pressurize the system. Objects can eject at high

velocity, thus becoming lethal projectiles.
Potential leakage points for the hub:
Figure 26. Potential leakage points.
Ref. Description QTY

1 Blade seal 4
2 O-ring for blade bolt 6x4
3 Plug (in the hub) 1
4 Seal between the hub and protective guard 1
5 Plug (in the cylinder) 1
6 Plug (in the flange) 1
7 Cylinder flange boltss n
8 Cylinder flange seal 1
Note: Please note that the images above are for illustration purposes only.
The blade bolts are weld-locked in the image to the left. Normally, this step
occurs later in the procedure.
If the hub and the propeller shaft are delivered separated, test points #3 (plug in the hub) and #4 (seal
between the hub and protective guard ) are added.
Also, beware of the fact the hole for the tool and the cover at the end of the shaft are potential leakage
points. Therefore, carefully check the plug and seals for this hole to ensure that they are not damaged.

INSTALLATION MANUAL
MPP HDX
2.7.9. PRESSURE TESTING
General
The pressure test equipment is delivered together with the OD box equipment. The pressure is
generated using the Caterpillar pumps and tanks included in the system.
Test Equipment
• 1 blind plug
• 1 adapter with blind plug and manometer
Figure 27. Pressure test equipment.
Ref. Description
1 Blind plug
2 Adapter with blind plug and manometer
Test Procedure

1. Run the unit to the mechanical stop ahead and astern a couple of times so that the system is
emptied of air.
2. The control valve on the pump is set at the normal pressure, 50 bar. The overflow valve is set at
60 bar. To be able to increase the pressure to 90 bar in the hub, both the valve on the pump and
the overflow valve must be adjusted.
Increase the pressure by 10 bar at a time alternately on the pump and the overflow valve. Start
with the pump.
3. Set the pitch to 80% astern.
4. Open the B connection (#3 in the figure below) between the valve manifold (#2) and the OD box
(#4).
5. Mount the specially designed blind plug with the manometer in the hose end that goes to the OD
box.
6. Also plug the B channel that goes out from the valve manifold (#5).
7. Ensure that the classification society testifies that a pressure of 90 is reached. Use this instruction
to explain to the class what is happening:
There is full pressure in the manometer until the piston reaches the surface of the hub. After that, the
leakage in the OD box makes the pressure peter out in the B channel, which can be observed on the

INSTALLATION MANUAL
MPP HDX
temporarily mounted manometer. However, the standard manometer of the system shows full
pressure.

INSTALLATION MANUAL
MPP HDX
After the Pressure Test

1. Ensure that the pump is NOT running.
2. Dismount the plugs and the manometer and then remount the coupling.
3. Start the pump and adjust the valves back to the standard levels: 50 bar for the control valve
and 60 bar for the overflow valve.

INSTALLATION MANUAL
MPP HDX
2.7.10. INSTALLING THE PROPELLER SHAFT

1. Thoroughly clean the tail shaft and stern tube, carry out a complete inspection for damage that
might have occurred during transportation.
2. Lubricate and protect all parts using thick oil in preparation for installation.
Note: Be careful not to damage the surfaces during lifting operations.
3. Mount the outer stern tube seal on the shaft in accordance with the manufacturer’s instructions.
4. Insert the tail shaft into the stern tube.
5. Mount a fixture unit (a clamp, for example, fixed to the hull) between the forward shaft seal and the
shaft coupling to prevent it from sliding aft:
Figure 28. Area for mounting the fixture unit.

Also, mark a reference point on the shaft and the hull to ensure that the shaft does not move during
launching.
6. Mount the blades in accordance with section 2.7.2.
7. Fit the shaft coupling in accordance with the shaft coupling instructions below.
8. Fit the inner stern tube seal in accordance with the manufacturer’s instructions.
9. Fit and secure the protective casing on the outer stern tube seal.
Figure 29. Schematic view of protective casing (grey area).

INSTALLATION MANUAL
MPP HDX
10. Check that the shaft has not moved during launching. Use the reference point you marked in step
number 5.

INSTALLATION MANUAL
MPP HDX
2.7.11. GUARDS AROUND THE PROPELLER SHAFT
Important Safety Notice

Serious injury can be prevented with proper guards around the propeller shaft. Caterpillar strongly
recommends installing fixed guards to these areas. It is the responsibility of the OEM or installer of this
propulsion system to ensure that guards are installed. All guards must meet all applicable
governmental, environmental, and safety guidelines, practices, regulations, and mandates.
WARNING: To avoid personal injury due to entanglement with moving

components, keep all guards and all covers in place. Install the propeller
shaft guard when the system is not in use.

INSTALLATION MANUAL
MPP HDX
2.7.12. FILLING THE HUB WITH OIL
Note: The vessel can be launched before filling the hub with oil.
For information on filling hydraulic and lubrication oil, please refer to the Operation and Maintenance
Manual, chapter 4 - Hydraulics. The oil can be filled when the coupling, intermediate shaft (if fitted),
gear and OD box have been mounted.
2.7.13. LOCKING BOLTS AND PLUGS BEFORE LAUNCHING

Check that all blade bolts, shaft flange bolts and plugs are locked. Weld the locking pins onto the bolt
heads or plugs using stainless steel electrodes (supplied by Caterpillar). For more information, please
refer to section 2.7.2.
Note: Make sure that stainless steel electrodes are used.

INSTALLATION MANUAL
MPP HDX
2.7.14. VERIFY CORRECT MOUNTING OF THE BLADES

Establish the direction of the propeller shaft. When the shaft and propeller are rotated, the leading
edge goes first:
Figure 30. Leading edge and trailing edge.

Ensure that the direction of rotation of the outgoing shaft of the gear and the propeller are the same.
If the blade is correctly mounted, the pitch through the water during one revolution by the root section
of the blade is similar in length to that for the tip section:
Figure 31. Correct blade mounting.

If the blade is incorrectly mounted, the pitch through the water during one revolution by the root
section of the blade is considerably less than that of the tip section:

INSTALLATION MANUAL
MPP HDX
Figure 32. Incorrect blade mounting.

INSTALLATION MANUAL
MPP HDX
2.7.15. MOUNTING A FLANGE JOINT

FITTED BOLTS
Fitted fasteners are used for mounting the flange joints.This type of fastener facilitates easier bolt
removal without damaging bolt holes, while complying with class rules for this type of joint.
Figure 33. Flange joint with bolts.
Perform the following steps to mount a flange joint:

1. Align the two flanges.
2. Using a rubber mallet, gently tap the bolts through the flanges.
Please note that the hole tolerance is ISO H7. However, if it is not possible to drive the screws
even though the flanges align, the holes can be reamed to tolerance ISO H9.
3. Tighten the nuts in accordance with the torque specified in the SHAFT ASSEMBLY drawing.
Note: For compliance with ABS Class rules, the nuts must be locked using high
strength chemical threadlocker suitable for large threads, Loctite 275 or
equivalent.
The ABS surveyor must be informed prior to locking the nuts in question. The
surveyor must witness that the procedure stipulated by the threadlocking
adhesive manufacturer is strictly followed.

INSTALLATION MANUAL
MPP HDX
2.7.16. OIL MOUNTED COUPLING - OMC
General
The Caterpillar OMC Coupling (Oil-Mounted Coupling) is a hydraulic-mounted Flange Coupling with
tapered inside diameter which is mounted on the tapered shaft end.
When mounting the Caterpillar OMC Coupling, it is slid onto the tapered shaft. Ordinary mineral oil is
then injected between the coupling and the shaft. A built-in hydraulic jack drives the coupling up the
taper on the shaft. When the coupling has reached its final position, an interference fit is created. For a
detailed instruction, please refer to section 0.
At the shop test, the coupling is mounted on the actual shaft. When the correct drive up is reached, a
line is marked 20 mm from aft end of the coupling. For information, a calculated drive up length is
stamped on the aft end of coupling.
2.7.17. SCOPE OF SUPPLY
Figure 34. Caterpillar OMC Coupling.
Figure 35. Coupling tool kit.
Ref. Description
1 Two injectors
2 One hydraulic pump

INSTALLATION MANUAL
MPP HDX
3 Spanner for shaft nut

INSTALLATION MANUAL
MPP HDX
MOUNTING THE OMC COUPLING

1. Thoroughly clean the seating of the shaft and flange coupling and the surface of the coupling that
will be in contact with the shaft nut. Lubricate the seatings with mounting oil. Position the flange
coupling on the tapered end of the shaft.
2. Coat the outer sealing surface on the shaft nut with mineral oil. Take care not to damage the
sealing rings. Screw the shaft nut up close to the surface of the shaft, using the special spanner
provided (item 3 in Figure 35).
3. Accurately measure the diameter at point B, see the shaft assembly drawing, using a micrometer.
Check that the tapered surfaces are in contact. Then measure the distance between the end of
the shaft and the forward surface of the flange.
4. Connect the hydraulic pump to the shaft nut and pump oil until air-free oil flows through the vent
hole. Stop pumping and close the hole.
Figure 36. Vent hole.
5. Connect the injectors as displayed in Figure 35 and start injecting oil until it emerges all around
the periphery at the aft end of the coupling.
6. After injecting oil with both injectors for a couple of minutes, start the hydraulic pump, thus driving
up the coupling on the shaft. The injection of oil between the coupling and the shaft should be
continued during the entire drive-up process in order to maintain the oil film.
The drive-up is completed when the aft end of the coupling is 20 mm from the marking line on the
shaft (please refer to the PROPELLER SHAFT ASSEMBLY drawing). At this position, the diameter of
the coupling in point “B” has increased by the dimension stated on the assembly drawing. The drive-up
length stated on the drawing is the calculated drive-up length
Note: If the injector pressure is lost during the operation, the drive-up must
be stopped until pressure is regained.

INSTALLATION MANUAL
MPP HDX
7. Open the pressure reduction valve (see Figure 37) on the injectors to release the oil between the
coupling and the shaft. This takes about 5 minutes. The pressure in the hydraulic hand pump must
remain unchanged for about 20 minutes to prevent slide back and possible damage to the
coupling.
Figure 37. Pressure reduction valve.
8. Disconnect the injector and the pump, but let the oil remain in the hydraulic unit. Seal the oil ducts
with the appropriate plugs.
2.7.18. DISMOUNTING INSTRUCTIONS
Note: Be extremely careful not to damage the tapered surfaces during

the removal operation described below.

1. Connect the same equipment as was used during the mounting. Set the oil pressure in the
hydraulic hand pump to about 15 N/mm². Do not forget to release air through the ventilation hole.
2. Inject oil with both injectors, until it is pressed out between the coupling and the shaft. Pump up
the pressure and continue pumping for four minutes.
3. Open the return valve on the hydraulic hand pump to allow the flange coupling to slide off the
shaft. Continue injecting oil during the whole operation. Should the coupling fail to move, change
the injector oil to a thicker type.

INSTALLATION MANUAL
MPP HDX
2.8. OIL PIPES
2.8.1. GENERAL
The oil pipes are mounted in the following parts:

• Propeller shaft (#1 in Figure 38)
• Intermediate shaft (#2)
• Gear (#3)
• OD box (#4)
Figure 38. Oil pipes mounted in shafts and OD box.

INSTALLATION MANUAL
MPP HDX
2.8.2. OIL CHANNELS
General
The pipe assembly in the shaft comprises four channels. Channel A (pitch ahead) is the center pipe.
Channel B (pitch astern) runs in the shaft itself. The four peripheral pipes handle lubrication in and out,
L & D.
The outside of the pipe assembly and inside of the propeller shaft is the inlet lubrication flow and
reverse flow line for the lubrication oil displaced during pitch setting.
Oil Channels, Cross-section
Figure 39. Oil channels in the pipe assembly.
Ref. Description
A Pitch ahead
B Pitch astern
L Lubrication in
D Lubrication out
Note: If the pipe in the shaft is disconnected, the square in the piping must
be engaged with the square in the piston rod. See image below.
Figure 40. Pipe assembly.

The square locks the pipe in the piston rod.

INSTALLATION MANUAL
MPP HDX
2.8.3. INSTALLING MALE COUPLINGS INTO THE PIPE ASSEMBLY
General
After contact is made between the coupling male end and the female end of the pipe assembly, the
male end must be tightened as specified in the Pipe Tightening Guide below. The same procedure
applies when connecting two pipe assemblies. Note where threadlocker must and must NOT be used.
Note: Threadlocker must be MEDIUM strength, Loctite 243 or equivalent.
Example Shaft Line

The image below displays an example shaftline consisting of an MPP hub, a propeller shaft including
two intermediate shafts, and an HDX OD-Box.
Figure 41. Example shaft line.
Ref. Note Perf. by

A The propeller shaft pipe is normally delivered mounted and locked. Factory
B Intermediate shaft pipes are connected to the next shaft pipe with a threaded coupling. These Yard
must ALWAYS be secured using threadlocker.
C The extension pipe located furthest astern is connected to the next shaft pipe (if more than Caterpillar Certified
one) with a threaded coupling, which MUST NOT be secured using threadlocker. Service Engineer
The oil distributor pipe is connected to the extension pipe furthest ahead (more than one
extension pipe possible) with a threaded coupling. This connection MUST be secured using
threadlocker.

INSTALLATION MANUAL
MPP HDX
Note: Applying threadlocker in the wrong location, or omitting threadlocker

where required, can make future disassembly work complicated and time
consuming.
Shaft Line, Detail View
Figure 42. Example shaft line, detail view.
Ref. Description
D Distance to tighten (mm)
Pipe Tightening Guide

Shaft Line Thread (pitch) D (mm) Revolutions [n]
HB 50 M20x2.5 15 6
HB 75 M30x2 18.5 ~9
HB 90 M39x4 24.5 ~6
HB 105 M45x4.5 33.5 ~7.5
HB 130 M56x4 37 ~9
HB 160 M56x4 37 ~9
HB 160 M72x4 40 10
Table 2. Pipe tightening guide.

INSTALLATION MANUAL
MPP HDX
2.8.4. INSTALLING THE GEAR SHAFT PIPES

The gear shaft pipes are mounted by Caterpillar before delivery. This section describes how to mount
the pipe assembly after service.
The pipes are mounted in the gear shaft in a row, beginning with the pipe closest to the propeller
shaft. The mounting is to be performed in accordance with the figure below. In order to facilitate future
disassembly, each coupling should be mounted using Loctite 243 (medium strength) or equivalent on
the surfaces marked with an X (see the figure below and Figure 44), except the pipe closest to the
propeller shaft pipe.
The number of extension pipes varies depending on the ship and gear box design. Note that not all
designs require extension pipes.
The OD box shaft (together with the connected chain of extension pipes) must be turned to be
connected to the propeller shaft pipe at the front
Figure 43 Insert pipes in the gear shaft.

INSTALLATION MANUAL
MPP HDX
Figure 44. Apply threadlocker to part of the control edge surface.

For the intermediate pipe and extension pipes 1 and 2 displayed in Figure 43, apply Loctite 243
(medium strength) or equivalent to part of the control edge surface seen in the image above
(approximately 25% of the control edge surface).
2.8.5. MOUNTING THE PROPELLER SHAFT
Perform the following steps to mount the propeller shaft:

1. Insert the propeller shaft into the stern tube and keep a gap to the next portion of the shaft line of
about 100 mm.
Figure 45. Insert the propeller shaft into the stern tube.
2. Insert the shaft pipe into the propeller shaft and gently tighten it without damaging the outer pipes:

INSTALLATION MANUAL
MPP HDX
Figure 46. Tighten the shaft pipe.

3. When the connection is firm, pull the shafts together and connect them.
4. When the shaft line is fully connected, the OD box can be assembled:

INSTALLATION MANUAL
MPP HDX
2.9. OD BOX
2.9.1. PIPE CONNECTIONS

The hydraulic connection is done with hoses directly connected to the piping in accordance with the
hydraulic diagram. For information on hose length, please refer to the PCU MECHANICAL drawing.
Figure 47. Pipe connections for the OD box.

INSTALLATION MANUAL
MPP HDX
2.9.2. INSTALLATION BY THE YARD
General
The following instruction gives information on how to do a temporary mounting of the outer parts of the
OD box so that the yard can prepare all pipe and hose connections before a Caterpillar representative
does a permanent installation and test runs the system.
WARNING: For safety and practical reasons, a platform should be

integrated into the hull from where installation and maintenance work on
the OD box can be performed.
Mount the connection flange (#1 in Figure 48) on the gearbox (#2) and then mount the outer rings
(#3), excluding the feedback unit, on the connection flange
Figure 48. Temporary mounting of the OD box.

For detailed information about installing the OD box, please refer to the PCU MECHANICAL drawing.
2.9.3. BEFORE INITIAL STARTUP

Before initial startup, ensure that the OD box with its hoses and tanks are clean (please refer to the
section on flushing the pipes in the Hydraulics chapter), filled and aired. Also, make sure that the
header tank is always filled.

INSTALLATION MANUAL
MPP HDX
3. HYDRAULIC SYSTEM
3.1. INTRODUCTION
In order to ensure the correct function, maximum efficiency and durability of the propulsion system it is
essential that the following basic principles are observed during the design and installation of the
hydraulic tank and piping system.
The hydraulic system provides servo pressure for changing the pitch and hub lubrication. The pitch
control unit consists of two main parts: the oil distributor and the cylinder.
The oil distributor is mounted on the forward end of the reduction gear box and connected to the
gearbox secondary shaft. The cylinder is an integral part of the propeller hub.
The hydraulic system is pressurized with a header tank, which in turn can be air-pressurized.
Figure 49. Hydraulic system.

INSTALLATION MANUAL
MPP HDX
3.1.1. HYDRAULIC POWER UNIT (HPU) OVERVIEW

For information about HPU layout, please refer to the tank unit drawing.

INSTALLATION MANUAL
MPP HDX
3.2. INSTALLATION
3.2.1. PLACING THE HYDRAULIC AND HEADER TANKS
Figure 50. Header tank placement.
1. The header tank must be placed so that the nominal oil level in the header tank is 4-7 meters
above the nominal oil level in the hydraulic tank (#1 in the above figure). This is to achieve the
drive of the oil circulation.
2. If possible, the nominal oil level in the header tank should be at a height above the shaft center
line (#2) approximately 1.3 x the (H) distance between the shaft center line and the max load
water line. This is to ensure the pressure balance in the hub and to compensate for the difference
in density between water and oil.
3. The nominal oil level in hydraulic tank must be 0.5-6 meters above the shaft center line (#3). This
is to avoid too much pressure on the OD box seals so that they don’t wear in advance.
4. The recommended minimum distance between the bottom of the OD box and the top of the sump
tank (#4) is 0.5 m, however at least 0.25 m.
5. The nominal oil level in the hydraulic tank must be above the shaft center line for the system to be
to self-bleeding.
6. The header and hydraulic tanks must be placed to enable easy access for maintenance and
adjustment. Also, it must not be exposed to open atmosphere where it can be damaged by rain or
dust.

INSTALLATION MANUAL
MPP HDX
3.2.2. PIPE WORK

Flow rates are calculated using the pipe dimensions stated in the Hydraulic system drawing. Any
deviation from these dimensions must be approved by the Caterpillar Technical department.
To avoid air locks in the spillway overflow and L channels that could
jeopardize the function, piping between the header tank and hydraulic tank
must NOT have any horizontal sections.
For detailed information, please refer to the attached hydraulic scheme.

INSTALLATION MANUAL
MPP HDX
3.2.3. FLUSHING THE OIL PIPES

It is the responsibility of the yard to clean the pipes that the yard has installed. Only those pipes must
be flushed. The hydraulic equipment delivered by Caterpillar is cleaned and plugged at the factory and
must not be flushed by the yard.
During the installation, the yard must be able to show proper documentation to prove that the system
is cleaned to 20/18/15, according to ISO 4406 (equivalent to NAS grade 9) and that there are no
leaks.
When flushing the pipes, the yard MUST NOT use the pumps and filters included in the Caterpillar
hydraulic system. No equipment delivered by Caterpillar must be included in the flushing procedure.
3.2.4. LENGTH OF PIPING

The pipe length should be kept as short as possible to avoid friction losses in the system.
3.2.5. ELBOWS AND BENDS

Elbows must be kept to a minimum. Bend radius should be the practical maximum.

INSTALLATION MANUAL
MPP HDX
3.2.6. INSTALLATION AND SETTING TO WORK

1. Check that all protective covers and transportation plugs are removed.
2. Assemble the pipe work between the main unit and the hydraulic system, and ensure maximum
cleanliness of all internal surfaces at all times.
3. Fill the hydraulic system with recommended oil – please see the appendix.
Ensure the pump housing is filled with hydraulic fluid before the pump is
set into operation.
4. Start the pump and then check for the correct rotation. Check the pressure setting, (see technical
specification for standard factory setting).
5. Check the hydraulic tank level and fill to the correct level.
6. Test the sensors.
3.2.7. ADJUSTMENT OF WORKING PRESSURE

If the working pressure deviates from the default pressure (see the technical specification), it should
be adjusted. To do this, turn the pressure regulator screw on the pump. Inwards increases pressure,
outwards decreases pressure.
Figure 51. Pressure regulator screw.
If the working pressure is increased, you have to ensure that the working pressure is 10 bar lower than
the relief valve pressure.

INSTALLATION MANUAL
MPP HDX
3.2.8. OIL DRAINAGE OF THE HUB

The lubrication oil in the hub can be drained using the plugs described below.
Figure 52. Oil plug.
Figure 53. The two oil plugs in the hub.

INSTALLATION MANUAL
MPP HDX
LOCKING THE PLUG

The valve screw should only be lightly tightened, final sealing is achieved using the plug and the
washer. After fitting, the sealing plug is locked using a stainless steel rod, spot welded at each end.
When welding, care should be taken not to damage the rubber seal.
When weld-locking the plugs, ensure that you weld (#1 in ) the pin (#2) to the hub (#3), not to the plug
itself (#4). This to avoid melting the rubber-steel washer (#5):
Figure 54. Weld-locking plugs.
Note: Ensure that the plug, rod and sealing washer are made of stainless
steel.
3.3. SYSTEM CLEANLINESS

The system comprises two filters:
1. Duplex pressure filter mounted between the pump pressure connection and the control valve. The
filter has a differential pressure alarm to indicate that the in-service filter needs to be replaced. A
change-over valve is provided to switch filter units. When offline, the filter cartridge can be
replaced without removing the system pressure and without system interruption.
2. An offline filter (return filter for some installations).
Note: New oils often contain impurities. For this reason, the filter must be
checked and cleaned if necessary at the first convenient opportunity after
an oil change or top-up.
To guarantee reliable function of the system, the cleanliness must be maintained at least according to
ISO 4406, 20/18/15 (equivalent to NAS grade 9).

INSTALLATION MANUAL
MPP HDX
4. REMOTE CONTROL SYSTEM

INSTALLATION MANUAL
MPP HDX
4.1. GENERAL
The system should be installed and wired according to the layout drawing. The wire requirements
should be met or exceeded. External connections to other systems should be isolated on the output
side. For example, the digital outputs have relay contacts in the Caterpillar MPC800 system, the digital
inputs should have potential free connections to other systems.
No grounding or connection to other point of potential is allowed.
The units are not to be installed in heavily vibrating locations, such as directly on an engine. The
central unit must be installed in an air-conditioned room. If it is installed in the engine room,
appropriate ventilation must be provided.
The units withstand temperatures up to 70 degrees Celsius, but high temperatures for prolonged
periods of time will affect the lifetime of the system. It is recommended that the ambient temperature
normally does not exceed 35 degrees Celsius. The panels are mounted in frames. On installation, first
the naked frames should be mounted, and then the panel parts could be fitted into the frames. This
facilitates the panel installation and also makes it possible to protect the panels from dents and
scratches.

INSTALLATION MANUAL
MPP HDX
5. TECHNICAL DATA
5.1. OVERVIEW
MAIN UNIT
Caterpillar Order 7364M
Type MPP620
Propeller Quantity Twin
Hub Type MPP620
Propeller Diameter 2500
Material Bronze
No. of Blades 4
Rotation, seen from aft Outwards turning (over the top)
Classification BV
Ice Class No Ice
Rated Power 1520 kW
Propeller Speed 215 RPM
HYDRAULIC SYSTEM
Pump Type AXIAL PISTON PUMP
Motor Type 3 PH, 4 POLE
System Pressure 50 BAR
REMOTE CONTROL SYSTEM

Type MPC 800
Control Panels
Bridge One Twin main bridge panel
One Twin bridge wing panel
Engine Room -
Supply Voltage 24VDC
Power Consumption Max. 2x300W

INSTALLATION MANUAL
MPP HDX
6. ACCESSORIES
• STERN TUBE (SVENSKA BEARIG)

• FWD AND AFT BEARING (THORDON)
• ROPE GUARD (SVENSKA BEARING)
• BOSSES (SVENSKA BEARIG)

6.4. NOZZLE (DMC)
6.7. NET CUTTER

INSTALLATION MANUAL
MPP HDX
• STERN TUBE (SVENSKA BEARIG)

• FWD AND AFT BEARING (THORDON)
• ROPE GUARD (SVENSKA BEARING)
• BOSSES (SVENSKA BEARIG)

SVENSKA BEARING STERN TUBE
INSTALLATION GUIDELINES
WITH
PART LIST & ASSEMBLY DRAWINGS
SVENSKA BEARING STERN TUBE INSTALLATION GUIDELINES
Rev: A 3-100-2060-000 Page: 2 of 15
Table of Contents
General and Safety ......................................................................................................................................... 3
Intended use ................................................................................................................................................... 3
Information regarding the Installation Guidelines ................................................................................ 3
Special notation used............................................................................................................................. 3
Liability and warranty ........................................................................................................................... 3
Copyright protection ............................................................................................................................. 4
Delivery................................................................................................................................................. 4
Disposal................................................................................................................................................. 4
Safety .................................................................................................................................................... 4
Contents of the Installation Guidelines ................................................................................................. 5
Changes and conversions to the equipment .......................................................................................... 5
Responsibility of the customer .............................................................................................................. 5
Requirements of the personnel .............................................................................................................. 5
Work Safety .......................................................................................................................................... 6
Personal protective gear ........................................................................................................................ 6
Order Specification ........................................................................................................................................ 7
Preparation before the installation of the Stern Tube ..................................................................................... 7
Unpacking ............................................................................................................................................. 7
Visual check .......................................................................................................................................... 8
Disassembly .......................................................................................................................................... 8
Cleaning ................................................................................................................................................ 9
Installation ................................................................................................................................................... 10
Mounting of the Stern Tube ................................................................................................................ 10
Mounting of the Adapter Ring ............................................................................................................ 10
Final alignment of the Stern Tube................................................................................................................ 11
Fixing of the Welding and mounting of the Cover Ring ..................................................................... 11
Pressure test before the epoxy resin filling ......................................................................................... 11
Filling of the epoxy resin ............................................................................................................................. 12
Final assembly ............................................................................................................................................. 13
Bolts at the AFT Flange ...................................................................................................................... 13
Temperature sensor connection box .................................................................................................... 13
Protection of the installed Stern Tube ................................................................................................. 13
Screw tightening torque table ...................................................................................................................... 13
Stern Tube handling for avoiding problems during operation ..................................................................... 14
POLIGONO INDUSTRIAL SETE PIAS

Existing law protects Svenska Bearing's right of possession to this document.
PARCELA 34
The design or the document must not, without permission of the company, be
36634- CAMBADOS
published, copied, reproduced, manufactured or exploited in any other
PONTREVEDRA / SPAIN
unauthorized way
TEL.: +34 986520909
Rev: A 3-100-2060-000 Page: 3 of 15
General and Safety

Explanation of symbols
Important safety-related notes in this Installation Guidelines are identified by symbols.
The notes stated regarding work safety must definitely be adhered to and complied with. Conduct yourself with
particular care in these cases to avoid accidents, personal injury and property damage.
WARNING! Danger of injury or mortal danger!

This symbol identifies notes that, if not complied with, can lead to health impairment,
injuries, permanent bodily damage or to death.
ATTENTION! Danger to material assets!
This symbol identifies notes that, if not complied with, can lead to damage, malfunctions
and/or breakdown of the equipment.
NOTE!
This symbol labels tips and information that must be observed to ensure efficient and
trouble-free handling of the equipment.
Intended use
The Svenska Bearing Stern Tube supplied (also referred to as "Stern Tube" in the following) is to be used
exclusively for the bearing of a rotating ship tail shaft in a tube housing between the AFT boss and the bulkhead.
Information regarding the Installation Guidelines

This Installation Guidelines describes how to handle and install the equipment safely and correctly.
The safety notes and instructions stated, as well as the local accident prevention guidelines applicable for the
area of use and general safety conditions must be observed.
Before starting any work on the equipment, read through the Installation Guidelines completely, in particular the
chapter on Safety and the corresponding safety notes. You must have understood what you have read.
The Installation Guidelines is a component of the equipment. It must be kept accessible at all times in close
proximity to the equipment (e.g. in the machine control room, general control rooms). The Installation
Guidelines must always be passed on to third parties with the equipment.
Special notation used

The numbers in brackets ( ) mark the position numbers of the relevant drawings.
Liability and warranty

All information and notes in this Installation Guidelines were collated while taking into consideration the
applicable regulations, the status of technology and our many years of discoveries and experiences.
The Installation Guidelines must always be kept accessible in direct proximity to the equipment for all persons
who are working on or with the equipment.

Read through this Installation Guidelines carefully before starting any work on or
with the equipment! The manufacturer assumes no liability for damages and
disruptions that arise from non-compliance with the Installation Guidelines.
The texts and illustrations do not necessarily correspond to the scope of delivery. The drawings and graphics do
not correspond to a ratio of 1:1

PARCELA 34
36634- CAMBADOS
PONTREVEDRA / SPAIN
unauthorized way
TEL.: +34 986520909
Rev: A 3-100-2060-000 Page: 4 of 15
Copyright protection
The Installation Guidelines must be treated as confidential. It is determined exclusively for those persons
working on and with the equipment.
All content-related information, texts, drawings, pictures and other representations are protected as defined by
copyright protection law and are subject to other industrial property rights. Any improper utilization is liable to
prosecution.
It is not permitted to pass on the Installation Guidelines to third parties, to make reproductions in whatever type
or form - even extracts - or to recycle and/or communicate the contents without written permission by
SVENSKA BEARING (manufacturer). Violations incur the obligation to pay compensation. All other rights
reserved.
We reserve the right to exercise industrial property rights.
Delivery
Examine the delivery on receipt for transport damage.
Report any damage immediately to the carrier and make a note of it on the delivery note.
Check the scope of delivery immediately for completeness.
Contact the manufacturer as soon as possible if any parts are missing.

Only operate the equipment with parts that belong to the scope of delivery.
Disposal
If no agreement has been made regarding return or disposal, dismantled components are to be recycled
following appropriate dismantling:
• Scrap metal material remains
• Take plastic elements to plastics recycling
• Dispose of remaining components that are sorted according to material composition

Electrical scrap, electronic components, lubricants and other auxiliary substances as
well as some metals (e.g. cadmium) are subject to hazardous waste treatment and
may only be disposed of by permitted specialist companies!
Safety
At the time of its development and manufacture, the equipment was built according to applicable, recognized
rules of technology and is considered to be safe to operate.
However, risks can arise from this equipment if it is not used by appropriately trained personnel, or if it is
operated incorrectly or not according to the intended use.
The Chapter "Safety" gives an overview of all-important safety aspects for the optimum protection of persons
and the safe, trouble-free operation of the equipment.
In addition to this, the other chapters in this Installation Guidelines contain concrete safety notes identified by
symbols to avert danger. Furthermore, pictogram, signs and labels located on the equipment must be observed.
This means that they may not be removed and must be kept in a good, legible condition.
Operational safety is only guaranteed if the equipment is used according to the intended use.

Any use that goes beyond the intended use and/or any other use of the equipment
is prohibited and is not considered intended use. Claims of any kind against the
manufacturer and/or his representatives that arise from damage due to non-
intended use of the equipment are excluded. The customer is solely liable for any
damage arising from non-intended use.

PARCELA 34
36634- CAMBADOS
PONTREVEDRA / SPAIN
unauthorized way
TEL.: +34 986520909
Rev: A 3-100-2060-000 Page: 5 of 15
Intended use also includes correct adherence to the operating conditions as well as the information and
instructions of this Installation Guidelines.
The equipment may only be operated with the parts listed in the scope of delivery.
Contents of the Installation Guidelines

Each person authorized to carry out work on or with the equipment must have read and understood the
Installation Guidelines before starting work on the equipment. This also applies if the relevant person has
already worked with this kind of equipment or similar equipment or if that person was trained by the
manufacturer.
Knowledge of the contents of the Installation Guidelines is one of the prerequisites to protect personnel against
danger, and to avoid errors so that the equipment is operated safely and trouble-free.
The customer is recommended to get confirmation proving that personnel have acknowledged the contents of
the operational manual.
Changes and conversions to the equipment

To avoid danger and to ensure optimum performance, no changes or attachments and conversions can be carried
out on the equipment which have not been explicitly authorized by the manufacturer.
All pictogram, signs and labels located on the equipment must be kept in a good, legible condition and may not
be removed. Pictogram, signs and labels that have been damaged or become illegible are to be replaced as soon
as possible.
Responsibility of the customer

This Installation Guidelines must be kept in direct proximity to the equipment (e.g. in the machine control room)
and must be accessible at all time to persons working on and with the equipment. Observe the information in the
Installation Guidelines completely and without limitation! Together with the safety notes and instructions stated
in this Installation Guidelines, the local accident prevention guidelines applicable for the area in which the
equipment is used and the general safety guidelines as well as the applicable environmental protection
conditions must be adhered to and complied with. The customer and the personnel authorized by him are
responsible for the trouble-free operation of the equipment and for clear allocation of responsibilities with
regard to installation, operation, servicing and cleaning the equipment.
Requirements of the personnel

Only authorized and trained expert personnel may work on and with the equipment. Personnel must have
received instruction regarding potential dangers.
Expert personnel are defined as whoever can assess the work allocated to him and recognize potential dangers
based on his expert training, knowledge and experience, as well as his knowledge of pertinent conditions.
If personnel do not have the necessary knowledge, they must be trained.
Responsibilities for work on and with the equipment (installation, operation, servicing and maintenance) must
be clearly determined and adhered to, so that there is no unclear distribution of competency with regard to
safety.
Only those persons who can be expected to work reliably may work on and with the equipment. Avoid any
mode of operation that impairs the safety of persons, the environment or the equipment.
Persons who are under the influence of drugs, alcohol or reaction-impairing medication must never work on or
with the equipment.
When selecting personnel, the age- and profession-related regulations applicable at the place where the
equipment is being used are to be observed.
The customer must also make sure that non-authorized persons are kept a sufficiently safe distance away from
the equipment.
Personnel are obliged to report to the customer immediately about any changes to the equipment that impair
safety.

PARCELA 34
36634- CAMBADOS
PONTREVEDRA / SPAIN
unauthorized way
TEL.: +34 986520909
Rev: A 3-100-2060-000 Page: 6 of 15
Work Safety
Personal injuries and material damage during work with and on the equipment can be avoided by following the
safety notes and instructions stated in this Installation Guidelines.
Non-compliance with these notes can lead to persons being endangered and damage to or destruction of the
equipment.
If the safety notes and instructions stated in this Installation Guidelines and the accident prevention guidelines
applicable for the place of use and general safety conditions are not complied with, then all liability obligations
and claims for damage compensation against the manufacturer or his representatives are excluded.
Personal protective gear

The following should be worn when working on and with the equipment, in line with the work at hand:
Protective work clothing

Close-fitting work clothing (low tear-resistance, no wide sleeves, no rings or other
jewelry, etc.)
Safety shoes
To protect against heavy, falling parts and slipping on slippery floors.
Protective gloves
To protect the skin against friction, abrasions, piercing and deeper injuries to the
hands and to protect against contact with health-harming substances.
Safety helmet
To protect against falling and flying parts and materials.

PARCELA 34
36634- CAMBADOS
PONTREVEDRA / SPAIN
unauthorized way
TEL.: +34 986520909
Rev: A 3-100-2060-000 Page: 7 of 15
Order Specification
CUSTOMER: CATERPILLAR 7364M
BUILDING YARD: TBA
NEW BUILDING NUMBER: Detroit Brasil LTDA C416
CLASSIFICAION SOCIETY: BV
DRAWING NUMBER: 3-100-2060-000 0

Preparation before the installation of the Stern Tube
Unpacking
After the Factory Acceptance Test (FAT) the stern tube is packed and delivered in packed condition. If or when
the packing is broken the customer has to ensure that the corrosion protection and the cleanliness of the stern
tube is guaranteed.
All single part materials are packed in named bags and boxes.
For storage of the Stern Tube the following requirements must be followed:
• Store the Stern Tube in dry and moderately heated rooms only.
• Make sure that the Stern Tube is stored on the packing foundation.
• Make sure that the stern tube rests immovably.
The end covers of the Stern tube packing are equipped with
inspection holes for enabling the yard to do inspections during the storage
time.
Close the inspection hole immediately afterwards!
Unpack the Stern Tube nearby to the assembly place to avoid damage during internal transport. For lifting use
only textile straps, no steel ropes, to avoid damage to the Stern Tube.

DO NOT USE FORK LIFTS in the stern tube openings for lifting the Stern Tube. As
damage of the bearing surface metal will happen, and the bearings have to be renewed.
WARNING! Danger of injury or mortal danger!
All to be moved parts are heavy and may cause health impairment, injuries, permanent
bodily damage or to death in case of accident.

PARCELA 34
36634- CAMBADOS
PONTREVEDRA / SPAIN
unauthorized way
TEL.: +34 986520909
Rev: A 3-100-2060-000 Page: 8 of 15
Lift, transport and unpack the stern tube as shown in the lifting note on the packing.
Marked on the Stern tube are the prescribed lifting points, as indicated on the above picture. The stern tube must
be lifted with two (2) approved and adequate textile stripes/slings one at each indicated lifting area.
When lifting the Stern tube, make sure that the handling element do not cause damaged to the goods.
Visual check
Check the received Stern Tube items against the delivery notes to ensure that nothing has been damaged during
transport and that no items are missing.
Disassembly
The Adapter Ring (5) must be disassembled from the Stern Tube:
Loosen the Screws (34) and dismount the Adapter Ring (5).
NOTE!
There are numbers of O-Rings (11) and (35) which are used to seal off the Adapter Ring.
These sealing must be handled with care.
NOTE!
Take care that none of the O-Rings (35) gets lost. A missing O-Ring will cause leakages.

PARCELA 34
36634- CAMBADOS
PONTREVEDRA / SPAIN
unauthorized way
TEL.: +34 986520909
Rev: A 3-100-2060-000 Page: 9 of 15
Stern Tube FWD end
Cleaning
The anti-corrosion preservation on all mechanically machined surfaces must be removed carefully and all
surfaces must be cleaned.

PARCELA 34
36634- CAMBADOS
PONTREVEDRA / SPAIN
unauthorized way
TEL.: +34 986520909
Rev: A 3-100-2060-000 Page: 10 of 15
Installation
General mounting sequence:
The Stern Tube itself consist of two main parts, the Stern Tube (1) including the AFT (2) and the FWD Stern
Tube Bush (3) and the Adapter Ring (5). All further parts are used for fixing these parts, to ensure the function
of the Stern Tube Bushes and for checking the operating data.
The Stern Tube can be installed using different methods. The shipyard can choose the method most suitable for
them. The commonly used method used is to insert the Stern Tube from the AFT side using chain blocks or
pushing it in a short distance and then pulling it from the inside of the ship, also using chain blocks.
NOTE!
All parts are marked with “TOP”. Make sure that these marks are in “TOP” position,
to avoid problems during the installation
Mounting of the Stern Tube

Mounting sequence:
Insert the Stern Tube (1) through the AFT boss until the forward end is coming out at the engine room side.
Mounting of the Adapter Ring

Mounting sequence:
Prior to the installation of the Adapter Ring (5) the Welding Ring (6), the O-Ring (12) and the Cover Ring (7)
have to be put on the FWD Stern Tube end.
Insert the O-Ring (11) into the Adapter Ring (5). Put the six O-Rings (35) into their grooves and fix them with
grease.
Lift the Adapter Ring and push it on the forward end of the Stern Tube.
NOTE!
Check that the O-Ring (11) is in position. A damage can cause leakages.
NOTE!
Check that the O-Rings (35) are in position and that no O-Ring gets lost. A damage can
cause leakages. A missing O-Ring will cause leakages.
Insert and tighten the Screws (34) and secure them with LOCTITE.
NOTE!
The O-Rings (11) and (35) are used to seal off the Adapter Ring. These sealing
must be handled with care.

PARCELA 34
36634- CAMBADOS
PONTREVEDRA / SPAIN
unauthorized way
TEL.: +34 986520909
Rev: A 3-100-2060-000 Page: 11 of 15
Final alignment of the Stern Tube

The final alignment of the Stern Tube including the installed Stern Tube bushes to the given neutral axis of the
shaft line must be done by the building yard.
Our recommendation for the alignment procedure is as follows:
- Take the recesses of the AFT Stern Tube Bush as reference.
- Bring it in position, align it and fix it to the AFT boss.
- Use the AFT Stern Tube Bush centre line as zero line for the FWD Stern Tube Bush and end.
- Align and fix the FWD Stern Tube end.
For helping the yard during the alignment work the Stern Tube is equipped with several alignment aids. These
are mainly the Adjustment Screws (33) and the Alignment Screws (41) and (47) which are shown in View A
and Section G-G. In general, the Stern Tube is aligned with these twelve screws at the AFT end. The
Adjustment Screws (33) are pre-installed with the nominal resin thickness of 20 mm. Move the Stern Tube into
the stern boss until the Adjustment Screws (33) get in contact with the stern boss.
Before the final alignment can start the length of the four Holders (40) have to be cut according to locality and
the holders have to be welded under an angle of approximately 35° from the horizontal centre line
NOTE!
Make sure that the holders (40) do not cover the Adjustment Screws (33).
Press the Stern Tube with the horizontal Alignment Screws (41) against the stern boss. Move the Stern Tube
with the radial Alignment Screws (47) to the given centre line.
The combination of the Adjustment Screws (33) and the Alignment Screws (41) allows to move the Stern Tube
FWD end into position. Loosening the Adjustment Screws on one side and tightening the Alignment Screws at
the same side will move the Stern Tube to the other side. Similarly, the alignment works in vertical direction.
For helping to align the stern tube FWD end additionally two Holders (40) and Alignment Screws (41) and (47)
at the FWD end, see View B. These are keeping the Stern Tube FWD in position or can move it radially.
The Stern Tube is machined with a high level of accuracy. See also the transmitted dimension sheets. The yards
target during the installation should be to reach this level.
The recommended alignment deviance, when using laser equipment, is, due to the high accurate pre-alignment,
0.02 mm / m i.e. 0.1 mm / 5 m. The shipyard must approve the alignment in writing!
After the Stern Tube is aligned to its final position it must be fixed until the epoxy resin filling is completed.
Fixing of the Welding and mounting of the Cover Ring

Mounting sequence:
After the Stern Tube is aligned the Welding Ring (6) must be welded to the bulkhead according to yard´s
standard. A small welding seam with a throat depth of 5 to 8 mm is totally sufficient.
NOTE!
Make sure that the O-Ring (12) gets no heat during the welding.
A damage can cause leakages.
Move the O-Rings (12) and the Covering Ring towards the Welding Ring (6). Insert and tighten the Screws (27)
and secure them with LOCTITE.
Pressure test before the epoxy resin filling

This sequence is to be used at the aft flange of the stern tube (1) and at the welding ring (6).
The pressure test sequence.
Fit a pressure gauge to the air vent connection at the top of the flange or the ring.
Connect compressed air with a pressure of 0.3- 0.5 bars to the epoxy resin connection at the bottom of the flange
or the ring.

PARCELA 34
36634- CAMBADOS
PONTREVEDRA / SPAIN
unauthorized way
TEL.: +34 986520909
Rev: A 3-100-2060-000 Page: 12 of 15
Turn the compressed air off with a valve. Wait a few minutes and check the pressure gauge for drop of pressure.
If there has been none or only a small drop of pressure you can go further with filling of the epoxy resin. The
skill to judge the pressure drop can only be achieved through experience gained during actual installations. If
there has been a substantial pressure drop you must check with soap water to find the air leakage.
Filling of the epoxy resin

The epoxy resin filling must be done by a company which is class approved in presence of the local class
surveyor.
The epoxy resin filling has to be done by a company which is class approved and in presence of the local class
surveyor.
The filling sequence is similar for both the aft and the forward end.
The filling of the epoxy resin should be done through the hole at the bottom of the aft flange of the Stern Tube
(1) or the Welding Ring (6). Check the arrangement drawings to find out the thread size that is used.
NOTE!
The app. resin filling amounts are shown on the order cover page. When the resin
filling amount comes close to these values the pumping speed should be reduced.
In case the resin reaches the venting opening, the inner pressure increases
immediately, and resin leakages may occur at the resin space seals

PARCELA 34
36634- CAMBADOS
PONTREVEDRA / SPAIN
unauthorized way
TEL.: +34 986520909
Rev: A 3-100-2060-000 Page: 13 of 15
Final assembly
Bolts at the AFT Flange
The Stern Tube AFT Flange is pre-drilled with a remaining wall thickness of app. 3mm for avoiding a resin
leakage during the filling process.
After the resin is hardened the yard must drill through the remaining wall thickness and the resin. Then the
threads for the fixing bolts (22) must be drilled and cut into the AFT boss.
NOTE!
Svenska Bearing recommends the use of high-speed steel tools for this installation step.
I. Drill and tap the holes for the screws M16x80 (22) at the AFT Stern Tube Flange.
II. Insert the screws M16x80 (22), including the rubber-steel washer (23), tighten them and secure them
with LOCTITE.
NOTE!
The rubber-steel washers do have sealing function!
Make sure that all rubber -steel washers are in position. The loss of one rubber-steel washer
may cause leakages.
Temperature sensor connection box
Mount the temperature sensor connection boxes where it is convenient at the engine room bulkhead.
Protection of the installed Stern Tube
After the Stern Tube is completely mounted it is very important to protect the White Metal surface of the Stern
Tube bushes. A useful protection would be for example plywood covers at both ends of the Stern Tube.
Screw tightening torque table

Tightening torque [Nm]
Standard: ISO 898-1:2013 ISO 3506-1
Bolt size Material steel 8.8 Material A2/A4-70

M10 47 33
M12 81 57
M16 197 140
M20 385 273
M24 665 472

PARCELA 34
36634- CAMBADOS
PONTREVEDRA / SPAIN
unauthorized way
TEL.: +34 986520909
Rev: A 3-100-2060-000 Page: 14 of 15
Stern Tube handling for avoiding problems during operation

For avoiding any problems during the operation of the Stern Tube the following instruction of the bearing maker
Thordon have to be achieved. (The original of the Thordon paper can be found in the enclosure)

PARCELA 34
36634- CAMBADOS
PONTREVEDRA / SPAIN
unauthorized way
TEL.: +34 986520909
Rev: A 3-100-2060-000 Page: 15 of 15

PARCELA 34
36634- CAMBADOS
PONTREVEDRA / SPAIN
unauthorized way
TEL.: +34 986520909
PART LIST
&
ASSEMBLY DRAWINGS
ORDER COVER PAGE
Drawing number: 3-100-2060-000
Date: 2019-06-18 Name: Wenzel
Customer Caterpillar Propulsion
Customer Order Number: 7364M.70
Yard TBA
Newbuilding number Detroit Brasil LTDA C416
Delivery Date September 20th , 2019
Number Off Units 2 per Hull
Classification Society 3.2 BV
Shaft Dia Aft Bearing Ø 240 h7
Shaft Dia FWD Bearing Ø 225 h7
Shaft Journal Surface Rz 6,3 or better
Stern Tube Length 4600

MAPROM INBOARD SHAFT SEAL M225
Shaft Seal FWD
Seal Type: ISM225SO
Chock-Fast Volume AFT App. 14 Litres
Chock- Fast Volume FWD App. 4,5 Litres
Surface Treatment Sandblasting + primer
Test Pressure 1 bar water / 0.2 bar air
POLIGONO INDUSTRIAL SETE PIAS Existing law protects Svenska Bearing's right of possession to this
PARCELA 34 document. The design or the document must not, without
36634- CAMBADOS permission of the company , be published, copied, reproduced,
PONTREVEDRA / SPAIN manufactured or exploited in any other unauthorized way
TEL.: +34 986520909
PARTS LIST
DRAWING-No.: PAGE 1 OF 2
STERN TUBE 3-100-2060-000-I 2019-06-20
POS. NO. PART NAME DRAWING-No./ DIN MATERIAL
1 1 STERN TUBE 3-100-2060-010 STEEL
AFT BEARING, THORDON

2 1 TG-32983 THORDON SUPPLY
COMPAC
FWD BEARING, THORDON
3 1 TG-32984 THORDON SUPPLY
COMPAC
5 1 ADAPTER RING 3-100-2060-040 STEEL
6 1 WELDING RING 3-100-2060-050 STEEL
7 1 COVER RING 3-100-2060-051 STEEL
8 1 SEALING L= 1094 mm 4-100-1000-053 NITRILE
11 1 O-RING Ø356x8 NITRILE
20 2 GUIDE PIECE 4-100-1000-027
21 1 LOCK NUT 4-100-1000-028
MC6S M16x80
22 6 SCREW
A4-70 ISO 4762
23 6 WASHER GBR M16 RUBBER/ STEEL
M10x50
27 8 SCREW
8.8 ISO4017
33 4 ADJUSTMENT SCREW 4-100-1000-067
TEL.: +34 986520909
PARTS LIST
DRAWING-No.: PAGE 2 OF 2
STERN TUBE 3-100-2060-000-I 2019-06-20
POS. NO. PART NAME DRAWING-No./ DIN MATERIAL
M10x60
34 6 SCREW
A4-70 ISO 4762
40 6 HOLDER M16 4-100-1000-039
M16x80
41 6 ALIGNMENT SCREW
8.8 ISO4017
45 1 ENDLESS STEEL BAND 8 mm
46 1 TURN BUCKLE
M16x80
47 6 ALIGNMENT SCREW
8.8 ISO4017
50 1 AFT RETAINING RING 3-100-2060-052 CC333G
51 1 FWD RETAINING RING 3-100-2060-054 CC333G
M8X25
52 12 SCREW
A2-70 ISO 4762
53 1 ROPE GUARD 3-100-2060-053 STEEL
M12X35
54 8 SCREW
A4-70 ISO4017
70 1 AFT BOSS 3-100-2060-070
71 1 FWD BOSS 3-100-2060-071
TEL.: +34 986520909
STERN TUBE LENGTH =4600
SHAFT DIA
LENGTH BETWEEN BOSSES =4355

Ø 240 h7
65 760 490 180

G1" STERN TUBE
C E CIRCULATION INLET
SHAFT DIA
( Ø 569 )
Ø 225 h7
Ø 545
Ø 540
Ø 358
Ø 398
Ø 564
Ø 538
Ø 398
Ø 358
F
FWD SEAL
225 120 MAPROM M225
45 F 114,5 D ISM225SS0
196 490
TO BE WELDED
BY YARD
196
E G1/2 RESIN VENTING
CONNECTION G1 STERN TUBE
VENTING CONNECTION
H-H MIRRORED IN THE BOTTOM
FOR WATER FILLING
M16, DEPTH 35/45 35
TO BE CUT BY YARD
AFTER STERN TUBE
ALIGNMENT AND RESIN
HARDENING ACCORDING
TO CHAPTER 8 OF THE
INSTALLATION
GUIDELINES.
Ø 400
( Ø 569 )
( Ø 545 +5 )
( Ø 540 )
+0,2
Ø 279,25 +0,1
10
( 225 ) ( 120 )
( 45 )
D
C
F-F
WEIGHT:
STERN TUBE COMPL. APP. 998 kg
STEEL BOOSES APP. 1115 kg
ISO 128 DRAWING No.
CONTRACT No.
A
(AFT END) G1/2 RESIN B G1/2 RESIN
VENTING
H CONNECTION
(FWD END) VENTING
CONNECTION
G1 WATER
G VENTING
CONNECTION
45
°(
8x
)
)
(6x
60°
45°
G
35°
H
,5
22,5°
±0
40
Ø3
PS I STB PS
STB
35°
I
35°
M16, DEPTH 37/46
G1/2 RESIN G1 WATER G1/2 RESIN

G-G FILLING FILLING FILLING
MOVED INTO CONNECTION CONNECTION CONNECTION
BEFORE INSTALLATION
OF POS.53 CUTTING
SECTION
CONNECTION TO SHIP
SRUCTURE TO BE DONE I-I
BY YARD. TO BE CUT
AFTER RESIN
HARDENING.
33
Ø 470
TO BE SECURED BY YARD ISO 128 DRAWING No.
CONTRACT No.
BY WELD SPOT OR LOCTITE
ITEM QTY. DRAWING
ALL DIMENSIONAL INFORMATION IS BASED ON A MACHINING TEMPERATURE DESCRIPTION MATERIAL REMARKS
NO. NUMBER
OF 21 C, UNLESS STATED OTHERWISE. MACHINE GROOVES ONLY WHERE SHOWN
1 1 BEARING THORDON COMPAC TG-
2 1 PLAIN KEY BRONZE C95400 TG-
3 1 RETAINING RING BRONZE TG-

DIN6912-M12X25, BOLT HEAD
4 6 SOCKET HD CAP SCREW BRONZE C95400 TG-23363
TACK WELDED TO THE KEY
SOCKET HEAD CAP SCREW; HEAD
5 6 AISI 316 SS DIN912-M8X30 PURCHASE
DRILLED FOR LOCKING WIRE
DRILL & TAP 490 (HOUSING LENGTH) HOUSING BY OTHERS

FOR M8 S.H.C.S.
6 PLACES A 15 DRILL & TAP
2 4
FOR M12 S.H.C.S.
6 PLACES
14(KEY)
18(REF)
60°
(TYP)
30(KEY)
40+0.25
0 82±0.13
299
B.C. 241.42
5 X 82 = 410
(INSTALLED I.D.)
281
263(REF)
317 263 (HOUSING I.D.)
MINIMUM INSTALLED CLEARANCE: 1.42
RUNNING CLEARANCE: 0.93

A GAP 485.07 (BEARING LENGTH)
(NOMINAL)
GAP
THERMAL EXPANSION ALLOWANCE: 0.19
WATER SWELL ALLOWANCE: 0.30

SECTION A-A
TEMPERATURE RANGE: 45 C TO -2 C
REV. DESCRIPTION DATE DWN CKD APPV
SHAFT DIA.: = 240 h7
HOUSING DIA.: = 281 H7 PROPOSAL THORDON BEARINGS INC.

DATE: 04-JUN-2019
+0.5 BURLINGTON, ONTARIO, CANADA
HOUSING LENGTH: = 490
0 THIS DRAWING IS THE PROPERTY OF THORDON BEARING INC. ALL USE IS STRICTLY PROHIBITED WITHOUT PRIOR WRITTEN CONSENT.
CET DESSIN EST DE PROPRIETE DE THORDON BEARING INC. TOUTE USAGE C'EST STRICTEMENT INTERDIT SAUF PERMISSION ECRIT PRECEDENT.
DO NOT SCALE THIS DRAWING. WORK TO DIMENSIONS SPECIFIED DWN/DESS SIGN. CKD/VER SIGN. APPVL/APP SIGN.
GENERAL NOTES: J.PATINO
UNLESS SHOWN OTHERWISE, MACHINE TOLERANCES ARE:
CUSTOMER/CLIENT DATE MRP NO. SIZE
01. MATERIAL: SEE PART LIST FORWARD LINEAR UP TO 1m(40") +/-0.5mm (±0.020")
ECHETALDE B
02. DIMENSIONS ARE EXPRESSED IN MM UNLESS NOTED OTHERWISE. OVER 1m(40") +/-1.0mm (±0.040") SVENSKA
03. DO NOT SCALE THIS DRAWING. WORK TO DIMENSIONS SPECIFIED. ANGULAR: +/-0.25°
TITLE/TITRE DRAWING NO. DU DESSIN REV.
04. TOLERANCES FOR ALL DIMENSIONS SHALL BE NONCUMULATIVE. THORDON COMPAC TG-32983
SURFACE FINISH: 3.2 mm Ra (125 minch)
05. BREAK ALL CORNERS AND DEBURR ALL SHARP EDGES. AFT BEARING OF
06. ALL FILLET AND RADII DIMENSIONS ARE NOMINAL UNLESS NOTED OTHERWISE. THORDON MATERIAL SURFACE FINISH TO BE DETERMINED
ONLY BY USE OF COMPARATOR ASSEMBLY
SHEET
FEUILLE 1 DE 1
ITEM QTY. DRAWING
ALL DIMENSIONAL INFORMATION IS BASED ON A MACHINING TEMPERATURE DESCRIPTION MATERIAL REMARKS
NO. NUMBER
OF 21 C, UNLESS STATED OTHERWISE. MACHINE GROOVES ONLY WHERE SHOWN
1 1 BEARING THORDON COMPAC TG-
2 1 PLAIN KEY BRONZE C95400 TG-

DIN6912-M12X25, BOLT HEAD
3 3 SOCKET HD CAP SCREW BRONZE C95400 TG-23363
TACK WELDED TO THE KEY
225 (HOUSING LENGTH)

HOUSING BY OTHERS
DRILL & TAP

FOR M12 S.H.C.S.
3 PLACES 3 2
A
30(KEY)
19 (REF) 13(KEY)
75±0.13 35.50+0.25
0
2 X 75 = 150 226.36
(INSTALLED I.D.)
246 264H7
(REF) (HOUSING I.D.)
AXIAL RETENTION
REQUIRED
MINIMUM INSTALLED CLEARANCE: 1.36 1

RUNNING CLEARANCE: 0.90 GAP
222.74 (BEARING LENGTH)
GAP
A
(NOMINAL)
THERMAL EXPANSION ALLOWANCE: 0.18
WATER SWELL ALLOWANCE: 0.29 SECTION A-A

TEMPERATURE RANGE: 45 C TO -2 C
REV. DESCRIPTION DATE DWN CKD APPV
SHAFT DIA.: = 225 h7
HOUSING DIA.: = 264 H7

PROPOSAL
DATE: 04-JUN-2019
THORDON BEARINGS INC.
BURLINGTON, ONTARIO, CANADA
+0.5 THIS DRAWING IS THE PROPERTY OF THORDON BEARING INC. ALL USE IS STRICTLY PROHIBITED WITHOUT PRIOR WRITTEN CONSENT.
HOUSING LENGTH: = 225 CET DESSIN EST DE PROPRIETE DE THORDON BEARING INC. TOUTE USAGE C'EST STRICTEMENT INTERDIT SAUF PERMISSION ECRIT PRECEDENT.
0 DO NOT SCALE THIS DRAWING. WORK TO DIMENSIONS SPECIFIED DWN/DESS SIGN. CKD/VER SIGN. APPVL/APP SIGN.
GENERAL NOTES: J.PATINO
UNLESS SHOWN OTHERWISE, MACHINE TOLERANCES ARE:
CUSTOMER/CLIENT DATE MRP NO. SIZE
01. MATERIAL: SEE PART LIST FORWARD LINEAR UP TO 1m(40") +/-0.5mm (±0.020")
ECHETALDE B
02. DIMENSIONS ARE EXPRESSED IN MM UNLESS NOTED OTHERWISE. OVER 1m(40") +/-1.0mm (±0.040") SVENSKA
03. DO NOT SCALE THIS DRAWING. WORK TO DIMENSIONS SPECIFIED. ANGULAR: +/-0.25°
TITLE/TITRE DRAWING NO. DU DESSIN REV.
04. TOLERANCES FOR ALL DIMENSIONS SHALL BE NONCUMULATIVE. THORDON COMPAC TG-32984
SURFACE FINISH: 3.2 mm Ra (125 minch)
05. BREAK ALL CORNERS AND DEBURR ALL SHARP EDGES. FWD BEARING OF
06. ALL FILLET AND RADII DIMENSIONS ARE NOMINAL UNLESS NOTED OTHERWISE. THORDON MATERIAL SURFACE FINISH TO BE DETERMINED
ONLY BY USE OF COMPARATOR ASSEMBLY
SHEET
FEUILLE 1 DE 1
SEAWATER LUBRICATED PROPELLER
SHAFT BEARINGS - A VOIDING P ROBLEMS
THE ISSUES
A review of bearing failures in marine applications has revealed two major reasons associated
with bearing failures. These two major reasons are Marine Growth and Water Flow. This
document looks at both problems and presents the causes and possible solutions of the issue.
MARINE GROWTH
Marine growth on the shaft liner will prematurely wear a bearing. These deposits, including
calcium carbonate deposits will disrupt the hydrodynamic film and create an abrasive
environment for the bearing.
Typical marine growth on shaft Material plating on the shaft liner
Preventative Measures
• Turn the shaft 2.5 revolutions every 2-3 days while alongside or at anchor to help
reduce marine growth build up.
• Fresh water pumped into stern tube when the ship is idle will inhibit marine growth in the
strut and stern tube bearings. A flow of 1x the water volume in the stern tube per day
should be sufficient but can be adjusted for local environmental conditions.
• Active cathodic protection systems which are not operated properly and maintained can
lead to material plating out on the shaft liner, leading to abrasive wear
WATER FLOW
Insufficient water supply or poor quality water can lead to bearing failure. Common design and
installation mistakes include:
• Orifice plates placed in water supply line by others restricting the flow of water to the
stern tube. In one application the seal manufacturer had placed an orifice plate in the
water flow line because he felt there was too much water going to the stern tube.
• Bearing lubrication supply line valves are closed. After the bearing failure the valves
Updated: April 13, 2011

WATER FLOW (continued)
should be re-opened.
• A single cooling water line feeding multiple systems and the stern tube supply is at the
end of line. If other items divert the water supply, there may be insufficient water flow to
the bearing. One solution is to place a flow meter (with alarm) to monitor flow
under varying ship operational conditions.
• Corrosion in supply pipe. There have been occasions where a mild steel pipe was
substituted for the normal Copper-Nickel piping. The steel pipe corroded on the pipe
ID enough to restrict water flow to the stern tube.
• Sufficient opening between streaming cap (fairwater) and the propeller shaft to ensure
adequate water flow to the bearing. As a general rule the opening between the shaft
and streaming cap should be 20x the cross sectional area of the sum of all bearing
grooves.
Note: Future marine growth will reduce this opening and should be kept to a minimum.
• Sufficient holes should be placed in the rope guard to prevent a blockage of water
exiting the bearing. As a general rule, the area of the holes should be 20x cross
sectional area of the sum of all bearing grooves.
• Flow meter with alarm should be used to indicate water flow to the bearings. You can
have sufficient pressure or a pressure gauge but no water flow.
• Bearing cooling should be from a sole raw water cooling source and NOT post cooling.
A common problem is when engine cooling water is used to lubricate the bearings.
• A dedicated pump should be used for bearing lubrication and not an engine driven
pump.
COMPAC Seawater Lubricated Stern Tube Bearing System
For further information, please contact your local Thordon Distributor or Thordon Bearings.
ZERO POLLUTION l HIGH PERFORMANCE l BEARING SYSTEMS
3225 Mainway, Burlington, Ontario L7M 1A6 Canada Tel: +1.905.335.1440 Fax: +1.905.335.4033 www.ThordonBearings.com
Ch. 1 PROPELLER SHAFT BEARINGS
1.5 LUBRICATION source of clean water for bearing lubrication. A strainer or
cyclone separator system can be used. Thordon Bearings
1.5.1 SEAWATER
manufactures a self contained Water Quality Package to
Water is the most common lubricant used with Thordon ensure an adequate supply of clean water is consistently
propeller shaft bearings. Water serves three purposes in being delivered to both the forward seal and the bearings
the operation of the bearing. First, it forms a thin layer of – see Figure 10. The life of the bearings will be extended
hydrodynamic film between the shaft and bearing which if clean lubricating water is supplied to the bearings.
reduces wear. Second, a flow of water removes heat
generated during rotation of the shaft. Third, the water Figure 10: Thordon Water Quality Package
flow facilitates the removal of abrasive particles which can
accelerate bearing wear. In order to accomplish this, a
positive flow of cooling water from a pump source is
recommended. The minimum flow rate required is 0.15
litres per minute per mm (1 U.S. gallon per minute per
inch) of shaft diameter. The water pressure should be
sufficient to overcome hydrostatic pressure from the
draught of the vessel and flow losses, and to ensure
positive flow at the aft end of the stern tube when the
vessel is fully loaded. If vessel has two stern tubes, two
water supply pipes are preferable to one large supply pipe
that is split. The cooling water should be as close as
possible to the temperature of the water in which the
vessel is operating. Water which has already been used to
cool the main engine, gear box or other machinery before
it reaches the bearings may not be suitable. Water over
40°C (104°F) should not be used as it may have a
detrimental effect on the Thordon bearing.
A pumped flow of water to a Thordon strut bearing is not

normally required. Movement of the ship provides sufficient
flow. Fairwaters and rope guards must be arranged so as
1.5.2 OIL
not to impede water flow to the bearings. However, if the
vessel spends a significant amount of time with the shaft Although Thordon can operate in oil lubrication, it is not
turning and little or no forward or aft movement of the the preferred lubricant for propeller shaft bearings
vessel (as in dynamic positioning or station keeping), a because it does not have the heat dissipation capacity of
pumped flow of water to the strut bearings is water. Although all Thordon grades are chemically
recommended. Such a flow will also impede ingress of compatible with petroleum lubricants, please consult with
abrasive water when the vessel operates in shallow water. Thordon Bearings before installing Thordon in an oil filled
stern tube.
Water should be injected ahead of the inboard bearing in
a stern tube. Thordon bearings can run without water flow
for a limited time, but any sign of heating should be 1.5.3 GREASE
investigated immediately and corrected. For larger Grease lubrication of Thordon propeller shaft bearings is
installations, water flow monitoring (see section 3.4 of not recommended because grease cannot facilitate heat
this manual) is recommended to ensure that an adequate dissipation readily. Although all Thordon grades are
flow of cool water is being maintained. If a vessel chemically compatible with petroleum lubricants, please
equipped with Thordon elastomeric bearings spends a consult with Thordon Bearings before installing Thordon
significant amount of time manoeuvring in very shallow or where grease is used.
dirty water, consideration should be given to providing a
10
DIA. 540 TO BE MACHINED
BEFORE SAW CUT.
SAW CUT 2-4 SUFFICIENT
45
°(
8x
)
Ø1
4
45°
22,5°
45°
MOVED INTO
NET CUTTER
CUTTING AREA
46,6
( Ø 569 )
Ø 545 +5
12
88
196 -3
12
CONTRACT No.
ISO 128
60
DRAWING No.
33
16
Ø 532 +3 (AFTER WELDING)
Ø 540 +2 (AFTER MACHINING)

( Ø 564 )
760 +5
( 53 )
59
Ø 564 +5
Ø 398 ±1
Ø 458
ISO 128 DRAWING No.

CONTRACT No.
490 +5
( 40 )
59
Ø 538 +5
Ø 398 +5
Ø 458
ISO 128 DRAWING No.

CONTRACT No.
INSTALLATION MANUAL
MPP HDX

INSTALLATION MANUAL
MPP HDX

IOM Manual
M0325
Installation, Operation & Maintenance of

Stopping system 322493
Consisting of two hydraulically operated disc brakes SKD 65 with supports
and one Compactus unit
Customer: Caterpillar Propulsion Singapore Pte Ltd

Customer order no: PO133866-BPI
Order no: O2161084 (Dellner Brakes AB reference)
Project no:
Project: 7224
DELLNER BRAKES AB Vikavägen 144 SE-791 95 FALUN SWEDEN Phone: +46 (0)23-78 30 50 Fax: +46 (0)23-77 06 90
[email protected] www.dellner-brakes.com Org.nr/F-skatt: 556553-1299 VAT-no: SE556553129901
Table of contents
Table of contents
1. INTRODUCTION ....................................................................................................................................... 3
1.1 THE DELLNER BRAKES STOPPING, TURNING AND LOCKING SYSTEM .......................................................................... 3
1.2 READING THIS MANUAL ................................................................................................................................... 3
1.3 SAFETY ........................................................................................................................................................ 4
1.4 OVERALL SYSTEM GUIDE AND TECHNICAL DATA .................................................................................................... 5
1.5 LIFTING ........................................................................................................................................................ 6
1.6 HYDRAULIC OIL .............................................................................................................................................. 7
2. INSTALLATION ......................................................................................................................................... 8
2.1 MECHANICAL ................................................................................................................................................ 8
2.2 HYDRAULIC ................................................................................................................................................... 9
2.3 ELECTRICAL................................................................................................................................................... 9
3. MAINTENANCE ...................................................................................................................................... 10
3.1 GENERAL.................................................................................................................................................... 10
3.2 MAINTENANCE SCHEDULE ............................................................................................................................. 10
3.3 PREVENTIVE MAINTENANCE ........................................................................................................................... 11
3.4 CORRECTIVE MAINTENANCE ........................................................................................................................... 11
4. RECOMMENDED SPARE PARTS.............................................................................................................. 12
4.1 STOPPING UNIT ........................................................................................................................................... 12
4.2 COMPACTUS UNIT ........................................................................................................................................ 12
5. APPENDIX ............................................................................................................................................. 13
Document ID: M0325 Dellner Brakes AB, 2016. All rights reserved.
Issue: 2 The manufacturer reserves the right to modification without special notice.
Page: 2 Stopping system 322493.
Introduction
1. Introduction
1.1 The Dellner Brakes Stopping, Turning and Locking system

The Stopping, Turning and Locking (STL) system is a multi-modular system with requested
functions contained in one physical unit (only one customer interface).
Stopping Dellner Brakes hydraulic disc brakes handle the stopping operation.
The brake system and hydraulic cylinders, integrated into a mechanical linkage,
are used to index turning the shaft. The brake disc is finally positioned
Turning manually or together with an intelligent PLC based control system.
The turning system is used to positioning one of the brake discs outer
peripheral slots to align with the locking device and the tapered pawl is
Locking inserted (manually, hydraulically or electrically) to mechanically lock the shaft
in place.
The STL- systems are modular which means that they are based on modules that allow the
user to choose the function(s) and capacity needed. All from single S, T or L functions,
combined dual functions in terms of SL, ST or TL to a complete STL system can be selected.
1.2 Reading this manual

In addition to this Installation, Operation and Maintenance (IOM) manual (manual no.
M0325) there are several reference documents which are listed in the appendix (see chapter
5). In case of differences between documents, this manual shall prevail followed by the
documents in the appendix list in the order from up to down.
Operation and Maintenance instructions are intended for personnel with experience of
similar activities. The manual doesn’t contain detailed instructions to guide inexperienced
personnel through the operation and maintenance procedures. Please consult Dellner
Brakes AB (DBAB) before proceeding if personnel are uncertain in how to follow the
instructions.
Introduction
1.3 Safety
Safety precautions concerns Your safety as well as safety of others and undertaking could
also result in serious damage to the equipment if, for example, the warning text is ignored.
The manual describes which safety precautions to take when working with the Stopping
system in general.
The warning sign indicates that there is great risk of personal injury as well
Warning: as serious damage to product if the warning text is ignored.
The caution sign indicates that minor personal injury as well as damage to
the product or major operating faults can occur if the caution text is ignored.
Caution:
The note text draws attention to important information which facilitates the
Note: reading of the instruction.
Properly warning and/or caution and/or note texts are mentioned in associated description
and shall be read very carefully.
Undertaking work may either directly, or indirectly, create risks to safety and health. It is the
user’s responsibility to ensure that appropriate controls and precautions are identified and
applied as well as making all relevant hazard identifications and risk assessments of all
activities associated with the use of this manual. It is also the user’s responsibility to design
and implement safety systems of work and to supply safety equipment and training to
anyone using this manual to work on products to which it relates.
Neither this manual or its use in any way absolves the user from their
responsibility to identify controls, precautions, hazards and risks of all
Note: activates described in this manual are implemented.
Introduction
1.4 Overall system guide and technical data
Items delivered from Dellner Brakes AB are listed in Table 1.1 and shown in drawing
3224931. It is defined that one Stopping system consists of two Stopping units (one disc
brake SKD 65 with support) designed to operate with two 25 mm thick brake discs (not
supplied by DBAB) and one Compactus unit.
Table 1.1 (Scoop of supply per system)

Description No. of items Weight per unit Art. & Drawing no.
[kg]
Stopping unit 2 38 3224942
ON/OFF indicator SKD 65 2 1 218465
Compactus Unit 1 50 321596-03
S unit electrical terminal box 2 1 321850
Compactus electrical terminal box 1 6 321851
Table 1.2 (Stopping performance per shaft)

Disc brake No. of Braking radius, R Operating Braking Braking torque 4
type brakes pressure, p force, F
[m] [bar] [N/bar] [Nm]
SKD 65 1 RBrake disc - 0,04 100 273 RxpxF
Braking torque is calculated with a coefficient of friction,  = 0.42 (valid for

clean and dry brake disc and bedded in friction material). For more
Note: information, see appendix no. 2.
1
See appendix 1
2
See appendix 1.1
3
See appendix 1.2
4
E.g. a Ø1000 mm brake disc would give the following braking torque: (0,5-0,045) x 100 x 273 = 12500 Nm.
Introduction
1.5 Lifting
Warning: Be always very careful when handling equipment over head.
1.5.1 Stopping unit

Guideline weight: 38 kg
The S unit can be lifted by connecting a suitable strap to a lifting device, e.g. a crane.
1.5.2 Compactus unit

Guideline weight: 56 kg
The CU is equipped with two eye bolts (M12), which are located on top of the CU (see
drawing no. 319596-05). The CU can be lifted by connecting both eye bolts to a lifting device
e.g. a crane, by using one or more lifting straps.
5
See appendix 1.2
Introduction
1.6 Hydraulic oil
Figure 1.1 shows the average viscosity versus temperature curves for the most commonly
used oils subdivided in three groups, each one with a different viscosity. Manufacturers of
hydraulic pumps and motors find their best operating conditions with oil having a viscosity
around 30 cSt at operating temperature. Since the average operational temperature of
hydraulic circuits is about 50C, the oil often used is the oil corresponding to curve B.
Table 1.3 (ISO VG standards)

Curve ISO VG standard
A 32
B 46
C 68
Figure 1.1 (Viscosity diagram)
We, Dellner Brakes AB, recommend a conventional hydraulic fluid based on mineral oil,
which shall be compatible with nitrile rubber and polyurethane (used materials in seals). The
oil shall at least fulfil ”Vickers M-2950-S (mobile hydraulic systems)” and at least have a
purity 20/17 according to ISO 4406.
Hydraulic oil shall be chosen so that viscosity at working temperature in your system is 30
cSt.
Table 1.4 (Example of suitable oils)

Manufacturer Type (ISO VG 32) Type (ISO VG 46)
BP Bartran 32 Bartran 46
TEXACO Rando HD 32 Rando HD 46
SHELL Tellus oil 32 Tellus oil 46
Installation
2. Installation
2.1 Mechanical
Exposed mounting surfaces are corrosion protected with DINITROL 77B or equal at delivery.
Assure to clean these surfaces with a solvent prior to installation.
2.1.1 Stopping unit

According to drawings and instructions in appendixes.6
2.1.2 Compactus Unit

According to drawings and instructions in appendixes.7
6
See appendix 1, 1.1, 1.1.1 and 2
7
See appendix 1.2 and 5
Installation
2.2 Hydraulic
2.2.1 Hydraulic tubing

The hydraulic tubes (not supplied by Dellner Brakes AB), which is to be used in the hydraulic
tube assembly, is recommended to be seamless steel tubes according to DIN 2391/C, dim.
Ø12x1,5. The tubes and fittings have to be carefully cleaned internally and blown through
with compressed air. All tubes are also recommended to be “flushed” with hydraulic fluid
before assembly. Observe to avoid restrictions smaller than Ø5 mm in the hydraulic tube
assembly.
The hydraulic tubing shall be connected according to the hydraulic circuit diagram (drawing
no. 319596-0C8). All connections points are of type 12L and fits with the above hydraulic
tube recommendation.
It is very important to keep the hydraulic assembly in cleanest possible

Note: manner to avoid dirt in the hydraulic system.
2.2.2 Oil filling

The utmost possible cleanliness must be maintained when filling oil into a hydraulic system.
In order to secure the purity degree of the oil also new oil must be filtrated before it is filled
into the system. This should be done by pumping the oil to the tank of the system via the
filling cap by means of a filling unit provided with a filter.
 Use hydraulic oil according to recommendations in chapter 1.6.

 Observe the level gauge on the oil tank during filling so that the right quantity is filled
into the tank. The oil level shall be seen at the upper marking of the level gauge.
 During commissioning of the S system the oil level will most likely decrease so that one
or more refills are necessary.
2.3 Electrical
Use the electrical terminal boxes (see drawing no. 3224939) and connect according to the
electrical circuit diagram (drawing no. 145210).
8
See appendix 1 and 3
9
See appendix 1
10
See appendix 7
Maintenance
3. Maintenance
3.1 General
Ensure to have the vicinity clean and free from dirt and the hydraulic system depressurised
prior to removal of any hydraulic system component. Protect the Compactus Unit and the
electrical items by keeping the cabinet doors closed. Be extra careful at oil filling since dirt in
the oil will damage the hydraulic system.
3.2 Maintenance schedule
Table 3.1 (Maintenance schedule)

When Every Every Every Every
I = Inspection, O = Operation, R = Replacement needed month 6 months year 10 years
Stopping unit - 322494
Exercise the brake units O
Brake pads R* I R
Sliding surfaces I
Seals R
Compactus unit- 319596-0
Exercise the Compactus unit O
Oil R I R
Air filter R R
Air processing unit R
Pneumatic/Hydraulic power pack R
Replacement when needed = Corrective maintenance. Otherwise Preventive maintenance
*) Brake pads to be replaced when there is 2 mm friction material left
The Compactus unit is recommended to be used every month or as a

Caution: minimum exercised once a year. When in storage the Compactus unit must
be exercised with lubricated air once a year in order to avoid dried out seals
(substantial replacement procedure).
Maintenance
3.3 Preventive maintenance
The preventive maintenance recommended in Table 3.1 ensures reliability and function of
the S system throughout its service life.
It is important to inspect and exercise the S system monthly in order to:
 Verify the function.

 Identify any problems (broken or damaged switches, leakage etc).
 Relubricate all internal seals to prevent leakage.
 Check the brake pads for wear and damage.
We strongly recommend that the function of the S system is verified as a

Note: bare minimum once a year.
At normal circumstances, Dellner Brakes AB recommends replacing the air filter twice per
year. If your air is much polluted, more frequently replacements are recommended.
We recommend to once a year:
 Inspect the oil quality and level in tank.

 Inspect sliding surfaces and unprotected surfaces and lubricate if needed.
 Inspect friction surfaces of the brake disc and clean if needed.
Every ten years we recommend a major overhaul of the S system as described in Table 3.1.
The brake disc is recommended to be inspected and degreased before

Caution: operating the S system.
3.4 Corrective maintenance

Corrective maintenance is needed if problems are identified during inspection. Minor
corrective maintenance such as replacement of switches etc. is done with support from
assembly drawings. The most common procedures for major corrective maintenance are
described in manuals for sub systems e.g. disc brake.
Use test connectors and measure the pressure with a pressure gauge to
Caution: ensure that the hydraulic system is depressurised prior to removal of any
hydraulic system component.
Recommended spare parts
4. Recommended spare parts

Below is a list of recommended spare parts for the S-system. For more information please
see specific manuals for each component in the appendix.
4.1 Stopping unit

Table 4.1 (Recommended spare parts for S unit)
Description Appendix. no. / Drawing. no. / Art. no. Quantity needed
chapter Det. no. per S system
Brake pad, organic 321802/2 320909-1 4 pcs
Seal kit, nitrile / 1.1.1 321802/8-9 216865-1 2 sets
polyurethane
Proximity switch 1.1.2 23-18465/2 319206 4 pcs
4.2 Compactus unit

Table 4.2 (Recommended spare parts for CU)
Description Appendix. no. / Drawing. no. / Art. no. Quantity needed
chapter Det. no. per S system
Solenoid valve 319596-0/4 200-35-140 2 pcs
1.2
Replacement filter 319596-0/4 AF30P-060S 1 pcs
Appendix
5. Appendix
Table 5.1 (Appendix list)
Appendix no. Document ID. Type Name Pages
1 322493 rev 1 Drawing Stopping system 1
1.1 322494 rev 0 Drawing Stopping unit 1
1.1.1 321802 rev 1 Drawing Disc brake SKD 65 1
1.1.2 23-18465 rev 2 Drawing ON/OFF indicator SKD 65 1
1.2 319596-0 rev 0 Drawing Compactus unit 1
2 M0011-8 Manual Disc brake SKD 35, 50, 65, 15

80
3 319596-0C rev 0 Hydraulic circuit Compactus unit 1
diagram
4 319596-0- Product specification Compactus unit 1
O2161084 rev 1
5 M0177-5 Manual Compactus unit 44+6
6 1452-141223 Electrical circuit Stopping system 10

diagram
7 AI04-011E-03 Instruction Bedding in procedure 2
3
5
755 400
PI
600
B1
B2
DR1
PORT STARBOARD
25 Represents hydraulic tubing (customer supply).
700 4 Recommended hydraulic tube dimension: 12x1,5 according to DIN 2391/C.
Connections: 12L .
Flange 480 Represents electrical wiring (customer supply).

For more information, see electrical circuit diagram (dwg. 1452).
~423
For installation interfaces, dimensions and

315
tolerances, see sub assembly drawings.

157,5
File: C:\AutodeskVaultBrakes\Designs\Orders\O2161084 (7224)\322493.idw

5 1 321851 Compactus electrical terminal box 400x300x155 6
4 2 321850 S-unit electrical terminal box 125x80x57 0,8
2 1 3 1 319596-0 Compactus unit 42,7
315 429 2 2 218465 ON/OFF indicator SKD 65 0,2
1 2 322494 Stopping unit 38,1
Det. nr. Antal Artikelnummer Ben mning Vikt [kg]
Material Dimension Weight
Det. no. Number Article number Name
Konstr./Des. Ritad Kontr. Skala Vikt/Weight Ers tter/Replaces Ersatt av/Replaced by
A2 TL Drawn
TL Control
PMi Scale
1 : 10 126,9 kg
Stopping system E
Original project: 7224 Datum/Date

Ritn. nr
2016-02-05 Draw. no. 322493 Sheet 1 /1
Painting system: S units: TB 218527, CU & TB: Supplier standard Denna handling r upphovsr ttsligt skyddad och f r inte, utan This document is copyright legislationed protected and must
tillst nd fr n Dellner Brakes AB, delges eller verl mnas till not, without permission from Dellner Brakes AB, be given or
utomst ende. vertr delse medf r ansvar. handed over to any outsider. Trespass give rise to responsibi-
Top coat color: Munsell No. 7.5 BD 7/2 lity.
Rec. tightening torque:
79Nm
Disc diameter
1 197Nm 17 Max flange = Dia - 110

10
2 3
157,5 0,5
140
315
(315)
4
140
7
8 11
6 Dim A = 157,5 0,5

Disc radius + 79 0,5
5
280
Hydraulic inlet port
Connection: 12L (315)
2x M10
(For eye bolts, not supplied by DBAB)
29*
25
315
~193
11 1 000912006030 Screw MC6S 8.8 FZB M6x30 0

10 6 100912010040 Screw MC6S 12.9 M10x25 0
File: C:\AutodeskVaultBrakes\DESIGNS\Articles and Products\Brakes\SKD 65\322494.idw

9 0,6m 7284012015 Hydraulic tube 12x1,5 0
8 1 5390-01-12 Tube clamp 12 0
7 2 6050-12-12 Fitting EVW 12L 0,1
6 2 6042-12-12 Fitting W 12L 0,1
5 1 6070-12-12 Fitting EVL 12L 0,2
4 2 6009-12-04 Fitting GE 12L, G/ED 1/4" 0,1
3 1 217629-13 Spacer SKD 65 t=13 1,4
2 1 321802-5 Disc brake SKD 65 17,3
1 1 322495 Support 18,2
Konstr./Des. Ritad Kontr. Skala Vikt/Weight Ers tter/Replaces Ersatt av/Replaced by
24 A2 TL Drawn
TL Control
PMi Scale
1:3 38,1 kg
~191 Stopping unit E
Datum/Date
*) 2mm air gap between brake housing/pad and brake disc SKD 65 2016-02-05
Ritn. nr
Draw. no. 322494 Sheet 1 /1
(on both sides of the disc) if the disc brake is installed Denna handling r upphovsr ttsligt skyddad och f r inte, utan This document is copyright legislationed protected and must
according to nominal axial installing dimension (see dim. A). tillst nd fr n Dellner Brakes AB, delges eller verl mnas till
utomst ende. vertr delse medf r ansvar.
not, without permission from Dellner Brakes AB, be given or
handed over to any outsider. Trespass give rise to responsibi-
lity.
No. Change. Date. Intr. Appr.
1 Pos. 1 updated, now 6x M10 threads, O 2014-11-11 TL MA
39343
b = Brake disc thickness

A-A
b+4
2x Hydraulic inlet port
Connection: Internal thread G 1/4" b 2 8 9 4 1
43
15 6 14 7
~154
40
141
10 5
95
Outer diameter
Rec. tightening torque: 3 of brake disc
81Nm
12 13 11
A 104 + b
197Nm
143
163
B
6x M10 15
1
15 2 215543 Plastic plug 0

14 2 215334 Nipple G 1/4" 0
13 6 000125170000 Washer BRB 8.8 FZB 17x30x3 0
12 3 006924016000 Nut M6M locking 8.8 FZB M16 0
11 3 000931016140 Screw M6S 8.8 FZB M16x140 0,3
10 4 218384 Return spring 0
File: C:\AutodeskVaultWork\DESIGNS\ARTICLES AND PRODUCTS\BRAKES\SKD 65\321802.idw

~168 + b
9 2 5773065007 U-ring T20 0

38 + b
8 2 5755065000 Wiper DK 65 0
7 2 5703014000 Bonded seal G 1/4" 0
Warning! 6 2 216290 Bleeder 0
Manual for this brake must be read 5 4 215531 Return spring screw 0
before installation. For installation, 4 2 204548 Piston 0,9
operation and maintenance, request 3 4 215530 Guide pin 0,1
manual from Dellner Brakes AB. 2 2 215527-A Brake pad 1,5
1 2 215271 Brake housing 5,5
Assembly instruction: Det. no. Number Article number Name
All parts to be cleaned thoroughly before Konstr./Des. Ritad Kontr. Skala Vikt/Weight Ers tter/Replaces Ersatt av/Replaced by
assembly. Sliding surfaces and seals to

A2 TL Drawn
TL Control
PMi Scale
1:2 17,4 kg
115
be greased with cylinder lubricant, E
Mecman order no. 435-1 or equal. Disc brake SKD 65
with return springs (1 bar) Datum/Date
Ritn. nr
Max working pressure: 10 MPa 2014-03-03 Draw. no. 321802 Sheet 1 /1
Denna handling r upphovsr ttsligt skyddad och f r inte, utan This document is copyright legislationed protected and must
Test pressure for the brake: 13,5 MPa tillst nd fr n Dellner Brakes AB, delges eller verl mnas till not, without permission from Dellner Brakes AB, be given or
lity.
Nr. Ändring Datum Inf. Godk.
No. Change Date Intr. Appr.
1 Pos. 1 & 2 was 218466 & 218467 05-04-20 PMi PM

2 Text corrected 08-10-30 PMi PM
1,5
1 2 85
A (2:1)
155
Detail view A shows recommended air gap 3
between proximity switch and brake pad
back plate at released condition. The air
gap might need to be finally adjusted at
commissioning.
Proximity switch shall indicate (lose
signal) when the disc brake is applied
(before 2 mm back plate travel from
released condition).
3 4 000912006012 Screw MC6S 8.8 FZB M6x12

2 2 319206 Proximity switch NO, Sn 2 mm 2 m cable 10-30 VDC, 200mA
1 2 319203 Switch bracket
Det. nr Antal Artikelnummer Benämning Vikt [kg]
Det. no. Number Art.no. Name Material Dimension Weight
Konstr./Des. Ritad Kontr. Skala Vikt Ersätter/Replace Ers.av/Replaced by
A3 JB Drawn
JB Control Scale
1:2
Weight
PÅ/AV indikering SKD 65 E
File: G:\SKD 65\23-18465.idw

Datum/Date
ON/OFF indicator SKD 65 2001-10-12
Ritn. nr
Draw. no. 23-18465
Denna handling är upphovsrättsligt skyddad och får inte, utan This document is copyright legislationed protected and must
tillstånd från Dellner Brakes AB, delges eller överlämnas till not, without permission from Dellner Brakes AB, be given or
utomstående. Överträdelse medför ansvar. handed over to any outsider. Trespass give rise to responsibi-
lity.
25 Pneumatic inlet port

24 Max. supply pressure: 10 bar
600 Max. regulated pressure: See below *)
23
400 560 20
28 1 13 22 14 12
27
20
26
4
1V3
1V4 PI
1Z6
15
16
17 B1 B2
600
560
16 2
17
1P1
1V1
1V2
22
1Z1
1Z2 DR1
1Z3
1Z4
1Z5
9 4x n8,5
10 10 5 21 29 30 31 6 7 8 Hydraulic outlet ports Drainage port
Max. oulet pressure: See below *)
11 Product specification: 319596-0
31 4 000125084000 Washer BRB 8.8 FZB 8,4x16x1,5
1V5 12 18 19 20 30 4 006924008000 Nut M6M locking 8.8 FZB M8
(to be sealed at assembly) 29 2 319287 Threaded bar 8.8 FZB M8x270
M1 28 4 00012564000 Washer BRB 8.8 FZB 6.4x12x1.5
M2 27 4 006924006000 Nut M6M locking 8.8 FZB M6
26 4 000931006014 Screw M6S 8.8 FZB M6x14
Note: 25 2 000125125000 Washer BRB 8.8 FZB 12,5x35x3
Cabinet door not shown in upper left view. 24 2 006924012000 Nut M6M locking 8.8 FZB M12
Trap door / 10x Mounting screws, 23 2 319183 Eye bolt FZB M12
22 0,9 m 7284012015 Hydraulic tubes GK ø12x1,5
could be opened at service *) Pressure step up ratio: 44.
21 0,45 m 7284008010 Hydraulic tubes GK ø8x1
Max. hydraulic outlet pressure is specific for Your installation,
20 2 8303-00-12 Test connector DKLO 12L, M16x2
see product specification or contact Dellner Brakes AB. 19 2 6035-12-12 Fitting DKLO 12L
18 2 6043-12-12 Fitting T 12L
**) Plus max. 5 l hydraulic fluid. 17 3 5601-02-18 Bonded seal M18
16 3 6045-12-12 Fitting SV 12L
15 1 6089-12-06 Fitting EVGE 12L, G/ED 3/8"
14 1 6042-12-12 Fitting W 12L
13 1 6009-12-06 Fitting GE 12L, G/ED 3/8"
12 3 6009-12-04 Fitting GE 12L, G/ED 1/4"
11 1 6130-00-08 Plug 8L
10 2 5703014000 Bonded seal G 1/4"
9 1 6045-08-08 Fitting SV 8L
8 1 5703012000 Bonded seal G 1/8"
7 1 6050-08-08 Fitting EVW 8L
6 1 6003-08-02 Fitting GE 8L, GB 1/8"
5 1 534-421-003-0 Safety valve G 1/4" (2-6 bar)
4 1 319275 Air processing unit
2 1 319597 Pneumatic/Hydraulic Power Pack
File: PRODUCTS\HYDRAULICS\COMPACTUS\319596-0.idw
C:\AutodeskVaultWork\DESIGNS\ARTICLES AND
1 1 AS06064 Cabinet 600x600x400
Cabinet door - Left hanged A2 PMi Drawn
PMi Control
MO Scale
1:5
Weight
43 **)
Machinery plate Compactus unit LP80-12/B4 K1 E
Datum/Date
(BWN 1 L-NN-1-1-G24) Ritn. nr
2013-02-12 Draw. no. 319596-0
lity.
Installation, Operation and
Maintenance

Manual

from Dellner Brakes AB

Hydraulically activated disc brakes

type SKD 35, 50, 65, 80

Manual no: M0011‐8
Customer:
Customer order
no:
DBAB order no:

Published by:

DELLNER BRAKES AB
Vikavägen 144
SE‐791 95 FALUN
SWEDEN

Telephone: + 46 (0)23 – 78 30 50
Telefax: + 46 (0)23 – 77 06 90

Internet address: www.dellner‐brakes.com
E‐mail: info@dellner‐brakes.com

1. TABLE OF CONTENTS
TABLE OF CONTENTS ______________________________________________ 2
A. Technical description disc brake SKD ________________________________ 3
B. Assembly instructions disc brake type SKD ___________________________ 5
C. Maintenance instruction disc brake SKD _____________________________ 6
D. Hydraulic oil ___________________________________________________ 7
E. Part list and drawing SKD 35 ______________________________________ 8
F. Part list and drawing SKD 50 _____________________________________ 10
G. Spare parts and drawing SKD 65 __________________________________ 12
H. Spare parts and drawing SKD 80 __________________________________ 14

© Copyright Dellner Brakes AB, 2002. All rights reserved
The manufacturer reserves the right to modification without special notice
Manual for SKD 35, 50, 65, 80.
2

2. A. Technical description disc brake SKD
2.1 General description:
Disc brakes of type SKD are direct acting and are activated by hydraulic‐ or air pressure. The
braking power achieved is directly proportional to the applied pressure. The brake consists
of two symmetrical brake halves and is designed for a brake disc thickness of 12 mm. Should
a thicker brake disc be required, the brakes can be supplied with a spacer. Each brake half is
supplied with two cylindrical guiding pins which transmit the tangential braking force from
the brake pads to the brakes. This means that the brake piston is not subjected to any radial
energy and as a result, contributes to a longer life for the brakes. Each brake half is supplied
with two retracting springs, which pull the brake pad back at brake release. The brake pad
wear is automatically compensated through increased stroke by the piston.
When the brakes are used with air activation it is preferred to remove the return spring
screws.
2.2 Technical data:
Table 1
Type Tangential brake force* Air gap brake pad / brake disc
SKD 35 8000 N 2 x 2.0 mm
SKD 50 16200 N 2 x 2.0 mm
SKD 65 27300 N 2 x 2.0 mm
SKD 80 41400 N 2 x 2.0 mm

* Valid at 100 bar hydraulic pressure. External losses not accounted for.
Values are calculated with μ=0,42.

Max. hydraulic pressure = 100 bar
2.3 Friction material
The standard friction material used on the brake pads is a non‐asbestos organic material.
Max. continuous rubbing speed is 21 m/s and max. continuous temperature is 300 oC. Other
materials are available for more demanding applications.
2.4 Seal material
Nitrile is used as a standard material in seals. If chosen hydraulic oil is not suitable together
with nitrile, EPDM is available. If the operational oil temperature is over 100 oC, viton is
available.
3
2.5 Corrosion protection
The standard Dellner brakes are protected against corrosion due to following:
• Return spring material are stainless steel
• All bolts are electrically galvanized
• The brakes are painted with a two pack epoxy paint
2.6 Options
Indicators: Indicators can be used as options for this brake, indicating on/off and brake pad
wear. Versions with a micro switch and with a proximity switch are available for selected
brakes. Please contact DBAB for information.

Spacer: Is used between the caliper halves when the brake disc is thicker then 12 mm.
Thickness of spacer = brake disc thickness ‐ 12 mm.

4

3. Assembly instructions disc brake type SKD
Install the brake with the air bleeder screws as high as possible.

The brake unit should be installed and adjusted parallel with the brake disc, installing
tolerance +/‐0.5 mm.

Before finally tightening of the mounting screws, apply the brake, tighten the screws, release
the brake and check the installing tolerance again.

Bleed any air from the brake.

Check that the discs angular throw in relation to the support does not exceed the
permissible values, see below.

The hydraulic tubes which are to be connected to the disc brake have to be seamless steel
tubes according to DIN 2391 / c, (St. 35) (dim. see table).
The tubes have to be cleaned internally by compressed air before assembly.

Before the brake is taken into operation the friction material on the brake pads have to be
bedded in. Use the brake to brake the machine down to stop a couple of times. Do not
overheat the brake pads. Max. recommended temperature on the brake disc surface is 200°
C. The brake pads are ready for operation when the entire surface colour have turned into
black from the brand new grey colour.
5

4. Maintenance instruction disc brake SKD
4.1 Deaeration procedure
1. Pressurize the brake.
2. Mount a draining hose on the air bleeder nipple and open it carefully and keep it open
until all air is exhausted.
3. Close the deaeration nipple.
4. Repeat 1‐3 on all brake cylinders.

NOTE: The brake pads will loose friction if they are contaminated with oil or grease. The
brake pads should be replaced if the friction material has absorbed oil or grease.
4.2 Replacement of brake pads procedure
The brake pads are to be replaced when 2 mm friction material is left.

1. Depressurize the brake.
2. Remove the guide pins and the return spring screws.
3. Slide brake pad up and out.
4. Slide new brake pad in.
5. Install guide pins and return spring screws.
6. Tighten the screws due to the tightening table on the general drawing.

NOTE: New brake pads have to be bedded in before full friction is achieved (see above,
chapter B).
6

5. Hydraulic oil
5.1 Recommended oil
Diagram below show the average curves viscosity versus temperature for the most
commonly used oils subdivided in three groups each one with a different viscosity.
Manufactures of hydraulic pumps and motors find their best operating conditions with an oil
having a viscosity around 30 cSt at the operating temperature. Since the average operation
temperature of hydraulic circuits is about 50°C, the oil mostly used is that corresponding to
curve B.

Hydraulic oil shall be chosen so that viscosity at working temperature in your system is 30
cSt.

Table 2
Curve ISO‐VG standard
A 32
B 46
C 68

5.2 Oil volume SKD brakes
Table 3
Type Volume 1 Volume 2 Connection pipe ∅ x t
SKD 35 15.2 cm3 6 cm3 8x1,0
SKD 50 31.2 cm3 18 cm3 8x1,0
SKD 65 52.8 cm3 43 cm3 10x1,0
SKD 80 80 cm3 62 cm3 10x1,0

Volume 1: Max. working oil volume in the brake with worn out brake pads.
Volume 2: Oil volume in released brake.
Recommended oil viscosity at working temperature, approx. 30 cSt.

NOTE: Standard material in rubber seals is nitrile. Check that used oil is applicable with
nitrile rubber.
7

6. Part list and drawing SKD 35
6.1 Part list

Det. no. Quantity Description Art. no.
1 2 Caliper half 215269
2 2 Brake pad 215508‐A
3 4 Guide pin 215511
4 2 Piston 215512
5 4 Return spring screw 212207
6 2 Bleeder 216290
7 2 Seal TT G 1/8” 5703012000
8 2 Stripper 5755035000
9 2 O‐ring 5725342030
10 4 Return spring 215830
11 2 Screw M6S 10x120 8.8 000931010120
12 2 Nut locking M10 8.8 006924010000
13 4 Washer BRB 17x30x3 000125105000
14 2 Nipple G 1/8” 215333
15 2 Plug 215543
16 2 Wear indicator, option 215514‐A
‐ 1 Spacer, option 217627‐xx*

* Depending on the spacer thickness.

6.2 Recommended spare parts

Description Art. no. Material remark Remark
Brake pad 215508‐A Organic (standard) 2 pcs / brake
Brake pad 215508‐B Low friction 2 pcs / brake
Brake pad 217871 Semi metal 2 pcs / brake
Brake pad 218049 Sinter metal 2 pcs / brake
Seal kit 216863‐1 Nitril rubber (standard) 1 pcs / brake
Seal kit 216863‐2 EPDM rubber 1 pcs / brake
Seal kit 216863‐3 Viton rubber 1 pcs / brake

8

7. F. Part list and drawing SKD 50
7.1 Part list

Det. no. Quantity Description Art. no.
1 2 Caliper half 215270
2 2 Brake pad 215519‐A
3 4 Guide pin 215522
4 2 Piston 215523
5 4 Return spring screw 216011‐1
6 2 Bleeder 216290
7 2 Seal TT G 1/8” 5703012000
8 2 Stripper 5755050000
9 2 U‐ring 5773050007
10 4 Return spring 215826‐1
11 3 Screw M6S 12x120 8.8 000931012120
12 3 Nut locking M12 8.8 006924012000
13 6 Washer BRB 13x42x2 000125130000
14 2 Nipple G 1/8” 215333
15 2 Plug 215543
16 2 Wear indicator, option 215524‐A
‐ 1 Spacer, option 217628‐xx*

* Depending on the spacer thickness.


Brake pad 215519‐2 Low friction 2 pcs / brake
Brake pad 215521‐1 Semi metal 2 pcs / brake

10

8. Spare parts and drawing SKD 65

Brake pad 215527‐AL Low friction 2 pcs / brake

12
6x M10 was 4x M10, drawing updated. CO
1 2014-12-17 TL PMi
39343
A-A ( 1 : 2 )
~163
~143 197Nm
45 45 104 + b
12 13 11
30
81Nm 3 Outer diameter
of brake disc
10 5
~141
40
7 14 6 15
2x hydraulic inlet port 8 9 4

Connection: internal thread G 1/4 b
1 2
b+4
b = Brake disc thickness

14 2 215334 Nipple G 1/4" 0
~168 + b
13 6 000125170000 Washer BRB 8.8 FZB 17x30x3 0

38 + b

11 3 000931016140 Screw M6S 8.8 FZB M16x140 0,3
File: C:\AutodeskVaultWork\DESIGNS\ARTICLES AND PRODUCTS\BRAKES\SKD 65\215526-A.idw

10 4 216078 Return spring 0
9 2 5773065007 U-ring T20 0
8 2 5755065000 Wiper DK 65 0
7 2 5703014000 Bonded seal G 1/4" 0
6x M10 15 before installation. For installation, 4 2 204548 Piston 0,9
1 operation and maintenance, request 3 4 215530 Guide pin 0,1
A manual from Dellner Brakes AB. 2 2 215527-A Brake pad 1,5
115 1 2 215271 Brake housing 5,5
Ben mning
Assembly instruction: Det. nr.
Det. no.
Antal
Number
Artikelnummer
Article number Name
Material Dimension Vikt [kg]
Weight
assembly. Sliding surfaces and seals to A2 Drawn

NL Control
JL Scale
1:2 17,4 kg
be greased with cylinder lubricant,
E
Datum/Date
Ritn. nr
Max working pressure: 10 MPa
2014-12-17 Draw. no. 215526-A Sheet 1 /1
Test pressure for the brake: 13,5 MPa tillst nd fr n Dellner Brakes AB, delges eller verl mnas till not, without permission from Dellner Brakes AB, be given or
lity.

9. Spare parts and drawing SKD 80

Brake pad 215536‐L Low friction 2 pcs / brake
Return spring screw 215603 4 pcs / brake
Return spring 216076 Stainless steel 4 pcs / brake
14
1 Pos. 1 updated, was 4x M16. CO 39267. 2014-12-17 TL MA
2 Drawing updated.CO: 43826. 2015-01-19 OK TL
b
6 7 14 15 To be secured with Loc-Tite 2 2 2 8
9 4
243 or equivalent. 1
A
10 5
55
110
43
182
Outer diameter
122
of brake disc
A Rec. tightening torque:

118+b
11 12 13
385Nm
B 182+b
184
197Nm
204
B(1:2) 1
6x M16 30

14 2 215335 Nipple G 3/8" 0,1
13 8 000125170000 Washer BRB 8.8 FZB 17x30x3 0
11 4 000931016150 Screw M6S 8.8 FZB M16x150 0,3
File: C:\AutodeskVaultWork\DESIGNS\ARTICLES AND PRODUCTS\BRAKES\SKD 80\213649-C.idw

10 4 216076 Return spring 2,25x12x40 0
48+b
9 2 5773080007 U-ring SKY 80 0,1

8 2 5755080000 Wiper DK 80 0
7 2 5703016000 Bonded seal G 3/8" 0
before installation. For installation, 4 2 205774 Piston SKD 80 1,8
operation and maintenance, request 3 4 215539-1 Guide Pin 0,2
manual from Dellner Brakes AB. 2 2 215536-A Brake pad SKD 80 2,8
1 2 213650-2 Brake housing SKD 80 11,4
Assembly instruction: Det. nr. Antal Artikelnummer Ben mning Vikt [kg]
assembly. Sliding surfaces and seals to A2 Drawn
JB Control Scale
1:2 34,6 kg
90 be greased with cylinder lubricant,
E
Datum/Date
Ritn. nr
Max working pressure: 10 MPa
2001-03-02 Draw. no. 213649-C Sheet 1 /1
Test pressure for the brake: 16 MPa tillst nd fr n Dellner Brakes AB, delges eller verl mnas till not, without permission from Dellner Brakes AB, be given or
lity.
Document name Head line Date Page no.
COMPACTUS UNIT
PRODUCT SPECIFICATION LP80-12/B4 K1 (BWN 1 L-NN-1-1-G24) 2016-02-26 1 (of 1)
Issuer Approved by Contract / Order no. Contract name Document ID Revision
Tobias Lindkvist Pär Mikaelsson - / O2161091 7225 319596-0 1
Product no. Assembly drawing Assembly drawing, PHPP Hydraulic circuit diagram Assemly / test instruction
319596-0 319596-0 319597 319596-0C -
No. Pos. Qty. Art. no. Description Remarks

2 1 319597 Pneumatic Hydraulic Power Pack LP80-12/B4 K1 (BWN 1 L-NN-1-1-G24) Acc. to doc. ID. D 7280 H & E 7282 B
2 1P1 1 321157 Pump unit Acc. to doc. ID. D 7280 & E 7282
2 1Z1 1 - Oil tank 7 litre (usable 5 litre) Acc. to documet ID. E 7282 B
2 1Z2 1 - Filling cap Acc. to documet ID. E 7282 B
2 1Z3 1 402-50-005 Level gauge
2 1Z4 1 - Manifold sub plate Acc. to documet ID. D 7470 B/1
2 1V1 1 200-35-140 Solenoid valve WN 1 N-G24 24 V DC
4 1 319275 Air processing unit Max. supply: 10 bar (145 PSI)
4 1Z6 1 AN200-02 Silencer G1/4
4 1V3 1 VHS30-F03 Shut off valve
4 1V4 1 AWK30K-F03DE Pressure regulator with filter and gauge Setting: 2,3 bar (33 PSI)
5 1V5 1 534-421-003-0 Safety valve (2-6 bar) Setting: 3 bar (43,5 PSI)
20 M1 1 8303-00-12 Test connector DKLO 12L (M16X2)
Record of changes:
Revision Date Description of change Signature Approved
1 2016-11-14 Safety valve setting changed. PSI-value for pressure regulator updated. OK PMi
319596-0-O2161084 rev 1.pdf, page 319596-0-O2161091, rev. 1

Installation, Operation and
Maintenance
Manual
with spare parts lists
From Dellner Brakes AB
Compactus unit
Manual no: M0177-5

Customer: -
Customer order no: -
DBAB order no: -
Published by:
DELLNER BRAKES AB Telephone: + 46 (0)23 - 78 30 50

Skyfallsvägen 2 Telefax: + 46 (0)23 - 77 06 90
SE-79177 FALUN www.dellner-brakes.com
SWEDEN [email protected]
TABLE OF CONTENTS
1. Introduction _________________________________________________________ 3
1.1 General description _________________________________________________________ 3
1.2 Pneumatically operated Hydraulic Power Pack (PHPP) _____________________________ 4
1.3 Technical data _____________________________________________________________ 4
2. Installation instructions ________________________________________________ 5
2.1 Lifting ___________________________________________________________________ 5
2.2 Mechanical _______________________________________________________________ 5
2.3 Hydraulic and pneumatic_____________________________________________________ 6
2.4 Electrical _________________________________________________________________ 6
3. Operation instructions _________________________________________________ 7
4. Maintenance instructions ______________________________________________ 8
4.1 General __________________________________________________________________ 8
4.2 Oil level inspection and refilling/changing _______________________________________ 8
5. Hydraulic oil _________________________________________________________ 9
6. Recommended spare parts ____________________________________________ 10
7. Part lists and drawings _______________________________________________ 11
7.1 Compactus units with one hydraulic outlet port __________________________________ 11
7.1.1 Compactus unit without pressure switch - Art. no. 319535 __________________________________ 11-15
7.1.2 Compactus unit with pressure switch - Art. no. 319535-1 ___________________________________ 16-20
7.1.3 Pneumatically operated Hydraulic Power Pack (PHPP) - Art. no. 319555________________________ 21
7.2 Compactus units with two hydraulic outlet ports _________________________________ 22
7.2.1 Compactus unit without pressure switches - Art. no. 319596 _________________________________ 22-26
7.2.2 Compactus unit with pressure switches - Art. no. 319596-1 _________________________________ 27-31
7.3 Compactus units with three hydraulic outlet ports ________________________________ 33
7.3.1 Compactus unit without pressure switches - Art. no. 321121 _________________________________ 33-37
7.3.2 Compactus unit with pressure switches - Art. no. 321121-1 _________________________________ 38-42
8. Appendix list ________________________________________________________ 44
Dellner Brakes AB, 2012. All rights reserved.

The manufacturer reserves the right to modification without special notice.
Manual for Compactus unit
2
1. Introduction
1.1 General description
Figure 1.1.1 (Closed Compactus unit) Figure 1.1.2 (Open Compactus unit)
The Compactus unit is a hydraulic unit (installation envelope W680xH600xD400)

with a Pneumatically operated Hydraulic Power Pack (PHPP). The Compactus unit
consists of the following four major sub-assemblies:
• Cabinet (W600xH600xD400 - IP 66)

• PHPP
• Air processing unit
• Electrical connection box (W200xH200xD80 - IP 66)
The PHPP and the air processing unit are assembled inside the lockable cabinet,
which keeps the equipment clean and free from dirt. The Compactus unit is also
equipped with external fittings (combined with rubber bonded seal washers) for
pneumatic connection, hydraulic connection and oil drainage. The PHPP shall be
supplied with pneumatic pressure through the air processing unit consisting of a shut
off valve, a pressure regulator with filter and pressure gauge and a safety valve. The
regulator and safety valve are adjusted before delivery and the safety valve is also
secured with a lock wire.
The lockable electrical connection box is assembled on the right side of the cabinet.
The connection box shall be considered as interface between the hydraulic system
and an external control system. The connection box shall be supplied with control
power through conduits which are located on the bottom side of the box.
3
The cabinet and the electrical connection box are delivered painted in grey shade
(RAL 7032).
Figure 1.1.2 shows a Compactus unit with one hydraulic outlet port, but models are
available where it is possible to control a number of hydraulic outlet ports
individually and/or simultaneously by adding solenoid valves to the PHPP. Models
where each hydraulic outlet port is equipped with a pressure switch for hydraulic
pressure ON/OFF detection are also available (adjusted and secured with a lock wire
before delivery).
1.2 Pneumatically operated Hydraulic Power Pack (PHPP)
The PHPP is a valve-controlled, two-way plunger pump on the principle of

pneumatic hydraulic pressure intensifier. The low-pressure piston with large area on
the drive-side (pneumatic side) pushes the piston with smaller area (hydraulic side)
against a high fluid pressure outlet. The pump works with oscillating strokes and the
stroke reversal is automatic via a direct mounted, self-piloted 4/2-way valve, which
receives a reverse impulse always in the end positions on the pneumatic piston. Pump
characteristics are equal to a load-controlled pump, i.e. the stroke frequency slows
down with the delivery flow decreasing while the hydraulic system pressure rises
steadily until a balance between the pneumatic and hydraulic forces is achieved
where the stroke will stall. At this point where no more air is consumed depends on
the adjustment pressure on the pneumatic side. The pump will restart automatically if
the hydraulic pressure will decrease in effort to maintain a constant hydraulic outlet
pressure.
1.3 Technical data
Table 1.3.1 (Technical data)

Pump type Step up Max. pneumatic Adjustment Operating Control power
ratio supply pressure pressure pressure2
1 2
LP 80-12 1:44 10 bar / 145 PSI 24 V DC
1
Adjustment pressure shall be adjusted with the pressure regulator (secondary
pneumatic supply pressure). For recommended setting pressure, see specific
documentation valid for your installation.
2
Operating pressure is calculated by multiplying secondary pneumatic supply
pressure with the step up ratio (no losses considered). For recommended operating
pressure, see specific documentation valid for your installation.
Used seal material in the PHPP is nitrile.
Used fittings and tubes are electroplated as corrosion protection.
4
2. Installation instructions
The below installation instructions are general for all Compactus models and
therefore it is important that the correct reference drawings valid for your installation
are used during the installation (see chapter 7).
When complete installation has been carried out, it is important that the operation
instructions according to chapter 3 are followed.
2.1 Lifting
The Compactus unit is equipped with two

eyebolts (M12), which are located on top
of the cabinet. The Compactus unit could
be lifted by connecting both eyebolts to a
lifting device e.g. a crane, by using one or
more lifting straps. The dot in figure 2.1.1
symbolizes the lifting device connection
point for the strap(s).
Figure 2.1.1 (Lifting points)
2.2 Mechanical
The back side of the cabinet shall be considered as primary mounting surface (4x
mounting holes, Ø8,5).
The Compactus unit shall be mounted in the vicinity of the hydraulic consumer
device e.g. disc brake. If not possible, please contact Dellner Brake AB if the height
difference is more than 10 meter.

5
2.3 Hydraulic and pneumatic
The hydraulic tubes (not included in delivery), which is to be connected to the

Compactus unit, is recommended to be seamless steel tubes according to DIN
2391/C, dim. Ø12x1,5. The tubes and fittings have to be carefully cleaned internally
and blown through with compressed air. All tubes are also recommended to be
“flushed” with hydraulic fluid before assembly. Observe to avoid restrictions smaller
than Ø5 mm in the hydraulic tube assembly.
NOTE: It is very important to keep the hydraulic assembly in cleanest possible

manner to avoid dirt in the hydraulic system.
Hydraulic tubes shall be connected from the hydraulic outlet port(s) to the hydraulic
consumer device e.g. disc brake.
Hydraulic tubes shall be connected from the pneumatic inlet port to the pneumatic
pressure source.
Table 2.3.1 (Connection points)

Connection point Fitting type
Pneumatic inlet port, PI
SV 12L
Hydraulic outlet port(s), B1, B2 etc.
2.4 Electrical
Use the electrical connection box and connect the Compactus unit to the electric
control system according to the electric wiring diagram for the Compactus unit valid
for your installation.

6
3. Operation instructions
The below operation instructions are general for all Compactus models and therefore
it is important that the correct reference drawings valid for your installation are used
during the operation (see chapter 7).
Prior to the first actuation of Compactus unit, i.e. solenoid valve(s) energized and
hydraulic outlet port(s) pressurized, the following shall be checked:
1. Oil has been filled into the tank (pos. 1Z1). If not, see chapter 4.2.
2. The shut of valve (included in the air processing unit, det. no. 4) is in open
position. If not, open it.
3. The pressure gauge (included in the air processing unit and assembled to the
pressure regulator) shows a permissible value valid for your installation. If not,
correct the pressure with the regulator.
To pressurize the hydraulic outlet port(s) the solenoid valve(s) shall be energized.
If the Compactus unit has more than one hydraulic outlet port, the ports can be
pressurized individually and/or simultaneously e.g:
• To pressurize port B1: Energize solenoid valve 1V1.

• To pressurize port B2: Energize solenoid valve 1V2.
• To pressurize port B1 and B2: Energize solenoid valve 1V1 and 1V2.
a.s.o.
When the solenoid valve(s) is energized the PHPP will start and pump oil to fulfil
pistons strokes and finally pressurize the hydraulic outlet port(s) with the correct
operating pressure.
To depressurize the hydraulic outlet port(s) respectively solenoid valve shall simply
be de energized.
NOTE: The pressurizing sequence is not important. Each hydraulic outlet port can
be pressurized and depressurized without affecting the remaining hydraulic
outlet ports.
If the hydraulic pressure capacity appears to decrease it is recommended to

check that the pneumatic supply pressure is within permissible values.

7
4. Maintenance instructions
The below maintenance instructions are general for all Compactus models and
are used during the maintenance (see chapter 7).
4.1 General
Ensure to have the vicinity of the Compactus unit clean and free from dirt prior to
removal of any hydraulic system component. Protect the hydraulic, pneumatic and
electrical components by keeping the cabinet doors closed. Be extra careful at oil
filling since dirt in the oil will damage the hydraulic system.
NOTE: It is recommended to turn the shut off valve (included in the air processing
unit, det. no. 4) into closed/vented position prior to any major maintenance
tasks (e.g. removing system components), but do NOT forget to restore its
position afterwards.
4.2 Oil level inspection and refilling/changing
The oil should be inspected ones a year. If it has turned black, change it. Use new
clean oil according to chapter 5. The changing interval is specific for Your
installation, please contact Dellner Brakes AB for further recommendation.
1. Ensure that the solenoid valve(s) are de energized (hydraulic system

depressurized).
2. Locate drainage port DR1 and use an empty container to avoid oil spillage.
3. Remove the plug and drain the oil (self pressure) into the container.
4. Reassemble the plug, remove the filling cap (pos. 1Z2) and fill the tank with new
oil. The oil level shall be seen in the top of the level gauge (pos. 1Z3).
5. Reassemble the filling cap.
NOTE: Oil level inspection shall be done when hydraulic system is depressurized.
It is recommended to deaerate the hydraulic system after oil change

8
5. Hydraulic oil
Figure 5.1 shows the average viscosity versus temperature curves for the most
commonly used oils subdivided in three groups, each one with a different viscosity.
Manufacturers of hydraulic pumps and motors find their best operating conditions
with oil having a viscosity around 30 cSt at operating temperature. Since the average
operational temperature of hydraulic circuits is about 50°C, the oil often used is the
oil corresponding to curve B.
Table 5.1 (ISO VG standards)

Curve ISO VG standard
A 32
B 46
C 68
Figure 5.1 (Viscosity diagram)
We, Dellner Brakes AB, recommend a conventional hydraulic fluid based on mineral
oil, which shall be compatible with nitrile rubber (used materials in seals). The oil
shall at least fulfil ”Vickers M-2950-S (mobile hydraulic systems)” and at least have
a purity 20/17 according to ISO 4406.
Hydraulic oil shall be chosen so that viscosity at working temperature in your system
is 30 cSt.
Table 5.2 (Example of suitable oils)

Manufacturer Type (ISO VG 32) Type (ISO VG 46)
BP Bartran 32 Bartran 46
TEXACO Rando HD 32 Rando HD 46
SHELL Tellus oil 32 Tellus oil 46

9
6. Recommended spare parts
The below spare part list (table 6.1) is general for all Compactus models and
are used when choosing spare parts (see chapter 7).
Table 6.1 (Recommended spare parts)

Description Det. no. Pos. Art. no. Quantity remark
1
Solenoid valve - e.g. 1V1 200-35-140
Replacement filter 42 - AF30P-060S 1 pcs / unit
1
Pressure switch 6 e.g. 1S1 200-90-510
1
Quantity needed per Compactus unit is equal to the number of hydraulic outlet
ports on the Compactus unit valid for your installation.
2
Replacement filter concerns spare part to det. no. 4 (air processing unit) and is
assembled to the pressure regulator.
NOTE: Separate solenoid to valve can not be supplied.
At normal circumstances, Dellner Brakes AB recommends replacing the

filter twice per year. If your air is much polluted, more frequently
replacements are recommended.
Check that the Compactus unit valid for your installation is equipped with
pressure switch(es) before ordering.

10
COMPACTUS UNIT
PRODUCT SPECIFICATION LP80-12/B4 K1 (BWN 1 L-N-1-1-G24) 2006-10-18 1 (of 1)
Pär Mikaelsson Peter Mikaelsson -/- - 319535 2
319535 319535 319555 319535C -

2 1 319555 Pneumatic Hydraulic Power Pack LP80-12/B4 K1 (BWN 1 L-N-1-1-G24) Acc. to doc. ID. D 7280 H & E 7282 B
2 1Z3 1 402-50-005 Level gauge
Setting pressure: See specific
4 1V3 1 AWK30K-F03DE Pressure regulator with filter and gauge documentation valid for your installation
5 1V4 1 534 421 003 0
534-421-003-0 Safety
S f t valve
l (2-6
(2 6 bar)
b ) d
documentation
t ti valid
lid for
f your installation
i t ll ti
Record of changes:
1 2007-06-12 Art. no. for pos. 1V1 corrected, was 200-35-225 PMi PM
Art. no. for pos. 1P1 added
319535.xls, page 319535-M0177, rev. 2

25 Pneumatic inlet port 1 Pos. 29, 30 and 31 added 07-04-26 PMi PM

23
80 400 560 20
28 1 13 22 14 12
27
20
26
4
1V2
200
1V3 PI
1Z5
15
16
3
17 B1
600
560
16 2
17
1P1
1V1
1Z1
22 1Z2
1Z3 DR1
1Z4
9 4x n8,5
10 10 5 21 29 30 31 6 7 8 Hydraulic outlet port Drainage port
1 Max. oulet pressure: See below *) Product specification: 319535
11
31 4 000125084000 Washer BRB 8.8 FZB 8,4x16x1,5
30 4 006924008000 Nut M6M locking 8.8 FZB M8
1V4 12 18 19 20 Cable gland for electric control supply
29 2 319287 Threaded bar 8.8 FZB M8x270
(to be sealed at assembly) Grip range: 11 -17 mm
28 4 00012564000 Washer BRB 8.8 FZB 6.4x12x1.5
26 4 000931006014 Screw M6S 8.8 FZB M6x14
25 2 000125125000 Washer BRB 8.8 FZB 12,5x35x3
Note: 24 2 006924012000 Nut M6M locking 8.8 FZB M12
Cabinet door not shown in upper left view. 23 2 319183 Eye bolt FZB M12
Trap door / 10x Mounting screws, 22 0,65 m 7284012015 Hydraulic tubes GK ø12x1,5
19 1 6035-12-12 Fitting DKLO 12L
see product specification or contact Dellner Brakes AB. 18 1 6043-12-12 Fitting T 12L
17 2 5601-02-18 Bonded seal M18
**) Plus max. 5 l hydraulic fluid. 16 2 6045-12-12 Fitting SV 12L
14 1 6042-12-12 Fitting W 12L
13 1 6009-12-06 Fitting GE 12L, G/ED 3/8"
12 2 6009-12-04 Fitting GE 12L, G/ED 1/4"
11 1 6130-00-08 Plug 8L
10 2 5703014000 Bonded seal G 1/4"
9 1 6045-08-08 Fitting SV 8L
8 1 5703012000 Bonded seal G 1/8"
7 1 6050-08-08 Fitting EVW 8L
200
6 1 6003-08-02 Fitting GE 8L, GB 1/8"

3 1 319575 Connection box 200x200x80
1 1 AS06064 Cabinet 600x600x400
Cabinet door - Left hanged Electric connection box door - Screwed A2 PMi Drawn
PMi Control
PM Scale
1:5
Weight
43 **)
G:\3D-CAD\Hydraulic units (DH

File: 2000)\Compactus\319535.idw
Datum/Date
(BWN 1 L-N-1-1-G24) Ritn. nr
2006-10-18 Draw. no. 319535
lity.
COMPACTUS UNIT WITH PRESSURE SWITCH
PRODUCT SPECIFICATION LP80-12/B4 K1 (BWN 1 L-N-1-1-G24) 2008-04-30 1 (of 1)
Pär Mikaelsson Peter Mikaelsson -/- - 319535-1 1
319535-1 319535-1 319555 319535-1C -

2 1 319555 Pneumatic Hydraulic Power Pack LP80-12/B4 K1 (BWN 1 L-N-1-1-G24) Acc. to doc. ID. D 7280 H & E 7282 B
2 1Z3 1 402-50-005 Level gauge
5 1V4 1 534 421 003 0
534-421-003-0 S f t valve
Safety l (2-6
(2 6 bar)
b ) d
documentation
t ti valid
lid for
f your installation
i t ll ti
6 1S1 1 200-90-510 Pressure switch DG36 (4-12 bar) documentation valid for your installation
Record of changes:
319535-1.xls, page 319535-1-M0177, rev. 1

26
80 400 560 20
31 1 15 25 16 14
4x n8,5
30
20
29
4
1V2
200
1V3 PI
1Z5
17
18
3
19 B1
600
560
18 2
19
1P1
1V1
1Z1
25 1Z2
1Z3 DR1
1Z4
11
34 4 000125084000 Washer BRB 8.8 FZB 8,4x16x1,5
12 12 5 24 32 33 34 8 9 10 Hydraulic outlet port Drainage port
Max. oulet pressure: See below *) 32 2 319287 Threaded bar 8.8 FZB M8x270
13
1S1 31 4 00012564000 Washer BRB 8.8 FZB 6.4x12x1.5
(to be sealed at assembly) 2x Cable gland for electric control supply 30 4 006924006000 Nut M6M locking 8.8 FZB M6
1V4 6 7
(to be sealed at assembly) Grip range: 11 -17 mm 29 4 000931006014 Screw M6S 8.8 FZB M6x14
28 2 000125125000 Washer BRB 8.8 FZB 12,5x35x3
14 20 21 22 23 26 2 319183 Eye bolt FZB M12
Note: 25 0,65 m 7284012015 Hydraulic tubes GK ø12x1,5
M1 Cabinet door not shown in upper left view. 24 0,45 m 7284008010 Hydraulic tubes GK ø8x1
Setting pressure for pressure switch (1S1): See product specification. 23 1 6107-12-08 Fitting KOR 12/8L
21 1 6035-12-12 Fitting DKLO 12L
*) Pressure step up ratio: 44.
Trap door / 10x Mounting screws, 20 1 6044-12-12 Fitting K 12L
could be opened at service 19 2 5601-02-18 Bonded seal M18
see product specification or contact Dellner Brakes AB. 18 2 6045-12-12 Fitting SV 12L
**) Plus max. 5 l hydraulic fluid. 16 1 6042-12-12 Fitting W 12L
15 1 6009-12-06 Fitting GE 12L, G/ED 3/8"
14 2 6009-12-04 Fitting GE 12L, G/ED 1/4"
13 1 6130-00-08 Plug 8L
12 2 5703014000 Bonded seal G 1/4"
11 1 6045-08-08 Fitting SV 8L
10 1 5703012000 Bonded seal G 1/8"
9 1 6050-08-08 Fitting EVW 8L
8 1 6003-08-02 Fitting GE 8L, GB 1/8"
7 1 200-90-509 Adapter DG3-Y8 8L
6 1 200-90-510 Pressure switch DG36 4-12 bar
200

1 1 AS06064 Cabinet 600x600x400
A2 PMi Drawn
PMi Control
PM Scale
1:5
Weight
43 **)

File: 2000)\Compactus\319535-1.idw
Cabinet door - Left hanged Electric connection box door - Screwed
Datum/Date
(BWN 1 L-N-1-1-G24) PS Ritn. nr
2008-04-30 Draw. no. 319535-1
Product specification: 319535-1 lity.
1 Text updated 08-05-05 PMi PM

~201
1P1 1V1
1Z2
A
~364
1Z3
1Z1
242,5
200 200
Drainage port DR (G 1/8")
255
B (1:2)
225 A (1:2)
B
4x n9
130
1Z4
Hydraulic outlet port

Pneumatic inlet port (G 1/4")
PH1 (G 1/4")
1 Product specification: 319535-X, i.e. 319535 or 319535-1 or 319535-2 a.s.o.

A3 PMi Drawn
PMi Control
PM Scale
1:5
Weight

Pneumatic/Hydraulic Power Pack E
Datum/Date
LP 80-12/B4 K1 (BWN 1 L-N-1-1-G24) Ritn. nr
2006-11-02 Draw. no. 319555
lity.
COMPACTUS UNIT
319596 319596 319597 319596C -

2 1Z3 1 402-50-005 Level gauge
5 1V5 1 534-421-003-0 Safety valve (2-6 bar) documentation valid for your installation
Record of changes:
1 2007-06-12 Art. no. for pos. 1V1 and 1V2 corrected, was 200-35-225 PMi PM
319596.xls, page 319596-M0177, rev. 2

25 Pneumatic inlet port 1 Pos. 29, 30 and 31 added 07-04-26 PMi PM

23
80 400 560 20
28 1 13 22 14 12
27
20
26
4
1V3
200
1V4 PI
1Z6
15
16
3
17 B1 B2
600
560
16 2
17
1P1
1V1
1V2
22 1Z1
1Z2 DR1
1Z3
1Z4
1Z5
9 4x n8,5
1 Max. oulet pressure: See below *) Product specification: 319596
11
31 4 000125084000 Washer BRB 8.8 FZB 8,4x16x1,5
Cable gland for electric control supply 30 4 006924008000 Nut M6M locking 8.8 FZB M8
1V5 12 18 19 20 29 2 319287 Threaded bar 8.8 FZB M8x270
28 4 00012564000 Washer BRB 8.8 FZB 6.4x12x1.5
M2 26 4 000931006014 Screw M6S 8.8 FZB M6x14
25 2 000125125000 Washer BRB 8.8 FZB 12,5x35x3
19 2 6035-12-12 Fitting DKLO 12L
17 3 5601-02-18 Bonded seal M18
14 1 6042-12-12 Fitting W 12L
13 1 6009-12-06 Fitting GE 12L, G/ED 3/8"
12 3 6009-12-04 Fitting GE 12L, G/ED 1/4"
11 1 6130-00-08 Plug 8L
10 2 5703014000 Bonded seal G 1/4"
9 1 6045-08-08 Fitting SV 8L
8 1 5703012000 Bonded seal G 1/8"
7 1 6050-08-08 Fitting EVW 8L
200
6 1 6003-08-02 Fitting GE 8L, GB 1/8"

1 1 AS06064 Cabinet 600x600x400
PMi Control
PM Scale
1:5
Weight
45 **)

Datum/Date
(BWN 1 L-NN-1-1-G24) Ritn. nr
2006-12-07 Draw. no. 319596
lity.
COMPACTUS UNIT WITH PRESSURE SWITCHES
319596-1 319596-1 319597 319596-1C -

2 1Z3 1 402-50-005 Level gauge
Record of changes:
319596-1.xls, page 319596-1-M0177, rev. 1

26
80 400 560 20
31 1 15 25 16 14
4x n8,5
30
20
29
4
1V3
200
1V4 PI
1Z6
17
18
3
19 B1 B2
600
560
18 2
19
1P1
1V1
1V2
25 1Z1
1Z2 DR1
1Z3
1Z4
1Z5
11
34 4 000125084000 Washer BRB 8.8 FZB 8,4x16x1,5
13 32 2 319287 Threaded bar 8.8 FZB M8x270
1V5 1S2 2x Cable gland for electric control supply 30 4 006924006000 Nut M6M locking 8.8 FZB M6
6 7 (to be sealed at assembly) Grip range: 11 -17 mm 29 4 000931006014 Screw M6S 8.8 FZB M6x14
(to be sealed at assembly)
28 2 000125125000 Washer BRB 8.8 FZB 12,5x35x3
14 20 21 22 23 26 2 319183 Eye bolt FZB M12
M2 Setting pressure for pressure switches (1S1 & 1S2): See product specification. 23 2 6107-12-08 Fitting KOR 12/8L
21 2 6035-12-12 Fitting DKLO 12L
15 1 6009-12-06 Fitting GE 12L, G/ED 3/8"
14 3 6009-12-04 Fitting GE 12L, G/ED 1/4"
13 1 6130-00-08 Plug 8L
12 2 5703014000 Bonded seal G 1/4"
11 1 6045-08-08 Fitting SV 8L
10 1 5703012000 Bonded seal G 1/8"
9 1 6050-08-08 Fitting EVW 8L
8 1 6003-08-02 Fitting GE 8L, GB 1/8"
7 2 200-90-509 Adapter DG3-Y8 8L
200

1 1 AS06064 Cabinet 600x600x400
A2 PMi Drawn
PMi Control
PM Scale
1:5
Weight
45 **)

File: 2000)\Compactus\319596-1.idw
Datum/Date
(BWN 1 L-NN-1-1-G24) PS Ritn. nr
2007-11-02 Draw. no. 319596-1
1 Text updated 08-01-11 PMi PM

~201
1P1 1V1 1V2
1Z2
A
~364
1Z3
1Z1
242,5
200 200
255
B (1:2)
225
A (1:2)
1Z4 1Z5
B
4x n9
130
Pneumatic inlet port (G 1/4") Hydraulic outlet port Hydraulic outlet port
PH1 (G 1/4") PH2 (G 1/4")
1 Product specification: 319596-X, i.e. 319596 or 319596-1 or 319596-2 a.s.o.

A3 PMi Drawn
PMi Control
PM Scale
1:5
Weight

Datum/Date
LP 80-12/B4 K1 (BWN 1 L-NN-1-1-G24) Ritn. nr
2006-12-07 Draw. no. 319597
lity.
COMPACTUS UNIT
PRODUCT SPECIFICATION LP80-12/B4 K1 (BWN 1 L-NNN-1-1-G24) 2012-01-23 1 (of 1)
321121 321121 321133 321121C -

2 1 321133 Pneumatic Hydraulic Power Pack LP80-12/B4 K1 (BWN 1 L-NNN-1-1-G24) Acc. to doc. ID. D 7280 H & E 7282 B
2 1Z3 1 402-50-005 Level gauge
Record of changes:
1 2012-03-14 Art. no. for pos. 1V1, 1V2 and 1V3 corrected, was 200-35-120 PMi PM
321121.xls, page 321121-M0177, rev. 1


23
80 400 560 20
28 1 13 22 14 12
27
20
26
4
1V4
200
1V5 PI
1Z7
15
16
3
17 B1 B2 B3
600
560
2
16
1P1
17 1V1
1V2
1V3
1Z1
22 1Z2
1Z3 DR1
1Z4
1Z5
9 1Z6 4x n8,5
Max. oulet pressure: See below *) Product specification: 321121
11
31 4 000125084000 Washer BRB 8.8 FZB 8,4x16x1,5
Cable gland for electric control supply 30 4 006924008000 Nut M6M locking 8.8 FZB M8
1V6 12 18 19 20 29 2 319287 Threaded bar 8.8 FZB M8x270
28 4 00012564000 Washer BRB 8.8 FZB 6.4x12x1.5
M2 26 4 000931006014 Screw M6S 8.8 FZB M6x14
M3 25 2 000125125000 Washer BRB 8.8 FZB 12,5x35x3
19 3 6035-12-12 Fitting DKLO 12L
17 4 5601-02-18 Bonded seal M18
14 1 6042-12-12 Fitting W 12L
13 1 6009-12-06 Fitting GE 12L, G/ED 3/8"
12 4 6009-12-04 Fitting GE 12L, G/ED 1/4"
11 1 6130-00-08 Plug 8L
10 2 5703014000 Bonded seal G 1/4"
9 1 6045-08-08 Fitting SV 8L
8 1 5703012000 Bonded seal G 1/8"
7 1 6050-08-08 Fitting EVW 8L
200
6 1 6003-08-02 Fitting GE 8L, GB 1/8"

File: PRODUCTS\HYDRAULICS\COMPACTUS\321121.idw
1 1 AS06064 Cabinet 600x600x400
PMi Control
PM Scale
1:5
Weight
47 **)
Datum/Date
(BWN 1 L-NNN-1-1-G24) Ritn. nr
2012-01-23 Draw. no. 321121
lity.
0 1 2 3 4 5 6 7 8 9
CONNECTION BOX
200x200x80MM
QTY. POS. DESCRIPTION MANUFACTURE
1 CABINET IL202008 200X200X80 ELDON
X1 TERMINAL WDU 2,5 WEIDMULLER

10
2919602
CONDUIT M25 RUTAB

1
1476114
X1
CONDUIT
1xM25
2
Date 23.Jan.2012 =
CONN. BOX 321122
Desig. FNE
LAYOUT 06116-4 +
23.Jan.2012
COMPACTUS UNIT p. 1
Rev.date Verif.
Revision Norm
DELLNER BRAKES 2 p.
0 1 2 3 4 5 6 7 8 9
BRAKE (VALVE 2)
BRAKE (VALVE 3)
BRAKE (VALVE 1)
CONTROLSIGNAL
CONTROLSIGNAL
CONTROLSIGNAL
0V SPARE
SKD
SKD
SKD
1 2 3 4 5 6 7 8 9 10
BLACK
BLACK
BLACK
BLUE
BLUE
BLUE
1 2 3
1 2 1 2 1 2
VALVE VALVE VALVE

Pos.1V1 Pos.1V2 Pos.1V3
1
Date 23.Jan.2012 =
CONN. BOX 321122
Desig. FNE
FIELD WIRING 06116-4 +
23.Jan.2012
COMPACTUS UNIT p. 2
Rev.date Verif.
Revision Norm
DELLNER BRAKES 2 p.
COMPACTUS UNIT WITH PRESSURE SWITCHES
PRODUCT SPECIFICATION LP80-12/B4 K1 (BWN 1 L-NNN-1-1-G24) 2012-01-23 1 (of 1)
321121-1 321121-1 321133 321121-1C -

2 1 321133 Pneumatic Hydraulic Power Pack LP80-12/B4 K1 (BWN 1 L-NNN-1-1-G24) Acc. to doc. ID. D 7280 H & E 7282 B
2 1Z3 1 402-50-005 Level gauge
Record of changes:
1 2012-03-14 Art. no. for pos. 1V1, 1V2 and 1V3 corrected, was 200-35-120 PMi PM
321121-1.xls, page 321121-1-M0177, rev. 1

26
80 400 560 20
31 1 15 25 16 14
4x n8,5
30
20
29
4
1V4
200
1V5 PI
1Z7
17
18
3
19 B1 B2 B3
600
560
2
18 1P1
19 1V1
1V2
1V3
1Z1
25 1Z2
1Z3 DR1
1Z4
1Z5
11 1Z6
34 4 000125084000 Washer BRB 8.8 FZB 8,4x16x1,5
13 32 2 319287 Threaded bar 8.8 FZB M8x270
1V6 1S2 2x Cable gland for electric control supply 30 4 006924006000 Nut M6M locking 8.8 FZB M6
6 7 1S3 Grip range: 11 -17 mm 29 4 000931006014 Screw M6S 8.8 FZB M6x14
(to be sealed at assembly)
(to be sealed at assembly) 28 2 000125125000 Washer BRB 8.8 FZB 12,5x35x3
14 20 21 22 23 26 2 319183 Eye bolt FZB M12
M2 Setting pressure for pressure switches (1S1, 1S2 & 1S3): See product specification. 23 3 6107-12-08 Fitting KOR 12/8L
M3 22 3 8303-00-12 Test connector DKLO 12L, M16x2
21 3 6035-12-12 Fitting DKLO 12L
15 1 6009-12-06 Fitting GE 12L, G/ED 3/8"
14 4 6009-12-04 Fitting GE 12L, G/ED 1/4"
13 1 6130-00-08 Plug 8L
12 2 5703014000 Bonded seal G 1/4"
11 1 6045-08-08 Fitting SV 8L
10 1 5703012000 Bonded seal G 1/8"
9 1 6050-08-08 Fitting EVW 8L
8 1 6003-08-02 Fitting GE 8L, GB 1/8"
7 3 200-90-509 Adapter DG3-Y8 8L
200

File: PRODUCTS\HYDRAULICS\COMPACTUS\321121-1.idw
1 1 AS06064 Cabinet 600x600x400
A2 PMi Drawn
PMi Control
PM Scale
1:5
Weight
47 **)
Datum/Date
(BWN 1 L-NNN-1-1-G24) PS Ritn. nr
2012-01-23 Draw. no. 321121-1
0 1 2 3 4 5 6 7 8 9
CONNECTION BOX
200x200x80MM
1 CABINET IL202008 200X200X80 ELDON
X1 TERMINAL WDU 2,5 WEIDMULLER

18
2919602
CONDUIT M25 RUTAB

2
1476114
X1 PE
EARTH LINE
1 PE MALMBERGS
2099062
CONDUIT
2xM25
2
Date 23.Jan.2012 =
CONN. BOX 321123
Desig. FNE
LAYOUT 0852-2 +
23.Jan.2012
COMPACTUS UNIT p. 1
Rev.date Verif.
Revision Norm
DELLNER BRAKES 2 p.
0 1 2 3 4 5 6 7 8 9
BRAKE (VALVE 1)
BRAKE (VALVE 2)
BRAKE (VALVE 3)
CONTROLSIGNAL
CONTROLSIGNAL
CONTROLSIGNAL
0V
BRAKE STATUS
BRAKE STATUS
BRAKE STATUS
B1 ON/OFF
B2 ON/OFF
B3 ON/OFF
SKD
SKD
SKD
1 2 3 4 5 6 7 8 9 8 9 10 11 12 13 14 - 18
BLACK
BLACK
BLACK
BLACK
BROWN
BLACK
BROWN
BLACK
BROWN
BLUE
BLUE
BLUE
BLUE
BLUE
BLUE
SPARE
1 2 3 4 5 6
1 2 3 1 2 3 1 2 3
1 2 1 2 1 2
PRESSURE PRESSURE PRESSURE

VALVE VALVE VALVE SWITCH SWITCH SWITCH
Pos.1V1 Pos.1V2 Pos.1V3 Pos.1S1 Pos.1S2 Pos.1S3
1
Date 23.Jan.2012 =
CONN. BOX 321123
Desig. FNE
FIELD WIRING 0852-2 +
23.Jan.2012
COMPACTUS UNIT p. 2
Rev.date Verif.
Revision Norm
DELLNER BRAKES 2 p.
1V2
~201
1P1 1V1 1V3
1Z2
~364
1Z3
1Z1
242,5
200 200
255
A (1:2)
B (1:2) 1Z5
225
1Z4 1Z6
B Hydraulic outlet port

4x n9 PH1 (G 1/4")
130
PH2 (G 1/4")
Pneumatic inlet port (G 1/4")
PH3 (G 1/4")
Product specification: 321121-X, i.e. 321121 or 321121-1 or 321121-2 a.s.o.
File: PRODUCTS\HYDRAULICS\COMPACTUS\321133.idw
A3 PMi Drawn
PMi Control
PM Scale
1:5
Weight
Datum/Date
LP 80-12/B4 K1 (BWN 1 L-NNN-1-1-G24) Ritn. nr
2012-02-01 Draw. no. 321133
lity.
8. Appendix list
Table 8.1 (Appendix list)

Appendix no. Document ID. Type Name
1 B 7280 Manual Pneumatically operated hydraulic pump type LP

44
Brief operation manual
for pneumatically operated hydraulic pump type LP
acc to D 7280 and D 7280 H
1. Pneumatic and hydraulic connection

Pressure medium Driving component Compressed air prepared with usual commercial maintenance devices;
and pressure (air side) Operating pressure pL = 1.5 ... 10 bar
Water content in the air conforming ISO 8573-1 class 2 (3)
Pump component Hydraulic oil 10.. .68 mm²/s (ISO VG 10 to VG 68 as per DIN 51 519)
(hydraulic side) Viscosity range appr. 4.. 1500 mm²/s, opt. operat. appr. 10. .500 mm²/s
For perm. hydraulic pressure phydr. see D 7280 (H)
Maintenance unit Commercially available maintenance devices, consisting of air filter (filter cartridge approx. 5µm) with
water separator, pressure control valve (press, reducer), oiler and manometer are required for perfect
preparation of compressed air and safe functioning of the pumps (see sect. 4)
Recommended size of Type LP 80 LP 125 LP 160

the maintenance unit
Norm. flow % l/min 800 1600 2500
Temperatures Compressed air: -10 ... +60°C,

Ambient: -10 ... +40°C
Hydraulic fluid: 0 ... +80°C (see also sect. 5)
2. Characteristic curve 1.4

Guideline figures for the pump delivery and pressure in dependance on the pneumatic
pressure. The guidelline figures for the air consumption are based on standard conditions.
2.1. Size LP 80
Standstill pressure
O Basic Perm. pressure rating max.

pr per type
es at
r
Standstill Corresp. pneum.

ba
su ing
L 6
re a pressure (bar) pressure (bar)

p ir
p
at
L 7
Hydraulic operating pressures pHy (bar)
ba 8 700 7.1
n
io
r
pt
Air consumption Qair (lpm)
LP80- 10 630
m
su
1)
on
12 430 10
rc
Ai
16 240
pL = ppneum.
1) This reduced max. permissible pressure rating for

the standard version is caused by the common
pressure outlet port P. This also applies to hydraulic
power packs acc. to D 7280 H
Delivery flow Q (lpm)
HAWE HYDRAULIK GMBH & CO. KG B 7280

STREITFELDSTR. 25 • 81673 MÜNCHEN Operation manuel pump LP
November 2001-02
B 7280 page 2
2.2. Size LP 125
Standstill pressures
2) Basic Perm. pressure rating max.
Op ess
1)
type
pr
r
er ure
Standstill Corresp. pneum.
ba
at
L6
ing p L
pressure (bar) pressure (bar)
p
at
air 7 ba
n
8 700/(1500) 2) 2.9/ (6.2) 2)
io
pt
m
10 700/(1500) 2) 4.5/ (9.7) 2)
r
1)

su
on
12 700 6.5
rc
Ai
LP125-16 600
18 470
1)
20 380 10
25 240
30 160
pL = ppneum.
1) This reduced max. permissible pressure

rating for the standard version is caused by
the common pressure outlet port P. This also
applies to hydraulic power packs acc. to
D 7280 H
2) For the max. permissible pressure for version
..-8E and ...-10E (without piping)
2.3. Size LP 160
Standstill pressures
Basic Perm. pressure rating max.

type
Op ess
2) Standstill Corresp. pneum.

pr
er ure
pressure (bar) pressure (bar)

at
r
ba
ing p L
L6
air 7 ba
8 700/(1500) 2) 1.8/ (3.8) 2)

p
at
10 700/(1500) 2) 2.8/ (5.9) 2)

d

an
r
em
1) 12 4
rd
Ai
2) LP160-16 700 7.1

18 9.2
1) 20 620
25 390 10
1) 30 265
pL = ppneum.
1) This reduced max. permissible pressure

rating for the standard version is caused by
the common pressure outlet port P. This also
applies to hydraulic power packs acc. to
D 7280 H
2) For the max. permissible pressure for version
..-8E and ...-10E (without piping)

B 7280 page 3
3. Mounting instruction
Installation position like illustrated in the dimensional drawings (i.e. suction ports down, pressure ports and muffler up) as this
eases automatic bleeding of the hydraulic pump elements. A lateral or downward orientation is also possible, see sect. 3.2.2).
3.1. Installation in customer-furnished oil tanks
Note torque of fastening screws

(sections 3.2.3)
Oil level at max.

priming volume
Oil level after max.

withdrawal during
operation
Volume superseding:
Tank bottom LP 80.. appox. 0.9 l with fluid level distance h , 15 - 20 mm to the mounting area
LP 125.. appox. 2.2 l with fluid level distance h , 20 - 25 mm to the mounting area
LP 160.. appox. 3.1 l with fluid level distance h , 25 - 30 mm to the mounting area
3.2. Installation outside an oil tank

Position the pump in such a way that the oil level is always within the area of the upper half of the pump or higher. The pump should
not be installed at a position where it is permanently above the fluid level. This would involve use of foot valves to prevent the suc-
tion pipe from running emty during prolonged stand-still periods. Place the opening of the return pipe below the lowest expected
oil level. The suction pipes must be well sealed (see also section 5.3).
3.2.1. Usual arrangement, with pump in factory adjusted original condition

Two possible fastening methods (for fastening thread, see section 3.2.3)
Hanging position, using fastening thread B 1; Side position, using fastening thread B 2
note torque (sect. 3.2.3)
Spacers between
tank and pump
Return pipe
Two suc-
tion pipes Example:
Suction pipes made from pre-
cision pipes, connected with
Tubing pipe fittings
Dirt strainer. e.g. wire grating with
mesh size approx. 0.6 ... 0.8 mm
B 7280 page 4
3.2.2. Silencer position horizontal or downward
While taking into consideration the best position for the suction pipes, or in special operating circumstances as in sect. 5, the pump
cylinders can be turned by 90° in to different positions after loosening the screws b .
Restriction for LP 80: The pump can only be installed laterally like in illustration a) as complete unit (state of delivery). It is not pos-
sible to rotate the hydraulic cylinders in relation to the pneumatic cylinder. The other installations like illustration b or below are not
possible due to design reasons.
Pump position with horizontal suction connection Pump position with suction connection
a) Pump, as assembled by HAWE entering vertically from bottom to top
Pump mounted with cylinders turned by 180°
Distance
plates for wall
spacing
Two suc-
tion pipes
b) Pump mounted with cylinders turned by 90°

Spacers be-
tween tank
Suction and pump
pipes to
oil tank
Suction pipes
to oil tank
Spacers between
tank and pump
3.2.3 Dimensions for mounting and piping
Fastening thread Max. torque Compressed Pressure Suction

B1 B2 (Nm) air connection port port
P1/P2
LP 80 M8,15 deep M6,12 deep 19 G 1/4 G 1/4 G 3/8
LP 125 8-16 M8,15 deep M6,12 deep 23 G 3/8 G 1/4 G 1/2

18-30 G 3/8
LP 160 8-16 M8,15 deep M8,15 deep 23 G 1/2 G 1/4 G 1/2

18-30 G 3/8
B 7280 page 5
4. Compressed air connection and initial operation

Source of com- Pressure gauge to deter-
pressed air mine consumer end
5µm pressure
Maintenance 3/2-way valve 1) with stan- Pump

unit dard rated flow as mainte- LP 80..,
nance unit, for starting and LP 125 ..
stopping the pump with relief or
of the pump-side com- LP 160..
pressed air supply pipe Pressure pipe
to consumer
1. Set the pressure reducing valve on the maintenance unit to the lowest supply air pressure (approx. 1.5 bar). The air start valve
should be on stop.
2. Loosen the pressure pipe at the consumer sufficiently so that enclosed air can escape. Open the air start valve and wait for the
oil to come.
3. Air start valve on stop. Tighten the pressure pipe, and after starting the pump again, pressurize the unloaded consumer several
times and move it to and fro. Then turn the pressure reducing valve up as in 1 to required supply air pressure (step by step if
necessary), unit the desired end pressure, e.g. standstill pressure, is shown on the manometer of the pressure pipe to the
hydraulic consumer.
The maintenance unit in the compressed air supply pipe is obligatory, since it alone ensures smooth operation by filtering, moisture
separation and oil ing (= preperation of compressed air). It has a pressure reducing valve to limit the air pressure, which is
necessary on the hydraulic side to fix the standstill pressure.
Attention: Observe the max. air pressure rating for air pumps piped by HAWE!
A pressure reducing valve has to be used when the pump is supplied via compressed air cylinders. The pumps type LP do not fea-
ture any pressure valve on the pneumatic side !
Any industrial standard hydraulic oil (ISO VG 10) or spindle oil (ISO
VG 5 to 10) may be used in the pneumatic maintenance unit. The dy-
namic seals of piloting and main plunger of the reversal control valve
should be lubed regularily when connected to oil-free pneumatics
and frequent every-day use is intended. Suited are longterm lubes
e.g. Autol TOP 2000 from Co. Autol, Paradiesstraße 14, D-97080
4
1 Würzburg.
3 The maintenance intervalls depend on the indivdual operation con-
ditions e.g. a 3-4 month interval for 3-shift permanent operation.
See also notes in sect. 5
2
1
3
4
6
1 Remove cover plate including O-rings.

2 Push out the main plunger (any side) the sleeve remains in the housing.
Lube the visible sections of the O-rings.
Reinstall the plunger in the housing (sleeve).
3 Reinstall the cover plate including O-rings. 1) Industrial standard pneumatic reducers
4 Remove the tapped plugs including the copper seal rings. can be installed at port L, if the thread of
port A at the pneumatic directional valve
5 Push the piloting plunger (any side) out of the housing. and port L at the air driven pump type LP
Lube the visible sections of the O-rings. are differing. The largest possible diameter
Reinstall the plunger in the housing. for the air line should be used always.
6 Reinstall the tapped plugs including the copper seal rings.
B 7280 page 6
5. Supplementing note for prolonged operation periods

Any pressurized gas (or gas mixture) will cool down due to the thermodynamic regularity, when decompressed suddenly (adiabat-
ic). This will cause also cool down of the surrounding material where the decompression happens and where the gas is routed
through. The stand still periods during normal usual working cycles are usually sufficient that these components come to ambient
temperature again.
But white frost or internal icing may occur (dep. on the moisture in the compressed air), when the pump is running for prolonged
periods. This effect is also visible at other pneumatic tools where the working speed is cut down and even stand-still is caused by
iced control elements. Pumps type LP are prone to such malfunction when permanently operated for more than 20 minutes and air
pressure is higher than 4 bar. A good preventive measure is adding anti-freeze-lubricant (like for truck brakes) in the service unit of
the compressed air. This will cut down the freezing point and will additionally lube the dynamic (moving) seals on the pneumatic side
of the pump. It is advantageous to install the pump with the silencer directing sideward or downwards as any excess antifreeze
condensing at the silencer will drop down and not drip into the movement reversal valve again. Evidently this is not possible with
complete hydraulic power packs from HAWE as the silencer is always vertically upwards.
Freezing of the pump components may happen when the air to drive the pump is too cold (below the perm. temperature range). This
may happen especially when cylinders are used as source but also when the pump is running over prolonged periods, as compressed
gases cool down strongly, when decompressed.
A recommended anti-freeze-lubricant is e.g. "Klüberbio LR 6-15" from Co. Klüber Lubication, D-81379 München, Geisenhausenerstr. 7.
5.1. Optional leakage drain with type LP 125 and LP 160

A drain line is necessary, when the pump is installed outside the tank
and any leakage (drops only) are not permissible or unwanted, e.g.
due to clean room conditions etc.
The manual emergency actuation of

the piloting valve may be pushed alter-
nately inward when start-up problems
do occure (tool diameter max. 3 mm).
1 4 4 1
Union pipe
2
3
Drain line to the tank
The line consists of:
1 3 Hose nipple 6020 070
2
2 Hose 6020 077 a
1 Hose clamp T-PK-4 (FESTO)
3
1 3 Seal ring A 6x10x1 DIN 7603-Cu
4
4
0 1 2 3 4 5 6 7 8 9
WUPE001E 01.03.1994
JL AUTOMATIK AB
Tel: 0243-219900
Fax: 0243-219901
e-post: [email protected]
Customer : CATERPILLAR PROP.

Plant designation : S-SYSTEM
Drawing number : 1452
Commission : DELLNER BRAKES
Electrical Drawings
Highest 0-number :
Not used 0-number :
Remarks:
Created on : 08.Maj.2014 by : FNE Highest Page No. : 10

Processed on : 23.Dec.2014 by : MAA No. of pages : 10
2
Date 08.Maj.2014 =
CATERPILLAR PROP.
Desig. FNE 1452 +
23.Dec.2014
S-SYSTEM p. 1
Rev.date Verif.
Revision Norm
DELLNER BRAKES 10 p.
0 1 2 3 4 5 6 7 8 9
Table of content Column x: created autom. but modified manually WUPJ005 22.04.96
Page Page designation Supplementary field Date Editor X
1 23.Okt.2013 FNE
2 TABLE OF CONTENT 23.Okt.2013 FNE X
3 LAYOUT COMPACTUS 23.Okt.2013 FNE
4 LAYOUT S-UNITS 23.Okt.2013 FNE
5 BRAKE VALVES 23.Okt.2013 FNE
6 S-UNITS PORT & STBD SIDE 23.Okt.2013 FNE
7 CUSTOMER SIGNALS 23.Okt.2013 FNE
8 FIELD WIRING COMPACTUS 23.Okt.2013 FNE
9 FIELD WIRING 23.Okt.2013 FNE
10 FIELD WIRING CUSTOMER SIGNALS 23.Okt.2013 FNE
1 3
Date 08.Maj.2014 =
CATERPILLAR PROP.
Desig. FNE
TABLE OF CONTENT 1452 +
23.Dec.2014
S-SYSTEM p. 2
Rev.date Verif.
Revision Norm
0 1 2 3 4 5 6 7 8 9
MOUNTING PLATE CONNECTION BOX

400x300x155MM
1 CABINET MAS0403015 ELDON
TERMINAL WDU 2,5 WEIDMULLER

22 X1
K101
K102
K103
K104
2919602
CONDUIT M25 RUTAB

2
1476114
CONDUIT M20 RUTAB

3
1476113
K101 RELAY 24VDC 2CO LD/PB WEIDMULLER

4 -
X1 4025018
K104
CONDUITS
2xM25
3xM20
2 4
Date 08.Maj.2014 =
CATERPILLAR PROP.
Desig. FNE
LAYOUT 1452 +
23.Dec.2014
S-SYSTEM COMPACTUS p. 3
Rev.date Verif.
Revision Norm
0 1 2 3 4 5 6 7 8 9
CONNECTION BOX
80x125x57MM
S-UNIT
PORT SIDE
X2
2 CABINET KLIPPON 9529150000 WEIDMULLER
TERMINAL WDU 1,5 WEIDMULLER

8 X2+
X3 2919602
CONDUIT M25 RUTAB

2
CONDUITS 1476114
1xM25
CONDUIT M16 RUTAB
2xM16 4
1476112
CONNECTION BOX
80x125x57MM
S-UNIT
STBD SIDE
X3
CONDUITS
1xM25
2xM16
3 5
Date 08.Maj.2014 =
CATERPILLAR PROP.
Desig. FNE
LAYOUT 1452 +
23.Dec.2014
S-SYSTEM S-UNITS p. 4
Rev.date Verif.
Revision Norm
0 1 2 3 4 5 6 7 8 9
+24VDC /6.0
0V /6.0
X1 3 5
CUSTOMER
X1 4 6
X1 7 9
1 1
1V1 1V2
2 2
BRAKE BRAKE
VALVE VALVE
X1 8 10
X1 1 2
PORT BRAKE STBD BRAKE

+24VDC
ON/OFF ON/OFF
0V
4 6
Date 08.Maj.2014 =
CATERPILLAR PROP.
Desig. FNE
BRAKE VALVES 1452 +
23.Dec.2014
S-SYSTEM p. 5
Rev.date Verif.
Revision Norm
0 1 2 3 4 5 6 7 8 9
5.9/ +24VDC +24VDC /7.0

5.9/ 0V 0V /7.0
X1 11 12 15 16
S-UNIT S-UNIT
PORT SIDE STBD SIDE
X2 1 2 X3 1 2
2S1 2S2 3S1 3S2

BRAKE BRAKE BRAKE BRAKE
OFF OFF OFF OFF
X2 3 4 X3 3 4
X1 13 14 17 18
A1 A1 A1 A1
K101 K102 K103 K104

A2 A2 A2 A2
11 14 11 14 11 14 11 14
7.1 7.2 6.2 6.3
11 12 11 12 11 12 11 12
7.2 7.2 7.6 7.6
5 7
Date 08.Maj.2014 =
CATERPILLAR PROP.
Desig. FNE
S-UNITS 1452 +
23.Dec.2014
S-SYSTEM PORT & STBD SIDE p. 6
Rev.date Verif.
Revision Norm
0 1 2 3 4 5 6 7 8 9
11 11
K103 K104
11 11
K101 K102 6.6
12
6.6
12
6.1 6.2
12 12
21 22
X1 19 20
PORT BRAKE NOT OFF STBD BRAKE NOT OFF

(=SIGNAL) (=SIGNAL)
6 8
Date 08.Maj.2014 =
CATERPILLAR PROP.
Desig. FNE
CUSTOMER SIGNALS 1452 +
23.Dec.2014
S-SYSTEM p. 7
Rev.date Verif.
Revision Norm
0 1 2 3 4 5 6 7 8 9
X1 1 2 3 4 5 6 7 8 9 10
+24VDC
BLACK
BLACK
0V
REMOTE ACTIVATE
PORT BRAKES
REMOTE ACTIVATE
STBD BRAKES
BLUE
BLUE
POWER
SUPPLY
1 2
1 2 1 2
VALVE VALVE
Pos.1V1 Pos.1V2
7 9
Date 08.Maj.2014 =
CATERPILLAR PROP.
Desig. FNE
FIELD WIRING 1452 +
23.Dec.2014
S-SYSTEM COMPACTUS p. 8
Rev.date Verif.
Revision Norm
0 1 2 3 4 5 6 7 8 9
X1 11 12 13 14 15 16 17 18 X2 1 2 3 1 2 4 X3 1 2 3 1 2 4
1 2 3 4 1 2 3 4 1 2 3 1 2 3 1 2 3 1 2 3
5 6 7 8 9 10
1 2 3 1 2 3 1 2 3 1 2 3
1 2 3 4 1 2 3 4
+ - N0 + - N0 + - N0 + - N0
X2 1 2 3 4 X3 1 2 3 4
CABLE BETWEEN CABLE BETWEEN

COMPACTUS AND S-UNIT COMPACTUS AND S-UNIT
PROXIMITY SWITCH PROXIMITY SWITCH PROXIMITY SWITCH PROXIMITY SWITCH
PORT SIDE STBD SIDE
2S1 2S2 3S1 3S2
8 10
Date 08.Maj.2014 =
CATERPILLAR PROP.
Desig. FNE
FIELD WIRING 1452 +
23.Dec.2014
S-SYSTEM p. 9
Rev.date Verif.
Revision Norm
0 1 2 3 4 5 6 7 8 9
X1 19 20 21 22
PORT BRAKE STBD BRAKE

STATUS STATUS
(SEE PAGE 7) (SEE PAGE 7)
9
Date 08.Maj.2014 =
CATERPILLAR PROP.
Desig. FNE
FIELD WIRING 1452 +
23.Dec.2014
S-SYSTEM CUSTOMER SIGNALS p. 10
Rev.date Verif.
Revision Norm
1(2)
BEDDING‐IN PROCEDURE FOR DELLNER DISC BRAKES

General
In order to achieve the optimum performance from Dellner disc brakes for a particular
application, it is important that the interface between the brake pads and the disc be
properly bedded or burnished.

The bedding‐in of the pads with the disc is generally a two step process. The first step is to
get the entire surface of the brake pads in full contact with the disc. Next is to generate
more and more heat between the pads and disc to burn off loose particles of friction
material and remove high spots from the pad surface.

Preparations
Before starting the process, check to be sure that the brake pads and the disc are clean and
dry. If the pads are contaminated with oil, it may be necessary to replace them. Oil soaked
pads will not provide the rated capacity of the brake. If the disc is dirty with grease or oil,
clean the surface with a solvent that leaves no residue. If the braking area of the disc is rusty,
clean it with a fine grade of abrasive paper and remove the dust with a clean cloth and
solvent.

Process time
The time required for the bedding process will vary depending of the severity of the required
braking duty. This can best be determined on the job site based on the observed
performance of the brake pads during the conditioning process.

Brakes that will be engaged frequently under dynamic conditions must first be worked lightly
to insure that the high spots are removed from the pads and that full contact with the disc is
achieved.

Pressure applied brakes
For pressure applied brakes, first apply 10% to 15% of the full pressure and allow the unit to
slip against the rotating disc until the surface reaches approximately 100° C. Stop and allow
the disc to cool. Slowly increase the pressure and slipping time until the disc surface reaches
approximately 200° ‐ 250° C. (For the maximum continuous operating temperature for the
friction material being used ‐ see Dellner Brakes Technical Specification manual TS0001.)

Allow the disc to cool to near ambient and repeat the process until full rating of the brake is
achieved.
AI04-011E-03

If the disc surface starts to glaze showing shiny deposits of friction material on the disc
surface, reduce the pressure and/or disc speed and progress more slowly to full brake
capacity. Remove any glazing from the disc surface with a fine grade of abrasive paper.
DELLNER BRAKES AB Tel: Fax: Org.nr/VAT no: Internet / e‐mail:
Vikavägen 144 023‐78 30 50 023‐77 06 90 556553‐1299 www.dellner‐brakes.com
SE ‐ 791 95 FALUN +46 23 78 30 50 +46 23 77 06 90 SE556553129901 info@dellner‐brakes.com
SWEDEN
2(2)
Spring applied, pressure released brakes
Spring applied, pressure released brakes require the same conditioning, but pressure on the
brake pads is increased by slowly reducing the applied pressure (back pressure) until the
maximum run‐in temperature and design capacity of the brake is reached.

Brakes used in light duty service may provide sufficient capacity without the run‐in
procedure. This can be determined on the job site before the units are put into full service.

After the run‐in procedure, adjust the air gap for spring applied brakes to the recommended
minimum, inspect and clean the units and they are ready to be put into service.
AI04-011E-03
DELLNER BRAKES AB Tel: Fax: Org.nr/VAT no: Internet / e‐mail:

Vikavägen 144 023‐78 30 50 023‐77 06 90 556553‐1299 www.dellner‐brakes.com
SE ‐ 791 95 FALUN +46 23 78 30 50 +46 23 77 06 90 SE556553129901 info@dellner‐brakes.com
SWEDEN
INSTALLATION MANUAL
MPP HDX
6.4. NOZZLE (DMC)

INSTALLATION MANUAL
MPP HDX

BV2122 Installation and alignment
Rigid fastening, metal seat chocks for heavy marine gearboxes

with longitudinal mounting arrangement
2018-11
BV2122
Table of contents
Table of contents
1 Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
1.1 Field of application and purposes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
1.2 Safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
1.2.1 Personnel qualification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
1.2.2 Safely lifting the gearbox . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
2 Installation and alignment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4

2.1 Responsibility for installation and alignment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
2.2 Preparations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
2.3 Setting up the gearbox . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
2.4 Alignment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
2.4.1 General information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
2.4.2 Connection to propeller shaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
2.4.3 Foundation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
2.4.4 Connection to engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
2.4.5 Connection to PTO or PTI shaft (if present) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
2.4.6 Alignment check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
2.5 Connecting gearbox components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
2.5.1 Connecting the valve control and supervision system . . . . . . . . . . . . . . . . . . . . . 20
2.5.2 Connecting the shaft brake. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
2.5.3 Connecting the heat exchanger . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
2.5.4 Connecting the electric stand-by pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
1
BV2122
Introduction
1 Introduction
1.1 Field of application and purposes
This operation description applies to heavy marine gearboxes with rigid fasten-
ing, metal seat chocks and longitudinal mounting arrangement. It does not apply
to light marine gearboxes in accordance with BV2378.
1.2 Safety
1.2.1 Personnel qualification

Carry out work on the gearbox only if you have the required technical know-how.
Certain work requires special qualifications:
• qualification in handling transport aids and lifting equipment when the gear-
box is to be transported or lifted
• qualified mechanic for all mechanical work
• qualified electrician for all work on electrical components
• knowledge of the necessary protective devices, safety measures, applicable
rules, safety regulations, and operating conditions
Please contact REINTJES service, if:
• you do not have the qualifications stated above,
• you are unsure how to carry out certain work,
• the gearbox appears to require work not described in this manual.
2
BV2122
Introduction
1.2.2 Safely lifting the gearbox
WARNING!
The gearbox can fall over if it is transported inappropriately or with unsuit-
able transport aids, lifting equipment and/or slings.
Persons hit by the gearbox can suffer life-threatening injuries and can be killed.
 Make sure that transport is carried out only by persons competent in the use
of transport aids and lifting equipment.
 Before every transport of the gearbox, make sure that nobody is in the gear-
boxʼs hazardous area.
 Use only transport aids, lifting equipment, and slings that are approved for
the anticipated load and in perfect technical condition. The gearbox weight
(without operating oil but including special accessories) is stamped on the
type plate.
 Transport aids and lifting equipment must be designed to be able to safely
hoist the load, hold it and set it down again.
 Observe the regulations and instructions provided by the manufacturer of the
transport aids, lifting equipment, and slings.
 Use only the lifting eyes intended for lifting the gearbox. The lifting eyes are
marked with signs and are indicated in the drawing of installation. Lifting eyes
on components, e.g. motor, are only intended for lifting these components
and not for lifting the whole gearbox.
 Secure slings to all of the eyebolts intended for this purpose using shackles.
 Never put slings around shaft ends, pipes, or other externally mounted parts.
 Make sure that the sling angle does not exceed 45° from the perpendicular.
Use a traversing bridge if necessary.
NOTICE
Danger of damage to the gearbox!
 When transporting the gearbox, make sure that you do not damage its
packaging, if further storage is intended afterward.
 Avoid slings pressing against pipes or externally mounted parts. Use a tra-
versing bridge if necessary.
3
BV2122
Installation and alignment
2 Installation and alignment

2.1 Responsibility for installation and alignment
The shipyard is responsible for gearbox installation and alignment.
2.2 Preparations
WARNING!
 Observe the warnings in chapter 1.2.2 Safely lifting the gearbox.
1. Remove the gearbox packaging (films, transport packaging).

2. Check the gearbox for damage.
3. Remove any dust or dirt.
2.3 Setting up the gearbox
Installation location
There must be enough space for the installation personnel in the working area.
Consider free spaces as indicated in the drawing of installation. The foundation
must be designed to absorb the gearbox weight and working loads.
Consider sufficient space for disassembling housing and shafts during later
maintenance work.
Work steps
1. Before setting up the gearbox, make sure that you have these documents:
a. operating manual
b. drawing of installation
c. supervision plan
d. alignment calculation (optional)
2. Make sure that you have fully read and understood all information concerning
alignment.
3. Place the gearbox on the foundation in the intended position.
4. Secure the gearbox against shifting on the foundation until it has been
aligned and permanently fastened.
5. Protect the gearbox from corrosion, contamination and damage.
The drawing of installation represents the basis for installation and alignment of
the gearbox. This drawing includes all dimensions and values relevant for instal-
lation and alignment of the gearbox. You will find the applicable drawing number
for your gearbox on the order confirmation.
You can obtain the drawing of installation from REINTJES by providing the gear-
boxʼs serial number.
REINTJES service
E-mail: [email protected] or
on working days: phone +49 5151 104 0
in emergencies and on weekends: phone +49 5151 104 237
4
BV2122
2.4 Alignment
2.4.1 General information

1. Determine the permissible horizontal and vertical GAP and SAG values for
all shaft connections. Take into account the technical information (alignment
calculation, thermal expansion and manufacturer's information) applying to
the units to be connected.
2. Consider the thermal expansion of engine, gearbox, auxiliary units, and foun-
dation at operating temperature.
3. Take into account possible engine displacement due to torque influence.
4. In addition, take into account thermosetting effects for the cast resin founda-
tion. Request detailed information on this from the cast resin manufacturer.
5. For gearboxes with bell housing please note that the alignment and the foun-
dation of the engine directly affect the output side of the gearbox.
6. Carry out the alignment work only after the vessel is afloat with absolutely no
ground contact with the sea bed.
7. The vessel should be equipped as far as possible. Missing heavy equipment,
e.g. winches, cranes, must be duly considered.
8. Carry out the alignment work in the early morning. Direct sunlight can influ-
ence the alignment result.
The best precondition for a trouble-free gearbox operation is a precise alignment
of:
• the gearbox output shaft with the propeller shaft
• the gearbox input shaft with the engine shaft
• the auxiliary drive shafts with the connected auxiliary units (if present)
If torsionally flexible couplings are used, precise alignment with the engine will
also be required. Any misalignment will have negative effects on the service life
of gearbox and auxiliary units.
REINTJES will only recognize the alignment as complete, if you have completely
documented the alignment of propeller shaft to gearbox, gearbox to engine, and
gearbox to connected auxiliary units.
5
BV2122
2.4.2 Connection to propeller shaft
Fig. 2-1: Gearbox foot with fastening options (rigid fastening)
1 alignment screw 3 surface for lateral collision chocks

2 hole for foundation bolt 4 surface for collision chocks
Fig. 2-2: Gearbox foot with fastening options (resilient fastening)
1 base plate 4 alignment screw

2 hole for foundation bolt 5 bolts for temporarily fixing the base
3 surface for collision chocks plate
The process of alignment is basically identical for rigid and resilient fastening.
The difference is that with a rigid fastening the gearbox foot is fixed permanently
to the gearbox housing. With a resilient fastening the gearbox can be removed
from the base plate. It is possible to remove the gearbox from the base plate even
after the base plate is aligned and fixed with cast resin. The gearbox can then be
put back without another alignment.
For connecting the propeller shaft line with the gearbox, the propeller shaft and/
or the intermediate shaft must be in the static operating position.
That means:
 the propeller shaft and the intermediate shaft are in their bearings
 the propeller is mounted
 the intermediate shaft flanges are connected (if present)
 the flange facing the gearbox is in the alignment position (if necessary)
6
BV2122
Work steps:
1. Screw the alignment screws into the gearbox foot.
2. Fix the alignment screws for horizontal alignment to the foundation.
3. With the alignment screws, align the gearbox vertically and horizontally in
longitudinal and transverse directions with the propeller flange, according to
the specified data.
With a resilient fastening ensure that there is no distortion in the elastic elements
during the horizontal alignment. The base plates must be evenly displaced on
both sides of the gearbox.
4. Align the gearbox in accordance with the required GAP and SAG values.
5. With approved methods (gauges, laser), measure the vertical and horizontal
GAP value 4 as well as the vertical and horizontal SAG value 3 between the
gearbox flange 2 and the counter flange on the propeller side 1.
6. Set the horizontal GAP and SAG values to zero.

7. Observe the permissible tolerances:
SAG: Radial misalignment 0.05 mm (centreline run-out 0.025 mm)
GAP: Angular misalignment 0.1 mm/m
8. Document the GAP and SAG values.
9. Fix the gearbox to the foundation, see chapter 2.4.3 Foundation.
10. Check the GAP and SAG values.
11. Connect the propeller shaft to the gearbox output shaft after the gearbox is
firmly fixed to the foundation.
If you have a special, deviating installation situation, contact REINTJES service
prior to installation to discuss the necessary steps.
7
BV2122
2.4.3 Foundation
2.4.3.1 General information

1. Ensure that the gearbox is installed without distortion.
2. Observe the requirements for collision chocks and seat chocks, see chapter
2.4.3.3 Collision chocks and chapter 2.4.3.4 Seat chocks.
3. Insert the seat chocks between the gearbox foot and the top plate.
4. Loosen the alignment screws before tightening the foundation bolts.
5. For cast resin foundation:
Loosen the alignment screws only after the thermosetting of the cast resin is
finished.
6. After aligning the gearbox with the propeller shaft, screw the gearbox to the
foundation so that it is secured against shifting. Observe the requirements for
screw joints, see chapter 2.4.3.5 Screw joints.
7. Observe the requirements of classification societies.
Any other foundation type must be approved by REINTJES.
8
BV2122
2.4.3.2 Rigid fastening with metal seat chocks

The following combinations are permissible for fixing the gearbox:
Fig. 2-3: Metal seat chocks with four fitting bolts, through bolts and collision chocks for
propeller thrust AHEAD and ASTERN
1 engine side 4 collision chock

2 propeller side 5 metal seat chock
3 fitting bolt 6 through bolt
Fig. 2-4: Metal seat chocks with through bolts and collision chocks for propeller thrust and
lateral fixation
1 engine side 4 metal seat chock

2 propeller side 5 collision chock
3 through bolt
9
BV2122
Fig. 2-5: Metal seat chocks with four fitting stud bolts, through stud bolts and collision
chocks for propeller thrust AHEAD and ASTERN

2 propeller side 5 metal seat chock
3 fitting stud bolt 6 through stud bolt
Fig. 2-6: Metal seat chocks with through stud bolts and collision chocks for propeller thrust
and lateral fixation
1 engine side 4 metal seat chock

3 through stud bolt
10
BV2122
Fig. 2-7: Metal seat chocks with fitting bolts and through bolts without collision chocks
1 engine side 4 through bolt

2 propeller side 5 thrust bearing
3 fitting bolt 6 metal seat chock
The number of fitting bolts depends on the propeller thrust.
11
BV2122
2.4.3.3 Collision chocks
Fig. 2-8: Principle of a simple collision chock
1 gearbox foot 4 top plate

2 seat chock 5 cast resin seat chock
3 collision chock
The shipyard is responsible for the design and installation of the collision chocks.
Observe the following requirements:
1. The collision chocks are to be structurally designed so that they can with-
stand the maximum propeller thrust without taking into account the founda-
tion bolt preload.
2. Make the collision chocks from metallic material. Provide for a metal-to-metal
contact on both sides and secure the collision chocks against displacement.
3. Make the collision chocks wedge-shaped or double-wedge-shaped.
4. Fix the collision chocks with screws or by welding them over the entire wedge
length.
5. Observe the requirements for seat chocks, see chapter 2.4.3.4 Seat chocks.
12
BV2122
2.4.3.4 Seat chocks
Metal seat chocks

The metal seat chocks are designed to keep the gearbox in the desired position
and to transmit the reaction forces into the foundation as evenly as possible.
1. Use metal seat chocks preferably made of steel or cast steel as well as cast
iron.
2. Observe the height of metal seat chocks:
20 - 80 mm
3. Size of recesses: The recess surface in the metal seat chock should be less
than 20 % of the total surface of the metal seat chock.
4. Use only rectangular metal seat chocks.
5. Have the metal seat chock manufactured from one part. Shims or lining
plates are not permissible.
6. Fit metal seat chocks by die spotting on both sides. The bearing share
achieved must be at least 75 %.
7. Tack welding on metal seat chocks is not permissible.
8. Ensure that metal seat chocks are sufficiently dimensioned and closely fitted.
2.4.3.5 Screw joints
General information
The gearbox foundation bolts are fitting bolts and/or through bolts.
1. Calculate the foundation bolts according to the state of the art. Under all op-
erating conditions, the preload of the bolts must be higher than the workload.
2. Consider for the bolt elongation that the connection cannot be loosened by
settlement effects. We recommend an elongation of the screws of > 0.17 mm
for cast resin seat chocks and of > 0.25 mm for metal seat chocks.
3. Any lifting of the gearbox under dynamic stress must be excluded.
4. Contact REINTJES service for information on the working forces. When cal-
culating the bolts, also consider external forces e.g. added by mounted com-
ponents that have an impact on the gearbox.
5. Secure all screw joints against loosening.
6. The seats of bolt heads and nuts have to be plane-parallel. Ensure that the
seat under the bolt head and nut is sufficiently dimensioned in order not to
exceed the permissible surface pressure.
13
BV2122
Fitting bolts
The fitting bolts fix the gearbox on the foundation.
1. The geometry of the fitting bolts must be designed such that at least 50 % of
the height of the gearbox foot and 50 % of the height of the top plate are cov-
ered by each shaft.
2. Only use fitting bolts with a tensile strength of at least 8.8 in accordance with
ISO 898. The fitting bolt bores are predrilled.
When using metal seat chocks and a sufficient number of fitting bolts, the propel-
ler thrust can be transmitted through the fitting bolts into the foundation. In this
case, check the fitting bolts for bolt bearing pressure and shear. Position the fit-
ting bolts in the direct vicinity of the thrust bearing.
Fig. 2-9: Fitting bolts with metal seat chocks
1 hexagon nut 4 top plate

2 gearbox foot 5 fitting bolt
3 metal seat chock
14
BV2122
Through bolts
Only use through bolts with a tensile strength of at least 8.8 in accordance with
ISO 898.
The through bolts must comply with application-specific requirements and be
tightened to the specified torque.
Fig. 2-10: Through bolts with metal seat chocks

2 gearbox foot 5 through bolt
3 metal seat chock
15
BV2122
Fitting stud bolts

The fitting stud bolts fix the gearbox on the foundation.
1. The geometry of the fitting stud bolts must be designed such that at least
50 % of the height of the gearbox foot and 50 % of the height of the top plate
are covered by each shaft.
2. Only use fitting stud bolts with a tensile strength of at least 8.8 in accordance
with ISO 898. The fitting stud bolt bores are predrilled.
Fig. 2-11: Fitting stud bolts with metal seat chocks
1 hexagon nut 4 metal seat chock

2 bush 5 top plate
3 gearbox foot 6 castellated nut with split pin
16
BV2122
Through stud bolts

Only use through stud bolts with a tensile strength of at least 8.8 in accordance
with ISO 898.
The through stud bolts must comply with application-specific requirements and
be tightened to the specified torque.
Fig. 2-12: Through stud bolts with metal seat chocks
1 hexagon nut 4 metal seat chock

2 bush 5 top plate
2.4.4 Connection to engine

Does not apply when the gearbox is close-coupled to the engine by means of a
bell housing.
 The gearbox is aligned with the propeller shaft.
 The gearbox is firmly fixed to the foundation.
 The engine is aligned axially with the gearbox.
The space between gearbox and engine must correspond to the mounting
length of the flexible coupling. The axial reaction forces of the flexible cou-
pling on engine and gearbox shall be as low as possible. Observe the
specifications of engine and flexible coupling manufacturer.
Work steps:
1. With the alignment screws, align the engine horizontally in longitudinal and
transverse directions and vertically in front of the gearbox input flange, ac-
cording to the specified data.
GAP value as well as the vertical and horizontal SAG value.
17
BV2122
5. Consider the maximum permissible reaction forces exerted by the flexible

coupling on the gearbox input shaft.
FR = Δ r x Cr dyn
Δ r = radial shaft misalignment
Cr dyn = radial stiffness of the flexible coupling
A = engine side gearbox flange
B = engine flywheel
6. Determine the corresponding bending moment MB.
MB = 0.5 x Cax x D x X1
Cax = axial stiffness of the flexible coupling
D = diameter of the connection between flange and flexible coupling
X1 = measured angular misalignment (GAP value)
7. Inform REINTJES of the reaction force FR, the bending moment MB and the
distance L for approval.
L = S + X = distance from application point FR to big cone diameter of gear-
box input shaft
8. During all operations, observe the instructions of the engine and coupling
manufacturers.
10. Fix the engine to the foundation.
11. Connect gearbox and engine with the flexible coupling.
18
BV2122
2.4.5 Connection to PTO or PTI shaft (if present)

 The gearbox is aligned with the engine.
Work steps:
1. Align the auxiliary unit that is driven by the PTO or driving the PTI with the
alignment screws, horizontally in longitudinal and transverse directions, and
vertically in front of the PTO or PTI shaft of the gearbox, according to the
specified data.
coupling on the gearbox PTO or PTI shaft.
6. During all operations, observe the instructions of the auxiliary unit and cou-
pling manufacturers.
7. Fix the auxiliary unit to the foundation.
8. Determine the reaction forces of the flexible coupling, see chapter 2.4.4 Con-
nection to engine.
9. Connect PTO or PTI and auxiliary unit with the flexible coupling.
2.4.6 Alignment check
Engine alignment check

bell housing.
1. Check the gearbox foundation bolts for tightness.
2. Disconnect the flexible coupling on the engine.
3. Check the GAP and SAG values and compare them with the data specified
by the coupling manufacturer. In case of deviations, please contact
REINTJES service.
Propeller alignment check

2. Loosen the flange mounting screws on the propeller side.
3. Check the GAP and SAG values and compare them with the specified data.
In case of deviations, please contact REINTJES service.
19
BV2122
Auxiliary drive alignment check (if present)

2. Disconnect the flexible coupling.
REINTJES service.
2.5 Connecting gearbox components
2.5.1 Connecting the valve control and supervision system

1. Lay the cables for the valve control and supervision system to the gearbox
and connect them according to the supervision plan.
If a terminal box is installed on the gearbox, the cables for the valve control
and supervision system are completely connected on the gearbox itself.
2. Check the functioning of the valve control and supervision system in accor-
dance with the checklist for commissioning.
2.5.2 Connecting the shaft brake

1. Lay a compressed air line to the shaft brake control valve. The connection is
marked in the drawing of installation.
2. Install a dehumidifier in the compressed air system.
The initial pneumatic pressure must be 5 - 7 bar (500 - 700 kPa, 73 - 101 psi).
20
BV2122
2.5.3 Connecting the heat exchanger
Connecting the factory-equipped heat exchanger

Please note that the input cross-section of the heat exchanger on the water side
must not be varied!
Fig. 2-13: Connections of the heat exchanger

1. Install the pipes on the water side of the heat exchanger with SAE counter
flanges (see drawing of installation).
2. Make sure the pipes are laid vibration-free. We recommend using rubber/
steel-wire compensators.
3. Cooling sea water:
Install a filter in the cooling sea water circulating system.
Ensure sufficient corrosion protection in the water pipes (e.g. anodes).
4. Cooling fresh water:
Inform REINTJES, if an anticorrosive additive is admixed to the cooling fresh
water circulating system. The additive can reduce the cooling capacity of the
heat exchanger.
Gearboxes without factory-equipped heat exchanger

1) Prior to commissioning, connect a suitable heat exchanger to the gearbox.
a) The necessary specifications for a suitable heat exchanger are stated in
the technical description of the gearbox.
b) The connection points are marked in the drawing of installation.
21
BV2122
2.5.4 Connecting the electric stand-by pump
Fig. 2-14: Electric stand-by pump

If the electric stand-by pump is mounted on the gearbox, the pump is completely
supplied with all required pipes.
DANGER!
The electric stand-by pump is a live component.
Danger of death due to electric shock!
 Have all work on the electric stand-by pump only be carried out by qualified
electricians.
 Before carrying out any work on the electric stand-by pump, shut down power
supply and secure against unintentional restart.
WARNING!
If the pump operates in the wrong direction, excessive pressure could
build up. Pipes can burst and lubricants can escape.
Danger of severe injuries!
 Check the rotation direction of the pump when installing the electric circuits
for the pump motor.
1. Lay the electric supply line to the stand-by pump.

2. Connect the motor according to the enclosed circuit diagram. You will find the
circuit diagram in the terminal box of the pump motor.
3. Check the rotation direction with an induction instrument and properly con-
nect the electric lines. When the gearbox is put into operation, the pump must
operate in the specified direction.
4. If the electric stand-by pump is supplied separately, you must also lay and
connect the suction and pressure pipes between the pump and the gearbox.
You must also earth-wire the pump in accordance with technical standards.
5. Clean the pipes installed on board or changed during installation, e.g. by sub-
jecting them to acid treatment. The pipes must be free of dirt.
6. Observe the connection specifications (pipe cross section, pipe length and
number of pipe bends) which are stated in the separate drawings in the gear-
box documents.
22
BV2123 Installation and alignment
Rigid or resilient fastening,

cast resin seat chocks for heavy marine gearboxes with longitudinal mounting arrangement
2018-11
BV2123
Table of contents
Table of contents
1 Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
1.1 Field of application and purposes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
1.2 Safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
1.2.1 Personnel qualification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
1.2.2 Safely lifting the gearbox . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
2 Installation and alignment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4

2.1 Responsibility for installation and alignment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
2.2 Preparations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
2.3 Setting up the gearbox . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
2.4 Alignment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
2.4.1 General information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
2.4.2 Connection to propeller shaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
2.4.3 Foundation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
2.4.4 Connection to engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
2.4.5 Connection to PTO or PTI shaft (if present) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
2.4.6 Alignment check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
2.5 Connecting gearbox components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
2.5.1 Connecting the valve control and supervision system . . . . . . . . . . . . . . . . . . . . . 21
2.5.2 Connecting the shaft brake. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
2.5.3 Connecting the heat exchanger . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
2.5.4 Connecting the electric stand-by pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
1
BV2123
Introduction
1 Introduction
1.1 Field of application and purposes
This operation description applies to heavy marine gearboxes with rigid or resil-
ient fastening, cast resin seat chocks and longitudinal mounting arrangement. It
does not apply to light marine gearboxes in accordance with BV2378.
1.2 Safety
1.2.1 Personnel qualification

Carry out work on the gearbox only if you have the required technical know-how.
Certain work requires special qualifications:
• qualification in handling transport aids and lifting equipment when the gear-
box is to be transported or lifted
• qualified mechanic for all mechanical work
• qualified electrician for all work on electrical components
• knowledge of the necessary protective devices, safety measures, applicable
rules, safety regulations, and operating conditions
Please contact REINTJES service, if:
• you do not have the qualifications stated above,
• you are unsure how to carry out certain work,
• the gearbox appears to require work not described in this manual.
2
BV2123
Introduction
1.2.2 Safely lifting the gearbox
WARNING!
The gearbox can fall over if it is transported inappropriately or with unsuit-
able transport aids, lifting equipment and/or slings.
Persons hit by the gearbox can suffer life-threatening injuries and can be killed.
 Make sure that transport is carried out only by persons competent in the use
of transport aids and lifting equipment.
 Before every transport of the gearbox, make sure that nobody is in the gear-
boxʼs hazardous area.
 Use only transport aids, lifting equipment, and slings that are approved for
the anticipated load and in perfect technical condition. The gearbox weight
(without operating oil but including special accessories) is stamped on the
type plate.
 Transport aids and lifting equipment must be designed to be able to safely
hoist the load, hold it and set it down again.
 Observe the regulations and instructions provided by the manufacturer of the
transport aids, lifting equipment, and slings.
 Use only the lifting eyes intended for lifting the gearbox. The lifting eyes are
marked with signs and are indicated in the drawing of installation. Lifting eyes
on components, e.g. motor, are only intended for lifting these components
and not for lifting the whole gearbox.
 Secure slings to all of the eyebolts intended for this purpose using shackles.
 Never put slings around shaft ends, pipes, or other externally mounted parts.
 Make sure that the sling angle does not exceed 45° from the perpendicular.
Use a traversing bridge if necessary.
NOTICE
Danger of damage to the gearbox!
 When transporting the gearbox, make sure that you do not damage its
packaging, if further storage is intended afterward.
 Avoid slings pressing against pipes or externally mounted parts. Use a tra-
versing bridge if necessary.
3
BV2123
2 Installation and alignment

2.1 Responsibility for installation and alignment
The shipyard is responsible for gearbox installation and alignment.
2.2 Preparations
WARNING!
 Observe the warnings in chapter 1.2.2 Safely lifting the gearbox.
1. Remove the gearbox packaging (films, transport packaging).

2. Check the gearbox for damage.
3. Remove any dust or dirt.
2.3 Setting up the gearbox
Installation location
There must be enough space for the installation personnel in the working area.
Consider free spaces as indicated in the drawing of installation. The foundation
must be designed to absorb the gearbox weight and working loads.
Consider sufficient space for disassembling housing and shafts during later
maintenance work.
Work steps
1. Before setting up the gearbox, make sure that you have these documents:
a. operating manual
b. drawing of installation
c. supervision plan
d. alignment calculation (optional)
2. Make sure that you have fully read and understood all information concerning
alignment.
3. Place the gearbox on the foundation in the intended position.
4. Secure the gearbox against shifting on the foundation until it has been
aligned and permanently fastened.
5. Protect the gearbox from corrosion, contamination and damage.
The drawing of installation represents the basis for installation and alignment of
the gearbox. This drawing includes all dimensions and values relevant for instal-
lation and alignment of the gearbox. You will find the applicable drawing number
for your gearbox on the order confirmation.
You can obtain the drawing of installation from REINTJES by providing the gear-
boxʼs serial number.
REINTJES service
E-mail: [email protected] or
on working days: phone +49 5151 104 0
in emergencies and on weekends: phone +49 5151 104 237
4
BV2123
2.4 Alignment
2.4.1 General information

1. Determine the permissible horizontal and vertical GAP and SAG values for
all shaft connections. Take into account the technical information (alignment
calculation, thermal expansion and manufacturer's information) applying to
the units to be connected.
2. Consider the thermal expansion of engine, gearbox, auxiliary units, and foun-
dation at operating temperature.
3. Take into account possible engine displacement due to torque influence.
4. In addition, take into account thermosetting effects for the cast resin founda-
tion. Request detailed information on this from the cast resin manufacturer.
5. For gearboxes with bell housing please note that the alignment and the foun-
dation of the engine directly affect the output side of the gearbox.
6. Carry out the alignment work only after the vessel is afloat with absolutely no
ground contact with the sea bed.
7. The vessel should be equipped as far as possible. Missing heavy equipment,
e.g. winches, cranes, must be duly considered.
8. Carry out the alignment work in the early morning. Direct sunlight can influ-
ence the alignment result.
The best precondition for a trouble-free gearbox operation is a precise alignment
of:
• the gearbox output shaft with the propeller shaft
• the gearbox input shaft with the engine shaft
• the auxiliary drive shafts with the connected auxiliary units (if present)
If torsionally flexible couplings are used, precise alignment with the engine will
also be required. Any misalignment will have negative effects on the service life
of gearbox and auxiliary units.
REINTJES will only recognize the alignment as complete, if you have completely
documented the alignment of propeller shaft to gearbox, gearbox to engine, and
gearbox to connected auxiliary units.
5
BV2123
2.4.2 Connection to propeller shaft
Fig. 2-1: Gearbox foot with fastening options (rigid fastening)
1 alignment screw 3 surface for lateral collision chocks

2 hole for foundation bolt 4 surface for collision chocks
Fig. 2-2: Gearbox foot with fastening options (resilient fastening)
1 base plate 4 alignment screw

2 hole for foundation bolt 5 bolts for temporarily fixing the base
3 surface for collision chocks plate
The process of alignment is basically identical for rigid and resilient fastening.
The difference is that with a rigid fastening the gearbox foot is fixed permanently
to the gearbox housing. With a resilient fastening the gearbox can be removed
from the base plate. It is possible to remove the gearbox from the base plate even
after the base plate is aligned and fixed with cast resin. The gearbox can then be
put back without another alignment.
For connecting the propeller shaft line with the gearbox, the propeller shaft and/
or the intermediate shaft must be in the static operating position.
That means:
 the propeller shaft and the intermediate shaft are in their bearings
 the propeller is mounted
 the intermediate shaft flanges are connected (if present)
 the flange facing the gearbox is in the alignment position (if necessary)
6
BV2123
Work steps:
1. Screw the alignment screws into the gearbox foot.
2. Fix the alignment screws for horizontal alignment to the foundation.
3. With the alignment screws, align the gearbox vertically and horizontally in
longitudinal and transverse directions with the propeller flange, according to
the specified data.
With a resilient fastening ensure that there is no distortion in the elastic elements
during the horizontal alignment. The base plates must be evenly displaced on
both sides of the gearbox.
4. Align the gearbox in accordance with the required GAP and SAG values.
GAP value 4 as well as the vertical and horizontal SAG value 3 between the
gearbox flange 2 and the counter flange on the propeller side 1.
6. Set the horizontal GAP and SAG values to zero.

9. Fix the gearbox to the foundation, see chapter 2.4.3 Foundation.
11. Connect the propeller shaft to the gearbox output shaft after the gearbox is
firmly fixed to the foundation.
If you have a special, deviating installation situation, contact REINTJES service
prior to installation to discuss the necessary steps.
7
BV2123
2.4.3 Foundation
2.4.3.1 General information

1. Ensure that the gearbox is installed without distortion.
2. Observe the requirements for collision chocks and seat chocks, see chapter
2.4.3.4 Collision chocks and chapter 2.4.3.5 Seat chocks.
3. Insert the seat chocks between the gearbox foot and the top plate.
5. For cast resin foundation:
Loosen the alignment screws only after the thermosetting of the cast resin is
finished.
6. After aligning the gearbox with the propeller shaft, screw the gearbox to the
foundation so that it is secured against shifting. Observe the requirements for
screw joints, see chapter 2.4.3.6 Screw joints.
Any other foundation type must be approved by REINTJES.
8
BV2123
2.4.3.2 Rigid fastening with cast resin seat chocks

Fig. 2-3: Cast resin seat chocks with four fitting bolts, through bolts and collision chocks
for propeller thrust AHEAD and ASTERN

2 propeller side 5 cast resin seat chock
Fig. 2-4: Cast resin seat chocks with through bolts and collision chocks for propeller thrust
and lateral fixation
1 engine side 4 cast resin seat chock

3 through bolt
9
BV2123
Fig. 2-5: Cast resin seat chocks with four fitting stud bolts, through stud bolts and collision

Fig. 2-6: Cast resin seat chocks with through stud bolts and collision chocks for propeller
thrust and lateral fixation
1 engine side 4 cast resin seat chock

3 through stud bolt
10
BV2123
2.4.3.3 Resilient fastening with cast resin seat chocks

Fig. 2-7: Cast resin seat chocks with four fitting bolts, through bolts and collision chocks
for propeller thrust AHEAD and ASTERN

Fig. 2-8: Cast resin seat chocks with four fitting stud bolts, through stud bolts and collision

11
BV2123
2.4.3.4 Collision chocks
Fig. 2-9: Principle of a simple collision chock
1 gearbox foot 4 top plate

2 seat chock 5 cast resin seat chock
3 collision chock
The shipyard is responsible for the design and installation of the collision chocks.
1. The collision chocks are to be structurally designed so that they can with-
stand the maximum propeller thrust without taking into account the founda-
tion bolt preload.
2. Make the collision chocks from metallic material. Provide for a metal-to-metal
contact on both sides and secure the collision chocks against displacement.
3. Make the collision chocks wedge-shaped or double-wedge-shaped.
4. Fix the collision chocks with screws or by welding them over the entire wedge
length.
12
BV2123
2.4.3.5 Seat chocks
Cast resin seat chocks

1. Have the design, calculation and execution of the cast resin foundation car-
ried out by a company which is authorized for cast resin foundations.
This company must also submit the necessary drawings, calculations and
material data to the classification societies for approval.
2. When designing the foundation, note that the maximum seating stress values
between the gearbox and the cast resin seat chock indicated by the manu-
facturer must not be exceeded.
3. Observe the height of cast resin seat chocks:
The height must be normally 40 - 80 mm. The height of the cast resin seat
chock must always be smaller than its width and length. Also observe the in-
structions of the cast resin manufacturer
4. Ensure that cast resin seat chocks will only be stressed after thermosetting
is completed.
2.4.3.6 Screw joints
General information
The gearbox foundation bolts are fitting bolts and/or through bolts.
1. Calculate the foundation bolts according to the state of the art. Under all op-
erating conditions, the preload of the bolts must be higher than the workload.
2. Consider for the bolt elongation that the connection cannot be loosened by
settlement effects. We recommend an elongation of the screws of > 0.17 mm
for cast resin seat chocks and of > 0.25 mm for metal seat chocks.
3. Any lifting of the gearbox under dynamic stress must be excluded.
4. Contact REINTJES service for information on the working forces. When cal-
culating the bolts, also consider external forces e.g. added by mounted com-
ponents that have an impact on the gearbox.
13
BV2123
Fitting bolts
The fitting bolts fix the gearbox on the foundation.
1. The geometry of the fitting bolts must be designed such that at least 50 % of
the height of the gearbox foot and 50 % of the height of the top plate are cov-
ered by each shaft.
2. Only use fitting bolts with a tensile strength of at least 8.8 in accordance with
ISO 898. The fitting bolt bores are predrilled.
When using cast resin seat chocks the propeller thrust must not be transmitted
through the fitting bolts.
Fig. 2-10: Fitting bolts with cast resin seat chocks

2 gearbox foot 5 fitting bolt
3 cast resin seat chock
14
BV2123
Through bolts
Only use through bolts with a tensile strength of at least 8.8 in accordance with
ISO 898.
The through bolts must comply with application-specific requirements and be
tightened to the specified torque.
Fig. 2-11: Through bolts with cast resin seat chocks

2 gearbox foot (resilient mounting: 5 through bolt
base plate)
3 cast resin seat chock
15
BV2123
Fitting stud bolts

The fitting stud bolts fix the gearbox on the foundation.
1. The geometry of the fitting stud bolts must be designed such that at least
50 % of the height of the gearbox foot and 50 % of the height of the top plate
are covered by each shaft.
2. Only use fitting stud bolts with a tensile strength of at least 8.8 in accordance
with ISO 898. The fitting stud bolt bores are predrilled.
When using cast resin seat chocks the propeller thrust must not be transmitted
through the fitting stud bolts.
Fig. 2-12: Fitting stud bolts with cast resin seat chocks
1 hexagon nut 4 cast resin seat chock

2 bush 5 top plate
16
BV2123
Through stud bolts

Only use through stud bolts with a tensile strength of at least 8.8 in accordance
with ISO 898.
The through stud bolts must comply with application-specific requirements and
be tightened to the specified torque.
Fig. 2-13: Through stud bolts with cast resin seat chocks
1 hexagon nut 4 cast resin seat chock

2 bush 5 top plate
17
BV2123
Foundation bolts (REINTJES scope of supply)

If the foundation bolts are delivered by REINTJES, the following applies:
4. Tighten all foundation bolts with the tightening torque required for the specific
application.
Fig. 2-14: Foundation bolts (REINTJES scope of supply)
1 bush 4 cast resin seat chock

3 gearbox foot 6 through bolt
We recommend the following thicknesses for the cast resin seat chocks and the
top plate:
Cast resin seat chock 30 - 50 mm

Top plate thickness of the gearbox foot ± 10 mm
Tolerances of the thicknesses of cast resin seat chocks and top plate of up to
40 mm can be compensated for by machining the bush.
18
BV2123
2.4.4 Connection to engine

bell housing.
 The engine is aligned axially with the gearbox.
The space between gearbox and engine must correspond to the mounting
length of the flexible coupling. The axial reaction forces of the flexible cou-
pling on engine and gearbox shall be as low as possible. Observe the
specifications of engine and flexible coupling manufacturer.
Work steps:
1. With the alignment screws, align the engine horizontally in longitudinal and
transverse directions and vertically in front of the gearbox input flange, ac-
cording to the specified data.
coupling on the gearbox input shaft.
FR = Δ r x Cr dyn
Δ r = radial shaft misalignment
Cr dyn = radial stiffness of the flexible coupling
A = engine side gearbox flange
B = engine flywheel
19
BV2123
6. Determine the corresponding bending moment MB.

MB = 0.5 x Cax x D x X1
Cax = axial stiffness of the flexible coupling
D = diameter of the connection between flange and flexible coupling
X1 = measured angular misalignment (GAP value)
7. Inform REINTJES of the reaction force FR, the bending moment MB and the
distance L for approval.
L = S + X = distance from application point FR to big cone diameter of gear-
box input shaft
8. During all operations, observe the instructions of the engine and coupling
manufacturers.
10. Fix the engine to the foundation.
11. Connect gearbox and engine with the flexible coupling.
2.4.5 Connection to PTO or PTI shaft (if present)

 The gearbox is aligned with the engine.
Work steps:
1. Align the auxiliary unit that is driven by the PTO or driving the PTI with the
alignment screws, horizontally in longitudinal and transverse directions, and
vertically in front of the PTO or PTI shaft of the gearbox, according to the
specified data.
coupling on the gearbox PTO or PTI shaft.
6. During all operations, observe the instructions of the auxiliary unit and cou-
pling manufacturers.
7. Fix the auxiliary unit to the foundation.
8. Determine the reaction forces of the flexible coupling, see chapter 2.4.4 Con-
nection to engine.
9. Connect PTO or PTI and auxiliary unit with the flexible coupling.
20
BV2123
2.4.6 Alignment check
Engine alignment check

bell housing.
2. Disconnect the flexible coupling on the engine.
REINTJES service.
Propeller alignment check

2. Loosen the flange mounting screws on the propeller side.
3. Check the GAP and SAG values and compare them with the specified data.
In case of deviations, please contact REINTJES service.
Auxiliary drive alignment check (if present)

2. Disconnect the flexible coupling.
REINTJES service.
2.5 Connecting gearbox components
2.5.1 Connecting the valve control and supervision system

1. Lay the cables for the valve control and supervision system to the gearbox
and connect them according to the supervision plan.
If a terminal box is installed on the gearbox, the cables for the valve control
and supervision system are completely connected on the gearbox itself.
2. Check the functioning of the valve control and supervision system in accor-
dance with the checklist for commissioning.
2.5.2 Connecting the shaft brake

1. Lay a compressed air line to the shaft brake control valve. The connection is
marked in the drawing of installation.
2. Install a dehumidifier in the compressed air system.
The initial pneumatic pressure must be 5 - 7 bar (500 - 700 kPa, 73 - 101 psi).
21
BV2123
2.5.3 Connecting the heat exchanger
Connecting the factory-equipped heat exchanger

Please note that the input cross-section of the heat exchanger on the water side
must not be varied!
Fig. 2-15: Connections of the heat exchanger

1. Install the pipes on the water side of the heat exchanger with SAE counter
flanges (see drawing of installation).
2. Make sure the pipes are laid vibration-free. We recommend using rubber/
steel-wire compensators.
3. Cooling sea water:
Install a filter in the cooling sea water circulating system.
Ensure sufficient corrosion protection in the water pipes (e.g. anodes).
4. Cooling fresh water:
Inform REINTJES, if an anticorrosive additive is admixed to the cooling fresh
water circulating system. The additive can reduce the cooling capacity of the
heat exchanger.
Gearboxes without factory-equipped heat exchanger

1) Prior to commissioning, connect a suitable heat exchanger to the gearbox.
a) The necessary specifications for a suitable heat exchanger are stated in
the technical description of the gearbox.
b) The connection points are marked in the drawing of installation.
22
BV2123
2.5.4 Connecting the electric stand-by pump
Fig. 2-16: Electric stand-by pump

If the electric stand-by pump is mounted on the gearbox, the pump is completely
supplied with all required pipes.
DANGER!
The electric stand-by pump is a live component.
Danger of death due to electric shock!
 Have all work on the electric stand-by pump only be carried out by qualified
electricians.
 Before carrying out any work on the electric stand-by pump, shut down power
supply and secure against unintentional restart.
WARNING!
If the pump operates in the wrong direction, excessive pressure could
build up. Pipes can burst and lubricants can escape.
Danger of severe injuries!
 Check the rotation direction of the pump when installing the electric circuits
for the pump motor.
1. Lay the electric supply line to the stand-by pump.

2. Connect the motor according to the enclosed circuit diagram. You will find the
circuit diagram in the terminal box of the pump motor.
3. Check the rotation direction with an induction instrument and properly con-
nect the electric lines. When the gearbox is put into operation, the pump must
operate in the specified direction.
4. If the electric stand-by pump is supplied separately, you must also lay and
connect the suction and pressure pipes between the pump and the gearbox.
You must also earth-wire the pump in accordance with technical standards.
5. Clean the pipes installed on board or changed during installation, e.g. by sub-
jecting them to acid treatment. The pipes must be free of dirt.
6. Observe the connection specifications (pipe cross section, pipe length and
number of pipe bends) which are stated in the separate drawings in the gear-
box documents.
23
CONFIRMATION OF GEAR SHAFT INTERFACE DIMENSIONS
Make Model Sign Date
Gearbox REINTJES LAF 873 HLHR / 7.454:1 P M M A 1 ft, 4 3- 0 Ç -Ail
Order No. 7364M
Abtriebwelle Bemaßung Flansch Hull No. 0416

Rezess 5 mm; Flanschstärke 45 mm Yard Detroit Brasil
2 l 3 6 7 I 8 l 9 10 l 11 l 12
00.04 I C-13
771
[Q10.21
5
///// © 100.5
./
-----,,-..
b%' 7
I
- ____---
..e ,p,
.
.,
14
r.
C.,
CD CD
cS
C,
/SI o -31
' ' w...,,
25
iiìt .....
0.5 , • ..`G-
, ....
0 2x G1/4
fur Hydrculidencnt age tipfnU P
FOR hYDRALSALLY
0,05 A-B C,.SMANTLING
til0=14 tief/D
0,07 I A-B
TOLERANCED LIMITS
DIMENSION OF SIZE
.0,025
37 H7 0
r7-15 Li! 0.05 A-B
76 H7
.0,030
C,C:5 710 / 0
.0,040
,.••••
160 117 0
-0,017
OZ.• A-B 290 g6 -0,049
740
Blatt 1 Eihauze ntrig Standard-Ansichten

FADE t DRMING OF INSTALLATION STANDARO VIEWS
0 1 2 3 4 5 6 7 8 9
Eugen - Reintjes - Strasse 7

D-31785 Hameln
www.reintjes-gears.de
Phone. +49 (0)5151 - 104 - 0
Fax +49 (0)5151 - 104 - 300
Drawing number 0-211- 120947 - General Remark
"Schutzvermerk nach DIN 34 beachten" copyright: REINTJES GmbH, Eugen - Reintjes - Strasse 7, D-31785 Hameln
Gearbox LAF 873 HL-HR
Classification BV MMS
Engine producer MTU
Control voltage 24VDC Designation ENGLISH
Working pressure 20...25bar >45% of nominal speed

Project agent VOI
Commission Created on 18.06.2019
Instructions by
Number of pages 13
Ed.
Appr
VOI
KLA
18.06.2019 Gearbox
Commission
LAF 873 HL-HR Cover sheet
0-211- 120947 -
=
+
Page
F1
Modification Date Name Original Replaced by Replaced by Supervision Page 13
0 1 2 3 4 5 6 7 8 9
Table of contents
Page Page description supplementary page field
1 Cover sheet
2 Table of contents
3 Hydraulic diagram
4 Pressure switches
5 Pressure switches / Pressure transmitter
6 Temperature sensor - Temperature after oil cooler
7 Control valve - Main clutch
8 Terminal diagram =+-X000
9 Measuring points list
10 Monitor list
11 Terminal box
12 Pressure test valve
13 Grounding -Gearbox housing / Terminal box
Ed.
Appr
VOI
KLA
18.06.2019 Gearbox
Commission
LAF 873 HL-HR Table of contents
0-211- 120947 -
=
+
Page
F2
0 1 2 3 4 5 6 7 8 9
/4.8
-A74
P
-A128
/12.3 /4.0 /4.6 /12.4
-A35 -A103 -A125
P P
-A113
/12.2
MA MB
A B Main clutch
A B
/7.3
-V1
MP
MP
MP
-V1-a -V1-b
/7.4 /7.5
MP
P T
/6.3
-A55 -A480
MPS
Oil cooler T
P
/5.6
-A465
L T PS
Oil filter
P
-A43.1 P P -A43.2 -A128
/5.0 ‎Δ ‎Δ /5.2 /12.4
Gearbox pump
-A10
Dipstick
Lubrication oil
Ed.
Appr
VOI
KLA
18.06.2019 Gearbox
Commission
LAF 873 HL-HR Hydraulic diagram
0-211- 120947 -
=
+
Page
F3
0 1 2 3 4 5 6 7 8 9
Pressure switches
1-2 Pressure low
1-3 Pressure high
R = Resistor
delivery by
engine manufacturer
Feedback
Oil pressure too low - Alarm Main engine shut down
- Main clutch engaged
-A103 -A125 -A74

/12.3 /12.4 /12.5
P P P
/3.3 /3.3 /3.7
1 2 3 1 2 3 1 2 3
R
1 2 3 1 2 3 1 2 3
Shield Shield Shield
-W103 1 2 -W125 1 2 -W74 1 2 3
-X000 1 2 3 -X000 4 5 6 -X000 7 8 9 -X000 10 11 12 -X000 13 14 15
wiring by yard wiring by yard wiring by yard
-AS -MES -RC

Alarm system Main engine system Remote control system
Ed.
Appr
VOI
KLA
18.06.2019 Gearbox
Commission
LAF 873 HL-HR Pressure switches
0-211- 120947 -
=
+
Page
F4
0 1 2 3 4 5 6 7 8 9
Difference pressure switch Difference pressure switch

1-2 ready 1-2 ready
1-3 contaminated 1-3 contaminated
Filter element 1 - contaminated Filter element 2 - contaminated

Transmitter_Lube oil pressure
-A43.1 -A43.2
/3.1 /3.2 -A465
P P /12.5 P
‎Δ ‎Δ /3.7
1 2 3 1 2 3 I
0-6 Bar / 4..20 mA
1 2 3 1 2 3 1+ 2
Shield Shield Shield
-W43.1 1 2 3 -W43.2 1 2 3 -W465 1 2
-X000 16 17 18 -X000 19 20 21 -X000 22 23 -X000 24 25 -X000 26 27 28
wiring by yard wiring by yard wiring by yard
-AS -AS -AS

Alarm system Alarm system Alarm system
Ed.
Appr
VOI
KLA
18.06.2019 Gearbox
Commission
LAF 873 HL-HR Pressure switches /
Pressure transmitter
0-211- 120947 -
=
+
Page
F5
0 1 2 3 4 5 6 7 8 9
Sensor - Oil temperature after cooler

-A480
/3.3
-A480.1
-A480.2
2L / 2x Pt100
Pt100
Pt100
1 3 2 4
Shield
-W480 BN BU WH BK
-X000 29 30 -X000 31 32 33 34 -X000 35 36
wiring by yard
-AS -MES
Alarm system Main engine system
Oil temperature Main engine slow down

- Alarm
Ed.
Appr
VOI
KLA
18.06.2019 Gearbox
Commission
LAF 873 HL-HR Temperature sensor
- Temperature after oil cooler
0-211- 120947 -
=
+
Page
F6
0 1 2 3 4 5 6 7 8 9
Control valve - Main clutch

-V1 Main clutch engaged Main clutch disengaged
/3.6
24 VDC +/- 10%, 41W
impuls operated
-a -b
/3.5 /3.6
1+ U 2- 1+ U 2-
Plug
Plug
- -
+ +
Shield Shield
-W_V1.A 1 2 -W_V1.B 1 2
-X000 37 38 39 40
wiring by yard
-RC
Remote control system
Ed.
Appr
VOI
KLA
18.06.2019 Gearbox
Commission
LAF 873 HL-HR Control valve - Main clutch
0-211- 120947 -
=
+
Page
F7
0 1 2 3 4 5 6 7 8 9
Terminal diagram
-W103
-W125
-W74
-W43.1
-W43.2
-W465
-W480
-W_V1.A
-W_V1.B
Strip
Cable name
Cable name
=+-X000
C MC 2x0.75
ÖLFLEX HEAT
C MC 2x0.75
ÖLFLEX HEAT
C MC 3x0.75
ÖLFLEX HEAT
C MC 3x0.75
ÖLFLEX HEAT
C MC 3x0.75
ÖLFLEX HEAT
C MC 2x0.75
ÖLFLEX HEAT
C MC 2x0.75
ÖLFLEX HEAT 125
C MC 2x0.75
ÖLFLEX HEAT 125
Page / column
Connection
Connection
cable type
cable type
terminal
jumper
point
point
125
125
125
125
125
125
Function text Target designation Target designation
Oil pressure too low - Alarm -AS 1 -A103 1 1 /4.1
= -AS 2 -A103 3 2 /4.1
3 /4.1
4 /4.2
5 /4.3
6 /4.3
7 /4.4
8 /4.5
9 /4.5
Main engine shut down -MES 10 -A125 1 1 /4.6
= -MES 11 -A125 2 2 /4.6
12 /4.7
Feedback - Main clutch (com) -RC 13 -A74 1 1 /4.8
Feedback - Main clutch disengaged -RC 14 -A74 2 2 /4.8
Feedback - Main clutch engaged -RC 15 -A74 3 3 /4.9
Filter element 1 - (com) -AS 16 -A43.1 1 1 /5.1
Filter element 1 - ready -AS 17 -A43.1 2 2 /5.1
Filter element 1 - contaminated -AS 18 -A43.1 3 3 /5.1
Filter element 2 - (com) -AS 19 -A43.2 1 1 /5.2
Filter element 2 - ready -AS 20 -A43.2 2 2 /5.3
Filter element 2 - contaminated -AS 21 -A43.2 3 3 /5.3
22 /5.4
23 /5.5
Transmitter - Lubrication oil pressure -AS 24 -A465 1+ 1 /5.6
= -AS 25 -A465 2 2 /5.6
26 /5.8
27 /5.8
28 /5.9
29 /6.2
30 /6.2
Oil temperature - Alarm (Pt100) -AS 31 -A480 1 BN /6.3
= -AS 32 -A480 3 BU /6.4
Oil temperature - Engine slow down (Pt100) -MES 33 -A480 2 WH /6.5
= -MES 34 -A480 4 BK /6.5
35 /6.7
36 /6.7
Control valve - Main clutch engaged -RC 37 -zV1.1 1 /7.3
= -RC 38 -zV1.1 2 /7.4
Control valve - Main clutch disengaged -RC 39 -zV1.2 1 /7.5
= -RC 40 -zV1.2 2 /7.5
Ed.
Appr
VOI
KLA
18.06.2019 Gearbox
Commission
LAF 873 HL-HR Terminal diagram =+-X000
0-211- 120947 -
=
+
Page
F8
0 1 2 3 4 5 6 7 8 9
Measuring points list Note: XX - sequence alarm *Note: Time delay / Alarm suppression by customer
Pos. Measuring point Abbre. Responding value Function Function Function Alarm value Time delay Comment Function text
Low High Alarm slow down shut down
-A10 Pressure suction pipe P Connection point for gauge
-A35 Operating oil pressure P Visual indication at gearbox 0...40bar Manometer - Operating oil pressure
-A43.1 Filter difference pressure PDAH X X DP > 5bar Filter element 1 - contaminated
-A43.2 Filter difference pressure PDAH X X DP > 5bar Filter element 2 - contaminated
-A55 Oil temperature T Visual indication at gearbox 0...120°C / 32...248°F Temperature after oil cooler
-A74 Clutch oil pressure P X P > 17bar Feedback - Main clutch engaged
-A103 Operating oil pressure PAL X X P < 17bar *10sec - (Customer) Only during engagement of the clutch Oil pressure too low - Alarm
-A125 Operating oil pressure PALL X X X P < 15bar *10sec - (Customer) Only during engagement of the clutch Main engine shut down
-A465 Lube oil pressure PAL X X P < 0.2bar=4.53mA *Suppress below 70% of main engine max. rpm Transmitter_Lube oil pressure
-A480-A480.1 Oil temperature TAH X X T > 65°C Oil temperature - Alarm
-A480-A480.2 Oil temperature TAHH X X T > 70°C Oil temperature - Engine slow down
Ed.
Appr
VOI
KLA
18.06.2019 Gearbox
Commission
LAF 873 HL-HR Measuring points list
0-211- 120947 -
=
+
Page
F9
0 1 2 3 4 5 6 7 8 9
Monitor list
Pos. Manufacturer Designation Type number Measuring range Degree of protection
-A35 VDO Pressure gauge 63/0-40bar (0-550 PSI) 0-40bar (0-550PSi)

-A43.1 Hydac Difference pressure switch VD5 C.0/-TA ‎Δ-P 5bar IP 65
-A43.2 Hydac Difference pressure switch VD5 C.0/-TA ‎Δ-P 5bar IP 65
-A55 CNJW Thermometer G 1/2 - 0...120°C / 32...248°F 0...120°C / 32...248°F
-A74 Danfoss Pressure switch MBC 5100-3231-1DB04 5 - 20bar IP 65
-A465 Danfoss Pressure transmitter MBS 5100-1811-1DB04 0-6 bar /4..20mA IP 65
-A480 Noris Temperature sensor 2TP81-1-55 0-120°C IP 67
-V1 Kracht Control valve WL 4 F 10 P2 E 31 Z 02400 24 VDC +/- 10%; 41W; impuls operated IP 65
Ed.
Appr
VOI
KLA
18.06.2019 Gearbox
Commission
LAF 873 HL-HR Monitor list
0-211- 120947 -
=
+
Page
F
10
0 1 2 3 4 5 6 7 8 9
360 mm
160 mm
Cover
Cable glands
-A120
91 mm
-A21
Box
-A119
Cable glands
Ed.
Appr
VOI
KLA
18.06.2019 Gearbox
Commission
LAF 873 HL-HR Terminal box
0-211- 120947 -
=
+
Page
F
11
0 1 2 3 4 5 6 7 8 9
Transmitter - Lubrication oil pressure

Manometer - Operating oil pressure
Feedback - Main clutch engaged

Oil pressure too low - Alarm
Main engine shut down

/3.3 /4.0 /4.6 /4.8 /5.6
-A35 -A103 -A125 -A74 -A465
-A113 -A128
/3.3 /3.7
/3.7
Pressure test valve Pressure test valve
Ed.
Appr
VOI
KLA
18.06.2019 Gearbox
Commission
LAF 873 HL-HR Pressure test valve
0-211- 120947 -
=
+
Page
F
12
0 1 2 3 4 5 6 7 8 9
Terminal box
PE
Grounding point
Box
-W_GRD.1
Grounding cable
wiring by Reintjes
1x16mm² / gn-ye
Gearbox housing -
central grounding point
Safety note:
Gearbox housing has to be grounded by shipyard.
Ed.
Appr
VOI
KLA
18.06.2019 Gearbox
Commission
LAF 873 HL-HR Grounding -
Gearbox housing / Terminal box
0-211- 120947 -
=
+
Page
F
13
INSTALLATION MANUAL
MPP HDX

K.C. LTD. SHAFT EARTHING
DOCUMENT
REV(C) : 29/11/04
SPECIFICATION & SCOPE FOR Shaft Earthing Device
CLIENT BERG PROPULSION INTERNATIONAL PTE LTD.
TOTAL WEIGHT APPROX. 11.0 kgs
NO OFF PART NO DESCRIPTION
1 KCS0044 MILLI-VOLT METER WITH CABLE GLANDS
1 KCS005 SILVER ALLOY SLIP-RING
1 KCS0032 SHAFT EARTHING DOUBLE BRUSH HOLDER
1 KCS0022 SHAFT MONITORING SINGLE BRUSH HOLDER
1 KCS009 BRUSH HOLDER SUPPORT BAR
1 KCS010 INSULATED BRUSH HOLDER SUPPORT BAR
3 KCS0014 HIGH DENSITY SILVER GRAPHITE BRUSH
1 KCS006 1.5m x 50mm2 SHAFT EARTH CABLE
2 KCS011 STAINLESS STEEL BAND
1 KCS0151 PRESSURE TAPE (50mm)
1 KCS015 PRESSURE TAPE (19mm)
ABOVE ITEMS ARE REQUIRED PER EACH DEVICE.

TOTAL 2SETS ARE SUPPILIED PER SHIP IF TWIN SHAFT IS INSTALLED.
-1-
DOCUMENT
REV(H) : 29/06/09
1. Introduction
A turning propeller shaft on a ship becomes electrically insulated from the hull by the
lubricating oil film in the bearings and by the use of non-metallic bearing materials in
the tail shaft. When the shaft is insulated in this way an electrical potential can be
measured between the shaft and the hull and this can accelerate corrosion in the ship.
If the ship has a system of cathodic protection, whether it is sacrificial anode or an
impressed current system, the shaft insulation will prevent the propeller and the boss
from receiving protection.
The electrical potential between the shaft and the hull can also cause a heavy current
to flow in bearings when the oil film breaks down or is contaminated with seawater.
This current can cause deep pitting of the bearing surface. Excessive wear on the shaft
bearings can often be traced to this cause.
Now in addition it’s necessary to reduce the spark erosion causing the excessive wear
on main engine metal bearings and this shaft earthing is the most appropriate method.
All the troubles can be avoided and cathodic protection can be extended to the
propeller if the shaft is properly earthed with a propeller shaft slip ring. The
effectiveness of the shaft earthing system should ensure a maximum contact resistance
of no greater than 0.001 ohms for a water filled bearing and 0.01 ohms for an oil filled
bearing.
Our own tests indicate that high silver content brushes running on a silver track have
repeatable low conductivity that can maintain these limits and ensure a low resistance
contact is maintained even under dirty conditions.
The shaft earthing assembly comprises a pair of high silver content / graphite
compound brushes mounted in balanced brush holder, running on a silver alloy slip
ring.
Each brush holder has a adjustable spring tensioner which is supplied preset to the
minimum and results in a pressure of 225g/cm2.
At this pressure the expected life of the brush is in excess of one year.
2. Installation work by shipyard
- Assembling the intermediate shaft earthing assembly

- Attaching the intermediate shaft monitoring millivoltmeter & wiring
- Welding the brush holder support bar & Assembling the brush holder
-2-
DOCUMENT
REV(H) : 29/06/09
3. Installation
3.1 Slip ring
CAUTION : It is strictly required to install slip ring correctly according to following procedure
for the good performance of shaft earthing and longer life time of brushes.
3.1.1. Make clean the area where slip ring is positioned.
The area should be cleaned and prepared for a bright bare steel.
KEEP CLEAN
SHAFT
Approx.130mm
3.1.2. Fasten stainless steel bands (A & B) temporarily.
BAND (A) BAND (B)

130mm
SHAFT
KEEP CLEAN
3.1.3. Put the slip ring around the shaft and mark the overlapped part.
Cut the overlapped part at an angle of 45 O carefully, which is very important job.
MARK FOR CUT
BAND (A) BAND (B)
SHAFT
SLIP RING
-3-
DOCUMENT
REV(H) : 29/06/09
- After cutting properly rub the both edges of inner surface of slip ring with a fine-mesh file or
sand paper as below. Then secure slip ring very tightness around shaft;
SLIP RING
SLIP RING
45
45
°
°
SHAFT
SECURE SLIP RING
VERY TIGHTNESS
AROUND SHAFT.
FINE-MESH
FILE OR
SAND PAPER
CORRECT INSTALLATION
FILE INNER SURFACE OF SLIP RING
3.1.4. Fasten the slip ring around the shaft by the tightening stainless steel band (B).
When the slip ring is tightly installed no protrusion or gap is found.

In case there happens with protrusion or gap smoothly rub the protrusion with sand paper.
BAND (A) BAND (B)
SHAFT
3.1.5. Fasten the both edges of slip ring with 3/4” pressure tape for a preparation of tight
fastening of stainless steel band.
Apply the tape to the slip ring five times at the opposite direction of the shaft rotation.
BAND (A) BAND (B)
SHAFT
PRESSURE TAPE
(5 TIMES)
-4-
DOCUMENT
REV(H) : 29/06/09
3.1.6. Fasten the stainless steel band(A) over the pressure tape tightly by tightening fixing bolt
around the edge of slip ring.
BAND (A) BAND (B)
SHAFT
3.1.7. Fasten the stainless steel band(B) over the pressure tape tightly by tightening fixing bolt
around the edge of slip ring.
After tightening bands (A, B), bend the end part of band to the opposite direction to
prevent loosening during the shaft rotates.
BAND (A) BAND (B)
SHAFT
BAND
BAND TIGHTENING BOLT
BEND TO THE OPPOSITE

DIRECTION FINALLY
3.1.8. Apply 2” tape over both stainless steel bands (A & B) at the opposite direction of the shaft
rotation finally.
2" TAPE
SAHFT
MIN.30
WIDTH OF SLIP RING
AFTER FINAL INSTALLATION
WHERE BRUSHES RUN.
-5-
DOCUMENT
REV(H) : 29/06/09
3.2. Brush holder
3.2.1. Carefully study the drawing for correct installation and keep the distance of 3mm
between bottom of brush holder and slip ring surface.
3.2.2. Fit the brush holder to the support bar and align the assembly so that the brushes
are able to run centrally on the slip ring, and the brush holders assembly is to be
clear of the slip ring securing brackets when the shaft rotates.
Secure the assembly in this position by tightening the hexagon headed bolt at the
top of the brush holder body.
3.2.3. Do not adjust the tension of spring without approval from K.C.Ltd.
3.3. Shaft monitoring millivolt meter
3.3.1. The system comprises a bulkhead mounted panel that incorporates terminals and
a display meter. The system is self contained and requires no external power
supply.
3.3.2. For ease of interpretation the display meter is scaled up to 150mV.

As the meter reading rises above 80mV it is recommended that the slipring and
brushes be checked and cleaned.
4. Operation
4.1 The millivolt meter normally reads 150mV full scale.
4.2 Reading of below 80mV when shaft is turning at sea indicate proper grounding.
If readings are above 80mV, clean the faces of slip ring and brush with a clean
cloth.
4.3 The millivolt meter will read '0' when shaft is at rest because of the current
entering the propeller will return to the hull through main engine bearings and
engine foundation.
4.4 Check according to troubleshooting in case the millivolt meter reading is '0' when
shaft is turning at sea.
-6-
DOCUMENT
REV(H) : 29/06/09
5. Maintenance and service
5.1 This grounding assembly should be checked at least twice a week for cleanliness.
5.2 If there has been a build-up of oil, dirt, scale and rust on the slip ring face or
between slip ring and shaft, this should be removed with a degreaser, emery paper
and clean cloth.
5.3 Inspect and clean the brushes and brush holder to prevent their moving due to dirt
build-up. Inspect the brush copper leads (pig tails) to ensure they have not
become loose or corroded. The brush wear-down should be noted.
5.4 At the time of every dry dock, disassemble the slip ring and clean the surface of
the shaft right thereunder.
6. The life time of brushes
6.1 The brushes are getting worn out by metal touch with slip ring.
Therefore it’s strictly required to keep clean and smooth surface of slip ring, also to
carry out proper installation / alignment of brush holders as per our manual and
drawing. Otherwise it’s very hard to obtain the proper earthing and the proper life
time of brushes.
6.2 The brushes are consumable parts with wearing ratio approximately 2~3mm per 1,000
hours shaft rotation under proper installation.
The replacement time is shown by engraving the line (15mm from the top) on the
brushes.
Customer is requested to replace brushes with spares when the time comes.
6.3 Brushes are consumable parts as stated above and they are often consumed earlier but
it’s not a matter of guarantee claim for supplying extra brushes.
6.4 Use only our genuine silver graphite brushes for longer life and higher earthing
efficiency.
Contact K.C. LTD. for purchasing and indicate part number.
CAUTION
Customers are recommended for the purchase of genuine spare parts as imitated
parts make the system get fatally wrong.
Of course a quick technical support and maintenance services are guaranteed
with only our genuine parts.
-7-
K.C. LTD. Shaft Earthing Device
REV(D)18/06/09
Shaft Earthing Device

TROUBLE SHOOTING
NO. FAILURE POSSIBLE REASON REQUIRED ACTION

01 “O” millivolt 1) Shaft is at rest. 1) Check while engine runs.
on meter. 2) Insulated support bar is loosened 2) Tighten the insulated support bar
/ missing. of single brush holder.
3) Cable connection inside meter is 3) Make sure (+) and (-) in terminal
wrong. block.
4) Cable connection between single 4) Make sure cable connection of
brush holder(insulated support single brush holder(insulated
bar) and meter is untightened / support bar) is out of touch with
short circuit. hull.
5) Meter is faulty. 5) Check the reading at mV meter's
display and at the same time
measure the reading of millivolt
before millivolt-meter by tester
during ship's sailing.
Compare and judge. Then replace
meter.
6) Brushes are worn down. 6) Replace brushes.
7) Surface of slip ring is not clean 7) Clean the surface of slip ring
due to build-up of oil, dirt, scale with a degreaser, sand(emery)
and rust. paper and clean cloth.
8) Between slip ring and shaft is not 8) Dismantle. Then clean slip ring
clean due to build-up of oil, dirt, and shaft with a degreaser,
scale and rust. sand(emery) paper and clean
cloth.
※ Special remark We often receive claim of mV meter’s malfunction due to "0" reading. But the zero
reading doesn't always mean faulty earthing. So check regularly(once a week) for
maintenance and confirm the device is working in normal condition as follows;
1. For good installation

① Check if all brushes tightly get in touch with slip ring.
② Check the contact surface of sharp edge on slip ring.
③ Check and clear the surface of slip ring or between slip ring and shaft from any
oil/grease and rust.
④ Check tight connection of earthing cable.
2. For good working measurement

① Check the reading after removing one of the brushes fitted on double brush holder
during ship's sailing. Reading is zero or above zero.
② Check the reading after removing all brushes fitted on double brush holder during
ship's sailing. Reading is far above zero.
From the above check you can find the reading above 1mV with brush(es) removed
from double brush holder and also 0mV with double brushes fitted, which means
present 0mV reading proves good shaft grounding.
So don't worry about "0" reading at the present.
-8-
K.C. LTD. Shaft Earthing Device
REV(D)18/06/09
Shaft Earthing Device

TROUBLE SHOOTING
NO. FAILURE POSSIBLE REASON REQUIRED ACTION

02 Too high 1) Earthing cable is loosened. 1) Secure earthing cable
millivolt 2) Earthing cable size is small 2) Replace earthing cable as
(above 80 mentioned in drawing(above 50
mV) on SQ).
meter. 3) Surface of slip ring is not clean 3) Clean the surface of slip ring
due to build-up of oil, dirt, scale with a degreaser, sand(emery)
and rust. paper and clean cloth.
4) Between slip ring and shaft is not 4) Dismantle. Then clean slip ring
clean due to build-up of oil, dirt, and shaft with a degreaser,
scale and rust. sand(emery) paper and clean
cloth.
5) Brushes are worn down. 5) Replace brushes.
6) The imitated brushes are used. 6) Replace our high density low
resistant silver graphite brushes
as genuine spares.
03 The millivolt 1) The edge of slip ring is not 1) Make smooth edge preparation
value is smooth. by sand(emery) paper.
varied 2) The edge of slip ring is found 2) Dismantle and tightly install
widely. gap. again to remove the gap. When
the slip ring is tightly installed no
overlapped part or gap is found.
In case there happens
with overlapped part smoothly
rub the overlapped part with sand
(emery) paper.
3) The surface of slip ring got 3) Replace the old slip ring with
damaged. new one.
-9-
INSTALLATION MANUAL
MPP HDX
6.7. NET CUTTER

Dev. Order Deviation comprises Date Sign Check. Appr. Revis. Revision comprises Date Sign. Check. Appr.
Surface texture ISO/R 1302 Ra µm
A Hole changed from threaded M8 to Ø9 2011-03-02 NC
When not otherwise stated :
B Tot. length +5mm, sharp edges and hole for fastening updated accordingly 2011-03-11 NC Angle dimension tolerance shall comply with SS-ISO 2768-1 middle column.
Linear dimension tolerance shall comply with SS-ISO 2768-1 middle column. (See the table below)
Basic size Tolerances Basic size Tolerances

(0,5)- 3 ±0,1 (1000)- 2000 ±1,2
(3)- 6 ±0,1 (2000)- 4000 ±2
(6)- 30 ±0,2 (4000) 8000 ±3
(30)- 120 ±0,3 (8000)-12000 ±4
(120)- 400 ±0,5 (12000)-16000 ±5
(400)-1000 ±0,8 (16000)-20000 ±6
10x45° M5
20
10x45°
B R22
115
B B
84.9
84.9
B
68
B
51
B
third party nor be used for any unauthorized purpose. Contravention will be prosecuted in accordance with Swedish law.
This document must not be copied without our written permission, and the contents thereof must not be imparted to a
35
10
20 2x 9 10
A
Note:
MATERIAL:
1.4436, X4CrNiMo17-13-3
according to EN10250-4
(SS 2343)
ALTERNATIVE MATERIAL:
316L
according to AISI
Drawn Checked Approved E Previous dwg. Tot.weight
NC MN 16539 0.22
Sheet of Date
NET CUTTER 1 1 2011-01-27

Part No. Scale
BCP 490 - BCP 850 NK40467 1:1 A3
40467
Revis.
B
INSTALLATION MANUAL
MPP HDX
7. ALARM SYSTEM

System Alarms
MPP - Marine Propulsion Propeller
# Caterpillar: Confidential Green

# Caterpillar: Confidential Green
ALARM MONITORING SYSTEM
MPP - MARINE PROPULSION PROPELLER
PROPELLER EQUIPMENT MPP 760

ORDER NO. YARD NB NO.
7364M Detroit Brasil Ltda C416
Caterpillar Propulsion Production AB

# Caterpillar: Confidential Green www.catpropulsion.com
ALARM MONITORING SYSTEM
REVISION DESCRIPTION DATE SIGN.

1 Hydraulics done 2019-July-26 MA
2 Controls done 2019-Aug-6 LGG
Caterpillar Propulsion Production AB

# Caterpillar: Confidential Green www.catpropulsion.com
Revision: 7364M - SYSTEM ALARMS MANUAL SYSTEM ALARMS
TRUE TRUE FALSE

1
DESCRIPTION SIGNAL TYPE FUNCTION* SET POINT DELAY (s) COMMENT
CENTRAL UNIT
TRUE Control System A Fault On/Off P.F. Contact NC N/A N/A

TRUE Control System B Fault On/Off P.F. Contact NC N/A N/A
TRUE Power Supply A Fail On/Off P.F. Contact NC N/A N/A
TRUE Power Supply B Fail On/Off P.F. Contact NC N/A N/A
TRUE Power Supply C Fail On/Off P.F. Contact NC N/A N/A
TRUE Hub Lubrication Fault On/Off P.F. Contact NC N/A N/A
CONNECTION BOX - HYDRAULIC TANK UNIT
TRUE Oil Pressure Pitch Pump 2 Low On/Off Pressure Switch NC <10 bar 8 Autostart Pitch Pump 1
TRUE Oil Pressure Pitch Pump 1 Low On/Off Pressure Switch NC <10 bar 8 Autostart Pitch Pump 2
TRUE Oil Pressure Pitch System Low On/Off Pressure Switch NC <6 bar 5
TRUE Oil Temperature Pitch High On/Off Temp. Switch NC >60°C 5
TRUE Oil Level Pitch Low On/Off Level Switch NC <70% 4
TRUE Oil Pressure Pitch High On/Off Pressure Switch NC >55 bar 5
TRUE Oil Filter Pitch Blocked On/Off Pressure Switch NC >5 bar 10 Differential pressure
TRUE Oil Filter Lubrication Blocked On/Off Pressure Switch NC >2 bar 10 Differential pressure
STARTER UNIT - PUMP 1
TRUE Pump Started (103-105 Closed) On/Off P.F. Contact <10 bar Delay set in starter
TRUE Phase Fault Alarm & Voltage Alarm On/Off P.F. Contact 20V Treshold Voltage Window +/-20V
STARTER UNIT - PUMP 2
TRUE Pump Started (103-105 Closed) On/Off P.F. Contact <10 bar Delay set in starter
TRUE Phase Fault Alarm & Voltage Alarm On/Off P.F. Contact 20V Treshold Voltage Window +/-20V
LUBRICATION HEADER TANK
TRUE Oil Level Lubrication Low On/Off Level Switch NC <70% 5
* - Connections shown as normal condition (no alarm) Caterpillar Propulsion Production AB

Caterpillar: Confidential Green Refer to Installation Manual for drawing references www.catpropulsion.com
© 2014 Caterpillar CAT, CATERPILLAR, their respective logos, "Caterpillar Yellow", and the POWER
All Rights Reserved EDGE trade dress as well as corporate and product identity used herein, are
trademarks of Caterpillar and may not be used without permission.
INSTALLATION MANUAL
MPP HDX
8. APPENDIX - DRAWINGS

INSTALLATION MANUAL
MPP HDX
8.1. MECHANICS
Drawing Name Drawing Number

PROPULSION AR-MAIN 70196 Rev. F
HUB GP-PROPELLER 51930 Rev. A
SHAFT GP-PROP 70312 Rev. -
PCU-GEAR ASSEMBLY 70421 Rev. -
OD BOX ASSEMBLY 50361 Rev. -
PCU MECHANICAL 50381 Rev. -
DISC-BRAKE 70337 Rev. A
8.2. HYDRAULICS
See the hydraulic installation manual.
8.3. REMOTE CONTROL SYSTEM

See the remote control system manual (RC).

INSTALLATION MANUAL
MPP HDX
8.4. MECHANICAL DRAWINGS

A ITEM 50 WAS TO2254 REPLACED WITH ITEM 18 BK59176. EC244066 8 May 2018 MA BW NL
Angle dimension tolerance shall comply with SS-ISO 2768-1 middle column.
TO BE LOCKED IN BLADE ROOT TIGHTENING TORQUE: 910 Nm Basic size Tolerances Basic size Tolerances
WITH LOCTITE 242 OR EQUIVALENT OVERRULED BY TIGHTENING ANGLE, SEE SKETCH (0,5)- 3 ±0,1 (1000)- 2000 ±1,2
30 TIGHTENING TORQUE: 550 Nm (3)-
(6)- 30
6 ±0,1
±0,2
(2000)- 4000
(4000) 8000
±2
±3
OVERRULED BY TIGHTENING ANGLE, SEE SKETCH (30)- 120 ±0,3 (8000)-12000 ±4
(120)- 400 ±0,5 (12000)-16000 ±5
(400)-1000 ±0,8 (16000)-20000 ±6
16 9 7 48
28 8 47
21
a3 2x10 A
LOCTITE 243
26° a3 2x20
37 38 35
12
11,
20% OF TIGHTENING TORQUE 9
FULL TIGHTENING 29
°
7 11
,4
20% OF TIGHTENING TORQUE 11
,3
D (1.3 : 1)
8 FULL TIGHTENING
53
C (1.3 : 1) TORQUE:
60 SEE EXPANSION 45
B DOWEL DRAWING
187 Nm 10 45 1 54 12 49 5
A
18 A 36 31 32
17 B-B (1 : 4)
540
BLADE SEAL
52 OIL TYPE PART No.
MINERAL TO4480
EAL TO4480-V
The copying, distribution and utilization of this document as well as the communication of its contents to other without expressed authorization is prohibited. Offenders will be held liable for the payment of damages.
149 FEATHERING 60 8 WELD LOCKING LS1516

50
ASTERN 54 1 O-RING TO2855
53 1 O-RING 379,3x5,7 SMS 1586/87
TO2795
70 AHEAD 52 1 O-RING TO2772
99 51 1 O-RING 89,5x3 SMS 1586/87
TO2289
126 A 50
D 49 4 O-RING TO2249
C 48
47
24 O-RING
16 O-RING
TO1139
TO1136
E 46 1 O-RING TO2219
45 4 BLADE SEAL SEE TABLE
All rights reserved in the event of the grant of a patent, utility model or ornamental design registration. Caterpillar: Yellow Confidential ® Caterpillar Propulsion AB
38 2 SEAL SUPPORT DX4470

37 2 PISTON ROD SEAL TX3039
36 1 PISTON SEAL CR GH 390x365.5x8.1-AE1
TX4680
35 2 GUIDE RING LX4465
32 30 LOCKING WASHER BL3016

31 30 BOLT MC6S SM7040
30 8 BOLT MF6S SM3824
29 1 BOLT M6S SM1018
28 4 RETAINING RING LR3050
27 6 CIRCLIP LR3020-1
26 6 PLUG SR4087
25 4 PLUG SR4020
A 18 1 WASHER-SEAL 59176 BK59176

17 4 WIRE WINDER 46361 SEE ORDER
16 8 SLIDING DISC 29282 LB29282
15 1 PIPE GP-HUB 51928 AR51928
14 1 NUT GP-TENSION 54486 MA54486
LOCTITE 638 13 1 NUT GP-TENSION 55148 SEE ORDER
12 4 EXPANSION DOWEL 43912 CP43912
25 46 11 1 HEAD GP-ROD 51754/ 51755 SEE ORDER
10 4 MOUNT-BLADE SEE ORDER
9 4 TORQUE PIN 43879 CP43879
8 16 BOLT, SHAFT 43911 /46408 ICE SEE ORDER
27 Litre 7 24 BOLT, BLADE 43910 /46407 ICE SEE ORDER
6 1 DISC-PISTON 51651 MA51651
15 29 2 14 51 3 6 4 53 5 4 GUIDE BLOCK 46503 BT46503
4 1 ROD-HUB 51927 DS51927
3 1 PISTON-HUB 51650 CK51650
TORQUE: SEE MARKING ON NUT BODY 2 1 CYLINDER-HUB 51671 CK51671
11 27 26 13
LOCTITE 243 43 Litre B 1 1 HOUSING-HUB
ItemNo No.of Description
51804
Reference Material
PN51804
Part No.
Drawn Checked Approved Previous dwg. Tot.weight
TIGHTENING TORQUE: 255 Nm TORQUE: SEE MARKING BW Amm JG
E
851
ON NUT BODY Sheet of Date
OVERRULED BY TIGHTENING ANGLE: 1 1 17 Aug 2015
APPLY 20% OF TIGHTENING TORQUE FOR START POSITION 320 HUB GP-PROPELLER
Part No. Scale
THEN TURN 100°±22,5° TO FULL TIGHTENING PN51930 1:2.2 A1
600 (MPP 620F - 05)
Revis.
51930
425 E (1 : 1.5)
A-A A
Dev. Order Deviation comprises Date Sign Check. Appr. Surface texture ISO/R 1302 Ra µm

(0,5)- 3 ±0,1 (1000)- 2000 ±1,2
(3)- 6 ±0,1 (2000)- 4000 ±2
(6)- 30 ±0,2 (4000) 8000 ±3
(30)- 120 ±0,3 (8000)-12000 ±4
(120)- 400 ±0,5 (12000)-16000 ±5
(400)-1000 ±0,8 (16000)-20000 ±6
6680
PROPELLER SHAFT LENGTH Y = 6665

GEAR BOX FLANGE
8
ADD CORTEC VPCI-368 OR SIMILAR
A FROM RECESS TO CLADDED SURFACE
11 10
B
K=15
16
1457 Nm
6 7
9
A
4 1 2 3
99 L = 229
126 PIPE DESIGN LENGTH = 6337 244
A-A (1 : 5)
16 1 O-RING TO2760
15 1 O-RING TO2324
14 15 5 12 13 14 1 O-RING TO2736
10 4 BOLT M6S SM1532
9 8 CYLINDRICAL PIN 70431 CP70431
8 1 DISC-BRAKE 70337 AB70337
7 12 NUT MM2036
6 12 BOLT-FLANGE 53829 SE53829
5 1 RING-SEALING 70322 TR70322
4 1 GUARD-PROTECTIVE 70323 SK70323
3 1 OMC ASSEMBLY 70354 AK70354
2 1 PIPE GP-PROP 70429 AR70429
1 1 SHAFT-PROP 70311 AP70311
Item No. No.of Description Reference Material Part No.
THE CORRECT DRIVE UP LENGTH IS REACHED
WHEN THE AFT END OF THE COUPLING IS Drawn Checked Approved E Previous dwg. Tot.weight
20 mm FROM MARKING LINE. AE KRS 2262

Sheet of Date
SHAFT GP-PROP 1 1 04 Jul 2019

P = 1520kW B (1 : 1) Part No. Scale
RPM = 215 RPM AP70312 1:8 A2
CLASSIFICATION = BV, NO ICE (MPP620F)
Revis.
70312 -
Dev. Order Deviation comprises Date Sign Check. Appr. Rev. Revision comprises Date Sign. Check. Appr.

(0,5)- 3 ±0,1 (1000)- 2000 ±1,2
(3)- 6 ±0,1 (2000)- 4000 ±2
(6)- 30 ±0,2 (4000) 8000 ±3
(30)- 120 ±0,3 (8000)-12000 ±4
(120)- 400 ±0,5 (12000)-16000 ±5
(400)-1000 ±0,8 (16000)-20000 ±6
PIPE DESIGN LENGTH = 954
35
D=30
4
6 3 5
7 2 1
47 Nm
300 654 569
SECTION A-A 92 MIN: DISMANTLING SPACE

All rights reserved in the event of the grant of a patent, utility model or ornamental design registration. Caterpillar: YellowConfidential ® Caterpillar Propulsion AB
SCALE 1 : 2.5
8x 11
190
160 h11
P.C.D.
7 1 POTENTIOMETER EP3271
6 1 O-RING TO2680
4 1 EXTENSION PIPE 54698 AR54698
3 1 FLANGE–CONNECTION 56955 AF56955
2 1 PCU ELECTRICAL 61396 HD61396
1 1 PCU MECHANICAL 50381 HD50381
Item No. No.of Description Reference Material Part No.
AE 95
Sheet of Date
DISTRIBUTOR GP-OIL 1 1 01 Jul 2019

Part No. Scale
CONNECTION FLANGE INTERFACE
(HDX75 8xM10) HD70421 1:20 A1
Revis.
70421 -

(0,5)- 3 ±0,1 (1000)- 2000 ±1,2
(3)- 6 ±0,1 (2000)- 4000 ±2
(6)- 30 ±0,2 (4000) 8000 ±3
(30)- 120 ±0,3 (8000)-12000 ±4
79 Nm (120)- 400
(400)-1000
±0,5
±0,8
(12000)-16000
(16000)-20000
±5
±6
58 3 2 26 45 59 8 7 9 55 59 10 12 59 18 11
24 Nm
46 32
0
25 28
C 33
13
1 4 32 34
57
56
301
25 24 Nm
28 C (2 : 1.5)
B 15
5 47 33 17 33 32 31 6 35
48
LOCTITE 638
50
LOCTITE 638
NOTE!
AT FINAL ASSEMBLY-YARD INSTALLATION
TO BE LOCKED WITH LOCTITE 243
(MEDIUM STRENGTH) OR EQUIVALENT.
14
24 Nm
19 49 LOCTITE 638
LOCTITE 243
A 0,05 A 0,05 A B (2 : 1.5)
65
REPLACE WITH 15 TO MOVE CONNECTION FOR "L"
16 ALL EXTERNAL STEEL SURFACES TO BE PAINTED
0-PITCH
59 3 O-RING TO2654
Max. ASTERN 69 Max. AHEAD 204 58 1 O-RING TO2620
57 1 O-RING TO2315
56 3 O-RING TO2308
55 4 O-RING TO2294
50 2 WASHER BG1513
49 2 WASHER BG1007
A 48 2 PLUG SR4064
47 1 GUIDE RING LX7033
239
46 1 RADIAL SEAL TM2138
45 2 RADIAL SEAL TM2142
A

36 4 WASHER BRB BP1014
719 35 1 CHAIN CONN. LINK, STRAIGHT FOR 05B-1 KE2014
34 1 TORSION SPRING FR1011
33 3 BEARING KU00608
32 3 CIRCLIP LR3022
81 Nm 31 1 CIRCLIP LR2008
27 558
30 1 CYLINDRICAL PIN CP2080
29 29 12 LOCKING WASHER BL3012
27 28 16 LOCKING WASHER BL3008
29 26 6 BOLT MC6S SM2537
27 TO SECURE POSITION OF L-SEGMENT WHILE 25 17 BOLT MC6S SM2520
29 MOUNTING SCREWS, POS. 27 POSSIBLE CHANGE OF SEAL POSITION AT THE WEAR 19 2 SET SCREW 51227 CP51227
37 18 1 ROLLER CHAIN 54406 KE54406
45 8 17 1 DISTANCE SLEEVE 53219 HD53219
AREA FOR STAMPING 16 1 COVER 52757 HD52757
15 2 COVER 53042 HD53042
14 1 GEAR SHAFT ASSEMBLY 52739 HD52739
30 13 1 SEAL HOUSE 52740 HD52740
12 2 SEALING RING 50372 TR50372
11 1 OD HOUSE, SEGMENT L 50699 HD50699
24 Nm
25 10 1 OD HOUSE, SEGMENT B 50371 HD50371
9 1 OD HOUSE, SEGMENT D - A 50369 HD50369
36 8 2 DISTANCE WASHER 45798 HD45798
7 1 SEAL DISTANCE 50368 HD50368
6 1 BEARING SHAFT 53366 HD53366
WASHERS TO BE USED WITH M8 BOLTS 5 1 BEARING HOUSE 53367 HD53367
TO KEEP SEAL HOUSE IN POSITION WHILE 4 1 CENTER PIPE, FWD 50365 RS50365
TIGHTENING SPRING 3 1 CLAMP RING 50364 HD50364
2 1 OD SHAFT, FWD 50363 HD50363
1 1 OD SHAFT ASSEMBLY 50362 HD50362
ItemNo No.off Description Reference Material Part No.
Amm BW JG 77
Sheet of Date
OD BOX ASSEMBLY 1 2 08 Apr 2015

Part No. Scale
THE CHANNEL ENABLES SEAL LEAKAGE CHECK.
HDX 75 / 273 HDM50361 1:1.5 A1
Revis.
50361 -
- See Sheet1 - - - - When not otherwise stated :

(0,5)- 3 ±0,1 (1000)- 2000 ±1,2
"D" (3)- 6 ±0,1 (2000)- 4000 ±2
(6)- 30 ±0,2 (4000) 8000 ±3
(30)- 120 ±0,3 (8000)-12000 ±4
(120)- 400 ±0,5 (12000)-16000 ±5
(400)-1000 ±0,8 (16000)-20000 ±6
209,2
"D"
"A" 205,6
185,4
0-PITCH=719
D-D
"A"
"D" "B"
D
"L"
"L"
"B"
E-E "B"
Amm BW JG 56
Sheet of Date
OD BOX ASSEMBLY 2 2 08 Apr 2015

Part No. Scale
HDX 75 / 273 HDM50361 1:1.2 A1

Revis.
50361 -

(0,5)- 3 ±0,1 (1000)- 2000 ±1,2
6 (3)-
(6)- 30
6 ±0,1
±0,2
(2000)- 4000
(4000) 8000
±2
±3
(30)- 120 ±0,3 (8000)-12000 ±4
(120)- 400 ±0,5 (12000)-16000 ±5
(400)-1000 ±0,8 (16000)-20000 ±6
50
7 D A B L
A
CONNECTION FLANGE
SEE PCU ASSEMBLY
5
D
4
LENGTH OF HOSES, 1m
B
5
3 L
~280
50 65
504
2 92, MIN DISMANTLING SPACE
660
25
°
8 1 HYDRAULIC HOSE 47530 HS47530

5 2 WASHER BG1516
4 2 WASHER BG1515
3 1 PITCH SCALE 51838 NS51838
2 1 SENSOR HOUSING 49899 HD49899
30
1 1 OD BOX ASSEMBLY 50361 HDM50361

5
ItemNo No.off Description Reference Material Part No.

5
Drawn Checked Approved Previous dwg. Tot.weight

0
1,
E
26
Amm BW JG 97
19
Sheet of Date
CAN BE ROTATED IN STEPS OF 45° PCU MECHANICAL 1 1 08 Apr 2015
TO SUIT PIPING AND VISIBILITY. CAN BE ROTATED IN STEPS OF 90°. Part No. Scale
HDX 75 / 273 HD50381 1:2 A1

Revis.
50381 -

(0,5)- 3 ±0,1 (1000)- 2000 ±1,2
(3)- 6 ±0,1 (2000)- 4000 ±2
(6)- 30 ±0,2 (4000) 8000 ±3
2x M10 (30)- 120 ±0,3 (8000)-12000 ±4
24,5
(120)- 400 ±0,5 (12000)-16000 ±5
20
12,5 (400)-1000 ±0,8 (16000)-20000 ±6
A
700
25
NOTE: BRAKE DISC IS NON-SPLIT VERSION
A-A (1 : 2.5) Drawn Checked Approved E Previous dwg. Tot.weight

AE KRS 66
Sheet of Date
DISC-BRAKE 1 1 04 Jul 2019

Part No. Scale
Ø700, T=25 AB70337 1:4 A2

Revis.
OMC200
70337 A
INSTALLATION MANUAL
MPP HDX
9. APPENDIX – MPP OIL REQUIREMENTS

9.1. GENERAL INFORMATION
The oil supplier must always ensure that the oil is suitable to its purpose and meets the Caterpillar
requirements.
9.2. OIL REQUIREMENTS, MINERAL OIL

All oil must pass ISO 11158 or DIN 51524-
3
Viscosity, HDX: 32 cSt
Viscosity, BCX: 46 cSt
Load Carrying Capability: Load stage 11 or better according to ISO14635-1

HDX=gear mounted oil distributor
BCX=shaft mounted oil distributor
Important!
Failure to follow the oil requirements can shorten the service life of the
propulsion equipment.
10. APPENDIX – PRE-COMMISSIONING REPORT

10.1. PRE-COMMISSIONING CHECK LIST
This form must be filled out and returned to Caterpillar before the commissioning can start. Forward
this list to your contract engineer at Caterpillar when sending for the service engineer for
commissioning. A completed list will make the commissioning procedure more cost-effective.

INSTALLATION MANUAL
MPP HDX
CHECK LIST PRIOR TO COMMISSIONING

MPP MAIN PROPELLER
GENERAL
Yard no.:
Shipyard: Detroit Brasil
Customer: Commissioning date:
PROPELLER BLADE INSTALLATION Yes No

Lifting equipment for blades arranged
Supports for shafts arranged
Blade seals ready
Blade bolts ready
Torque wrench arranged
OD BOX/PITCH CTRL UNIT INSTALLATION Yes No

Propeller shaft installation completed
Intermediate shafts installation completed
Gear box installation completed
Shaft alignment completed
All coupling bolts tightened
OD box ready to install
HYDRAULIC SYSTEM Yes No

Hydraulic tank unit installed
PTO pump installed
Starters for pumps installed
Control valve installed
Tank for hub lubrication installed (MPP type)
Tank for stern tube/hub installed
All piping completed
External piping flushed to ISO 4406 (20/18/15)
Hydraulic tank filled with oil
Stern tube filled with oil
Power supply to Starter ready

INSTALLATION MANUAL
MPP HDX
ELECTRONICS Yes No
1. Electronic equipment installed:
a) Central unit
b) Local unit
d) ECR interface plate
e) Bridge interface plate
f) All panel frames mounted
2. All external cables terminated
3. All power supplies to Caterpillar System rdy to power "on"
STARTUP Yes No
M/E, G/B ready for interface check
Joystick/DP ready for interface check
SEA TRIAL Yes No

CPP system ready (complete)
M/E and gearbox ready
Joystick/DP system ready to check the interface
Check the servo filters (if applicable)
We confirm that the above work has been carried out.
Date: Yard representative: Signature:

INSTALLATION MANUAL
MPP HDX

7364M Main Propeller Installation Manual 2019 09-11-040022

Uploaded by

Copyright:

Available Formats

7364M Main Propeller Installation Manual 2019 09-11-040022

Uploaded by

Document Information

Copyright

Available Formats

Share this document

Share or Embed Document

Sharing Options

Did you find this document useful?

Is this content inappropriate?

Copyright:

Available Formats

7364M Main Propeller Installation Manual 2019 09-11-040022

Uploaded by

Copyright:

Available Formats

Installation Manual

MPP – Marine Propulsion Propeller

Caterpillar: Confidential Green

MPP620 1 Receipt and Storage

Installation Manual 2 Main Unit

Order No 7364M 3 Hydraulic System

9 Appendix – Oil Requirements

Document Version: 1 Date: September 11, 2019

Caterpillar: Confidential Green

Caterpillar: Confidential Green

2.7.3. DISMOUNTING A PROPELLER BLADE IN A NOZZLE

Caterpillar: Confidential Green

Caterpillar: Confidential Green

1. RECEIPT AND STORAGE

WARNING: Do not operate or work on this equipment unless you have

Caterpillar: Confidential Green

1.3. GENERAL HAZARD INFORMATION

Figure 1. Cat warning tag.

Figure 2. Personal Protective Equipment (PPE).

Caterpillar: Confidential Green

1.4. PRESSURIZED AIR AND WATER

1.5. FLUID PENETRATION

1.6. CONTAINING FLUID SPILLAGE

1.7. LINES, TUBES AND HOSES

Caterpillar: Confidential Green

1.8. ASBESTOS INFORMATION

1.9. DISPOSE OF WASTE PROPERLY

Figure 3. Proper waste disposal.

Caterpillar: Confidential Green

1.10. BURN PREVENTION

1.13. FIRE PREVENTION AND EXPLOSION PREVENTION

Caterpillar: Confidential Green

1.14. FIRE EXTINGUISHER

1.15. LINES, TUBES, AND HOSES

1.16. CRUSHING PREVENTION AND CUTTING PREVENTION

1.17. MOUNTING AND DISMOUNTING

Caterpillar: Confidential Green

1.18. BEFORE STARTING THE PROPULSION EQUIPMENT

1.19. STARTING THE PROPULSION EQUIPMENT

1.20. STOPPING THE PROPULSION EQUIPMENT

1.21. ELECTRICAL SYSTEM

Caterpillar: Confidential Green

1.22. GROUNDING PRACTICES

1.23. PRESERVATION BY THE VENDOR

1.24. CONSIGNEE'S/SHIPYARD'S QUALITY PROTECTION

Caterpillar: Confidential Green

1.25. CORROSION PROTECTION

Figure 4. Wooden covers.

Caterpillar: Confidential Green

Figure 6. Plug hole.

Caterpillar: Confidential Green

1.26. PROPELLER VS HULL – NOBLE POTENTIAL AND CORROSION

Caterpillar: Confidential Green

1.26.1. SHAFT GROUNDING TO PROTECT AGAINST STRAY CURRENT CORROSION

Caterpillar: Confidential Green

1.27. MAINTENANCE OF PROPELLER SYSTEMS TAKEN OUT OF

Finally, normal maintenance is recommended, whether the vessel is in operation or not.

Caterpillar: Confidential Green

1.28. LIST OF INSTALLATION RESPONSIBILITIES

Caterpillar: Confidential Green