Shottel

SERVICE MANUAL
VOLUME 1
Rudderpropeller SRP 1515 FP
Key Word: BONNY 39

Order Number: 14338705-1
Serial Numbers: SRP-119555/ SRP-119556
Input Power (kW): 2000
Input Speed (rpm): 1600
Minimum Operating Speed (rpm): 600
Classification Society: ABS
Distribution and Duplication Disclaimer

The distribution or duplication of this Service Manual and the utilisation We have checked the content of this Service Manual regarding
and communication of its content is not permitted, unless this has been compliance with the described hardware and software. Nevertheless,
expressly granted. variances cannot be ruled out, which means that we will not guarantee
Any violations will necessitate compensation. full compliance.
All rights reserved, particularly in the case of granting a patent or The information provided in this Service Manual is reviewed regularly,
registering a utility model. however, and any necessary amendments will be included in the
following issues. We will be grateful for any suggestions for
improvement.
TTD-db 14338705-1 19 May 2015 1/2

Revision History
Rev. Revision Chapter Description Document Document Document Document

No. Date No. No. Revision replaced added
DD.MM.YYYY Code
0 19/05/2015
SCHOTTEL GmbH
Mainzer Str. 99
56322 Spay/Rhein
GERMANY
Phone: +49 2628 61‐0
Fax: +49 2628 61‐300 and 61‐345
E‐mail: [email protected]
Internet: www.schottel.de
TTD-db 14338705-1 19 May 2015 2/2

Table of Contents
VOLUME 1
Rev. No. Part. No.
1 Technical Specification
Technical Specification ................................................................................ Rev. 0, 2014-09-02 ......... TS-52290
2 Installation Instructions
Installation Drawing ....................................................................................................... 15/0535 ........... 1188330
Pointer ........................................................................................................................... 09/0098 ........... 1108411
Alignment Data Sheet............................................................................................................. for ........... 1191153
Center of Gravity ........................................................................................................................ ........... 1201784
Schedule of Measuring Points .................................................................................. 07.12.2011 ........... 1188111
3 Operating, Mounting and Maintenance Instructions
Safety and Environmental Protection Regulation "SV 1" ...................................... 348/98 ........... 1099236
3.1 Mechanics
Operating Instructions SCHOTTEL RUDDER PROPELLER 1515 FP ............... 12/May. ........... 1191501
Lubrication Oil Specifications for SCHOTTEL Propulsion Units
with FP Propellers ............................................................................................... 15/0360 ........... 1145139
Shafting Installation Instruction ........................................................................... 14/1382 ........... 1191153
Installation Instructions for Propellers ................................................................. 13/June ........... 1197744
Propeller Installation Record Sheet SRP-SCD 1515 FP (Pusher Propeller) ........ 13/Nov ........... 1199454
Mounting and Maintenance of the Self-Aligning Roller Bearings
in Shaft Lines (two−lip seal) with Synthetic Lubricating Grease ......................... 11/1140 ........... 1167641
Installation Instructions for Bolted Connections and Sealants ............................ 14/0208 ........... 1180737
Preservation Instructions ....................................................................................... 641/02 ........... 1104097
3.2 Hydraulics
Operating Instructions Hydraulic System SST 612 ........................................... 12/March ........... 1189950
Hydraulic Oil Specifications for SCHOTTEL Propulsion Units ............................ 14/0100 ........... 1196665
Flushing Specification for Hydraulic Systems
with Variable Displacement Pump ...................................................................... 07/3151 ........... 1100933
Installation Specifications for Hydraulic Systems and their Components ........... 12/1810 ........... 1099237
3.3 Electrics
Control and Electrical System ............................................................................ 2014/10. ........... 1207405
Examples of Steering Manoeuvres ..................................................................... 13/April. ........... 1196570
User Documentation for System Display S-ODS V2.00.10 ................................. 13/Feb. ........... 1187801
Warning System ................................................................................................... 10/Feb. ........... 1176151
Speedronic Motor Control Unit MSV Id. No. 1115903 .......................................... July/00 ........... 1128284
Operating Instructions DCM Module ................................................................... 10/1597 ........... 1162900
Operating Instructions DPV Module ................................................................... 10/1598 ........... 1162901
4 Spare Parts Catalogue
en TTD-db Table of Contents 14338705-1 19 May 2015 1/2

Rev. No. Part. No.
5 Documents from Suppliers

Technical Description Mounting, Maintenance
and Repair of Propshafts with Flanged Universal Joints
for SCHOTTEL Part No. 1129696 .......................................................................... Edition 2007 ........... GEWES
Installation, Operation and Maintenance of Airflex VC Marine Clutches

for SCHOTTEL Part No. 1146427 .............................................................................................. ...... KENDRION
Operating Instructions Gear pump KF 2,5...200 ......................................................2012-09-25 .......... KRACHT
Compact Cooler Instruction Manual P Type Heat Exchanger

for SCHOTTEL Part No. 1143017 ............................................................................... Rev.C .... GEA BLOKSMA
Operating Instructions Shell - and - Tube Heat Exchanger

for SCHOTTEL Part No. 1181217 ................................................ Edition 07/2011 ...UNIVERSAL HYDRAULIK
6 Diagrams
6.1 Pneumatic Diagrams

Pneumatic Diagram Binder .............................................................................................. ........... 1149617
6.2 Hydraulic Diagrams

Hydraulic Circuit Diagram ................................................................................... 11/0454 ........... 1151373
VOLUME 2
6.3 Wiring Diagrams

Wiring Diagram SRP 1515 FP ............................................................................ 15/0578 ........... 1201903
Key for individual terms and letters in the Spare Parts Catalogue:
SSS XXXX YY Z/Z
Bsp. R/R Right/Right

Bsp. L/L Left/Left
FP Fixed Pitch Propeller

CP Controlable Pitch Propeller
Bsp. 1515 Size

Bsp. 2020
SCHOTTEL propulsion unit
HY Hydraulic
OI Operating Instructions SCHOTTEL
K Sub-assemblies (further partlist available)
L Operating Instruction Supplier
2/2 TTD-db Table of Contents 14338705-1 19 May 2015 en

1. Technical Specification
BLANK PAGE
Technical Specification
TUG-110244-06 / 14338705 / BONNY 39
TWO (2) SCHOTTEL RUDDERPROPELLER
TYP SRP 1515 FP
AS MAIN PROPULSION UNITS

Ship owner : Bonny Fair Development Ltd.
Ship yard : GuangZhou Nansha Xinghua
Shipbuilding Co Ltd
Ship building country : China
Building No. : BF-2262
Vessel type : ASD Tug
Operation area :
class : ABS
class notation : A1 E, Towing Vessel +AMS
SCHOTTEL Project no. : TUG-110244-06

SCHOTTEL project name : BONNY 39
SCHOTTEL order no. : 14338705
SCHOTTEL order code word : BONNY 39
Rev. No Issue Date Issue Description Originator/Dpt.

0 2014-09-02 Order Issue HF/VB
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CONTENTS
1. SCOPE OF SUPPLY ........................................................................................................... 4

1.1 List of components supplied by SCHOTTEL .............................................................. 4
1.2 Additional agreements................................................................................................ 4
2. TECHNICAL DATA .............................................................................................................. 5
2.1. THRUSTER ............................................................................................................... 5
2.2. PRIME MOVER ......................................................................................................... 9
2.3. POWER TRANSMISSION ........................................................................................ 9
3. DESIGN & CONSTRUCTION ............................................................................................ 10
3.1 GENERAL DESIGN FEATURES ............................................................................. 10
3.2 STEERING SYSTEM ............................................................................................... 13
4. AMBIENT CONDITIONS ................................................................................................... 14
5. POWER SUPPLIES ........................................................................................................... 14
6. COATING AND PAINT STRUCTURE ............................................................................... 15
7. ELECTRICAL SYSTEM ..................................................................................................... 16
7.1. Unit arrangement..................................................................................................... 16
7.2. Switch cabinet ......................................................................................................... 19
7.3. Desk configuration................................................................................................... 20
7.4 Interfaces & alarms .................................................................................................. 23
8. TECHNICAL DOCUMENTATION ...................................................................................... 24
9. COMMISSIONING ............................................................................................................. 24
10. TEST & CERTIFICATES ................................................................................................. 24
11. EXCLUSIONS .................................................................................................................. 25
Appendix A: INTERFACE DESCRIPTION ............................................................................. 26
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1. SCOPE OF SUPPLY
1.1 List of components supplied by SCHOTTEL

 2x SRP 1515 FP including nozzle
 Parts per thruster:
 steering system parts, according to chapter steering system
 bottom plate
 Shaftline parts, configuration according to chapter power transmission
 1x Forward bridge parts, configuration according to chapter desk configuration
 Warning Unit with panel(s), configuration according to chapter interfaces &
alarms
 1x Switch cabinet for SCHOTTEL control system
 per ship set:
 1x Toolset consisting of:
o Tools for dismounting of propeller
o Tools for dismounting of power input flange
o Tools for lower oil drainage
o Toolbox
 1x Spare parts to be supplied according to requirements of classification societies
for simple maintenance and service work to be done by onboard personnel,
basically consisting of:
o Mechanical parts:
This includes at least hydraulic hoses, upper gear box sealings, belts, oil
filters, anodes for coolers (one of each), as far as the unit is equipped with
these items.
o Electrical parts:
one set of printed circuit boards, relays and LEDs (depends on construction
of electrical system)
1.2 Additional agreements

none
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2. TECHNICAL DATA
2.1. THRUSTER
Power applied to input shaft : 2000 kW
Input speed : 1600 r.p.m
turning direction of Input shaft
seen on input shaft,
for thruster PS stern : clockwise
for thruster Stbd stern : clockwise
Type of construction : Z-drive

Installation into vessel : mounted from below, welded
Propeller Arm /Stem length : 3200 mm

Casing material lower gear box : GGG40
Weight excl oil & auxiliaries : 25,5 t (approximately)

Required oil charge : 2800 l (approximately)
Note: The final weight will be determined in the installation proposal.
Gear Reduction Ratio : 6,554
Nozzle : WAG 19A modified

Thruster rating
Working hours : < 3000 h / per annum
Load : intermittent
max. 10% full load
Overload : Prime mover torque can
exceed rated torque
for max. 10% (standard)
Operation area : Inland waterways with limited
water depth, Restricted coastal
service or Harbour service
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Propeller Design
Propellerlayout
bollard pull of 65 [metr.tons] expected at 2000 kW based on 9% TD. Please take note
that thrust deduction (TD) is mainly determined by the hull design and not in
SCHOTTEL`s responsability. Furthermore Bollard pull guaranty is subject to
compliance to the provisions of the following document “Recommendation for Bollard
Pull” SNQ 401 E latest version, available upon request.
Diameter : 2600 mm
Type : Fixed Pitch (Push)
turning direction of propeller
seen from AFT,
for thruster PS stern : counter clockwise
for thruster Stbd stern : clockwise
Lay out material : G-CuAI10Fe5Ni5-C (CU 3)

Number of blades : 4 or 5
Note:The final blade number will be determined on the basis of TVA calculations!
Design Type &

Manufacturing Standard : ISO 484/1981 (E). Tolerance Class I / II
Rating : 2000 kW
Propellers will be designed for a power consumption of 2000 kW and an input speed
into the thruster of 1600 r.p.m at a ship’s speed of 0 kn.
Steering
Type : SCHOTTEL Steering-System SST 612

Rotation Speed : 12 sec. /180°
Data for oil cooler (heat exchanger hydraulic oil / seawater or fresh water):
Required cooling water capacity : 2,5 m3/h
Max. water inlet temperature : 38 °C
Cooling capacity : 7,5 kW
p : 0,3 bar
Lubrication
Starter supply : SCHOTTEL

Starter type : direct start
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Lubrication system : by electrical lube oil pump

Power consumption : 1,8 kW
Data for oil cooler (heat exchanger lube oil / seawater or fresh water):
Required cooling water capacity : 2,5 m3/h
Max. water inlet temperature : 38 °C
Cooling capacity : 25 kW
p : 0,12 bar
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Sealing system
Propeller-, steering shaft sealing type : standard
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2.2. PRIME MOVER

Main Drive Motor : diesel engine
Type : CAT 3516C

Manufacturer : CAT
Supplier : not SCHOTTEL supply
Rated Power : 2000 kW
Speed : 1600 r.p.m.
Rotating direction (seen at flywheel) : counter clockwise
Mounting type : rigid
SAE housing type : not specified
Flywheel size : not specified
2.3. POWER TRANSMISSION

shaft line elements
No. Nomination
2 x Cardan shaft
1 x Hollow steel tube intermediate shaft with grease lubricated bearings
1 x Stub shaft with grease lubricated bearings
Shaftline length :6335 mm
Note: The final shaft line configuration will be determined on the basis of TVA
calculations!
Clutch:
It is a pneumatically activated marine clutch placed on the power input shaft of the
upper gear box of the SRP/STP by keyless shrink fit.
The clutch is disengaged if not in operation and it is designed for very smooth, silent
and frequent engaging.
The switch box, including the electro pneumatic control unit, will be delivered loose for
installation by the shipyard close to the SRP/STP.
Activation of the clutch by compressed air (yard supply), approx. 9..11 bar air pressure,
dependent on final version, exact value is given in the pneumatic diagram.
Emergency engaging is given by included home coming bolts.
Remarks:
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SCHOTTEL will carry out a TVA with a simplified engine model. SCHOTTEL will
propose suitable elastic coupling for power train and design the number of propeller
blades accordingly. This preliminary TVA is simply for SCHOTTEL warranty purposes
and not valid for classification purposes. Engine supplier or elastic coupling supplier
have to provide their own TVA, which can be approved by classification companies,
SCHOTTEL will supply mass elastic data of SCHOTTEL components.
3. DESIGN & CONSTRUCTION
3.1 GENERAL DESIGN FEATURES

Installation
The unit is supplied for well (well to be supplied by the yard) type mounting from below
and has a mounting flange integral with the stem/steering gear casing. The mounting
flange as well as the vertical stiffeners of the intermediate stem section has to be
welded to the ship's structure. The thrust of the unit is transmitted through
these connections, only.
Upper gearbox
Housing is made of spherocasting (GGG) and bolted to the thruster top plate. It
contains a set of helicoidal bevel gears, topped by a header tank.
The cyclo-palloid-type gear wheel/pinion is case-hardened and finish-machined after
hardening (H.P.G process) to Class 6 – DIN 3965.
All shafts in upper gear box are sealed by a lip-seal, running on a nitrated liner. All
stationary parts are sealed by O-rings.
Top plate
The top plate or mounting plate is a support element between upper gear and support
section.
Gearing
Below the topplate (within the support section) a slew bearing is located. It tops the
steering hub and is driven by actuators with torque enforcement through planetary
gear sets.
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Steering drives
Multiple vertically arranged hy-motors of proven type are part of the steering gear.
They are flanged onto a planetary reduction gear set in order to achieve suitable
rotating (steering) speed.
Thrust direction transmitter
A separate output shaft, driven by steering spur gear wheel is connected to a feedback
transmitter (electrical and mechanical), mounted onto the topplate. Suitable reduction
gives 1 : 1 synchronism with lower gearbox.
Support Section
The intermediate stem section is the connection between upper and lower gearbox.
Vertical stiffeners giving stability to the stem section are used to carry the well bottom
cover plate.
Steering pipe
Attached to the spur gear the steering pipe is the vertical connection between steering
gear and lower gear housing. It is manufactured from high quality casting (see
technical data), supported by solid roller bearing(s). Tightness is achieved by lip seals
with additional dirt protection, running on a ceramic coated ring of stainless steel.
Seals are easily accessible from outside of hull for inspection or change without
dismounting of thruster.
Transmission shaft
Connection between upper and lower gear's power transmission is achieved by a

vertical power transmission shaft, running inside the steering pipe. A helix or pump
wheel between these two pipes, rotated by the vertical power transmission shaft,
ensures constant oil circulation between upper and lower gear. Joint between upper
gear, lower gear and vertical power transmission shaft is of involute splined shaft type.
Lower Gearbox
The streamlined housing is made of high quality casting (see technical data) and has
an opening for fiberscope inspection.
It contains a set of cyclo-palloid-type bevel gears. The cyclo-palloid-type gear
wheel/pinion is case-hardened and finish-machined after hardening (H.P.G process) to
Class 6 – DIN 3965.
Tightness of propeller shaft is achieved by lip seals running on a tungsten carbide
coated ring of stainless steel. Seals are easily accessible from outside of hull for
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inspection or change without dismounting of thruster. All stationary parts are sealed by
O-rings.
Note: To prevent that nets and thin lines harm the propeller shaft sealings, the gap
between propeller hub and lower gear box housing include a labyrinth construction,
which cuts lines.
Lubrication system
An oil tank, directly mounted on top of upper gearbox, serves as compensating and
expansion tank.
During operation oil circulates in the unit, beeing cooled down in the immersed lower
section by heat dissipation through the surface of underwater parts to the surrounding
water.
The upper gear box is drained by a lube oil pump to avoid splash losses and
overheating of the lube oil.
During standstill, the upper gear is completely refilled with lube oil to prevent
condensation and corrosion.
Standard Nozzle
Modified WAGENINGEN 19A design, built of shipbuilding steel, inner plating made
from stainless steel, the nozzle is bolted to the thruster.
Structure of the nozzle is designed for speeds up to max 13 knots“.
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3.2 STEERING SYSTEM

SCHOTTEL Steering-System SST 612
Function
This is a full-follow up (FFU) electro-hydraulic steering system with non-follow up
(NFU) back-up system.
The SRP thrust can be directed to any desired direction around the vertical axis either
by turning the Copilot steering lever (if SCHOTTEL scope of supply) or through
external systems using a 4-20 mA signal.
The electronic control compares the presetting with the actual angle of the SRP and
transmits a signal corresponding to the differential angle to the hydraulic. If the
presetting angle is not equal to the angle of the SRP the control will be aligned.
The proportional steering system works in such a way that with small angle of steering
the corresponding steering speed is low and with bigger angle of steering the steering
speed is higher. Thus the steering speed is proportionally regulated by the steering
angle.
The SCHOTTEL SRP position is indicated via an electric feed-back system by a thrust
direction indicator. The thrust direction is also shown by a mechanical indicator on the
SRP.
In case of failure of the electronic steering system, the steering is automatically
switched over to a non-follow up (NFU) steering system.
Components
 Hydraulic power pack consisting of the following elements:
o 1 pulley and belt driven variable displacement hydraulic pump. The pump is
electronically controlled, producing hydraulic flow in both directions.
o Oil filter
 1 hydraulic tank with oil cooler and oil level gauge or dipstick
The shipyard must supply and install all pipe connections between hydraulic power
pack and hydraulic motors.
Flexible hose connections are provided by SCHOTTEL on the a.m. components.
SCHOTTEL installation instructions for hydraulic systems have to be observed.
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4. AMBIENT CONDITIONS
Maximum environmental temperature

during operation according to class
requirements : 50°C
Maximum environmental operation conditions:

Mechanical system:
Ambient air temperature : between 5°C and max. 55°C
Relative humidity of air : max. 95% without condensation
Seawater temperature : max. 32°C
Electric system:
Switch cabinets : 0°C - 50°C
Bridge parts (inside) : 0°C - 50°C
Bridge parts (outside) : (-)20°C - 50°C
Relative humidity of air : max. 95% without condensation
Vibration : 0,7g
5. POWER SUPPLIES
Electrical
For safe operation of the propulsion system SCHOTTEL requires the following power
supply from the ship's sources:
Switch cabinet
 380V/50Hz, 3Ph AC main power supply from the main switch board to the thruster
control system.
 220V/50Hz, 1Ph AC (F 16 A) power supply from the main switch board to the
SCHOTTEL switch box in the engine room (e.g. for service plug).
 24 V DC (+30% /-25%) with a max. ripple of 1 V (max. 300 W) for emergency

operation of the SCHOTTEL switch box.
 24 V DC (+30% /-25%) with a max. ripple of 1 V (fuse 2 A) from the emergency
switch box to the steering desk for emergency power supply of each thrust
direction indicator.
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6. COATING AND PAINT STRUCTURE
Upper gearbox as well as other metal parts inside the ship

sand blasting SA 2 ½ acc. DIN EN ISO 12944-4: 1998-07
2 x 2K Epoxy layer of anticorrosive primer approx. each 50-60µm
1 x 2K P.U. top coat, grey RAL 7000 approx. 50-60µm
Electric switchboxes*:
RAL 7035, structure
Panels*:
Black anodized aluminium
* If SCHOTTEL scope of supply.
Support section
1 x 2K Epoxy-resin-primer approx. 40 - 50 µm
3 x abrasion resistant coating 3 x approx. 100 - 125 µm
(2K Expoxy-resin)
Lower gearbox
(2K Expoxy-resin)
Nozzle
(2K Expoxy-resin)
Sacrificial Anodes
The outboard parts of each thruster are protected with anodes for at least 2
years:
Fitted to the nozzle.
Material : zinc
Mounting : welded
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7. ELECTRICAL SYSTEM
7.1. Unit arrangement
Thruster arrangement
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Bridge layout
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Unit arrangement
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7.2. Switch cabinet

Switch cabinet control system
The switch cabinet is the central component of the electric system. Incoming AC
voltage is converted and stabilized into 24 V DC voltage. Alternatively a 24V DC feed
line is also possible. Furthermore all necessary control elements, printed circuit
boards, fuses etc. are installed and wired inside. For easy connection of external
cabling terminal blocks with corresponding numbering are used.
The switch cabinet will be supplied loose for installation according to local space
requirement. Final position of switch cabinet should be selected regarding avoidance
of extreme temperatures, humidity and vibration.
Type of protection: IP 54
BUS – System
Communication between control panels (if panels are in SCHOTTEL scope of supply)
and switch cabinet control system in engine room is effected via a BUS system. For
the transport of data information in BUS system special shielded cables have to be
applied, type TCX(c) (with twisted pair wires). Data transfer between panels and
switch cabinet by shielded BUS cables may not be interrupted by terminals, due to
the risk of electromagnetic disturbances. Power cables have to be separated from
bus cables in cable channels. The recommended cable routings of SCHOTTEL are
based on IEC 61000-5-2.
The minimum distance between the cables class 2 (carrying slightly sensitive signals)
and class 4 (carrying strongly interfering signals) is specified with 500mm.
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7.3. Desk configuration

Detailed description of control panel arrangement. See example below.
The following components will be delivered wired with a cable tree of
1,2 m length to terminal strips.
Labelling language : english
Main: Aft:
Indicator: not used

Mounting: mounted in panel
Typ: Azimuth,RPM 96x96mm
Control-Panel:
Lever:
Typ: Copilot with handwheel
Stbd-Wing: PS-Wing:
not used not used
ECR:
not used
Following figures may be differing from the sold parts.
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Indicators
Azimuth Speed
Desk control Panel
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Control Lever
Copilot with handwheel
Fire Fighting mode
Switches fire fighting mode on and off. The speed of the engine/drive motor is
increased to the speed of the fire fighting system. Lights up when fire fighting mode is
switched on. Flashes when fire fighting mode is activated, the clutch of the fire fighting
pump is engaged and the pipes are filled.
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7.4 Interfaces & alarms

Interface to r.p.m. control
A lever for speed control (with defined position for clutch control, if a clutch is available)
is integrated in the COPILOT control lever. SCHOTTEL supplies COPILOT unit with a
sensor which is electrically connected to the SCHOTTEL thruster control system. The
signal is converted into a 4–20 mA signal to be connected to the switch cabinet of the
prime mover.
Interface to Autopilot-System
An interface for an Autopilot system is added. This function can be switched on from
the SCHOTTEL control panel (only on main desk and if certain conditions are
fulfilled). The Autopilot controls a steering angle of ± 45 degrees to the ahead thrust
direction. Override function of Autopilot is included via copilot lever control.
The following signals are sent to the AP-system:

 Potential free contacts “AP ON”
The following signals are sent by the AP-system:

 Steering angle setpoint 4-20mA signal for -45/+45 degrees
 Potential free contact “AP ready”
Interface to Fire-fighting System (Portside unit):
SCHOTTEL receives one potential free contact "FIFI MODE ON", closed when the fifi
mode is selected.
SCHOTTEL provides one potential free contact "FIFI MODE ACCEPT", closed when
engine speed is idle and pitch is in zero position (in case of CP-UNIT).
SCHOTTEL receives one potential free contact "FIFI PUMP IN SERVICE", closed
when the fifi clutch is engaged.
Alarms
The SCHOTTEL warning system supplies potential free contacts for “common alarm”
and “failure power supply SCHOTTEL warning system” to the ship warning unit. These
alarm signals are available at the terminals of the switch cabinet (control system).
All other alarms are connected to the SCHOTTEL warning system in the switch cabinet
of the control system.
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All alarms that are required according to class requirements for rudder machinery will
be indicated as “STATUS-SIGNALS” on the SCHOTTEL bridge panel (if panels are in
SCHOTTEL scope of supply).
All alarms will be indicated on the separate SCHOTTEL warning panel. Each warning
panel is equipped with an alarm acknowledge button. One panel will be mounted in
the front of the switchbox of the control system the other will be supplied loose for
mounting on bridge.
For detailed information about the alarm transmitter connection, see the attachment
“Interface Description”.
8. TECHNICAL DOCUMENTATION
 Installation documents (4 x paper, language: english)
 Operation manuals (4 x paper & 1 x CD, language: english)
9. COMMISSIONING
One service engineer(s) for in total Ten working days (10 hours/day) for final check
and commissioning per ship set. This also includes travel expenses and
accommodation for in total one trip(s).
If further days or travels are necessary which were not caused by SCHOTTEL, the
SCHOTTEL Service Price List valid at the time of the performance applies.
If applicable, participation at sea acceptance tests, harbour acceptance tests, FMEAs,

site acceptance tests, bollard pull tests or similar will be charged as above, as
SCHOTTEL has limited influence on duration.
10. TEST & CERTIFICATES
The propulsion system will be supplied with a certificate of: ABS
SCHOTTEL will effect the following tests:

 FAT for electrical & mechanical system
19.5.2015 HF TS-52290 24 / 26
TUG-110244-06 / 14338705 / BONNY 39
11. EXCLUSIONS
 Outer Wells
 Diesel engines / Electrical Prime Mover with controls (only interface 4-20mA)
 Slipping-clutch
 Braking system for the thruster
 Elastic couplings
 Autopilot
 Machinery materials such as electric power supply, lube oil, hydraulic oil, cooling
water, compressed air, batteries
 Starting equipment and alarms for electrically driven motors or hydraulic pumps
 Torsional Vibration Analysis (SCHOTTEL will provide a TVA for their scope of
supply, the TVA for the complete propulsion system including prime mover will be
set up by others)
 Protection of all moving parts, especially shaftline
 Installation of the system / components
 Electrical and hydraulic connections between SCHOTTEL-components and ship's
sources
 All parts not specifically indicated in the above specification as being part of our
scope of supply.
19.5.2015 HF TS-52290 25 / 26
TUG-110244-06 / 14338705 / BONNY 39
Appendix A: INTERFACE DESCRIPTION
delivery follows
19.5.2015 HF TS-52290 26 / 26
2. Installation Instructions
BLANK PAGE
BLANK PAGE
BLANK PAGE
BLANK PAGE
Refer to Shafting Installation Instructions 1191153
Alignment Data Sheet Rev. no.: 0
SCHOTTEL order: 14333717+720

SCHOTTEL project: TUG-110244-03+04
A= 5484,30 [mm] ± 16 [mm]
B= 1151,60 [mm] ± 8 [mm]
C= 3300,00 [mm] ± 3 [mm]
M= 4467,60 [mm]
1 2
Type: 41-90 Type: 41-90
Lz= 1050,00 [mm] Lz= 1050,00 [mm]
Lm= 1160,30 [mm] Lm= 1160,30 [mm]
K1=K2 ± 1= 583,80 [mm] K3=K4 ± 1 = 583,80 [mm]
See pointer drawing no.: 1108411
β= 7,5°
β1 = β2 = 7,5° ± 0,4° β3 = β4 = 7,5° ± 0,4°
Maximum misalignment engine/clutch (seen from above):= [mm]
Date: 02.04.2014 Person in charge: S.Brohlburg Installation drawing no.: 1188330
en Alignment Data Sheet 1/1

BLANK PAGE

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BLANK PAGE
IDNR: 1188111 Messstellenverzeichnis / schedule of measuring points
SRP 1515 FP
Abnahmegesellschaft / Classification:
Warnstellen / warning signals
Anordnung / location
Benennung Messung Meßgerät Fabrikat Ausgangssignal Auswertung durch Geber Einstellwert
discription alarm sensor Transmitter fabrikat signal connected to transmitter set-point
Öltemperatur max. Temperaturwächter Trafag Warnanlage am SRP ≥ 90 °C
On - Off
oil temperature max. temperature switch ISNT…. warning device at the SRP Ist:
Ölniveau min. Niveauschalter Barksdale Warnanlage am SRP
On - Off
ÖL SRP oil level min. level switch UNS VA warning device at the SRP
oil SRP Filterverschmutzung Differenzdruckschalter Warnanlage am SRP > 5 bar
Mahle On - Off
filter pollution differential pressure switch warning device at the SRP Ist:
Durchfluß min. Durchflußwächter Honsberg Warnanlage am SRP < 25 ltr/min
On - Off
oil flow min. flow switch VR 25 Ri warning device at the SRP Ist:
Hy-Öltemperatur max. Temperaturwächter Trafag Warnanlage am Hy. - Ölbehälter ≥65 °C
On - Off
hy-oil temperature max. temperature switch ISNT…. warning device at the Hy. - oiltank Ist:
Hy-Ölniveau min. Niveauschalter Barksdale Warnanlage am Hy. - Ölbehälter
On - Off
hy-oil level min. level switch UNS VA warning device at the Hy. - oiltank
Steuerungs Hydraulik
Filterverschmutzung Differenzdruckschalter Warnanlage am Hy.- Pumpenaggregat ≥ 2 bar
steering hydraulic Linde On - Off
filter pollution differential pressure switch warning device at the hy.- power pack Ist:
Hydraulikdruck max. Differenzdruckschalter Herion Warnanlage am Hy.- Pumpenaggregat ≥ 230,0 bar
On - Off
hy-pressure max. differential pressure switch BF18D-0882341 warning device at the hy.- power pack Ist:
Steueröldruck Differenzdruckschalter Herion Warnanlage am Hy.- Pumpenaggregat ≤ 10 bar
On - Off
stand by pressure differential pressure switch BF18D-0880641 warning device at the hy.- power pack Ist:
Schaltkupplung Eingangsdrucküberwachung Druckschalter Trafag Warnanlage in der Schalteinheit < 10,4 bar
ON - OFF
clutch pressure monitoring pressure switch 940.2379-905PVF16 warning device in the control unit Ist:
Prüfer: Abnahmegesellschaft:
Zustand: Änderung: Datum: Name: examiner: classification society:
SRP 1515 FP 07.12.2011 AAZ - M. Müller 1 von 2

BLANK PAGE
IDNR: 1188111 Messstellenverzeichnis / schedule of measuring points
SRP 1515 FP
Abnahmegesellschaft / Classification:
elektrische Anschlüsse / electrical connections
Anordnung / location
Benennung Bezeichnung Bauteil Fabrikat technische Daten Verwendung Bauteil Einstellwert
discription description component fabrikat technical data use for description set-point
Schmierölpumpe Drehstrommotor 400V Schmierölsystem am SRP
lube oil pump 3~ AC Motor 1,5 kW lube oil system at the SRP
SRP
Propellerdrehzahl Naeherungsschalter Schmersal GmbH 24 Volt Anzeige am SRP
propeller speed inductive proximity switch IFL-N-5-18-10STP NO indicator at the SRP
Schaltkupplung Kupplung eingekuppelt Druckschalter Trafag Rückmeldung in der Schalteinheit < 10,0 bar
ON - OFF
clutch clutch engaged pressure switch 940.2379-905PVS16 feed back signal in the control unit Ist:
Wellenanlage Wellendrehzahl Naeherungsschalter Schmersal GmbH 24 Volt Steuergeschwindigkeit an der Wellenleitung
shaft system shaft speed inductive proximity switch IFL-N-5-18-10STP NO steering speed on the shaft system
SRP 1515 FP 07.12.2011 AAZ - M. Müller 2 von 2

BLANK PAGE
3. Operating, Mounting and
Maintenance Instructions
BLANK PAGE
Safety and Environmental Protection Regulation ”SV 1”
Table of Contents
Preliminary remark . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
1 Safety regulations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
2 Transport and storage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Transport . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Storage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
3 Installation, Starting−up and Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Installation of SCHOTTEL Products . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Starting−up and operation (general) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Starting−up and operation of control systems . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
4 Maintenance and installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
5 Removing the underwater gears of SRP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
6 Welding . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
7 Noise protection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
8 Use of appliances causing noise fields . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
9 Environmental protection regulations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
en TDO−Ge Safety and Enviromental Protection Regulation “SV 1” 3 348/98 1099236 1/ 8

Preliminary remark
These ”Safety and Environmental Protection Regu- Where deviations between the German text and the
lations” shall provide the operator or technician re- foreign language text occur for idiomatic reasons, the
sponsible for operating, servicing, installing or re- German text is authoritative.
placing SCHOTTEL products, with information and
assistance. For this purpose, these regulations and The regulations and instructions quoted in this vol-
the accompanying operating and installation instruc- ume apply within the area of the Federal Republic of
tions must be read, understood and observed. Germany.
It must be ensured that the relevant regulations and In other countries, the statutory provisions applicable
instructions are readily available to everyone en- there shall be observed.
gaged in operation, maintenance and installation.
Observe protection mark in accordance to DIN 34!
We assume no liability for damages and breakdowns
”The passing on or copying of these documents, their
in operation which result from the failure to com-
utilization and the disclosure of their contents is pro-
ply with these regulations and the accompanying hibited, unless explicitly granted. All acts contrary to
operating and installation instructions.
this entitle us to claim for compensation. All rights re-
served in the case of a patent being granted or a de-
It is assumed that the user and/or technician is famil-
sign being registered.
iar with the product in question and has been
instructed on any possible risks involved.
References to pictorial illustrations in the text appear
in brackets.
As SCHOTTEL products are subject to further devel-
opment, we reserve the right to make any technical
alterations.
2 /8 TDO−Ge Safety and Enviromental Protection Regulation “SV 1” 3 348/98 1099236 en

1 Safety regulations
The safety regulations must always be used in com- does not comply with the regulations.
bination with the relevant operating and installation In the event of a fault, the cause must be established
instructions. immediately. If the fault cannot be defined or rectified
SCHOTTEL products are to be employed only for the in a correct and competent manner, it must be elimi-
use stipulated in the delivery cope. nated by qualified personnel.
To prevent accidents caused by slipping, negotiable
Any use other than this is considered contrary to reg- parts must be kept free of oil and grease.
ulations. The SCHOTTEL−Werft is not liable for dam-
ages resulting from this. The risk, in this instance, is In addition to the safety and environmental regula-
borne solely by the user. tions listed in these provisions, the safety regulations
of the trade association as well as the relevant regu-
The operator or technician is obliged to refuse to lations for the prevention of accidents must be obser-
carry out any work on SCHOTTEL products which ved.
2 Transport and storage
Transport
SCHOTTEL products which, due to their weight, can-

not be lifted without the use of auxiliary equipment,
must be fixed to a raising harness only at the lifting
points provided. If necessary, ask about possible lift-
ing points at the SCHOTTEL−Werft.
Both raising harness and hoist must be selected in

accordance to the load to be lifted.
Do not walk or stand below raised loads.
To prevent damage to bearings and gearwheels,

gears must be braced. 1
Example
The SRP should be braced against the direction of
rotation of operation with a pretension of 5000 to
6000 N (1/1). Figure 1
Use wooden edge protection for the propeller.

Storage empty units (e.g new units).
The interior areas of the SCHOTTEL products in

question are preserved, following the trial run on the This means:
test stand. Corrosion protection is sufficient for
approx. 6 months, when stored in dry environments In the case of units equipped with a vent valve,
(no sea climate). the same be opened.
In case of units equipped with a mushroom−type
Prior to launching y prior to every intial start−up it is vent, pressure compensation is already main-
necessary to top up oil tained.
To this effect it is necessary to observe the different
operating instructions. In the case of units which are only preas-
sembled, a provisional pressure compensation
If a SCHOTTEL unit is put out of operation or re- device with dust protection must be installed at
moved due to damage, then the unit must be filled a pipe connection.
with fresh oil during the storage period, in order to
prevent damage through corrosion.
ATTENTION
When storing in the open and/or with considerable The storage of electric components, for instance in-
changes in ambient temperature, pressure relief strument panels, switch cabinets etc. in the open is
must be maintained for oil−filled units, as well as for prohibited.
3 Installation, Starting−up and Operation
Installation of SCHOTTEL Products Starting−up and operation (general)
Before commencing installation, check that the The operating instructions of the relevant provisions
delivery is complete. All parts must be installed must be observed.
and/or removed in a competent manner.
Before putting SCHOTTEL products into operation,
The installation of SCHOTTEL products requires a check must be made for obvious defects and to en-
that: sure that all protection devices (e.g. cover plates) are
installed soundly. Defective units may not be put into
Only those personnel who possess sufficient operation.
technical expertise and the required equipment
shall be employed. Units with defective instruments, pilot lamps and/or
control elements may not be put into operation.
The installation proposals of SCHOTTEL−Werft
shall be observed, and/or requested as necess- The operator must make absolutely sure that no one
ary. is located within the danger zone of the unit before
putting this into operation.
The relevant technical regulations shall be ob-
served. The indicating instruments must be checked for cor-
rect functioning directly after starting−up, if neces-
Regulations of acceptance authorities under pri- sary the unit must be switched off again.
vate law and/or public law shall be complied
with.

Moving parts must be protected. If necessary, these Starting−up and operation of control
protection devices must be fitted subsequently. systems
Do not refuel in non−ventilated rooms and only when
the engine is switched off. An emergency stop of the ship is possible at all times;
Smoking is prohibited when refuelling. in the case of twin−propulsion units, both SRP pro-
Never check fuel level with an open flame. pulsion units should be swivelled to the outside by
180.
Combustion engines may only run in rooms where
adequate ventilation is ensured. The speed of the drive engines must be reduced be-
fore starting the control procedures for extreme ma-
noeuvres (if necessary down to idling speed).
Exhaust fumes are highly dangerous!
Never smoke or handle open fire in the vicinity of in-

flammable materials.
4 Maintenance and installation
Only tight−fitting, non−defective tools may be used. Smoking is prohibited when checking the acid level
”Worn out” spanners slip. of the batteries. Do not check the acid level of the bat-
Maintenance and installation work may only be car- teries using an open flame. Charge batteries in well−
ried out on units not in operation. ventilated rooms only.
Maintenance and installation work on electrical com- The fixing screw must be tightened with the appropri-
ponents may only be carried out when the unit is dis- ate torque in accordance to design, and secured
connected. Pipes and hoses under pressure must against accidental loosening in a suitable manner.
neither be tightened nor slackened. Please observe the relevant operating and installa-
Screw locking compound, sealing compound, oils, tion instructions.
acids, detergents and preservatives must not come
into contact with skin and eyes. During maintenance and repair work in the area
of rotary shaft seals and bearing races, these
Should an accident occur however, despite taking all must not be damaged.
precautions, then a doctor must be seen immediate- Rotary shaft seals and bearing races must not be
ly. painted over.
Protect them against heat, welding splashes and
Always wear protective glasses when cleaning parts abrasion dust, covering them if necessary.
with compressed air.
Benzine or any other easily inflammable substances

may not be used for cleaning the unit or its compo-
nents. Fuels and other materials required for opera-
tion must be stored only in containers which cannot
be mistaken for drink containers.
The handling of hot oil runs the risk of burning.
Do not heat oil, the oil or the vapors may ignite.

SCHOTTEL products which, due to their weight, can- When removing propellers and flanges which have to
not be lifted without the use of auxiliary equipment, be pressed on and off hydraulically, these must be
must be fixed to a raising harness only at the lifting secured against falling down with the pressure plate
points provided. If necessary, ask about possible lift- (2/2) specified.
ing points at SCHOTTEL−Werft.
Do not walk or stand in front of the pressure
Components to be removed which, due to their plate!
weight, cannot be lifted without the use of auxiliary
equipment, must be supported accordingly and fixed
to the raising harness at the lifting points provided for
this purpose. If necessary, ask about possible lifting
points at SCHOTTEL−Werft. The raising harness
and hoist must be selected in accordance to the load
to be lifted.
ÂÂ
Do not walk or stand under raised loads.
Unauthorized conversions and alterations

SCHOTTEL products are prohibited.
to
ÂÂ
Spare parts and assessories not supplied by the
SCHOTTEL−Werft are also not checked or accepted
by us. The installation and/or use of such parts may,
therefore,have a possible negative influence on the
design features of our products, so that the active 2
and/or passive safety of these is reduced.
SCHOTTEL−Werft is excluded from any liability

whatsoever for damages resulting from the use of Figure 2
such parts.

5 Removing the underwater gears of SRP
When removing the underwater gear−box, the power surface gear−box to and fro at the power inlet (3/3)
transmission shaft (3/4) may remain in the surface until the shaft sinks down to the underwater gear−
gear−box and drop down later uncontrolled ! There- box. Remove underwater gear−box together with the
fore, lower underwater gearbox a little and turn the power transmission shaft.
Figure 3

6 Welding
When carrying out welding work to or in the vicinity that no current can flow uncontrolled via bearings,
of SCHOTTEL products, the earthing terminal must bevel gears or similar.
be connected directly at the position of welding, so
7 Noise protection
Units may only be put into operation when all noise In the case of units where operators or mechanics
protection facilities have been properly installed and are exposed to a noise level of w85 dB (A), noise
closed. protection must be worn and used.
8 Use of appliances causing noise fields
Use of walkie−talkies, mobile phones as well as other Installation of external components into the
noise field generating appliances within the immedi- SCHOTTEL made steering electronics may cause
ate proximity of SCHOTTEL−steering systems may system breakdowns. Therefore it is absolutely
cause breakdowns, and possibly to the failure of the necessary to settle details with SCHOTTEL prior to
electronical steering unit. taking any action.
9 Environmental protection regulations
The relevant environmental protection regulations When carrying out maintenance or assembly work
must be observed. on products which have to be filled with oil or fuel, the
seals and washers removed should be replaced by
Substances causing damage to the environment (i.e. new ones. Following maintenance and assembly
oils, acids, preservatives and detergents) must be work, the unit and its connections must be checked
collected and disposed of in a non−polluting manner; for tightness.
the relevant laws governing water pollution control
must be complied with. Old batteries must be disposed of in a non−polluting
manner.
Used filter cartridges must be collected in a separate
container marked for this purpose and disposed of in Before transporting any SCHOTTEL products con-
a non−polluting manner. taining oil, the latter must be drained off first.

3.1 Mechanics
BLANK PAGE
Operating Instructions
SCHOTTEL RUDDER PROPELLER 1515 FP
TRANSLATION OF THE GERMAN ORIGINAL
These Operating Instructions are to be read and applied carefully to ensure safe operation and prevent
damage occurring to the propulsion system!
en STD-Wa Operating Instructions SRP 1515 FP 12/May 1191501 1/72

These Operating Instructions have been written with
the utmost care and attention to detail. However,
should you require any further information, please
contact:
SCHOTTEL GmbH
Mainzer Straße 99
56322 Spay, Germany
Phone +49 (0) 2628 610
Fax +49 (0) 2628 61300
E- mail [email protected]
a).
2/72 STD-Wa Operating Instructions SRP 1515 FP 12/May 1191501 en

Table of Contents
1 About these Operating Instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7

1.1 Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
1.2 Applicable Product Documents . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
1.2.1 SCHOTTEL GmbH: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
1.2.2 Other Applicable Product Documents for Operation of the Propulsion Unit . . . . . . . 7
1.3 Symbols and Diagrams . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
1.4 Restriction on Liability . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
1.5 Warranty . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
1.6 Warranty Conditions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
1.7 Customer Service . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
2 Safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
2.1 Shipyard's Responsibility . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
2.2 Operator's Responsibility . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
2.3 Staff Requirements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
2.3.1 Qualification of Specialist Staff . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
2.3.2 Requirements of Maintenance Staff for Propulsion Units . . . . . . . . . . . . . . . . . . . . . . . 12
2.3.3 Requirements of Maintenance Staff for Electrical Components . . . . . . . . . . . . . . . . . 12
2.4 Area of Application . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
2.5 Personal Protective Equipment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
2.6 Intended Use . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
2.7 Foreseeable Misuse . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
2.8 Safety and Monitoring Devices . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
2.9 Switching Off Devices . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
2.9.1 Disconnecting Electrical Components from the Power Supply . . . . . . . . . . . . . . . . . . 14
2.9.2 Deactivating the Activation Signal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
2.10 Safe Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
2.10 Electromagnetic Interference Fields . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
2.12 Ambient Conditions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
2.12 Sound Pressure Level . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
2.14 General Remaining Risks and Protective Measures . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
3 Safety Instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
3.1 Basic Safety Instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
3.2 Special Safety Instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
3.2.1 Prior to Transportation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
3.2.2 Transportation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
3.2.3 Commissioning and Resumption of Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
3.3 Operation and Shutdown . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
3.3.1 Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
3.3.2 Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
3.3.3 Storage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
3.3.4 Disposal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20

4 Technical Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
4.1 Condition on Delivery . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
4.2 Structure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
4.2.1 Above-Water Assemblies . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
4.2.1.1 Oil Expansion Tank . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
4.2.1.2 Lubrication Oil Maintenance Unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
4.2.1.3 Steering Motor and Planetary Steering Gear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
4.2.2 Underwater Assemblies . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
4.2.2.1 Underwater Gearbox . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
4.3 Operating Instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
4.3.1 Power Transmission . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
4.3.2 Steering and Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
4.3.3 Lubrication . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32
5 Transportation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34
5.1 Prior to Transportation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34
5.2 Transportation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36
6 Installation and Preparation for the Trial Run . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37

6.1 Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37
6.2 Preparation for the Trial Run . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38
6.2.1 Initial Fill . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38
7 Commissioning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39
7.1 Trial Run at the Pier . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40
7.2 Preparation for the Sea Trial . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42
8 Resumption of Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44
9 Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46
9.1 During Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46
9.2 Measures After Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48
9.3 Switching Between Filters in the Changeover Duplex Filter Unit . . . . . . . . . . . . . . . . . 49
10 Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50
10.1 Definition of Terms . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 52
10.2 Maintenance Schedule . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 52
10.3 Oil Specifications and Oil Quantities . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53
10.3.1 Lubrication Oil Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53
10.3.2 Lubrication Oil Quantity . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53
10.4 Filling/Refilling Oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54
10.4.1 Filling the Propulsion Unit with Lubrication Oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54
10.4.2 Refilling the Propulsion Unit with Lubrication Oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55
10.4.3 Filling the Planetary Steering Gear with Lubrication Oil . . . . . . . . . . . . . . . . . . . . . . . . 56
10.4.4 Refilling the Planetary Steering Gear with Lubrication Oil . . . . . . . . . . . . . . . . . . . . . . 56
10.4.5 Filling the Steering Motor with Hydraulic Oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 57

10.5 Pumping Out/Draining the Oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 58
10.5.1 Pumping the Lubrication Oil out of the Propulsion Unit
(Propulsion Unit in the Water) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 58
10.5.2 Draining the Lubrication Oil from the Propulsion Unit
(Propulsion Unit out of the Water) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 59
10.5.3 Draining the Lubrication Oil from the Planetary Steering Gear . . . . . . . . . . . . . . . . . . 60
10.6 Taking a Lubrication Oil Sample . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 61
10.7 Replacing a Filter Element in the Changeover Duplex Filter Unit . . . . . . . . . . . . . . . . 62
10.8 Checking the Underwater Assemblies . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 63
11 Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 65
11.1 Lubrication Alarms . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 66
11.2 General Propulsion Unit Malfunctions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 67
12 Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 68
13 Storage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70
13.1 Short-Term Storage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70
13.2 Long-Term Storage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70
14 Disposal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 71
14.1 Scrapping . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 71
14.2 Disposal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 72

BLANK PAGE

1 About These Operating Instructions
1.1 Introduction
These Operating Instructions describe operation of the SCHOTTEL RUDDER PROPELLER 1515 FP.
The SCHOTTEL RUDDER PROPELLER 1515 FP, referred to as "propulsion unit" in the following, is part of the entire
propulsion system supplied by SCHOTTEL GmbH.
The Operating Instructions are part of the Service Manual and are to be kept accessible to all staff at all times in the
immediate vicinity of the propulsion unit. Staff are to have read and understood these Operating Instructions
thoroughly before commencing any work. The basic prerequisite for work safety is the observance of all safety
instructions and other instructions provided.
Furthermore, the local accident prevention regulations and general safety provisions apply to the propulsion unit's
area of application.
1.2 Applicable Product Documents
1.2.1 SCHOTTEL GmbH:

The propulsion unit is to be operated in compliance with these Operating Instructions. These Operating Instructions
are supplemented by other project-related operating instructions and specifications in this Service Manual
("Applicable Product Documents").
These applicable product documents are supplied with these Operating Instructions in the Service Manual.
1.2.2 Other Applicable Documents for the Operation of the Propulsion Unit
Shipyard:
● Classification society acceptance reports
Operator:
● Instructions on accident prevention, occupational health and safety and environmental protection based on the
regulations applicable in the country of use

1.3 Symbols and Diagrams
Warning Notices
Warning notices are set apart from the rest of the text in these Operating Instructions. They are marked in colour and
introduced with a symbol and keywords that highlight the extent of the risk or hazard.
It is essential that warning notices are heeded and handled with great care to prevent accidents, personal injuries
and material damage from occurring.
DANGER
Indicates a hazardous situation which, if not avoided,
will result in death or serious injury.
WARNING
could result in death or serious injury.
CAUTION
could result in minor or moderate injury.
NOTICE
Indicates actions which may result in material damage.
Any warning notice within these Operating Instructions
is structured as follows:
KEYWORD
Cause of the danger
Consequences of the danger
▶ Measures to avert the danger
Tips and Recommendations
i INFORMATION
Instructions and information for efficient and
trouble-free operation.

Diagrams
References to illustrations are written in brackets in the text, e. g. (1/3). The first number refers to the illustration
number; the second number is the item number in the illustration. For example: (1/3) means figure 1, item 3. All
illustrations are schematic diagrams and do not make any claim to completeness.
Lists and Grouped Safety Instructions

● Items in a list and grouped safety instructions are introduced with a bullet point. The order in which they appear
does not represent their order of importance.
Instructions
▶ This sign is used for an instruction and indicates that an action is to be carried out. They may be followed by
additional information for the action that is to be carried out.
If instructions consist of several steps to be carried out in a sequence, these steps are numbered and listed
chronologically in the specified order.
For example:
1. Switch off the propulsion unit and make sure that it cannot be started up unintentionally.
2. Place a suitable collecting basin underneath the pressure filter.
Blank Page
Blank pages are deliberate and identified as such.

1.4 Restriction on Liability
All information and notices provided in these Operating Instructions have been compiled in consideration of the
applicable standards and regulations, the state of the art and the insights and experience we have gained over many
years.
SCHOTTEL GmbH will not accept any liability for any damage incurred as a result of the following circumstances:
● Failure to comply with these Operating Instructions;
● Using the propulsion unit for anything other than its intended purpose;
● Using staff that are not trained to deal with the task in question;
● Unauthorised structural, electrical or control-related modifications and repairs;
● Technical modifications;
● Using unapproved spare parts;
● Using unsuitable, unapproved operating materials, or
● Operating the propulsion system using safety and monitoring devices that are defective, improperly installed
or are not functioning properly.
The obligations stipulated in the Supply Contract, SCHOTTEL GmbH's General Terms and Conditions and Terms
of Delivery, and the applicable legal regulations in force at the time of concluding the Contract shall apply.
1.5 Warranty
SCHOTTEL GmbH shall not assume responsibility for any personal injuries or material damage that may occur as
a result of failing to comply with these Operating Instructions. Furthermore, any form of warranty granted by
SCHOTTEL GmbH shall become void, and responsibility shall be transferred to the operator.
1.6 Warranty Conditions

The warranty conditions stipulated by contract shall apply, provided that the propulsion unit is used as intended and
the Maintenance Instructions are observed. SCHOTTEL GmbH may request evidence of the Maintenance
Instructions being observed.
The trial run and sea trial of the propulsion unit are to be carried out by authorised SCHOTTEL GmbH employees.
Original spare parts from SCHOTTEL GmbH are to be used for maintenance and repair work. The full functionality
and safe operation of the propulsion system can only be guaranteed if spare parts supplied by SCHOTTEL GmbH
are used. The warranty shall become void if any parts are used other than original SCHOTTEL parts. SCHOTTEL
GmbH shall not assume any liability or warranty for any damage incurred by using other spare parts and accessories.
SCHOTTEL GmbH's General Terms and Conditions shall expressly apply to all orders placed
(www.schottel.de/agb). Requests for spare parts are to be made in writing.
The order form in the Service Manual is to be used for ordering original SCHOTTEL spare parts.
1.7 Customer Service

SCHOTTEL's Customer Service Department is available to provide technical information. For SCHOTTEL GmbH
contact details, see page 2. Furthermore, we are always interested in new information and learning about any new
experiences that arise from using our products and that may be useful in terms of improving them.

2 Safety
This section will provide an overview of all of the important safety aspects involved in providing staff with optimal
protection and ensuring the safest and smoothest operation possible.
Failure to comply with the safety instructions and other instructions set out in these Operating Instructions may result
in serious hazards arising. Therefore, staff are to observe all safety and other instructions set out in this section and
in these Operating Instructions and take the relevant safety measures.
2.1 Shipyard's Responsibility

The shipyard will hand over the propulsion unit to the operator after it has been installed in the respective vessel.
The shipyard is to make sure that the SCHOTTEL GmbH Service Manual is available at the propulsion unit's site of
operation in a legible condition and complete when the vessel is handed over to the operator.
2.2 Operator's Responsibility

The propulsion unit operator is responsible for complying with the applicable legal requirements of occupational
safety.
In addition to the occupational safety instructions within these Operating Instructions, the safety, accident prevention
and environmental protection regulations for the propulsion unit's area of application are to be observed.
The operator is obliged to:
● Keep informed about applicable occupational safety provisions, and investigate the additional risks arising from
the special working conditions at the propulsion unit's site of operation by carrying out a risk assessment. These
are to be implemented in the form of operating instructions for the propulsion unit.
● Check throughout the entire period of propulsion unit use whether the operating instructions provided represent
the latest version of rules and regulations, and to amend these, if necessary.
● Designate a large enough danger zone around the propulsion unit. This danger zone must not be accessible to
unauthorised persons during operation; a minimum one metre clearance around the propulsion unit is to be
ensured.
● Ensure that all employees handling the propulsion unit have read and understood the Operating Instructions.
Furthermore, the operator is to instruct the staff in safety matters at regular intervals and keep them informed
about risks.
● Provide staff with the necessary protective gear.
● Ensure that the propulsion unit is only operated in compliance with its intended use and only if it is in a perfect,
operational condition.
● Ensure that the Operating Instructions are always available at the propulsion unit's site of operation in a legible
condition and complete.
● Ensure that all of the safety instructions and warning notices attached to the propulsion unit are never removed,
and are kept clean and easily legible.

2.3 Staff Requirements
2.3.1 Qualification of Specialist Staff

The work described in these Operating Instructions is only to be carried out by qualified specialist staff. Specialist
staff are defined as persons who due to their professional training, knowledge and experience, as well as knowledge
of the pertinent stipulations, are in a position to:
● Carry out the work assigned to them safely, and correctly assess the implications of their work.
● Identify potential hazards independently.
● Take necessary measures to eliminate any hazards, especially those concerning risk of accidents.
Staff are to be trained and instructed regularly in all matters concerning occupational safety and environmental
protection.
When selecting staff, the regulations specific to age and profession that apply at the site of operation are to be
observed.
2.3.2 Requirements of Propulsion Unit Maintenance Staff

According to DIN 31051, maintenance covers the individual measures for preventative and corrective maintenance
and inspection. Everyone involved in maintenance needs to be familiar with and adhere to the Operating
Instructions.
The preventative maintenance staff (e.g. for replacing filter elements) are to:
● Have been instructed in the respective activity.
● Demonstrate special propulsion unit expertise to be able to carry out preventative maintenance work.
The inspection staff (e.g. for checking the oil level) are to:
● Be aware of the special risks involved in handling the propulsion unit. Special propulsion unit expertise is not
necessary for just inspection work.
The corrective maintenance staff (e.g. for replacing a defective temperature switch) are to:
● Be able to comprehend the function of the propulsion unit and subsystems, and their interaction with the function
of the entire propulsion system.
● Be able to understand technical drawings and the sub-functions of the propulsion unit.
● Have knowledge about the function and structure of the sub-systems (e.g. line systems).
2.3.3 Requirements of Maintenance Staff for Electrical Components

Work on electrical components is only to be carried out by an authorised qualified electrician or by a trained person
directed and supervised by a qualified electrician according to the electrical engineering regulations and safety
measures.

2.4 Area of Application
The propulsion unit's area of application is determined by the stipulated classification society in its acceptance
procedure. The intended use is to be taken into account when determining the area of application.
2.5 Personal Protective Equipment

At work, personal protective equipment is to be worn to keep risks to a minimum.
The instructions about personal protective equipment displayed in the work area are always to be followed.
The protective gear needed for respective tasks is always to be worn:

Protective workwear
Close-fitting work clothes with little resistance to tearing; close-fitting sleeves with no sticking out parts. This clothing
prevents the wearer getting caught on movable parts.
Safety footwear
Protects feet from heavy falling parts and helps prevent slipping over on slippery floors
Safety gloves
Protect hands from grazes, punctures or deeper cuts, irritating and caustic substances, and burns
Safety goggles
Protect eyes from flying parts and spraying liquid
Safety helmet
Protects the head from falling parts or injuries
Ear protectors
Protects the ears from excessively loud noises
2.6 Intended Use

The propulsion unit is used as the main and/or auxiliary propulsion unit for vessels.
The propulsion unit is only to be operated in a perfect technical condition in compliance with its intended use and the
Operating Instructions; furthermore, all operators of the propulsion unit need to be fully aware of all safety issues and
potential risks associated with its use. In particular, malfunctions that may affect safety are to be rectified
immediately.
The propulsion unit must not be installed and operated in areas where there is a risk of explosions.
No modifications, additions, or conversions are to be undertaken on the propulsion unit without prior written consent
from SCHOTTEL GmbH. Such modifications may endanger safety and are not considered to be compliant with
intended use.
The propulsion unit may only be operated on vessels that comply with the applicable specifications of the stipulated
classification society. Any other procedure is not considered to be compliant with intended use and is not permitted.
Any kind of claims based on damage due to improper use are exempt. The operator shall be solely responsible for
any damage that occurs as a result of improper use.
Intended use is also subject to:
● Adherence to all of the operator's applicable operating instructions
● Adherence to the directives within these Operating Instructions
● Undertaking the specified maintenance work
Any other kind of use is not considered to be compliant with intended use.

2.7 Foreseeable Misuse
Improper use is considered to be any kind of use of the propulsion unit other than that set out under "Intended Use".
Improper use is prohibited.
This includes:
● Structural modifications to the propulsion unit
● Structural modifications to propulsion unit control components
● Modifications to the software for propulsion unit control
● Modifications to the safety and monitoring devices
● Use of impermissible lubricants
2.8 Safety and Monitoring Devices

Safety and monitoring devices are designed to help rule out personal injuries and material damage.
The propulsion unit may only be operated when all safety and monitoring devices are in place and fully functional.
After triggering a safety and monitoring device, the propulsion unit may only be put back into operation, if:
● The cause of the malfunction has been eliminated;
● It is absolutely certain that resuming operation does not represent a danger to persons or materials.
Safety and monitoring devices may be removed, modified, rendered inoperative or have their effect altered by
persons in charge or experts for temporary intervention purposes only, as in the case of tests and examinations,
troubleshooting, rectification of damage or defects, and to replace components. Furthermore, these interventions
have to be adequate in terms of safety, or adequate contingency measures have to be taken with regard to safety.
The staff are to be instructed to exercise additional caution in these situations.
2.9 Switching Off Devices

To enable many of the operational sequences described in these Operating Instructions to be carried out safely, the
propulsion unit is first to be switched off, shut down and, if possible, secured by taking additional measures. The
required switch-off level depends on the relevant type of operational sequence. The switch-off levels are:
2.9.1 Disconnecting Electrical Components from the Power Supply

Before working on and accessing unprotected wires or connection points, disconnect the relevant electrical
components from all voltage sources.
1. Switch off the electrical components and connected accessories.
2. Make sure that these cannot be switched on unintentionally by locking and labelling the isolators and power
switches used to disconnect the electrical components and optional accessories from the mains.
2.9.2 Deactivating the Activation Signal

Before working on a component which receives an activation signal from a superordinate electrical or mechanical
control unit, the control unit is to be deactivated and measures taken to ensure it cannot be accidentally activated.
1. Switch off the superordinate control unit (e.g. SPS) or disconnect from the mains.
2. Remove the input signal cable from the component.
3. Set the pressure to zero or disconnect the voltage supply; dissipate any residual power.

2.10 Safe Operation
If it can be assumed that safe operation is no longer possible, switch the propulsion unit off immediately and make
sure that it cannot be switched on unintentionally.
Safe operation is no longer possible, if:
● Not all of the safety and monitoring devices are in place and fully functional.
● Persons might be put at risk by operating the propulsion unit.
● The propulsion unit is defective and/or leaking.
● The propulsion unit is visibly damaged.
● The propulsion unit displays malfunctions detected by measurement and control systems.
● The propulsion unit has been operated, stored or transported in unfavourable ambient conditions (e.g.
fumes/vapours; temperature).
● Unauthorised structural, electrical or control-related modifications, repairs or manipulations have been carried
out on the propulsion unit.
The propulsion unit may only be started up again if its safe operation can be guaranteed.
2.11 Electromagnetic Interference Fields

Interference fields from the surroundings can affect electrical components, as well as be generated by operating the
electrical components; these interference fields can in turn affect the surrounding components.
Source or target electromagnetic interference could be due to:
● Mains cables
● Signal and control cables
● Electric or electronic assemblies that radiate electromagnetic fields (e.g. mobile phones and computers), or
may be affected by them
Protection from electromagnetic interference fields is to be provided for operation of the propulsion unit. The relevant
specifications in this Service Manual (e.g. applicable product documents; Wiring Diagram) and the specifications
of the stipulated classification society are to be observed.
2.12 Ambient Conditions

The respective ambient conditions for using the propulsion unit are dependent on the area of application designated;
see the "2.4 Area of Application" section, page 13.
2.13 Sound Pressure Level

When the propulsion unit is used as intended, a noise level of 85 dB(A) may be exceeded in the unit's operating area.

2.14 General Remaining Risks and Protective Measures
Despite the propulsion unit's high level of integral safety, risk of injury and/or environmental damage cannot be ruled
out even in the case of correct conduct.
The propulsion unit is part of an entire propulsion system. New, additional hazards may arise as a result of the
interaction between different components.
DANGER WARNING
Voltage Hot surfaces
Hazard to life or risk of serious injuries due to electric Risk of sustaining burn injuries due to surfaces on the
voltage propulsion unit becoming hot during operation.
▶ Always observe the special safety provisions ▶ Only commence work once the propulsion unit
when working on any kind of electrical compon has sufficiently cooled down.
ents.
▶ Wear personal protective gear, especially heat-
▶ Work on electrical components is only to be car resistant safety gloves.
ried out by a qualified electrician.
▶ Switch off the power supply before commencing
work and make sure it cannot be switched on
unintentionally. WARNING
Hot oil
Risk of sustaining burn injuries due to hot oil during
DANGER operation.
▶ Only commence any work once the oil has suffi
Rotating components ciently cooled down.
Hazard to life or risk of serious injuries due to body ▶ Wear personal protective gear, especially heat-
parts being caught or pulled into rotating components resistant safety gloves.
▶ Do not reach into the danger zone.
▶ Do not place objects within the danger zone.
CAUTION
Slipping, falling and tripping over
DANGER Head injuries and cuts to limbs due to sharp edges
Malfunctions and pointed corners
Hazard to life or risk of serious injuries due to malfunc ▶ Keep the work area and walked-on areas clean.
tions or damage to individual components. ▶ Wear personal protective equipment, especially
▶ Any defective components which affect the protective clothing and a safety helmet.
safety and function of the propulsion unit are to
be replaced immediately. Always observe the
safety measures.

3 Safety Instructions
It is crucial that the safety instructions and warning notices cited in the following sections of these Operating
Instructions are observed in order to reduce risks to health and prevent hazardous situations.
i INFORMATION
Reading the basic or special safety instructions in this
section is not enough to ensure that the propulsion
unit is worked on safely. The safety instructions and
warning notices in the relevant sections need to be
observed in order to understand safety issues prop
erly and effectively avert danger.
3.1 Basic Safety Instructions

● The environmental and occupational safety regulations that apply at the site of operation are to be observed.
● Before start-up, the operator is to designate an appropriate danger zone. The danger zone must not be
accessible to unauthorised persons.
● The operator is responsible for procuring all current regulations that apply to the operation of the propulsion unit.
● The operator is to make sure the applicable regulations are available and instruct persons working with the
propulsion unit accordingly.
● The propulsion unit is only to be operated if it is in a perfect technical condition.
● All safety instructions and warning notices on the propulsion unit are to be observed and kept in a legible
condition.
● Personal protective equipment is always to be worn when working on and around the propulsion unit. Always
tie back long hair; never wear loose clothing or jewellery.
● Any malfunctions that may affect the safety of staff or the propulsion unit are to be rectified immediately.
● The propulsion unit is to be shut down immediately in the event of malfunction. The malfunction is to be rectified
immediately.
● The maintenance intervals stipulated in the Operating Instructions are to be observed and documented.
● The applicable product documents in this Service Manual are to be observed.
● Before any welding, flame cutting and grinding work is carried out, the propulsion unit and its surrounding area
are to be cleaned to remove any combustible substances. There is a risk of fire and explosion by this kind of
work. Welding, flame cutting and grinding work may only be carried out if this has been expressly approved by
a supervisor.
● Safety and monitoring devices that serve to avert danger must not be modified or removed.
● The direct supervisor is to be informed in the event of injuries occurring, however serious or minor. This person
will decide whether the operating instructions need to be amended.

3.2 Special Safety Instructions
3.2.1 Prior to Transportation

● Observe the dimensions and weights of the individual components.
● Only use lifting gear (e.g. crane or forklift truck) and slings (e.g. chains and ropes) that have been checked and
approved for the weight of the individual components and are in perfect condition.
● The operating and safety instructions for the lifting gear and slings are to be observed.
● Lifting gear and slings may only be used by persons trained and authorised to carry out this type of work.
● At least one other person has to be present when lifting, conveying and setting down the components. The load
is to be constantly watched when being lifted, conveyed or set down.
● Before transportation, the signaller and the slinger are to ensure proper communication by using agreed hand
signals, equipment or by radio.
3.2.2 Transportation
● Transportation of the individual components may only be carried out by a qualified specialist company.
● Only those transport means that comply with the applicable laws, acts and regulations are to be used.
● The individual components are to be attached, fastened and packaged in such a way that damage in transit can
be ruled out.
● The transport vehicle is to be equipped to ensure the safe transportation of the individual components in terms
of weight and dimensions and comply with the requirements for the safe transportation of the individual
components.
● The packaging material is to be disposed of properly.
3.2.3 Commissioning and Resumption of Operation

● The propulsion unit is to be inspected for visible external damage and defects prior to commissioning and every
time operation is resumed. If damage to the propulsion unit is established, switch it off and make sure it cannot
be started up unintentionally; notify the relevant services.
● Prior to commissioning and every time operation is resumed, make sure that no-one can be exposed to any
danger when the propulsion unit is started up.
● Prior to commissioning, the operator is to designate an appropriate danger zone around the propulsion unit. The
danger zone must not be accessible to unauthorised persons.
● Prior to commissioning and every time operation is resumed, check the function of all safety and monitoring
devices.
● When working on the propulsion unit when it is switched off, make sure that it cannot be started up
unintentionally.

3.3 Operation and Shutdown
● Make sure that no unauthorised persons are in the designated danger zone.
● Only operate the propulsion unit when all safety and monitoring devices are in place and fully functional.
● Ensure that all of the safety instructions and warning notices attached to the propulsion unit are always easily
legible and never removed.
● When handling operating materials and supplies, the safety regulations for the product concerned are to be
observed. Refer to and observe the safety data sheets.
3.3.1 Maintenance
● The stipulated maintenance intervals are to be complied with and documented.
● Switch off the propulsion unit and make sure it cannot be started up unintentionally before commencing any
maintenance work.
● Make sure the propulsion unit has cooled down before commencing maintenance work.
● Before commencing any maintenance work, close off access to the work area to any unauthorised persons.
Display an information sign to indicate the maintenance work in progress.
● Dispose of all operating materials and supplies in a safe and environmentally friendly way. When doing this,
always observe the regulations regarding the disposal of operating materials and supplies applicable at the site
of operation.
● Carry out visual inspections of the propulsion unit at regular intervals; see "Maintenance Schedule", page 52.
Rectify and document any defects that arise, e.g. loose screw fittings or scorched cables.
● Regularly clean the floor around the propulsion unit to avert the risk of slipping.
● After completing maintenance work, dismantled safety and monitoring devices are to be reinstalled and bolted
connections tightened according to specifications.
3.3.2 Removal
● Switch off the propulsion unit and make sure it cannot be started up unintentionally before commencing any
removal work.
● Before commencing any removal work, close off access to the work area to any unauthorised persons. Display
an information sign to indicate the removal work in progress.
of operation.
● When carrying out removal work regularly clean the floor around the propulsion unit to avert the risk of slipping.

3.3.3 Storage
● Always protect the edges of the propeller when bracing it.
3.3.4 Disposal
always observe the national and international regulations regarding the disposal of operating materials and
supplies.

4 Technical Description
4.1 Condition on Delivery
i INFORMATION
The technical data for the propulsion unit can be
found in the applicable product documents.
The propulsion unit is supplied as one unit.

The hydraulic system is supplied as a separate unit.
4.2 Structure
Above-water assemblies Hydraulic

system
Underwater assemblies
Fig. 1 Overview of propulsion unit
i INFORMATION
* Depending on the propulsion unit's installation
requirements, the shape and size of the supporting
cone plate and ribs may vary.

1 2 3 4 5 4 6 7
22 8
9
21
10
20
11
19
12
18 13
17
14
16
15
Fig. 2 Schematic diagram of propulsion unit (side view)

23 24 25 26 23
29
23 24 28 24 23 27
Fig. 3 Schematic diagram of propulsion unit (top view)

1 Above-water gearbox 16 Fixed-pitch propeller
2 Oil expansion tank * 17 Nozzle
3 Bevel gears of above-water gearbox 18 Steering tube bearing
4 Power input shaft bearing 19 Steering hub
5 Power input shaft 20 Oil level switch
6 Clutch ** 21 Supporting cone plate
7 Speed sensor 22 Lubrication oil pump
8 Revolving joint 23 Lifting eye (4 items)
9 Oil conveyor wheel 24 Steering motor and planetary steering gear
10 Supporting cone (3 items) *
11 Steering tube seal 25 Thrust direction feedback unit
12 Steering tube 26 Steering gear plate
13 Power transmission shaft 27 Ball valve (lubrication oil fill connection)
14 Underwater gearbox * 28 Lubrication oil maintenance unit *
15 Borehole for slings 29 Type plate
* See detailed description in these SCHOTTEL Instructions.

** See the manufacturer's documentation in this Service Manual.

4.2.1 Above-Water Assemblies
4.2.1.1 Oil Expansion Tank
1 2 3 4 5
6 7 8
10
Fig. 4 Oil expansion tank

1 Oil expansion tank 6 Screw plug
2 Breather valve 7 Sight glass
3 Vent pipe 8 Ball valve (optional)
4 Cover 9 Oil cooler
5 Overflow pipe 10 Oil level indicator

4.2.1.2 Lubrication Oil Maintenance Unit
1 2 3 4 5
8 7 6
Fig. 5 Lubrication oil maintenance unit

1 Oil temperature indicator (optional) 5 Temperature switch
2 Changeover duplex filter unit 6 Filter
3 Filter monitoring unit 7 Changeover lever
4 Flow control device 8 Test port

4.2.1.3 Steering Motor and Planetary Steering Gear
5 4
Fig. 6 Steering motor and planetary steering gear

1 Steering motor
2 Planetary steering gear
3 Revolving joint
4 Spur gear
5 Pinion

4.2.2 Underwater Assemblies
4.2.2.1 Underwater Gearbox
1 2 3
10 5
8 7 6
Fig. 7 Underwater gearbox
1 Propeller 6 Oil outlet
2 Propeller shaft seal 7 Magnetic plug
3 Power transmission shaft 8 Propeller shaft
4 Bevel gears 9 Propeller shaft bearing
5 Propeller shaft bearing 10 Propeller flange

BLANK PAGE

4.3 Description of Function
4.3.1 Power Transmission
The propulsive force is transmitted from the clutch (8/2) The speed sensor (8/3) detects the input speed at the
to the bevel gears in the above-water gearbox (8/1). clutch and transmits it to the speed indicator.
From there, it is transmitted to the propeller (8/7) via the
power transmission shaft (8/4), the bevel gears in the
underwater gearbox (8/5) and the propeller shaft (8/6).
1 2
7 6
Fig. 8 Power Transmission

1 Bevel gears of above-water gearbox 5 Bevel gears of underwater gearbox
2 Clutch 6 Propeller shaft
3 Speed sensor 7 Propeller
4 Power transmission shaft

4.3.2 Steering and Control
The propulsion unit can be steered on a full follow-up or This revolving joint allows the underwater gearbox
non-follow-up basis by means of three hydraulic (9/11) attached to the steering tube to keep turning
steering motors (9/5). clockwise or anti-clockwise without restriction. In this
way, the thrust can be aimed in any direction required,
The thrust direction handle (9/2) is used for full providing for the optimal combination of steering and
follow-up steering. The propulsion unit will rotate until propulsion.
the selected thrust direction has been reached.
The thrust direction determines the vessel's heading.
The illuminated buttons (9/3) are used for non-follow-up
steering. The propulsion unit will continue to rotate as The thrust direction is mechanically fed back from the
long as the relevant illuminated button is pressed. spur gear of the revolving joint to the thrust direction
feedback unit (9/14) via the reduction gear (9/13).
The electronic control unit (9/15) processes the signals
coming from either the thrust direction handle or the The thrust direction feedback unit transmits electrical
illuminated buttons and transmits these to the hydraulic signals to the electronic control unit and thrust direction
system (9/4). indicator (9/1).
The hydraulic system supplies the steering motors with The thrust direction feedback unit and thrust direction
hydraulic oil until the selected thrust direction is indicator display the position of the underwater gearbox
reached. and therefore the thrust direction of the propulsion unit,
but not the vessel's heading.
The steering motors drive the planetary steering gear
(9/6). The pinions (9/8) of the planetary steering gear
engage the spur gear (9/7) of the revolving joint (9/12).
The steering hub (9/9) with the steering tube (9/10) is
mounted on the revolving joint.
Key for figure 9

1 Thrust direction indicator 9 Steering hub
2 Thrust direction handle 10 Steering tube
3 Illuminated buttons 11 Underwater gearbox
4 Hydraulic system * 12 Revolving joint
5 Steering motor 13 Reduction gear
6 Planetary steering gear 14 Thrust direction feedback unit
7 Spur gear 15 Electronic control unit
8 Pinion
* For the hydraulic system function, see SCHOTTEL Instructions on the hydraulic system
and Hydraulic Circuit Diagram in this Service Manual.

1 2 3
15
5
6
7
14
8
9
10
12
13
7
11
Fig. 9 Steering and Control

4.3.3 Lubrication
A combined oil bath/splash lubrication system is used The temperature switch (10/4) monitors the oil
to lubricate the propulsion unit. temperature. If the temperature exceeds the maximum
permitted temperature, an alarm is activated.
The underwater gearbox (10/14), steering tube (10/13)
and supporting cone (10/10) are filled with lubrication oil The flow control device (10/3) monitors the flow rate of
(oil bath lubrication). the lubrication oil. An alarm is activated when the
minimum flow rate is not attained.
The oil conveyor wheel (10/11) conveys lubrication oil
from the supporting cone, through the steering tube and The oil temperature indicator (10/1) displays the
into the underwater gearbox. The lubrication oil rises temperature of the lubrication oil in _C.
through the power transmission shaft (10/12) into the oil
expansion tank (10/20). The oil level switch (10/16) monitors the oil level in the
supporting cone. An alarm is activated when the oil
The lubrication oil pump draws the lubrication oil out of level gets too low.
the supporting cone through the suction line of the
lubrication oil pump (10/15) and pumps it into the oil The oil condition can be checked during operation
expansion tank via the changeover duplex filter through the sight glass (10/7). The sight glass can also
unit (10/2). This reduces the oil level in the above-water be optionally secured by a ball valve (10/6).
gearbox (10/17). The vent pipe (10/22) and breather valve (10/21)
The lubrication oil rises up to the overflow pipe (10/23) ventilate the lubrication oil system.
in the oil expansion tank and flows through the oil An oil sample can be taken at the test port (10/24) while
boreholes in the bottom of the tank and the overflow the propulsion unit is in operation.
pipe into the above-water gearbox.
When the propulsion unit is not in operation, the oil level
Due to the centrifugal effect of the bevel gears (10/8), can be checked at the oil level indicator (10/19).
the lubrication oil is evenly distributed in the
above-water gearbox (splash lubrication) before The planetary steering gear (10/9) is sealed off from the
flowing back into the supporting cone. propulsion unit and filled with oil separately.
The oil cooler (10/5) in the oil return line and the water
surrounding the propulsion unit cool the oil.
The changeover duplex filter unit removes impurities
from the oil system. When the filter element is clogged,
a visual warning is displayed on the filter and an alarm
is activated.
Key for figure 10

1 Oil temperature indicator 13 Steering tube
2 Changeover duplex filter unit 14 Underwater gearbox
3 Flow control device 15 Suction line of lubrication oil pump
4 Temperature switch 16 Oil level switch
5 Oil cooler 17 Above-water gearbox
6 Ball valve (optional) 18 Lubrication oil pump
7 Sight glass 19 Oil level indicator
8 Bevel gears 20 Oil expansion tank
9 Planetary steering gear 21 Breather valve
10 Supporting cone 22 Vent pipe
11 Oil conveyor wheel 23 Overflow pipe
12 Power transmission shaft 24 Test port

1 2 3 4
5
24
20 21 22 23
ÓÓÓ
ÓÓÓÓÓ
ÓÓÓÓÓ
6
ÓÓÓÓÓ
ÓÓÓÓÓ
7
19 8
18 9
17
10
16
15
11
12
13
14
Fig. 10 Lubrication

5 Transportation
5.1 Prior to Transportation

To prevent material damage and serious or fatal injuries
it is crucial that the following points are observed:
● Prior to transportation, drain all operating materials
from the propulsion unit and dispose of them in line
with environmental regulations.
● The propulsion unit may only be lifted, conveyed
and set down by specialist staff trained and
qualified to do this work.
● Wear personal protective gear.
● The laws, acts and regulations applicable in the
country where it is used are to be observed.
● At least one other person has to be present when
lifting, conveying and setting down the
components. The load is to be constantly watched
when being lifted, conveyed or set down.
● It is crucial that proper communication is ensured
between the signaller and the slinger before lifting
commences.
● Observe the dimensions and weights of the
propulsion unit. Please refer to the shipping
documents and drawing of the propulsion unit in
this Service Manual for the weights and
dimensions.
● Only use lifting gear (e.g. crane or forklift truck) and
slings (e.g. chains and ropes) that have been
checked and approved for the weight of the
propulsion unit and are in perfect condition.
● The operating instructions for the lifting gear and
slings are to be observed.
● Lifting gear and slings may only be used by
persons trained and authorised to carry out this
type of work.

1 1
DANGER
Suspended load
Hazard to life or risk of serious injuries due to falling
load
▶ Wear a safety helmet.
▶ Do not go or linger under suspended loads.
Never leave components suspended in the
slings over a long period of time.
▶ Only attach the propulsion unit using the desig
nated suspension points.
1
1
DANGER
Fig. 11 Lifting eyes
Lifting and conveying in confined spaces
Hazard to life or risk of serious injuries when lifting in
confined spaces as the load may swing and tilt fol
lowing a collision. 1
▶ Do not go or linger in the danger zone.
● When lifting, use a crossbar (12/1) to prevent

damaging any sub-assemblies.
● When lifting the propulsion unit vertically, attach
the lifting gear to the four lifting eyes (11/1).
● When lifting the propulsion unit horizontally, attach
the lifting gear to two lifting eyes (12/3) and the
boreholes for slings (12/2).
Fig. 12 Attaching the lifting gear to the propulsion

unit

5.2 Transportation
it is crucial that the following points are observed: 2
● The propulsion unit may only be transported by 1
specialist staff trained and qualified to carry out
this task.
● Only use transportation means that comply with
the applicable laws, acts and regulations of the
country where they are used. 3
● The propulsion unit and related sub-assemblies
(e.g. oil expansion tank) are to be attached and
fastened in such a way that damage in transit can
ÏÏÏÏÏÏÏ
be ruled out. 4
● Observe the dimensions and weights of the
propulsion unit. Please refer to the shipping 2
2
documents and drawing of the propulsion unit in
this Service Manual for the weights and
dimensions.
● Make sure the transport vehicle is designed for the
safe transportation of the propulsion unit in terms
of weight, dimensions and requirements.
Ñ
ÏÏÏÏÏÏÏ
Ñ
● The packaging material is to be disposed of
properly.
ÏÏÏÏÏÏÏ
Ñ Ñ
● For transportation, the propulsion unit is be 4
attached to the transport frame provided (13/4)
and braced using the lifting eyes (13/2).
Fig. 13 Bracing the propulsion unit
i INFORMATION
Use a suitable protection device to prevent the pro
peller edges being damaged.
● The power input (13/3) and the propeller (13/1) are

to be braced against each other.

6 Installation and Preparation for the Trial Run
6.1 Installation
i INFORMATION ● A sufficient number of anodes are to be attached to
the hull to protect the propulsion unit against
The propulsion unit is treated with a preservative corrosion.
agent prior to delivery. If stored in dry ambient air (not
● Connect all lubrication oil and hydraulic lines and
sea air), the preservative provides sufficient protec
electrical cables to the propulsion unit according to
tion for approximately six months. The propulsion unit
the installation documents.
is to be installed within these six months.
● When connecting hydraulic lines to hydraulic
The propulsion unit is installed by the shipyard. To components and connections, always comply with
prevent material damage and serious or fatal injuries it the Hydraulic Circuit Diagram and the labels
is crucial that the following points are observed: provided.
● The propulsion unit may only be installed by ● Connect all electrical cables in accordance with
specialist staff trained and qualified to carry out the Wiring Diagram provided.
this task.
● The SCHOTTEL installation documents are to be
observed when installing the propulsion unit and
carrying out all flame-cutting, welding and
installation work; the shipyard will be provided with
these prior to the installation of the propulsion unit.
● The site where the propulsion unit is installed is to
be adequately ventilated and lit.
● Components (e.g. rigid lines, hose lines, and screw
fittings) which are not included in SCHOTTEL's
scope of delivery, but are provided by the shipyard
during installation, have to comply with all of the
characteristics given in the installation documents
(e.g. material; pressure rating).
NOTICE
Damage to seals
Seals may be damaged if exposed to diluting agents
during cleaning.
▶ Do not use any diluting agents when cleaning.
▶ Use petroleum naphtha, white spirit, diesel oil or
a wax remover.
● Clean any components that have been treated with

anti-corrosion agents.
● Do not damage seals and do not paint over them.
Provide protection from external influences (e.g.
heat; weld spatters) and cover, if necessary.

6.2 Preparation for Trial Run
6.2.1 Initial Fill
The propulsion unit has to be prepared for the trial run.
To do this, the measures described in this section are CAUTION
to be carried out. Slipping, falling and tripping over
● The propulsion unit may only be initially filled by Head injuries and cuts to limbs due to sharp edges
specialist staff trained and qualified to carry out and pointed corners
this task. ▶ Keep the work area and walked-on areas clean.
● Wear personal protective gear. ▶ Wear personal protective equipment, especially
protective clothing and a safety helmet.
● Make sure the propulsion unit cannot be started up i INFORMATION
unintentionally before commencing the initial fill. Once these measures have been taken, commis
● When handling operating materials and supplies, sioning (trial run at the pier) may be carried out by an
the safety regulations for the product concerned authorised SCHOTTEL employee.
are to be observed. Refer to and observe the
safety data sheets.
● Dispose of all operating materials and supplies in
a safe and environmentally friendly way. When
doing this, always observe the regulations
regarding the disposal of operating materials and
supplies applicable at the site of operation.
● Fill the following assemblies with the specified
operating materials; see "10.4 Filling/Refilling Oil"
section, from page 54:
* Propulsion unit
* Planetary steering gear
* Steering motor
DANGER
Voltage
Hazard to life or risk of serious injuries due to electric
voltage
▶ Always observe the special safety provisions
when working on any kind of electrical
components.
▶ Work on electrical components is only to be car
unintentionally.

7 Commissioning
DANGER WARNING
Hazard to life or risk of serious injuries due to electric Risk of sustaining burn injuries due to hot surfaces on
voltage the propulsion unit
▶ Always observe the special safety provisions ▶ Wear personal protective gear, especially heat-
when working on any kind of electrical resistant safety gloves.
components.
CAUTION
work and make sure it cannot be switched on Slipping, falling and tripping over
unintentionally. Head injuries and cuts to limbs due to sharp edges
and pointed corners
▶ Keep the work area and walked-on areas clean.
DANGER ▶ Wear personal protective equipment, especially
Damaged safety devices or components
Hazard to life or risk of serious injuries due to inef
fective safety devices or damaged components
▶ Prior to start-up, check that the safety and monit
oring devices are functioning properly.
▶ If damage to the propulsion unit occurs, switch it
off and make sure it cannot be started up uninten
tionally; notify the relevant services.
DANGER
Rotating components
Hazard to life or risk of serious injuries due to body
parts being caught or pulled into rotating components
DANGER
Oil may spray out under high pressure
Hazard to life or risk of serious injuries due to con
necting parts, hoses and lines on hydraulic equip
ment bursting
resistant safety gloves and safety goggles.
▶ Switch off the power supply immediately and wait
until any residual power has dissipated.
▶ Do not try and catch hold of lashing hoses.

7.1 Trial Run at the Pier
For the trial run at the pier, the measures set out in the
"6 Installation and Preparation for the Trial Run" section 1
have to have been completed and those described in
this section carried out:
1. Make sure the propulsion unit cannot be started up
unintentionally.
2
2. Make sure that no-one can be exposed to any
3. Check that all safety and monitoring devices are
functioning properly.
NOTICE
Damage to the propulsion unit due to incorrect
oil level
Propulsion unit components may become damaged
due to an insufficient oil level. Excessive lubrication oil
in the propulsion unit will cause increased operating
temperatures.
▶ Only check the oil level when the propulsion unit
is not in operation and the oil temperature and
ambient temperature are the same.
Fig. 14 Checking the lubrication oil level
4. Check the oil level in the propulsion unit.
Make sure the red indicator bar of the oil level
indicator (14/2) is up to the mark (14/1).
5. Check the oil level in the planetary steering gear. A
1
Type A
Remove the screw plug with the oil dipstick (15/1).
Make sure the lubrication oil is up to the mark on the
oil dipstick.
Type B
Make sure the lubrication oil is up to the middle of
the sight glass (15/2).
6. Check that all alarm and control systems are
functioning properly. 2 B
Fig. 15 Checking the oil level in the planetary

steering gear

i INFORMATION
During the initial operating hours of a new or repaired
propulsion unit or one that has been brought back into
operation, trapped air may escape from the propul
sion unit or planetary steering gear. Check all oil levels
several times in the initial operating hours and top up
the lubrication oil, if necessary.
7. Let the propulsion unit run for approx. two minutes

at a low speed; perform control commands several
times (speed; thrust direction).
NOTICE
oil level
temperatures.
8. Switch off the propulsion unit and check all oil

levels.
9. Check the propulsion unit for leaks.
i INFORMATION
Once these preparations have been made, the trial
run at the pier may be carried out by an authorised
SCHOTTEL employee. During the trial run at the pier,
all control functions are tested.

7.2 Preparation for the Sea Trial
The propulsion unit has to be prepared for the sea trial.
In this respect, the measures set out in the "7.1 Trial Run 1
at the Pier" section have to have been completed and
those described in this section carried out:
● Make sure that no-one can be exposed to any
2
● Inspect the propulsion unit for external visible
damage and defects before commencing the sea
trial. If damage or defects to the propulsion unit are
established, make sure it cannot be started up
unintentionally and notify the relevant services.
● Prior to the sea trial, the operator is to designate a
danger zone around the propulsion unit. The
danger zone must not be accessible to
unauthorised persons.

unintentionally.
Fig. 16 Checking the lubrication oil level

NOTICE
oil level
temperatures.


i INFORMATION
propulsion unit or one that has been brought back into
operation, trapped air may escape from the propul
sion unit. Check the oil level several times in the initial
operating hours and refill the lubrication oil, if neces
sary.
i INFORMATION
Once these measures have been completed, the sea
trial may commence. During the sea trial, the per
formance of the entire propulsion system is determ
ined by an authorised SCHOTTEL employee. The
results of the sea trial are documented in an accept
ance report and the required acceptance test of the
stipulated classification society is carried out.

8 Resumption of Operation
The propulsion unit is installed in the vessel ready for
operation. During a sea trial, the performance of the DANGER
entire propulsion system has been determined, an Damaged safety devices or components
acceptance report compiled and the required
acceptance test of the stipulated classification society
carried out.
▶ Prior to resumption of operation, check that the
To prevent material damage and serious or fatal injuries safety and monitoring devices are functioning
it is crucial that the following points are observed: properly.
● Inspect the propulsion unit for external visible ▶ If damage to the propulsion unit occurs, switch it
damage and defects before resuming operation. If off and make sure it cannot be started up uninten
damage to the propulsion unit is established, make tionally; notify the relevant services.
sure it cannot be started up unintentionally and
notify the relevant services.
● Wear personal protective gear. DANGER
● Make sure that no-one can be exposed to any Oil may spray out under high pressure
necting parts, hoses and lines on hydraulic equip
DANGER ment bursting
Voltage ▶ Wear personal protective gear, especially heat-
voltage ▶ Switch off the power supply immediately and wait
when working on any kind of electrical ▶ Do not try and catch hold of lashing hoses.
components.
ried out by a qualified electrician. CAUTION
▶ Switch off the power supply before commencing Slipping, falling and tripping over
unintentionally. Head injuries and cuts to limbs due to sharp edges
and pointed corners
Rotating components

unintentionally. 1

NOTICE 2
oil level
temperatures.

i INFORMATION Fig. 17 Checking the lubrication oil level
Once these measures have been taken, the propul

sion unit will be ready for operation.

9 Operation
9.1 During Operation

it is crucial that the following points are observed: DANGER
● Wear personal protective gear. Oil may spray out under high pressure
● The laws, acts and regulations applicable in the Hazard to life or risk of serious injuries due to con
country where it is used are to be observed. necting parts, hoses and lines on hydraulic equip
ment bursting
● Make sure that no unauthorised persons are in the
designated danger zone. resistant safety gloves.
● Ensure that all of the safety instructions and ▶ Switch off the power supply immediately and wait
warning notices attached to the propulsion unit are until any residual power has dissipated.
always easily legible and never removed.
● All safety and monitoring devices are operating.
● When handling operating materials and supplies,
the safety regulations for the product concerned WARNING
safety data sheets. Long-term malfunctions
Risk of serious injuries due to the failure of individual
components as a result of long-term malfunctions
DANGER ▶ Rectify malfunctions immediately.
Voltage ▶ Malfunctions are only to be rectified by specialist
Hazard to life or risk of serious injuries due to electric staff trained and qualified to carry out this task.
voltage ▶ If damage to the propulsion unit occurs, switch it
▶ Always observe the special safety provisions off and make sure it cannot be started up uninten
when working on any kind of electrical tionally; notify the relevant services.
components.
WARNING
Hot surfaces
DANGER Risk of sustaining burn injuries due to hot surfaces on
the propulsion unit
Rotating components ▶ Wear personal protective gear, especially heat-
Hazard to life or risk of serious injuries due to body resistant safety gloves.
▶ Do not place objects within the danger zone. CAUTION
Head injuries and cuts to limbs due to sharp edges
and pointed corners
▶ Wear personal protective equipment, especially

● If alarms or abnormal noises occur or the
lubrication oil has a milky appearance, perform the
appropriate tests as described in the
Troubleshooting section (see page 65).
Alarms are displayed on the vessel's alarm monitoring
system. Observe the following alarms:
* Oil level min.

1 2
* Oil temperature max.
Lubrication oil
* Volume flow min.
* Filter clogged
i INFORMATION
* For the steering hydraulics alarms, see SCHOTTEL
Instructions on the hydraulic system in this Service
Manual.
i INFORMATION
The hand lever of the ball valve is spring-loaded and
returns to the neutral position automatically.
Fig. 18 Checking the lubrication oil condition
● If installed, open the ball valve (18/2) for
inspection.
● Check the lubrication oil condition through the sight
glass (18/1). 1
● Check the contamination indicator (19/1) of the 2
changeover duplex filter unit (19/3).
A filter monitoring unit (19/2) monitors the filter
element in the changeover duplex filter unit that is 3
in use. Depending on the viscosity of the
lubrication oil, an alarm may be activated if the oil
temperature is ≤ 5 C, even though the filter
element is not clogged. If the alarm is still active
once the operating temperature has been
reached, this means that the filter element is
clogged.
The changeover duplex filter unit can be switched
from the clogged filter to the clean filter element
during operation (see page 49).
Replace the clogged filter element (see page 62).
● Listen out for any unusual noises coming from the
propulsion unit.
Fig. 19 Checking the contamination indicator

9.2 Measures After Operation
it is crucial that the following points are observed: CAUTION
● All work on the propulsion unit may only be carried Slipping, falling and tripping over
out by specialist staff trained and qualified for this Head injuries and cuts to limbs due to sharp edges
task. and pointed corners
● Wear personal protective gear. ▶ Keep the work area and walked-on areas clean.
● The laws, acts and regulations applicable in the ▶ Wear personal protective equipment, especially
● Ensure that all of the safety instructions and
warning notices attached to the propulsion unit are
always easily legible and never removed.
the safety regulations for the product concerned
safety data sheets.
DANGER
Voltage
voltage
components.
unintentionally.
WARNING
Hot surfaces
Risk of sustaining burn injuries due to hot surfaces on
the propulsion unit
▶ Only commence work once the propulsion unit
has sufficiently cooled down.
resistant safety gloves.

● Switch off the propulsion unit and make sure that it
1
cannot be started up unintentionally.
● Check the propulsion unit for leaks and loose
screw connections.
● Inspect the propulsion unit for external visible
damage and defects. If any are established, notify 2
the relevant services.
NOTICE
oil level
temperatures.
i INFORMATION Fig. 20 Checking the lubrication oil level
When the propulsion unit has reached operating tem

perature, the red indicator bar of the oil level indicator
(20/2) is above the mark (20/1).
● Check the oil level in the propulsion unit.

Make sure that the red indicator bar of the oil level
indicator is up to the mark. 1
2
9.3 Switching Between Filters in
the Changeover Duplex Filter 4
Unit
i INFORMATION 3
The changeover lever (21/3) points to the filter that is
not in use (21/2).
1. Squeeze the grip piece (21/1) and move the

changeover lever in the direction of the arrow as far
as it will go.
2. Replace the clogged filter element (21/4); (see
page 62). Fig. 21 Switching between filters in the changeover
duplex filter unit

10 Maintenance
The following points are to be observed during
maintenance:
● Maintenance work is only to be carried out by
specialist staff trained and qualified to carry out DANGER
this task. Voltage
● Wear personal protective gear. Hazard to life or risk of serious injuries due to electric
● The laws, acts and regulations applicable in the voltage
country where it is used are to be observed. ▶ Always observe the special safety provisions
● The stipulated maintenance intervals are to be components.
complied with. ▶ Work on electrical components is only to be car
● Switch off the propulsion unit and make sure it ried out by a qualified electrician.
cannot be started up unintentionally before ▶ Switch off the power supply before commencing
commencing any maintenance work. work and make sure it cannot be switched on
unintentionally.
● Before commencing any maintenance work, close
off access to the work area to any unauthorised
persons. Display an information sign to indicate the
maintenance work in progress. DANGER
● Refer to the "5.1 Prior to Transportation" section, Rotating components
page 34, for components that need slings and Hazard to life or risk of serious injuries due to body
lifting gear to be dismantled. parts being caught or pulled into rotating components
● Do not damage the seals and provide protection ▶ Do not reach into the danger zone.
from external influences (e.g. heat; weld spatters); ▶ Do not place objects within the danger zone.
cover, if necessary.
● Visually inspect the propulsion unit at regular
intervals as part of its maintenance. Rectify any DANGER
identified defects immediately.
Malfunctions
● When handling operating materials and supplies, Hazard to life or risk of serious injuries due to malfunc
the safety regulations and safety data sheets for tions or damage to individual components.
the product concerned are to be observed.
▶ Adhere to the maintenance schedule.
● Dispose of all operating materials and supplies in ▶ Any defective components which affect the
a safe and environmentally friendly way. When safety and function of the propulsion unit are to
doing this, always observe the regulations be replaced immediately. Always observe the
regarding the disposal of operating materials and safety measures.
● After completing maintenance work, dismantled
safety and monitoring devices are to be reinstalled
and loose bolted connections tightened.
● After completing maintenance work remove any
tools used from the propulsion unit area.

DANGER NOTICE
Oil may spray out under high pressure Malfunction due to paint on shaft seals and
anodes
necting parts, hoses and lines on hydraulic equip Paint can cause shaft seals and anodes to malfunc
ment bursting tion.
▶ Wear personal protective gear, especially heat- ▶ Cover the shaft seals and anodes before
resistant safety gloves and safety goggles. painting.
▶ Switch off the power supply immediately and wait ▶ Do not paint over the shaft seals and anodes.
WARNING
Hot surfaces
Risk of sustaining burn injuries due to hot surfaces on
the propulsion unit
▶ Only commence work once the propulsion unit
has sufficiently cooled down.
WARNING
Hot oil
Risk of sustaining burn injuries due to hot oil
ciently cooled down.
CAUTION
and pointed corners
NOTICE
Damage caused by high-pressure cleaners or
mechanical brushes
Shaft seals may become damaged by cleaning with
high-pressure cleaners or mechanical brushes.
▶ Cover the shaft seals before cleaning.

10.1 Definition of Terms
The purpose of maintenance is to uphold or restore the propulsion unit's functional reliability. Regular maintenance
of the propulsion unit and individual components helps to avert malfunctions and unscheduled downtimes, thus
ensuring the propulsion unit's availability.
The purpose of corrective maintenance is to restore the propulsion unit's functional reliability following malfunction
by replacing defective assemblies or parts.
10.2 Maintenance Schedule

Maintenance work is to be carried out on the propulsion unit at the following intervals:
Interval Work to be carried out

Daily * Check that all alarm and control systems are functioning properly.
After 50 operating hours * Change the lubrication oil in the planetary steering gear.
(after commissioning or repair only).
Every 1,000 operating hours; * Take a lubrication oil sample and have it analysed by an authorised labo
at least every six months ratory. If the oil analysis indicates that it is necessary, change the lubrica
tion oil in the propulsion unit and replace the relevant filter element in the
changeover duplex filter unit.
Annually * Check that all accessible screw connections are tight and re-tighten, if
necessary.
* Check that anodes are complete and in good condition; if necessary,
replace any missing and worn-out anodes.
Every 5 years * Change the hydraulic oil in the steering hydraulics.

* Change the lubrication oil in the planetary steering gear.
* Replace the hydraulic system hose lines.
* Check the steering tube seals and replace them, if necessary.
* Check the propeller shaft seals and replace them, if necessary.
* Check the condition of the propeller.
* Check the condition of the nozzle.
For further maintenance information regarding individual sub-assemblies, please see the separate
operating, installation and maintenance instructions in this Service Manual.

10.3 Oil Specifications and Oil Quantities
10.3.1 Lubrication Oil Specifications
See SCHOTTEL Instructions in this Service Manual.
10.3.2 Lubrication Oil Quantity

The oil quantity depends on the propeller arm length
(PAL) of the propulsion unit (see figure 22).
Refer to the drawing of the propulsion unit in the Spare
Parts Catalogue for the PAL.
The oil quantities specified in the following table are
reference values. Supply lines laid by the shipyard have
not been taken into account here.
For reserves, we recommend approximately 10% of the
PAL
oil quantity specified.
PAL Propulsion Oil quantities

[mm] unit [litres]
[litres]
3200 Approx. 2600 Approx. 4.2/gearbox
Fig. 22 Propeller arm length

10.4 Filling/Refilling Oil
NOTICE 2
1
Damage to the propulsion unit due to contami
nated oil being used
Propulsion unit components may become damaged.
▶ Use a pump with a filter unit and a ≤ 10 m filter
when filling or refilling the oil.
10.4.1 Filling the Propulsion Unit with

3
Lubrication Oil
unintentionally.
2. Remove the breather valve (23/1).
3. Remove the screw plug (23/2).
4. Open the ball valve (23/3).
NOTICE
Damage to the propulsion unit due to the wrong
lubrication oil being used
Propulsion unit components may become damaged. Fig. 23 Filling the propulsion unit with lubrication oil
▶ Follow the Lubrication Oil Specifications.
1
▶ Only use clean lubrication oil.
5. Pour lubrication oil into the ball valve until it is

visible within.
6. Close the ball valve and screw the screw plug back 2
making sure it is oil-tight.
NOTICE
oil level
temperatures.
7. Pour lubrication oil into the breather valve borehole

until the red indicator bar of the oil level indicator
(24/2) is up to the mark (24/3). Fig. 24 Checking the lubrication oil level
8. Clean the breather valve and screw it back in

10.4.2 Refilling the Propulsion Unit with
Lubrication Oil
1. Switch off the propulsion unit and make sure that it
1 2
2. Remove the breather valve (25/3). 3
NOTICE
Damage to the propulsion unit due to the wrong
lubrication oil being used
Propulsion unit components may become damaged.
▶ Always use the same oil used previously.
3. Pour lubrication oil into the breather valve borehole

until the red indicator bar of the oil level indicator
(25/2) is up to the mark (25/1).
NOTICE
oil level
due to an insufficient oil level. Excessive lubrication oil Fig. 25 Refilling lubrication oil in the oil expansion
in the propulsion unit will cause increased operating tank
temperatures.
4. Clean the breather valve and screw it back in


10.4.3 Filling the Planetary Steering Gear
with Lubrication Oil
unintentionally. 1 A
2. Remove the filler and bleed plug (26/2). 2
NOTICE
Damage to the planetary steering gear due to the
wrong lubrication oil being used
Planetary steering gear components may become
damaged. B 3
▶ Follow the Lubrication Oil Specifications.
3. Pour lubrication oil into the filler and bleed neck

(26/3).
Type A
4
Remove the screw plug with the oil dipstick (26/1).
Make sure the lubrication oil is up to the mark on the
oil dipstick.
Type B
Make sure the lubrication oil is up to the middle of
the sight glass (26/4). Fig. 26 Filling the planetary steering gear with
lubrication oil
4. Screw the filler and bleed plug back in.
10.4.4 Refilling the Planetary Steering

Gear with Lubrication Oil
2. Refill with lubrication oil (see the "Filling the
Planetary Steering Gear with Lubrication Oil"
section, steps 2 to 4).

10.4.5 Filling the Steering Motor with
Hydraulic Oil
unintentionally.
1
NOTICE
Damage to the steering hydraulics due to the
wrong oil being used
Steering hydraulic components may become dam
aged.
▶ Always use the same oil that is used in the
steering hydraulics.
▶ Use clean hydraulic oil only.
2. Remove the drain line (26/1) on the steering motor

and fill the steering motor with hydraulic oil.
3. Screw the drain line back on.
Fig. 27 Drain line

10.5 Pumping Out/Draining the Oil
i INFORMATION
Pumping out the lubrication oil can take a long time.
Therefore, SCHOTTEL recommends draining the 1
lubrication oil when the propulsion unit is out of the
water.
10.5.1 Pumping the Lubrication Oil out of

the Propulsion Unit (Propulsion
Unit in the Water)
Tools:
● Pump with oil-resistant hose
Minimum length: PAL + 1.5 m
Hose diameter: max. 18 mm
Hose end: bevelled at approx. 45o Fig. 28 Oil expansion tank cover
i INFORMATION
1
Pump out the lubrication oil straight after turning off
the propulsion unit, as it flows better at operating tem
perature.

ÓÓÓÓ
2. Have a suitable collecting basin at the ready.
3. Remove the cover (28/1).
4. Insert the pump hose (29/1) through the power
transmission shaft until it reaches the bottom of the
underwater gearbox.
5. Pump out all of the used oil into the collecting basin.
6. Remove the hose.
7. Clean the cover and the contact surface on the oil
expansion tank.
8. Coat the sealing face with liquid sealant; see
SCHOTTEL Instructions 1099235.
9. Put the cover back in place.
NOTICE
Damage to the propulsion unit due to lack of oil
Corrosion damage
▶ Fill the propulsion unit with lubrication oil. Fig. 29 Pumping out lubrication oil
10. Properly dispose of the used oil.

10.5.2 Draining the Lubrication Oil from
the Propulsion Unit
(Propulsion Unit out of the Water)
Tools:
Pipe with shut-off valve (included in the scope of 1
delivery)

unintentionally.
3. Remove the breather valve (30/1).
4. Remove the screw plug (31/1).
5. Close the shut-off valve (31/3).
6. Screw in the pipe (31/2) with the shut-off valve.
7. Open the shut-off valve and completely drain the
used oil into the collecting basin.
8. Remove the pipe with the shut-off valve.
9. Clean the screw plug and screw it in with a new seal
10. Remove the magnetic plug (31/4) and check
whether abraded particles have adhered to the
Fig. 30 Breather valve
magnet.
i INFORMATION
Slight abrasion is normal during the run-in period of
new or repaired propulsion units. Coarser abraded
particles indicate major wear or damage. In this case,
the propulsion unit is to be checked and repaired if
necessary.
11. Clean the magnetic plug and screw it in with a new

seal making sure it is oil-tight.
NOTICE 1
Damage to the propulsion unit due to lack of oil
Corrosion damage
▶ Fill the propulsion unit with lubrication oil.
4
12. Clean the breather valve and screw it back in 2
13. Properly dispose of the used oil. 3
Fig. 31 Draining lubrication oil from the propulsion

unit

10.5.3 Draining the Lubrication Oil from
the Planetary Steering Gear
i INFORMATION
1
Drain the lubrication oil straight after turning off the
propulsion unit, as it flows better at operating temper
ature.

2
3. Remove the filler and bleed plug (32/1).
4. Remove the drain screw (32/2) and completely
drain the used oil into the collecting basin.
5. Check whether abraded particles have adhered to
the drain screw magnet.
i INFORMATION
Slight abrasion is normal during the run-in period of
new or repaired planetary steering gear. Coarser
abraded particles indicate major wear or damage. In
this case, check the planetary steering gear and have Fig. 32 Draining the lubrication oil from the planetary
it repaired, if necessary. steering gear
6. Clean the drain screw and screw it in with a new

seal making sure it is oil-tight.
NOTICE
Damage to the planetary steering gear due to
insufficient lubrication oil
Corrosion damage
▶ Fill the planetary steering gear with lubrication oil.
7. Screw the filler and bleed plug back in.


10.6 Taking a Lubrication Oil Sample
Tools:
High-pressure hose (included in the scope of delivery)
i INFORMATION
The oil sample is to be taken while the propulsion unit 1
is running and at operating temperature to enable a
clear analysis of the oil condition.
1. Have an appropriate container ready to take the

sample.
2. Unscrew the dust cap from test port (33/1).
3. Connect the high-pressure hose to the test port
and take the oil sample.
4. Unscrew the high-pressure hose and screw the
dust cap back on.
i INFORMATION
We recommend sending a copy of the oil analysis to
the SCHOTTEL Service Department so that any ser
vice work required can be arranged in good time.
Fig. 33 Test port for taking a lubrication oil sample

10.7 Replacing a Filter Element in
the Changeover Duplex Filter
Unit
i INFORMATION
The clogged filter element can be changed while the
propulsion unit is running.
The changeover lever (34/3) points to the filter that is
not in use.
1
1. Place a suitable collecting basin under the
changeover duplex filter unit to catch any
lubrication oil that leaks out.
2. Loosen the bleed screw (34/1) by turning it two to
three times.
3. Unscrew the filter casing (34/2).
4. Remove the filter element (35/2) by turning it
slightly while pulling downwards.
5. Clean the filter casing thoroughly.
6. Check the condition of the O-ring on the filter
casing. If necessary, replace the O-ring with a new 2
one and lubricate it lightly.
3
7. Insert the new filter element into the filter head.
Fig. 34 Changeover duplex filter unit
8. Lightly lubricate the thread of the filter casing.
9. Fully screw the filter casing into the filter head and
then loosen it again by turning 1/8 to 1/2 a turn.
10. Switch the changeover lever (35/4) over to the new
filter and squeeze the grip piece (35/3) until the
lubrication oil coming out at the bleed screw (35/1)
is free of air bubbles. 1
11. Tighten the bleed screw and use the grip piece
again to check it is oil-tight.
12. Switch the changeover lever over to the other filter.
Fig. 35 Replacing a filter element in the changeover

duplex filter unit

10.8 Checking the Underwater
Assemblies
The following maintenance work is to be performed
when the propulsion unit is out of the water:
● Check the propeller for damage.
Major damage can cause tooth breakage inside
the gearboxes. 1
● Check the steering tube seal (36/1) for oil leaks. If
necessary, have the propulsion unit repaired.
NOTICE
2
Risk of corrosion due to missing and worn out
anodes
Corrosion damage
▶ Replace any missing and worn-out anodes.
● Check that the anodes on the propulsion unit (36/2)
and hull are complete and in good condition. If
necessary, replace any missing and worn-out
anodes.
● Check the gap (37/3) between the propeller hub
and underwater gearbox (37/2) for foreign bodies
and oil leaks. If necessary, dismantle the propeller, Fig. 36 Anodes
remove any foreign bodies and check the seals.
● Check that all fastening screws used for the
underwater gearbox and nozzle (37/1) are tight.
Fig. 37 Underwater assemblies

● Check the nozzle (38/1) for cracks.
● Check the condition of the underwater paint coat
and retouch it, if required. If necessary, have the
propulsion unit repaired.
i INFORMATION
Major damage to the underwater paint indicates
external influences which may cause greater
damage.
Consult the SCHOTTEL Service Department.
1
NOTICE
Malfunctioning shaft seals and anodes
Paint can cause shaft seals and anodes to malfunc
tion.
▶ Cover the shaft seals and anodes before
painting.
▶ Do not paint over the shaft seals and anodes.
Fig. 38 Nozzle

11 Troubleshooting
● Switch off the engine/motor and make sure it
cannot be started up unintentionally before
troubleshooting.
WARNING
Long-term malfunctions
▶ Rectify malfunctions immediately.
▶ Malfunctions are only to be rectified by specialist
staff trained and qualified to carry out this task.
Any deviations from the propulsion unit's usual

operating conditions indicate malfunctions and are to
be remedied immediately.
The table does not make any claim to completeness.
During operation, malfunctions may occur that are not
listed in the table.
If the malfunction cannot be rectified with the aid of this
table, please notify the SCHOTTEL Customer Service
Department.
Keep the following details handy:

● Type plate (complete)
● Type and extent of the malfunction
● Time and circumstances of the malfunction
● Suspected cause
Successful troubleshooting requires precise

knowledge of the propulsion unit structure and mode of
operation, and of the individual components.
Always proceed systematically and purposefully even
under time pressure. Randomly and rashly changing
the settings and removing components may mean that
the original cause of the fault can no longer be
established.

11.1 Lubrication Alarms
Malfunction Possible causes Remedy
Alarm: Insufficient oil level in the propulsion Check the lubrication oil level and fill
"oil level min." unit it up, if necessary. If the alarm occurs
again, have the propulsion unit
repaired.
Oil level switch defective or Check the functionality and

switching point set incorrectly. switching point of the oil level switch.
Correct the setting or replace the oil
level switch, if necessary.
Lubrication oil is leaking out of the Have the propulsion unit repaired.
propulsion unit
Alarm: Excessive oil level in the propulsion Check the oil level and pump some
"oil temperature max." unit lubrication oil out, if necessary.
Temperature switch defective or Check the functionality and

switching point set incorrectly switching point of the temperature
switch. Correct the setting or replace
the temperature switch, if neces
sary.
Wrong lubrication oil Change the lubrication oil; follow the

Lubrication Oil Specifications.
Lubrication oil pump malfunction Check the lubrication oil pump is

functioning properly; replace, if
necessary.
Oil cooler clogged or defective Check the oil cooler is working prop
erly; repair or replace, if necessary.
Alarm: Insufficient volume flow in lubrication Check the volume flow and monitor
"volume flow min." oil system the lubrication oil temperature.
Reduce the propulsion unit speed.
Flow control device defective Check that the flow control device is
functioning properly. Replace if
necessary.
Lubrication oil lines are leaking Seal the leaks.
Lubrication oil pump malfunction Check the lubrication oil pump is

functioning properly; replace, if
necessary.
Alarm: The lubrication oil has not yet Check the lubrication oil temper
"filter clogged" reached operating temperature ature. Reset the alarm.
Clogged filter element in the Switch the changeover lever over to

changeover duplex filter unit. the clean filter. Replace the clogged
filter element.

11.2 General Propulsion Unit Malfunctions
Excessive lubrication oil level in Propulsion unit is not watertight; Have the propulsion unit repaired.
propulsion unit ingressing water in propulsion unit
Lubrication oil has milky appearance Water in the lubrication oil Take an oil sample from the propul
sion unit and have it analysed by an
authorised laboratory. Change the
lubrication oil, if necessary.
Significant drop in propulsion unit's Foreign bodies in the vicinity of the Remove the foreign bodies. If neces
thrust propeller and nozzle sary, have the propulsion unit
repaired.
Propeller damaged Have the propulsion unit repaired.
Propulsion unit emits abnormal Loose cardan shaft fixture Check the cardan shaft fixture and
noises during operation tighten it, if necessary.
Cardan shaft assembled incorrectly Assemble the cardan shaft correctly,

observing the markings.
No grease in crosshead bearings of Check the cardan shaft crosshead

the cardan shaft bearings and lubricate them, if
necessary.
Cardan shaft has different deflection Check the deflection angles of the
angles cardan shaft. If necessary, re-align
the cardan shaft.
Foreign bodies in the vicinity of the Remove the foreign bodies. If neces
propeller and nozzle sary, have the propulsion unit
repaired.
Propeller damaged Have the propulsion unit repaired.
Propulsion unit bearings or toothed Have the propulsion unit repaired.

wheels damaged

12 Removal
● The propulsion unit may only be removed by Slipping, falling and tripping over
specialist staff trained and qualified to carry out Head injuries and cuts to limbs due to sharp edges
this task. and pointed corners
● The laws, acts and regulations applicable in the ▶ Wear personal protective equipment, especially
● Switch off the propulsion unit engine/motor and
make sure it cannot be started up unintentionally NOTICE
before commencing any removal work.
Environmental damage
● Before commencing any removal work, close off
access to the work area to any unauthorised Environmental damage caused by the improper dis
persons. Display an information sign to indicate the posal of materials harmful to the environment
removal work in progress. ▶ Observe the safety data sheets.
● When handling operating materials and supplies, ▶ Dispose of materials safely and in an environ
the safety regulations for the product concerned mentally friendly way.
are to be observed. Refer to and observe the ▶ Always observe the national and international
safety data sheets in this Service Manual. regulations regarding the disposal of materials.
DANGER
Voltage
voltage
components.
unintentionally.
WARNING
Operating materials harmful to health
Operating materials (e.g. oils; cleaning agents) may
be harmful to health when in direct contact with skin
(e.g. caustic burns; allergic reactions).
▶ Always wear personal protective equipment
when handling operating materials.

The following tasks are to be carried out when removing
the propulsion unit:
1. Switch off the propulsion unit engine/motor and
make sure it cannot be started up unintentionally.
2. Drain the operating materials according to the
instructions in the "10 Maintenance" section,
page 50.
3. Remove all electric cables properly.
WARNING
Risk of injury due to thermal and mechanical cut
ting work
Burns and cuts to limbs
NOTICE
Damage to the propulsion unit
The propulsion unit may become damaged during
thermal and mechanical cutting work.
▶ Only perform cutting work properly as set out in
4. Separate the welded joints between the vessel

structure and the propulsion unit by flame cutting
or grinding.
5. Separate all screw connections between the
propulsion unit and the vessel structure.
i INFORMATION
Once these measures have been taken, the propul
sion unit will no longer be joined to the vessel structure
and can be lifted. For lifting the propulsion unit, see
the "5 Transportation" section, page 34.

13 Storage
i INFORMATION
To prevent corrosion damage to the propulsion unit,
contact the SCHOTTEL Customer Service Depart
ment before placing it in short-term or long-term
storage. The SCHOTTEL Customer Service Depart
ment will draw up an individual storage procedure
schedule.
13.1 Short-Term Storage

For short-term storage the propulsion unit is removed
from the vessel and put into storage for a period of up to
six months.
● The storage area has to be clean and dry.
● Before putting the propulsion unit in short-term
storage, carry out all measures required to
equalise pressure in the propulsion unit; see
SCHOTTEL Instructions 1099236.
● If the propulsion unit is to be exposed to vibration
while in storage, it is to be attached to the transport
frame provided and braced tightly using the lifting
eyes, see the "5.2 Transportation" section,
page 36.
● The power input and the propeller are to be braced
against each other.
13.2 Long-Term Storage

For long-term storage the propulsion unit is removed
from the vessel and put into storage for longer than six
months.

14 Disposal
WARNING
NOTICE
Environmental damage caused by the improper dis
posal of materials harmful to the environment
▶ Observe the safety data sheets.
▶ Dispose of materials safely and in an environ
mentally friendly way.
▶ Always observe the national and international
regulations regarding the disposal of materials.
14.1 Scrapping
If the propulsion unit is no longer operational, the
operator is to ensure that the propulsion unit is properly
scrapped; this means a state in which it can no longer
be used for its intended purpose.
SCHOTTEL GmbH shall not assume any responsibility
for any personal injuries or material damage that may
occur as a result of individual parts of the propulsion unit
being reused for a purpose other than the intended use
of these parts.
The following parts are to be carried out when
scrapping the propulsion unit:
● Dismantle the propulsion unit into its individual
parts.
● Lock movable parts.
● Dispose of individual parts properly.

14.2 Disposal
The operator is to ensure that materials are disposed of
in an environmentally sound process. When doing this,
the regulations regarding the disposal of operating
materials and supplies applicable at the site of
operation are to be observed.
The disposal process is to include the recovery of basic
materials from the propulsion unit. These materials
might be able to be reused in a recycling process.
Materials harmful to the environment need to be
disposed off with extra care; these include:
● Plastic parts
● Rubber parts
● Electric parts
● Metal parts
● Operating materials and supplies

LUBRICATION OIL SPECIFICATIONS FOR SCHOTTEL
PROPULSION UNITS WITH FP PROPELLERS
SCHOTTEL GmbH
Mainzer Straße 99
56322 Spay
GERMANY
Phone: +49 (0)2628 / 61-0
Fax: +49 (0)2628 / 61-300
mailto: [email protected]
www.schottel.de
15/0360
1 About These Oil Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
1.1 Warranty . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
1.2 Hazards . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
1.3 Storage and disposal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
2 Quality requirements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
3 Permitted lubrication oils for fixed-pitch propellers and SPJ . . . . . . . . . . . . 9

3.1 Standard oils . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
3.2 Premium oils . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
TTD/Gö Lubrication Oil Specifications 1145139 15/0360 en 3/12

1 About These Oil Specifications
The operating materials used play a significant role in the service life, operational reliability and functionality
of SCHOTTEL propulsion units. For this very reason, it is absolutely crucial that the right oils are selected.
The oils to be used have been specified in these Oil Specifications.
These Oil Specifications are supplemented by other project-related operating instructions and
specifications in this Service Manual ("Applicable product documents"). These applicable product
documents are supplied with these specifications in the form of a Service Manual.
1.1 Warranty
Failure to comply with these Oil Specifications will render any claims made under SCHOTTEL GmbH's
warranty void. The use of approved oils is an integral part of the warranty conditions.
The oil supplier is responsible for the consistent, global quality of the specified products. and as such is to
declare product conformity with SCHOTTEL GmbH quality requirements. SCHOTTEL GmbH shall reserve
the right to request appropriate evidence of this from the propulsion system operator.
1.2 Hazards
Oils may be hazardous substances. When handling these substances, the relevant manufacturer safety
data sheets are to be observed.
1.3 Storage and disposal

Certain rules and regulations are to be observed for storage and disposal. These are to be derived from the
manufacturers' specifications, statutory provisions and technical rules and regulations in force in the
relevant country of use.
As these concern national specifications, it will not be possible to make a general statement on the
regulations to be observed within these Oil Specifications. Therefore, the propulsion system operator will be
obliged to find out about the applicable provisions. SCHOTTEL GmbH shall not assume any liability for
improper or illegitimate use of the approved oils.

2 Quality requirements
The lubrication oil supplier is responsible for the consistent, global quality of the specified products. and as
such is to declare product conformity with SCHOTTEL GmbH quality requirements. SCHOTTEL shall
reserve the right to request appropriate evidence of this.
The lubrication oils are to comply with the following quality requirements:
● CLP lubrication oil complying with DIN 51517-3 ● Compatibility with the internal gearbox coating
● The scuffing load capacity is to be > 12 used at SCHOTTEL
according to FZG test A 8.3/90, DIN 51354/2 ● Compatibility with the elastomer seals used at
● High micropitting resistance with scuffing load SCHOTTEL
stage ≥ 10 according to micropitting test FVA ● Compatibility with the liquid sealants used at
54 SCHOTTEL
● Roller wear < 30 mg according to FE 8 test, ● Compatibility with the lubricating grease used
DIN 51819-3 D-7.5/80-80 at SCHOTTEL
● Low foaming level with less than 15% foam
formation
● Compatibility with residues of the
preservation oil used at SCHOTTEL
For operation in Russian waters, the following applies:

● Lubrication oils conforming to GOST 23652-79.

To prevent material damage it is crucial that
the following information is observed:
NOTE
Damage to the propulsion unit due to
contaminated oil being used
Propulsion unit components may become
damaged.
▶ Use a pump with a filter unit and a ≤ 10 μm
filter when filling or refilling new or recycled
oil.
▶ It is imperative that the specified
maintenance intervals and oil analyses are
complied with.
NOTE
Damage to the propulsion unit due to wrong
oil being used
damaged
▶ Consult the SCHOTTEL Service
Department before using biological or
synthetic lubrication oil.
i INFORMATION
Only those oils are permitted for use in
SCHOTTEL propulsion units that contain agents
which increase corrosion protection and
resistance to ageing and decrease wear in mixed
friction conditions.
i INFORMATION
Regardless of their type, additives that are
subsequently added to the lubrication oil will alter
the oil in an unforeseeable manner. Consult the
SCHOTTEL Service Department before using
any type of additive.
8/12 TTD/Gö Lubrication Oil Specifications 1145139 15/0360 en

3 Permitted lubrication oils for fixed-pitch propellers
and SPJ
i INFORMATION
Never mix different lubrication oils.
3.1 Standard oils
i INFORMATION
For applications in Russia, SCHOTTEL GmbH
recommends lubrication oil complying with
GOST 23652-79 TAP-15V for light to medium
load standard applications.
Manufacturer SRP 10 FP to SRP 5000 FP SRP 320 FP

STP 110 FP to STP 5000 FP STP 320 FP
SCD 200 FP to SCD 5000 FP
SPJ 15, SPJ 55 to SPJ 520
Oil type Oil type
ADDINOL ADDINOL CLP 150 F ADDINOL CLP 100 F
ARAL Degol BG 150 Plus Degol BG 100 Plus
BP Energol GR-XP 150 Energol GR-XP 100
CASTROL Alpha SP 150 Alpha SP 100
CEPSA RADA XMP150 RADA XMP 100
CHEVRON Meropa 150 Meropa 100
ENI AGIP BLASIA FMP 150 AGIP BLASIA FMP 100
FUCHS RENOLIN CLP 150 Plus RENOLIN CLP 100 Plus
FUCHS
GEARMASTER CLP 150 GEARMASTER CLP 100
LUBRITECH
LUKOIL Steelo 150 Steelo 100
MOBIL Mobilgear 600 XP 150 Mobilgear 600 XP 100
OMV PETROL Gravis M 150 Gravis M 100

OFISI
Gravis MP 150 Gravis MP 100
OMV OMV gear HST 150 OMV gear HST 100

Oil type Oil type
Q8 Q8 Goya NT 150 Q8 Goya NT 100
SINOPEC Greatwall AP-HD 150 Greatwall AP-HD 100
STATOIL Load Way EP 150 Load Way EP 100
TEXACO Meropa WM 150 Meropa WM 100

Auriga EP 150 Auriga EP 100
TOTAL Carter EP 150 Carter EP 100

Carter XEP 150 Carter XEP 100
Epona Z 150 Epona Z 100
Tab. 1 Oil type SRP, STP, SCD und SPJ

Manufacturer Planetary steering gear SPJ 22
Oil type Oil type
ADDINOL ADDINOL CLP 150 F ADDINOL CLP 68 F
ARAL Degol BG 150 Plus Degol BG 68 Plus
BP Energol GR-XP 150 Energol GR-XP 68
CASTROL Alpha SP 150 Alpha SP 68
CEPSA RADA XMP150 RADA XMP 68
CHEVRON Meropa 150 Meropa 68
ENI AGIP BLASIA FMP 150 AGIP BLASIA FMP 68
FUCHS RENOLIN CLP 150 Plus RENOLIN CLP 68 Plus
FUCHS
GEARMASTER CLP 150 GEARMASTER CLP 68
LUBRITECH
LUKOIL Steelo 150 Steelo 68
MOBIL Mobilgear 600 XP 150 Mobilgear 600 XP 68
OMV PETROL Gravis M 150 Gravis M 68

OFISI
Gravis MP 150 Gravis MP 68
OMV OMV gear HST 150 OMV gear HST 68
Q8 Q8 Goya NT 150 Q8 Goya NT 68
SINOPEC Greatwall AP-HD 150 Greatwall AP-HD 68
STATOIL Load Way EP 150 Load Way EP 68
TEXACO Meropa WM 150 Meropa WM 68

Auriga EP 150 Auriga EP 68
TOTAL Carter EP 150 Carter EP 68

Carter XEP 150 Carter XEP 68
Epona Z 150 Epona Z 68
Tab. 2 Oil type planetary steering gear and SPJ 22

3.2 Premium oils
The use of GL 4/5 compliant premium oils can have beneficial effects in terms of wear and service life;
especially when used in propulsion units with worm-geared steering drives.
i INFORMATION
recommends lubrication oil complying with
GOST 23652-79 TAD-17i (SHAUMYANA) for
higher load applications.

Oil type Oil type
ADDINOL Eco Gear 150 M Eco Gear 100 M
CASTROL Optigear BM 150 Optigear BM 150

Tribol 1100 / 150 Tribol 1100 / 100
KLUEBER Klueber oil GEM 1-150 N Klueber oil GEM 1-150 N
Tab. 3 Premium oil type SRP, STP, SCD and SPJ
Manufacturer Planetary steering gear SPJ 22
Oil type Oil type
ADDINOL Eco Gear 150 M Eco Gear 68 M
CASTROL Optigear BM 150 Optigear BM 68

Tribol 1100 / 150 Tribol 1100 / 68
KLUEBER Klueber oil GEM 1-150 N Klueber oil GEM 1-68 N
Tab. 4 Premium oil type planetary steering gear and SPJ 22

SHAFTING INSTALLATION INSTRUCTION
SCHOTTEL GmbH
Mainzer Straße 99
56322 Spay
GERMANY
Phone: +49 26 28 / 61-0
Fax: +49 26 28 / 61-300
www.schottel.de
14/1382
Table of Contents
1 Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
1.1 About these Instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
1.2 Scope of documentation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
1.3 Copyrights and industrial property rights . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
1.4 Symbols and diagrams . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
2 Safety and Environmental Protection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9

2.1 Definition of the terms used for those with positions of responsibility . . . . . . . . . . . 9
2.2 Principles of work safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
2.2.1 General safety instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
2.2.2 Safety instructions for transportation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
2.2.3 Safety instructions for installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
2.2.4 Safety instructions for alignment and checking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
2.2.5 Safety instructions for start-up . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
2.3 Safety regulations for the handling of operating materials . . . . . . . . . . . . . . . . . . . . 12
2.4 Emissions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
2.5 Use of original spare parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
2.6 Environmental protection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
3 Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
3.1 Structure and mode of operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
4 Transportation and delivery . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17

4.1 Transportation conditions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
4.2 Condition on delivery . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
4.3 Inspection after delivery . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
5 Storage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
5.1 Storage methods and storage periods . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
6 Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
6.1 Required working conditions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
6.2 Operating materials . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
6.3 Documentation of measures; record sheets . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
6.4 Alignment proposal for universal shafts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
6.4.1 Vertical alignment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
6.4.2 Horizontal alignment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
6.5 Types of bearing bases . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
6.6 Installation of the intermediate shaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
6.7 Alignment of the intermediate shaft and bearing . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
6.8 Alignment of the cardan shaft deflection angles using pointers . . . . . . . . . . . . . . . 28
6.9 Installation of the cardan shaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
6.10 Installation of the bulkhead seal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
6.11 Installation of other shafting sub-assemblies . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
TTD/Gö Shaft Installation Instructions 1191153 14/1382 en 3/40

6.12 Checking the shafting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32
7 Start-up . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33
8 Technical data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35
8.1 Dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35
4/40 TTD/Gö Shaft Installation Instructions 1191153 14/1382 en

1 Introduction
1.1 About these Instructions
These Instructions describe the installation of SCHOTTEL shafting systems.
Shafting systems transfer the drive power from the engine/propulsion motor to the propulsion unit; it
comprises various subassemblies, e.g. cardan shaft and intermediate shaft. SCHOTTEL GmbH's shafting
systems are available in different versions and supplied as part of the overall system. See the SCHOTTEL
GmbH installation documents supplied for the relevant versions.
These Instructions are aimed at those who prepare, assemble, align, adjust and check shafting for
installation, as well as hand shafting over to the operator or shipyard.
Those authorised to carry out the work must fulfil the SCHOTTEL GmbH requirements; see 2.1 “Definition
of the terms used for those with positions of responsibility” section.
Staff are to have read and understood these Instructions thoroughly before commencing any work. The basic
prerequisite for work safety is the observance of all safety instructions and other instructions provided.
1.2 Scope of documentation
● Installation Drawing
● Individual drawings of the sub-assemblies
● Alignment Data Sheet for cardan shaft alignment
● Installation and alignment record sheets (drawn up by the person concerned)
● Other applicable SCHOTTEL specifications (depending on the other sub-assemblies to be installed)
These Instructions describe all measures necessary for safe installation and the proper alignment of shafting
for the variants available at the time of printing. The SCHOTTEL Service Department is to be consulted about
special customised designs prior to commencement of work. For SCHOTTEL GmbH contact details, see
page 2.
Installation instructions are supplied for every installation. These are to be kept safe and available for staff
at all times. If a set of installation instructions are no longer legible or are mislaid, a new copy is to be obtained
from the SCHOTTEL Service Department immediately.
Please contact the SCHOTTEL Service Department in the case of any queries, suggestions for
improvement, or errors.
1.3 Copyrights and industrial property rights

These Instructions or excerpts thereof may only be duplicated, translated or made available to third parties
with the express written consent of SCHOTTEL GmbH.

1.4 Symbols and diagrams
Warning notices
Warning notices are set apart from the rest of the text in these Operating Instructions. They are marked in
colour and introduced with a symbol and keywords that highlight the extent of the risk or hazard.
It is essential that warning notices are heeded and handled with great care to prevent accidents, personal
injuries and material damage from occurring.
DANGER
Indicates a hazardous situation which, if not
avoided, will result in death or serious injury.
WARNING
avoided, could result in death or serious injury.
CAUTION
avoided, could result in minor or moderate injury.
NOTICE
Indicates actions which may result in material
damage.
KEYWORD
Cause of the danger
Tips and recommendations
i INFORMATION

Diagrams
References to illustrations are written in brackets in the text, e. g. (1/3). The first number refers to the
illustration number; the second number is the item number in the illustration. For example: (1/3) means figure
1, item 3. All illustrations are schematic diagrams and do not make any claim to completeness.
Lists and grouped safety instructions

● Items in a list and grouped safety instructions are introduced with a bullet point. The order in which they
appear does not represent their order of importance.
Instructions
For example:
1. Switch off the propulsion unit and make sure it cannot be started up unintentionally.
▶▶ This symbol refers to continuation on the next page.

2 Safety and Environmental Protection
2.1 Definition of the terms used for those with positions of
responsibility
Shipyard
The shipyard is the natural or legal person that hands over the shafting to the operator following installation
in the respective vessel. The shipyard is to ensure that the necessary handover records and acceptance
documents are complete and in a legible condition when the vessel is handed over to the operator.
Furthermore, the shipyard is responsible for the complete creation and handover of the necessary
installation record sheets to SCHOTTEL GmbH.
Operator
The operator is the natural or legal person that uses the shafting as part of the entire propulsion system
supplied by SCHOTTEL GmbH, or on whose order the shafting is used.
Authorised person
Authorised persons are service technicians from the manufacturing company or those who fulfil the following
requirements:
● Completed a vocational qualification which clearly demonstrates the professional knowledge acquired.
The basis of verification should be in the form of vocational qualifications or comparable certificates.
● Professional experience that requires that the authorised person has had practice in carrying out
installation and alignment work for a verifiable period. In the process, the authorised person has learned
about the required tools and testing equipment, as well as the risks resulting from necessary actions and
the working environment.
● A current professional occupation within the field of the upcoming inspection of the shafting and an
appropriate advanced training qualification are absolutely essential. The authorised person has to have
experience in performing the upcoming inspection/testing or similar. Furthermore, the authorised
person must have state-of-the-art knowledge regarding the shafting to be inspected/tested and the risks
involved.
2.2 Principles of work safety

2.2.1 General safety instructions
● The environmental and occupational safety regulations that apply at the site of operation are to be
observed. The operator's operating instructions and shipyard safety regulations are to be obtained prior
to commencing work and observed during the work required.
● The shipyard is to be consulted before components are moved on a docked vessel. Introducing heavy
loads may cause the vessel to become unstable in the dock.
● The working area is to be taken into account during all work to be performed. Work performed in parallel
within this area, e.g. conveying with lifting gear, may put others at risk due to a lack of proper consultation.
● Any malfunctions or defects to the shafting sub-assemblies which may affect safety are to be remedied
immediately. If this is not possible, the SCHOTTEL Service Department is to be consulted immediately.
● Safety and monitoring devices must not be modified or removed.
● The direct supervisor is to be informed in the event of injuries occurring, however serious or minor.
● Installation work on electrical components may only be carried out if the propulsion system is
voltage-free.
● Personal protective equipment must be worn.
● Make sure that walked-on surfaces in the working area are kept free of oil and grease.

● Smoking is prohibited in operating areas.
● Before connecting the shafting to the engine/propulsion motor and propulsion unit make sure that they
2.2.2 Safety instructions for transportation
● Shipyard regulations regarding lifting operations are to be observed.
● Always observe the dimensions and weights of the individual components.
● The individual components are to be attached, fastened and packaged in such a way that damage in
transit can be ruled out.
● Only use lifting gear (e.g. crane or forklift truck) and slings (e.g. chains, ropes, and crossbars) that have
been checked and approved for the weight of the individual components and are in perfect condition.
● Only attach the shafting and its sub-assemblies using the designated suspension points. If necessary,
please enquire about attachment options in the SCHOTTEL Service Department.
● An adequate danger zone is to be designated prior to transportation work.
● At least one other person has to be present when lifting, conveying and setting down the components.
The load is to be constantly watched when being lifted, conveyed or set down.
● Before transportation, the signaller and the slinger are to ensure proper communication by using agreed
hand signals, equipment or by radio.
● Never stand or walk under suspended loads.
● The load is to be transported as close to the ground as possible and prevented from swinging.
● If the load is set in motion, e.g. due to strong winds, it is to be secured using a rope.
2.2.3 Safety instructions for installation
● Check the delivery is complete and in perfect order before installation.
● Make sure there are safety and warning labels attached to the shafting sub-assemblies and that these
are kept clean and in a legible state.
● Malfunctions within the working area that affect safety are to be reported to the responsible body
immediately. Stop all work until the malfunction has been remedied.
● Before commencing work make sure an adequate safety zone has been defined and marked out around
the working area. If this safety zone is failed to be observed by staff not involved in the installation
process, work is to be stopped until this safety zone is properly re-established.
● Before any welding, flame cutting and grinding work is carried out, the shafting, its sub-assemblies and
the surrounding area are to be cleaned to remove any combustible substances. There is a risk of fire and
explosion for this kind of work. Welding, flame cutting and grinding work may only be carried out if this
has been expressly approved by a supervisor.
● During welding work on or around the shafting make sure the earth terminal is attached in the immediate
vicinity of the weld to prevent currents from accidentally flowing across the bearings.
● Make sure shaft seals and track rings are protected against heat, weld spatters and swarf, by attaching
suitable covers.
● Only carry out installation work with suitable tools.
● Never use defective tools; such tools are to be replaced.

● Depending on type, fastening screws and bolts are to be tightened with the specified torque and secured
to prevent them from loosening. Refer to the installation documents for torques and the type of screw/bolt
retention needed.
● Make sure thread locker, sealant, oil, acid, cleaning agents or preservatives do not come into contact
with skin or eyes.
● If an accident occurs despite all safety precautions being taken, perform first aid immediately and call
a doctor.
● Fuels or other highly combustible substances must not be used to clean the propulsion system or its
parts.
● Make sure shaft seals and track rings do not become damaged during installation work.
● Shaft seals and track rings must not be painted over.
● Installation is to be documented on the designated form; see 6.3 “Documentation of measures; record
sheets” section.
● When work is interrupted, the shafting and its sub-assemblies are to be secured to prevent them from
moving unintentionally and a third party being put at any kind of risk. Open sub-assemblies are to be
covered to stop foreign substances from entering them.
2.2.4 Safety instructions for alignment and checking
● Record the alignment and checking of the shafting in the designated documents.
● Make sure the specified adjustment values and tolerances for aligning and checking the shafting are
adhered to. In case of non-observance of the specified tolerances always consult the SCHOTTEL
Service Department.
● Never use defective inspection, testing and adjustment equipment; such equipment is to be replaced.
● If inadmissible deviations are established during checks, the error is to be confirmed by rechecking these
before changing the setting.
2.2.5 Safety instructions for start-up
● Shafting systems may only be put into operation if they are in perfect, technical working order.
● Shafting is to be taken out of service immediately in the event of malfunctions. The malfunction is to be
rectified immediately.
● Make sure installation and alignment record sheets are available for the start-up and provided for the
SCHOTTEL GmbH staff involved in the start-up.
● An adequate danger zone is to be designated around the shafting prior to start-up. No-one is to enter or
remain in this danger zone during start-up.
● Moving parts of the shafting are to be covered by a protective device. If this is not included in SCHOTTEL
GmbH's scope of delivery this is to be installed by the shipyard.
● Any parts connected to the shafting (e.g. engine/propulsion motor, propulsion unit and hydraulic system)
also have to be ready for the start-up. This is to be communicated and confirmed with the workers and
companies involved. The shipyard and operator are always to be informed about start-up so that
malfunctions and risks arising from parallel work processes can be ruled out.

2.3 Safety regulations for the handling of operating materials
● The manufacturer's specifications regarding the operating materials to be used must be observed.
● Operating materials may only be stored in the designated containers. It is absolutely imperative that
these containers are not mixed up with ones used for foodstuffs, i.e. beverages. The storing of operating
materials in the vicinity of foodstuffs is prohibited.
● Smoking, eating and drinking is prohibited when working with operating materials.
● Avoid contact with skin, eyes and clothes.
● If operating materials get into the eyes, rinse out immediately with plenty of clean water. Call a doctor
immediately if the eyes become irritated.
● If oil is swallowed, do not induce vomiting; instead, call a doctor immediately and keep the label handy.
● After inhaling oil fumes or vapours get plenty of fresh air.
● If any operating materials come into contact with the skin wash off immediately both thoroughly and
repeatedly with water and soap.
● Remove any oil-soaked clothes immediately.
● Avoid spilling operating materials.
● Bind, absorb and dispose of any spilt operating materials immediately.
● Watch out for hot system parts within the working area. Oil or grease may ignite on hot components.
● Contaminated or drained operating materials must not be reused.

2.4 Emissions
During installation, risks may arise in the various work stages from the emissions explained in the following.
The measures taken to protect staff do not replace the national occupational health and safety regulations
applicable in the country of operation, or the safety regulations of the shipyard and operator.
Generated noise levels
When the shafting is used as intended, a noise level of 85 dB(A) may be exceeded within its operating area.
Ear protectors are to be worn.
Start-ups may only be carried out if all specified noise control devices have been installed and closed
properly.
Exhaust fumes
Combustion engines consume oxygen and release carbon dioxide, carbon monoxide and other poisonous
gases. Leaks in the exhaust system can be life threatening.
● Only start up combustion engines in closed rooms, if there is a sufficient air supply available.
Heat
Exhaust fumes or exhaust system components (e.g. exhaust pipes or flues) can be so hot that body contact
may result in skin burns; materials that get too close may also get burnt or scorched.
● Never touch hot exhaust pipes/flues.
● Keep combustible materials away from exhaust pipes/flues.
● Apply first aid immediately in the event of burns.
● Take fire fighting action immediately in the event of burning materials.
2.5 Use of original spare parts

Original spare parts and accessories have been specially designed for this shafting. It should be specifically
noted that only those parts and accessories supplied by Schottel GmbH have been tested and approved and
therefore guarantee full functionality and safe operation.
Please contact the SCHOTTEL Service Department if you have any queries.
2.6 Environmental protection

● Any operating materials and other materials accumulated during installation are to be collected and
disposed of according to national regulations applicable in the country of operation. Disposal is only
allowed at the designated sites. Never allow environmental pollution to occur.
● Operating materials must never be disposed of into the sewage system.
● Special care is to be taken close to water. If operating materials get into the water this may cause
irreparable damage to the environment.

3 Introduction
3.1 Structure and mode of operation
Shafting systems transfer the rotational motion and power output of the engine/propulsion motor (e.g.
combustion engine; AC motor) to the propulsion unit (e.g. SCHOTTEL rudder propeller). For manufacturing,
installation and functional reasons, the shafting system cannot consist of one single piece. The following
example demonstrates the structure of a shafting system (regardless of the different versions).
Shafting systems come in different varieties depending on the type of vessel, the vessel's structure, or design
factors.
The versions presented in the following make up the most frequently used combinations of sub-assemblies;
see figure 2. Due to the high number of possible variants, not all combinations can be presented.
The size of shafts and bearings depends on the speeds and torques that are to be transmitted; (see 8
“Technical data“ section).
8 9 10 11
1 2 3 4 5 6 7
Fig. 1 Shafting structure (example)
1 Engine/propulsion motor 7 Flexible shaft

2 Flexible coupling 8 Belt pulley
3 Countershaft 9 Cardan shaft
4 Cardan shaft 10 Clutch
5 Intermediate shaft 11 Rudder propeller
6 Bulkhead seal 12 External flange bearing

12
Fig. 2 Shafting variants

4 Transportation and delivery
4.1 Transportation conditions
DANGER
Suspended load
Hazard to life or risk of serious injuries due to
falling load
▶ Only attach the sub-assemblies using the
designated suspension points.
● Transport safeguards must not be removed until installation.

● Always transport parts horizontally. If upright transportation is unavoidable, shaft parts that move against
each other, e.g. in cardan shafts, have to be secured to prevent them sliding out.
● When moving by fork-lift truck, place wood underneath and only lift by the central part of the shafts.
● Pay attention to the lubricating nipple. Suspension ropes must not be placed over the lubricating nipple.
● Use synthetic ropes or lifting straps for crane transportation. If only steel ropes are available, use edge
protectors on the attachment points.
4.2 Condition on delivery

The shafting sub-assemblies are supplied preserved and packed. Screws, bolts and lock washers for
installing the shafting are part of the scope of delivery.
Sub-assemblies not produced by SCHOTTEL GmbH may be supplied unassembled. These have to be
assembled according to the corresponding manufacturer's documents for subsequent final assembly.
4.3 Inspection after delivery

The sub-assemblies are to be checked for completeness immediately after delivery. Get in contact with the
SCHOTTEL Service Department straightaway if there any discrepancies with the delivery documents.
Opened packaging is to be closed again after the inspection to protect the components from corrosion and
damage.
The supplied manufacturers' documents apply to sub-assemblies not produced by SCHOTTEL GmbH.

5 Storage
5.1 Storage methods and storage periods
i INFORMATION
The shafting sub-assemblies are preserved and
packed prior to delivery. If stored in dry ambient
air (not sea air), the preservative provides
sufficient protection for approximately six
months. The shafting is to be installed within these
six months. If this is not possible, all necessary
measures according to SCHOTTEL Instructions
“Preservation Instructions” are to be undertaken.
In the interim period between delivery and installation, or if work is interrupted, the shafting sub-assemblies
are to be properly stored. After the inspection, the shafts and accessories are to be stored in the original
packaging. The following instructions are to be observed in order to prevent damage caused by corrosion
or incorrect storage. If necessary, consult the SCHOTTEL Service Department.
● Store the shafting and accessories in a clean and dry place (e.g. warehouse). If this is not possible, the
parts are to be covered with suitable means (e.g. tarpaulins).
● Make sure there are no vibrations in the vicinity of the stored material.
● Transport safeguards must not be removed.
● Always store shafts horizontally.
● Store the shafts and accessories on a suitable base, e.g. wooden pallet.
● Only ever support shafts beneath the central shaft section. Joints, flanges, sliding elements, profile
protection and lubricating nipples must not be covered or stressed.
● Secure the shafts to stop them rolling away, if necessary, e.g. with wedges or prisms.
● The cardan shaft joints must not be bent beyond the permissible value when in storage.
● Do not stack shafts and their accessories. If items have to be stacked due to lack of space, wooden
frames are to be used to stop the shafts being damaged or rolling away.

6 Installation
6.1 Required working conditions
● The instructions on the Installation Drawing and any individual drawings are to be observed.
● The supplied manufacturers' documents apply to any sub-assemblies not produced by SCHOTTEL
GmbH.
● Make sure the ambient temperature specified in the Installation Drawing for the operating areas is
upheld.
● Casting resins may be harmful to health. Make sure the operating area is well ventilated during
installation of the intermediate shafts.
6.2 Operating materials

● Fill the bearings in accordance with SCHOTTEL instructions “Installation Instructions for Self-Aligning
Roller Bearings”.

6.3 Documentation of measures; record sheets
Any alignment and checking work is to be documented. The necessary record sheets for this are provided
by SCHOTTEL GmbH with the delivery or are to be drawn up by the shipyard. These records sheets are to
be given to the employee authorised by SCHOTTEL GmbH for the start-up. Refer to the Installation Drawing,
individual drawings and manufacturers' documents for values and tolerances.
A hard copy is required of any record sheets drawn up. There are no special requirements for their design.
However, SCHOTTEL GmbH states that record sheets should at least contain the following content:
General information in all record sheets:
● Customer and order number
● Project identifier
● Project name and identifier
● Place and date of creation and last amendment
● Person(s) responsible
● Date and persons responsible for review and approval
● Inspection/test item
● Inspection/testing equipment
● Inspection/test results with provision of units of measurement before and after installation.
Alignment record sheet for the cardan shafts:
● Deflection angles ß1 to ß4 compliant with the supplied Alignment Data Sheet.
Alignment record sheets for intermediate shafts, bearings, couplings and other components:
● Radial offset to opposite flange surfaces
● Angular offset to opposite flange surfaces
In addition, all activities involved in aligning the shafting and its sub-assemblies are to be digitally
photographed for the records and sent to SCHOTTEL GmbH prior to start-up.
The photographs are to meet the following minimum requirements:
● Components being photographed need to be easily identifiable; make sure there is sufficient
illumination.
● Make sure the photographs are always in focus and any markings clearly identifiable.
● The photographs must fully document the installation and alignment procedures.
● The working area is also to be included in the photographs to provide an overall impression of the
propulsion system and work carried out.
● Make sure the photographs depict the actual installation situation. Photographs of components or
alignment work outside of the propulsion system is not permitted.
The minimum requirement is shots of the following:
● General view of the shafting
● Detailed shots of the bases and bearings during installation and alignment
● Top view of the open floating bearings following alignment
● General and detailed shots of screw connections
● Shots of alignment of the cardan shafts with pointers (general and detailed shots)
● General and detailed shots of the other sub-assemblies being aligned

6.4 Alignment proposal for universal shafts
On principle power take off flange of clutch or shaft line have to be aliqned to the input flange of
Rudderpropeller after installation of the Ruderpropeller in the ship.
6.4.1 Vertical alignment
1. Install clutch and/or shaft line and align them provisionally according to the dimensions shown on the
approved SCHOTTEL installation proposal.
2. Put parallel rules vertically on the face of both the power take off flange of clutch and input flange of
Rudderpropeller; length of parallel rules approx. 1500 mm.
3. Measure the distance between the flanges (rules) in a height of 1/2 h. The distance shall correspond with
the distance stated in the SCHOTTEL installation proposal drawing.
4. Measure same distance on a radius of 1000 mm and align clutch and/or shaft line by putting distance
pieces underneath the bearings and/or clutch until the figures are within a tolerance of ± 2 mm.
5. Fix clutch and/or shaft line provisionally and check again and correct if necessary.

6.4.2 Horizontal alignment
1. Put two parallel rules of exactly same breath vertically on the face of power take off flange of clutch and/or
shaft line and fix it to the flange by clamps. Lenqthof rules at least h + flange diameter.
2. Put on rule horizontally across the vertical rules in a height of 1/2 h. Put a second rule horizontally on the
face of input shaft of SRP in a height of 1/2 h also.
3. Measure the distance between the outer edges of the horizontal rules and addition the breath one vertical
rule. The distance shall correspond with the figure stated in the approved SCHOTTEL installation
proposal.
4. See „Vertical alignment“, step 4.
5. Fix clutch and/or shaft line on counter foundation and check alignment again and corret if necessary.
6. Check vertical alignment again and correct if necessary.
7. Fix and secure clutch undlor shaft line on the counter foundation and install universal shaft according to
the separate instructions "Installation and maintenance of universal shafts".

6.5 Types of bearing bases
The types of bearing bases (3/1) used is the
shipyard's responsibility. SCHOTTEL GmbH
1 1
requirements of the bearing bases are listed in the
following:
● Minimum rigidity 500 kN/mm
● Capacity to support bearing mounts complying
with 8.1 “Dimensions” section.
6.6 Installation of the

intermediate shaft
The intermediate shaft is supplied with premounted
bearings. The fixed bearing is marked on the 1
bearing housing. Installation is to be carried out in
accordance with the Installation Drawing and the
drawing of the intermediate shaft.
Please note the following information:
● The intermediate shaft is to remain movable
until the cardan shaft is aligned with the
pointers.
Fig. 3 Bearing bases
● If there are any bulkhead seals, these are only
to be bolted on once the intermediate shaft has
been fully mounted and aligned.
● Floating bearings may slip during installation or
alignment; the self-aligning roller bearings (4/1)
then lie against the bearing housing (4/2).
Floating bearings have to sit in the centre of the
housing to compensate any displacement during 1
operation (e.g. also applies to deformation of the
vessel's hull).
● Make sure grease outlets are on the top side of
the bearings.
● Installation is to be documented by
photographs; see 6.3 “Documentation of
measures; record sheets”.
Fig. 4 Checking the floating bearings are

centred

6.7 Alignment of the intermediate shaft and bearing
Testing and adjustment equipment:
● Laser-assisted shaft alignment system (preferable)
● Ruler
● Own testing equipment suitable for measuring work.
Alignment of the intermediate shaft and bearings is to be recorded and documented in photographs; see 6.3
“Documentation of measures; record sheets”. Refer to the Installation Drawing and drawing of the
intermediate shaft for measurements, limit values and tolerances. Measurements set out in the 8.1
“Dimensions” section also apply to the bearings.
The bearings can be aligned sing spacers or casting resin.
The following information applies when aligning the bearings using spacers:
● Spacers must cover the entire flange surface.
● The minimum thickness is 10 mm.
The following information applies when aligning the bearings using casting resin:
● Only casting resin approved by the ship classification society is to be used.
● The casting resin is to be cast by a specialist company.
● Observe the specifications of the casting resin manufacturer regarding processing and curing times.
● Align the bearing and fix into place using adjusting screws prior to casting.
● In addition, an adequately sized plate is to be attached under the bearing foot.
● Only tighten the bearing fastening screws/bolts once the casting resin has completely hardened.

After alignment:
● Check the floating bearings (5/1) are centred;
align if necessary.
● Use roll pins to fix the bearings into place.
● Pin bearing mounts to the base.
1
i INFORMATION
The pinning of the bearing mount and base is
important for subsequent positioning during
removal or maintenance and repair work. Refer to
the bearing drawing for the number and position
of the pin boreholes needed; see the 8.1
“Dimensions” section.
● Screw on the bulkhead seal, if present; see

6.10 “Installation of the bulkhead seal” section.
Fig. 5 Checking the floating bearings are

centred

6.8 Alignment of the cardan shaft deflection angles using pointers
The deflection angle is aligned prior to installation. Pointers are mounted instead of cardan shafts.
● Cardan shafts may have different lengths and deflection angles.
● However, the deflection angles of a cardan shaft have to be identical.
● Refer to the Installation Drawing for permissible lengths and deflection angles.
● Every cardan shaft is to be aligned separately.
● Both pointer tips of a cardan shaft must be the same length. The lengths are to be checked prior to
alignment and adjusted if necessary.
● Alignment of the deflection angle is to be recorded and documented in photographs; see 6.3
“Documentation of measures; record sheets”.
Fig. 6 Alignment of the cardan shafts

NOTICE
Damage to the shafting due to incorrect
installation and alignment
Incorrectly installed and aligned cardan shafts
produce forces and vibration which may destroy
the shafting and attachment parts, as well as the
engine/ propulsion motor or gears.
▶ The cardan shafts are to be aligned prior to
installation.
▶ Always observe the permissible tolerances.
i INFORMATION
The shipyard is responsible for providing the
pointers. SCHOTTEL will provide a drawing to
use for their production. Please contact the
SCHOTTEL Service Department if you have any
queries.
1. Mount four pointers on the counter flanges of the cardan shafts.
2. Shift the shafts until the tips of the pointers touch.
3. Measure any deviations at the pointer tips. The maximum permissible deviation at the pointer tips is 2
mm in any plane.
4. Shift the shafts until the deviation at the pointer tips is within the permissible tolerance. If necessary,
adjust the length of the pointers. However, both pointers on a cardan shaft must be the same length.
5. Enter the measured values on the alignment record sheet.

6.9 Installation of the cardan
shaft NOTICE
The cardan shaft deflection angles are to be aligned Damage to the cardan shaft due to incorrect
using pointers prior to installation; see 6.9 installation
“Alignment of the deflection angle of the cardan If the cardan shaft length compensation section is
shafts using pointers” section. mounted right up to the limit stop, damage may
occur to both the cardan shaft and the entire
i INFORMATION shafting due to thermal expansion during
operation.
If the angle is off, bolts cannot always be inserted
from the cardan shaft side. To make installation ▶ Therefore, align the cardan shaft so that
easier the bolts are to be inserted from the there is enough room for length
intermediate shaft flange side and the nuts compensation on both sides following
screwed on from the opposite side. This also installation.
makes it easier to check bolted connections
● Align the cardan shafts with the connecting
during start-up, as loose nuts are immediately
flanges and mount.
noticeable.
● Observe the required torque; see the
● Remove any transport safeguards prior to Installation Drawing in the supplied documents.
installation.
● Clean any dirt, grease, anti-rust agents and
paint from the front sides of the cardan shaft
flange and connecting flange prior to
installation.
● Check the connecting flange prior to
installation. Its shape and size must conform to
the respective cardan shaft flange.
● Never swap the sliding element or other cardan
shaft parts of different cardan shafts. The
cardan shafts would otherwise be incorrectly
balanced.
● If it is necessary to pull the the cardan shaft
completely out of the sliding element the exact
marking is to be observed when putting both
components back together.
● Never turn the cardan shaft by the joint with
assembly tools, such as push-on pipes or lever
rods. Lubricating nipples and seals may
become damaged.
● For shafting with two cardan shafts these have
to be installed offset at 90° to each other.
● If the cardan shaft is painted, make sure that the
area for length compensation is not painted.
● Check whether the cardan shaft is assembled
exactly according to the marking on the sliding
element.

6.10 Installation of the bulkhead seal
The bulkhead seal is to be installed according to the Installation Drawing and the drawing of the intermediate
shaft.
● Bulkhead seals are only to be bolted on following alignment of the intermediate shaft.
● Transport brackets are to be removed prior to fixture.
Bulkhead seals may be versions with radial or axial seals. The following information is to be observed for
installation:
● For intermediate shafts that need smoothing in the bulkhead seal area make sure the smoothed areas
are absolutely clean.
● The bulkhead seal is only to be shifted within the shaft's smoothed area.
6.11 Installation of other shafting sub-assemblies

Other sub-assemblies (e.g. belt pulleys and clutches) are to be installed according to the Installation Drawing
and individual drawings.
Any sub-assemblies not produced by SCHOTTEL GmbH (e.g. flexible couplings and shafts) are to be
installed according to the Installation Drawing and manufacturers' documents.
NOTICE
Risk of damaging the cardan shaft due to
incorrect installation
Check the specified direction of rotation when
installing components.
▶ Refer to the supplied drawings or
manufacturers' documents.

6.12 Checking the shafting
Testing and adjustment equipment:
● Laser-assisted shaft alignment system (preferable)
● Ruler
● Own suitable inspection/testing equipment for the inspection/testing
Once the shafting is installed and aligned the following aspects are to be fully checked:
● Adherence to measurements and tolerances.
● Adherence to the required torques for screw connections.
● Correct installation and filling of the bearings with permitted operating materials in compliance with the
SCHOTTEL "Installation Instructions for Self-Aligning Roller Bearings".
● Pinning of the bearing mounts to the bases.
● Obvious damage to shafting components.
● Proper performance of installation and alignment work.
i INFORMATION
Refer to the Installation Drawing, individual
drawings, manufacturer's documents and
supplied documentation for the measurements,
tolerances and adjustment values.

7 Start-up
Start-up is carried out by an authorised SCHOTTEL
GmbH employee and documented in a
commissioning report. After start-up, the whole
system supplied by SCHOTTEL is transferred to
the responsible division of the shipyard until its
handover to the operator.
The system has to be prepared for the start-up. In
this respect, the measures set out in the "6.12
“Checking the shafting“ section have to be
completed and those described in the following
carried out:
● Compilation of the necessary record sheets to
hand over to the authorised SCHOTTEL GmbH
employee.
● Ensuring that the necessary safety measures
for start-up are in place as set out in the 2.2.5
“Safety instructions for start-up“ section”.
● Making all necessary preparations for start-up
in accordance with the operating instructions
for the sub-assemblies of the entire system;
e.g. propulsion unit, hydraulic system, control
and electrical systems.
During start-up, adherence to limit values for
vibration and temperatures are checked, as are
any unusual noises from the shafting.
i INFORMATION
Bearing temperatures may be increased (up to
130 °C) during the shafting run-in period. Once
the seals have been run in and grease has been
evenly distributed in the bearings, the
temperatures will drop to a normal level (< 80 °C).
Fig. 7 Vibration velocity (RMS) in the bearing
housing

8 Technical data
8.1 Dimensions
Refer to the Installation Drawing and individual drawings for the dimensions of the different shafting
sub-assemblies and their respective weights. The following table and drawings apply to the installation and
alignment of the bearing mounts and bearings.
Measurement table for the various types of bearing installation

Ref. Unit
Shaft diameter a mm 180 170 150 140 125 110 100 90 80
Housing centre b mm 190 180 170 170 150 140 125 112 100
Housing base c mm 80 75 70 60 50 45 45 40 35
Spacer length d mm 590 590 590 600 550 460 460 420 420
Spacer width e mm 240 240 240 235 205 185 175 160 160
Bearing plate length f mm 760 760 760 760 620 580 580 570 570
Bearing plate width g mm 380 380 380 380 350 290 230 180 180
Borehole spacing for h mm 480 450 430 470 420 350 350 320 290
fastening screws/
bolts
Borehole spacing for i mm 120 110 100 - - - - - -
fastening screws/
bolts
Borehole spacing for j mm 680 680 680 670 620 580 530 520 520
adjusting screws
Borehole spacing for k mm 200 200 200 170 170 170 180 130 130
adjusting screws
Borehole spacing for l mm 600 570 570 590 540 450 490 460 460
fastening screws/
bolts
Borehole spacing for m mm 300 260 260 250 250 220 - - -
fastening screws/
bolts
Bearing plate thick n mm min. min. min. min. min. min. min. min. min.
ness 40 40 40 40 40 40 40 40 40
Casting resin layer o mm 20 20 20 20 20 20 20 20 20
Cast riser p mm 15 15 15 15 15 15 15 15 15
Joint q mm 20 20 20 20 20 20 20 20 20
Spacer thickness r mm 12 12 12 12 12 12 12 12 12
Roll pin Ø s mm 20 20 20 12 12 8 8 8 8
Roll pin position t mm 520 490 470 506 458 378 378 348 317

Measurement table for the various types of bearing installation
Roll pin position u mm - - - 58 54 44 44 39 35
Tightening torque v Nm 350 350 350 350 350 200 200 200 150
Housing fixture w Nm 665 665 665 1310 1310 665 665 665 386
(M24) (M24) (M24) (M30) (M30) (M24) (M24) (M24) (M20)
Casting resin fixture x Nm 1350 1350 1350 1350 1350 670 670 670 670
to base (M30) (M30) (M30) (M30) (M30) (M24) (M24) (M24) (M24)

1
b
2
ÇÇ
ÓÓ
c
3
ÇÇ
ÓÓ
s ÇÇ
ÓÓ
Ó 4
6
r
a
h
d
ÇÇ
ÓÓ
Ó
ÇÇ
Ó
i
ÇÇ 5
Fig. 8 Bearing installation using spacers (for

shaft diameters > 100 mm)
1 Base
2 Limit stops and adjusting bolts (installed by
the yard)
3 Roll pin „s“ (installed by the yard)
4 Fastening screws „x“ (installed by
SCHOTTEL)
5 Fastening screws „y“ (installed by the yard)
6 Spacer „r“ (installed by the yard)

1
2 p
o
ÓÓÇ
3
4
ÓÓÇ
Ó
ÓÓÇ
Ó
ÇÇÇ
5
ÓÓÇ
ÓÇ
ÓÓÓ
Ç
ÓÓÔ
Ó
Ç
q
a
j
ÓÓÓ
Ç
ÓÓÇÇ
Ó
Ç Ç
ÓÓÓ
Ç 6
ÓÓÇ 7
ÓÓ
8
n 9
k
m
g
Fig. 9 Bearing installation using casting resin (for shaft diameters > 100 mm)
1 Base
the yard)
3 Casting mould
4 Adjusting screws (installed by the yard, to be
removed after casting process)
SCHOTTEL)
8 Fastening screws „z“ (installed by the yard)
9 Mounting plate „n“

1
b
2 c
s
4
r
h
d
a
6
Fig. 10 Bearing installation using spacers (for shaft diameters < 110 mm)
1 Base
the yard)
SCHOTTEL)
6 Spacer „r“ (installed by the yard)

1
o
2
3 4
q
Ö 6
Ö
f
j
l
9
n
k
g
Fig. 11 Bearing installation using casting resin (for shaft diameters < 110 mm)
1 Base
the yard)
3 Casting mould
4 Adjusting screws (installed by the yard, to be
removed after casting process)
SCHOTTEL)
8 Fastening screws „z“ (installed by the yard)
9 Mounting plate „n“

INSTALLATION INSTRUCTIONS FOR PROPELLERS
ÌÌÌÌÌÌÌÌÌÌÌÌÌÌÌÌ
SCHOTTEL GmbH
Mainzer Straße 99
56322 Spay
GERMANY
Phone: +49 (0)2628 / 61-0
Fax: +49 (0)2628 / 61-300
Mailto: [email protected]
www.schottel.de
Table of Contents
1 About these Installation Instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
1.1 Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
1.2 Symbols and diagrams . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
1.3 Restriction on liability . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
1.4 Warranty . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
1.5 Warranty conditions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
2 Safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
2.1 Staff requirements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
2.1.1 Qualification of specialist staff . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
2.2 Lifting gear and slings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
2.3 Personal protective equipment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
3 Tool Kit and Auxiliary Materials . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11

3.1 Tool kit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
3.2 Auxiliary tools and materials . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
4 Propeller Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
4.1 Checking the contact pattern . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
4.2 Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
4.2.1 Preparing the propeller hub . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
4.2.2 Preparing the propeller shaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
4.2.3 Tool mounting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
4.2.4 Propeller hub end position . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
4.2.5 Expanding the propeller hub . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
4.2.6 Shifting the propeller hub . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
5 Final Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
5.1 Reworking the propeller flange . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
5.2 Installing the propeller flange . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
6 Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
TTD/Sl Installation Instructions for Propellers 1197744 13/June en 3/21

1 About these Installation Instructions
1.1 Introduction
These Installation Instructions describe installation of propellers from the SRP 1010 FP to 4500 FP series.
Make sure the Installation Instructions are always kept available for the relevant staff.
Staff are to have read and understood these Installation Instructions thoroughly before commencing any
work. The basic prerequisite for work safety is the observance of all safety instructions and other instructions
provided.
Furthermore, the local accident prevention regulations and general safety provisions apply to the propulsion
system's area of application.

Diagrams
References to diagrams are written in brackets in the text, e. g. (1/3). The first number refers to the diagram
number; the second number is the item number in the diagram.
For example: (1/3) means diagram 1, item 3.
All diagrams are schematic and do not make any claim to completeness.
● Items in a list and grouped safety instructions are introduced with a bullet point. The order in which they
Instructions
For example:
2. Place a suitable collecting basin underneath the pressure filter unit.
▶▶ This symbol refers to continuation on the next left page.

Warning notices
Warning notices are set apart from the rest of the text in these Operating Instructions. They are marked in
colour and introduced with a symbol and keywords that highlight the extent of the risk or hazard.
DANGER
WARNING
CAUTION
NOTE
damage.
Any warning notice within these Operating
Instructions is structured as follows:
KEYWORD
Cause of the danger
i INFORMATION
6/21 TTD/Sl Installation Instructions for Propellers 1197744 13/June en

1.3 Restriction on liability
All information and notices provided in these Operating Instructions have been compiled in consideration of
the applicable standards and regulations, the state of the art and the insights and experience we have gained
over many years.
SCHOTTEL GmbH will not accept any liability for any damage incurred as a result of the following
circumstances:
● Failure to comply with these Operating Instructions
● Using the propulsion unit for anything other than its intended purpose
● Using staff that are not trained to deal with the respective task
● Unauthorised structural, electrical or control-related modifications and repairs
● Technical modifications
● Using unapproved spare parts
● Using unsuitable, unapproved operating materials
● Operating the propulsion system using safety and monitoring devices that are defective, improperly
installed or are not functioning properly.
The obligations stipulated in the Supply Contract, SCHOTTEL GmbH's General Terms and Conditions and
Terms of Delivery, and the applicable legal regulations in force at the time of concluding the Contract shall
apply.
1.4 Warranty
SCHOTTEL GmbH shall not assume responsibility for any personal injuries or material damage that may
occur as a result of failing to comply with these Operating Instructions. Furthermore, any form of warranty
granted by SCHOTTEL GmbH shall become void, and responsibility shall be transferred to the operator.
1.5 Warranty conditions

The warranty conditions stipulated by contract shall apply, provided that the propulsion unit is used as
intended and the maintenance instructions are observed. SCHOTTEL GmbH may request evidence of the
maintenance instructions being observed.
The trial run and sea trial of the propulsion unit are to be carried out by authorised SCHOTTEL GmbH
employees.
Original spare parts from SCHOTTEL GmbH are to be used for maintenance and repair work. The full
functionality and safe operation of the propulsion system can only be guaranteed if spare parts supplied by
SCHOTTEL GmbH are used. The warranty shall become void if any parts are used other than original
SCHOTTEL parts. SCHOTTEL GmbH shall not assume any liability or warranty for any damage incurred by
using other spare parts and accessories.
SCHOTTEL GmbH's General Terms and Conditions shall expressly apply to all orders placed
(www.schottel.de/agb). Requests for spare parts are to be made in writing.

The SCHOTTEL Service Department is available to provide technical information. For SCHOTTEL GmbH
contact details, see the cover sheet. Furthermore, we are always interested in new information and learning
about any new experiences that arise from using our products and that may be useful in terms of improving
them.

2 Safety
This section will provide an overview of all of the important safety aspects involved in providing staff with
optimal protection and ensuring the safest and smoothest operation possible.
Failure to comply with the safety instructions and other instructions set out in these Installation Instructions
may result in serious hazards arising. Therefore, staff are to observe all safety and other instructions set out
in this section and in these Installation Instructions and take the relevant safety measures.
2.1 Staff requirements

There must be a sufficient number of staff available to carry out the work described in these Installation
Instructions.
2.1.1 Qualification of specialist staff
The work described in these Installation Instructions is only to be carried out by qualified specialist staff.
Specialist staff are defined as persons who due to their professional training, knowledge and experience, as
well as knowledge of the pertinent stipulations, are in a position to:
● Carry out the work assigned to them safely, and correctly assess the implications of their work;
● Identify potential hazards independently;
● Take necessary measures to eliminate any hazards, especially those concerning risk of accidents;
2.2 Lifting gear and slings

Only lifting gear (e.g. crane or forklift truck) and slings (e.g. chains and ropes) that have been checked and
approved for the weight of the individual components and are in perfect condition may be used.
2.3 Personal protective equipment

The protective equipment needed for respective tasks is always to be worn:
Safety footwear
Safety gloves
Safety goggles
Safety helmet

3 Tool Kit and Auxiliary Materials
3.1 Tool kit
i INFORMATION
The propeller installation tool kit is included in the
scope of delivery.
Propeller installation tool kit:
1 2
4 3
Fig. 1 Tool kit
1 Hydraulic pump
2 Hydraulic nut
3 Crossbar (2x)
4 High-pressure line

3.2 Auxiliary tools and materials
i INFORMATION
The auxiliary tools and materials for propeller
installation are not included in the scope of
delivery.
Auxiliary tools and materials for propeller

installation:
● Lifting gear
● Digital temperature meter
● Calliper
● Feeler gauge
● Cleaning agent
● Hydraulic oil
● Collecting basin

4 Propeller Installation
i INFORMATION 1 2
Classification societies stipulate that a trial
installation is to be carried out for all new
propellers to smooth or settle the surfaces, thus
ensuring the optimal transmission of torque to the
propeller.
4.1 Checking the contact

pattern
NOTE
Wrong cleaning agent
The propeller shaft seal may be damaged. Fig. 1 Cleaning
▶ Cover the propeller shaft seal.
▶ Do not use any diluting agents for cleaning. 1 2
1. Thoroughly clean the seat of the propeller hub

(1/1) and the propeller shaft (1/2).
2. Evenly paint the seat of the propeller shaft (2/2)
with marking paint (coat thickness of 0.005 to
0.010).
3. Measure the temperature on the propeller hub
and shaft.
i INFORMATION
The difference in temperature between the
propeller hub and shaft must not exceed 5 °C.
Fig. 2 Applying the marking paint
4. Attach the propeller hub to the lifting gear.
5. Carefully lift the propeller hub.
DANGER
Suspended load
falling propeller
▶ Ensure the propeller cannot fall off by
securing it properly.
6. Carefully slide the propeller hub onto the

propeller shaft.
7. Make sure the propeller hub does not get
jammed.
8. Pull the propeller hub off.

9. Check the contact pattern on the propeller hub
1 2
(3/1) and propeller shaft (3/2).
i INFORMATION
Contact pattern requirements:
▶ Make sure the contact area is over 75% of the
total area.
▶ Make sure the contact pattern fully encircles
the tapered ends.
▶ Make sure the contact pattern is evenly
distributed across the remaining part of the
seat.
▶ Make sure the contact pattern meets the
requirements of the classification societies.
Fig. 3 Testing
10. Rework the propeller hub, if the contact pattern
does not comply with requirements.
11. Repeat steps 1 to 9 until the contact pattern
complies with requirements.

4.2 Installation
4.2.1 Preparing the propeller hub
propeller hub to catch any oil that leaks out.
2. Remove the G ¼" screw plugs from the
boreholes in the propeller hub.
3. Blow out the boreholes with compressed air.
1
4. Thoroughly clean the seat (4/1).
5. Lightly lubricate the seat with the same oil used
in the hydraulic pumps.
4.2.2 Preparing the propeller shaft
Fig. 4 Preparing the propeller hub
NOTE
Wrong cleaning agent
The propeller shaft seal may be damaged. 1
▶ Cover the propeller shaft seal.
▶ Do not use any diluting agents for cleaning.
1. Thoroughly clean the seat (5/1).

2. Lightly lubricate the seat with the same oil used
in the hydraulic pumps.
4.2.3 Tool mounting
1. Carefully slide the propeller hub onto the
propeller shaft making sure it does not get
jammed.
2. Place the propeller flange (6/3) with the O-ring Fig. 5 Preparing the propeller shaft
groove facing outwards against the hydraulic
nut (6/4).
3. Screw the propeller flange onto the propeller
hub crosswise using eight hexagon screws.
4. Tighten the screws evenly and gradually until 1 2 3
the cylindrical piston of the hydraulic nut has
completely retracted.
5. Mount crossbars (6/2) on the propeller flange.
6. Mount the hydraulic pumps (6/1) on the
crossbars.
Fig. 6 Tool mounting

4.2.4 Propeller hub end position
1
i INFORMATION
The propeller hub end position is to be Y
recalculated every time the hub is remounted.
1. Apply 100 bar pressure to the hydraulic nut

(7/1).
2. Measure the gap between the propeller hub
and propeller flange to 0.1 mm accuracy
(dimension Y).
3. Enter the measured value (Y) on the Propeller
Installation Record Sheet (see within this
Service Manual).
Fig. 7 Propeller hub end position
4. Determine the path of displacement (S) in
accordance with the temperature value (t)
recorded on the Propeller Installation Record
Sheet.
5. Record the path of displacement (S) on the
Propeller Installation Record Sheet. Z
6. Determine the end position measurement (Z).
(See the formula on the Propeller Installation
Record Sheet)
Fig. 8 Propeller hub end position

4.2.5 Expanding the propeller hub 2 3
i INFORMATION
To bleed the high-pressure lines only screw the
screw fittings into the propeller hub loosely.
1. Connect hydraulic pumps (9/2) and (9/3) to

connections (9/B) and (9/A).
2. Fill the hydraulic pumps with hydraulic oil.
3. Operate the hydraulic pumps until the hydraulic
oil comes out of the connections free of
bubbles.
4. Firmly tighten the screw fittings. D A
B
5. Continue operating the hydraulic pumps until C
the oil coming out of the borehole (9/D) is free of
air bubbles.
6. Screw the screw plug into the borehole.
WARNING
High pressure
components flying off with force.
▶ Never go or linger behind the propeller
flange.
7. Continue operating the hydraulic pumps.

Fig. 9 Expanding the propeller hub
8. The propeller hub is expanded hydraulically.
i INFORMATION
The propeller hub is sufficiently expanded when
hydraulic oil starts emerging at the front and rear
edges.

4.2.6 Shifting the propeller hub 1
i INFORMATION
To bleed the high-pressure line only screw the
screw fitting into the hydraulic nut loosely.
1. Remove the screw plug from the connection

(10/C) in the hydraulic nut (10/2).
2. Install the hydraulic pump (10/1) at the
connection (10/C).
3. Operate the hydraulic pump until the hydraulic
oil comes out of the connection free of bubbles.
4. Firmly tighten the screw fitting.
C
WARNING
High pressure
components flying off with force.
▶ Never go or linger behind the propeller
flange.
5. Continue operating the hydraulic pump.

6. The propeller hub is shifted hydraulically.
Fig. 10 Shifting the propeller hub

5 Final Assembly
1. Slide the O-ring (12/1) onto the liner (12/2) and
1 2 3
lubricate well.
2. Carry out the steps described in section 4.2.
3. Continuously measure the distance between
the propeller hub and propeller flange until
dimension (Z) is attained.
4. Once dimension (Z) is attained, relieve the
pressure on hydraulic pumps (11/2 and 11/3).
5. Keep applying pressure to the hydraulic pump
(11/1) for approx. 20 minutes more; then
relieve the pressure.
6. Check dimension (Z) once more.
A
7. Remove the hydraulic pumps, hydraulic nut B E
and propeller flange.
8. Screw the screw plugs into boreholes (11/B),
(11/A) and (11/E).
Fig. 11 Relieving the pressure
Fig. 12 Mounting the O-ring

5.1 Reworking the propeller
flange
1. Determine distance (X) between the propeller
hub (13/2) and propeller shaft (13/1) and record
the measured value on the Propeller
Installation Record Sheet.
2. Rework the propeller flange to dimension (X)
entered on the Propeller Installation Record
Sheet. X
NOTE
1 2
Great deviation in axial run-out
The propeller flange and hub may be damaged.
Fig. 13 Reworking the propeller flange
▶ When reworking to dimension (X), the
permissible axial run-out of 0.05 mm is to be 1 2 3 4 5
observed.
3. Punch dimension X, the propeller number and

the gearbox number into the propeller flange.
5.2 Installing the propeller

flange
1. Thoroughly clean the front end of the propeller
hub (14/5), propeller shaft (14/4), and
boreholes.
2. Insert the O-ring (14/3) into the propeller flange
(14/2) and lubricate well. X
3. Apply liquid sealant to the propeller flange; (see

the SRP drawing in the Spare Parts Catalogue). Fig. 14 Installing the propeller flange
4. Position the propeller flange against the
propeller hub (14/5).
5. Insert fastening bolts (14/1) with thread locker
applied; (see the SRP drawing in the Spare
Parts Catalogue).
6. Tighten the fastening bolts crosswise applying
the specified torque.

6 Removal
The propeller hub is expanded to remove the
propeller in the same way as described for
installation in section 4.2.5. The propeller is
released from the propeller shaft taper with a loud
bang.
i INFORMATION
Mark the underwater gearboxes, propellers and
propeller flanges that make up a set before their
removal to prevent any mix-ups during
installation.

Propeller Installation Record Sheet SRP/SCD 1515 FP
(Pusher Propeller)
Project no.:
Order no.:
The reference value marked in the table is to be compared to the value indicated on the SRP/STP drawing.
If the reference value is different, please contact the SCHOTTEL Service Department.
SRP/SCD:
Materials: GS-CuAl10Fe5Ni5-C (CC333G)
Path of displacement S dependent on temperature t
t [°C] 60 55 50 45 40 35 30 25 20 15 10 5 0 -5 -10 -15 -20
s [mm] 3,84 3,92 4,00 4,09 4,17 4,25 4,33 4,42 4,50 4,58 4,67 4,75 4,83 4,91 5,00 5,08 5,16
Installation
Installation Installation Installation Installation
1 2 3 4
SRP/STP ID no.
Propeller no.:
Temperature (t) [°C]
Displacement (S) [mm]
Dimension (Y) [mm]
Dimension (Z) [mm] Formula: Z = Y + S
Dimension (X) [mm]
en TTD-FS Propeller Installation Record Sheet SRP/SCD 1515 FP (Pusher Propeller) 13/Nov 1199454 1/1
Mounting and Maintenance of the Self−Aligning Roller
Bearings in
Shaft Lines (two−lip seal)
with synthetic lubricating grease
Table of Contents
1 Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Required mounting conditions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
New lubrication . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Mounting on the shaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Measuring the radial bearing clearance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
2 Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Lubricant recommendation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Lubrication schedule . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Regreasing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
en MIX−Fr Mounting and Maintenance of the Self−Aligning 11/1140 1167641 1/ 7

Roller−Bearings in Shaft Lines (two−lip seal)
Preliminary Remark
These instructions shall be of information and help for Given that SCHOTTEL systems are subject to further
every person engaged in initial start−up, operation and development we reserve the right of technical
maintenance of SCHOTTEL systems. This requires to modifications.
read, understand and observe these documents.
Important instructions relevant to technical and
These instructions are to be made available to operational safety are pointed out by the following
everybody carrying out works on the system. symbols:
We do not accept any liability for damages and troubles
in operation resulting from disregard of these ! CAUTION
instructions.
It is taken for granted that every user is familiar with the Indicates working and operating methods that are to be
systems and informed on all possible dangers. strictly observed to exclude any risk for persons.
!
Only trained personnel is allowed to carry out any work
on the system. ATTENTION
References to illustrations in the text are written in Refers to working and operating methods that are to be
brackets, e.g. (1/3). The first number indicates the strictly observed to avoid damages to or destruction of
illustration number in the manual, the second number the material.
is the position number in the illustration.
All illustrations are diagrammatic projections without NOTE
any claim for completeness.
Any technical modification to SCHOTTEL systems not Indicates exceptional features in the working process
carried out by personnel appointed by SCHOTTEL that are to be observed.
does require written consent.
This excludes modifications or control settings detailed i INFORMATION
in our instructions.
Application references and information.
During any work carried out on SCHOTTEL systems it
is required to observe the Safety and Environmental
Protection Regulations as well as the relevant laws in
force in the respective country of utilization.
These instructions were elaborated with utmost care.

In case of further information required, please contact:
SCHOTTEL GmbH
Mainzer Straße 99
D−56322 Spay
Phone +49 (0) 2628 / 61−0
Fax +49 (0) 2628 / 61−300
E−Mail [email protected]
2/ 7 MIX−Fr Mounting and Maintenance of the Self−Aligning Roller−Bearings in 11/1140 1167641 en

1 Installation
Required mounting conditions

The following horizontal, vertical and transverse
admissible vibration speeds at the bearing housings
are valid for the bearings herein described:
v max x 10 mm/s (RMS).
The installation is carried out in three steps:

1. New lubrication of the bearing.
2. Mounting the bearing on the shaft.
3. Measuring and setting the radial bearing
clearance.
Figure 1
New lubrications
New or clean and washed bearings are to be filled with
the specified grease quantity as follows:
2
* Fill the bearing gaps (2/2) with grease.
* Distribute the remaining grease in the housing 1 1
such that there is no untreated surfaces.
* Fill the gap between the two sealing lips (2/1) with
d
grease.
Diameter of the Grease quantity

bearing seat ”d” new filling
[mm] [g]
70 280
80 430
90 630 Figure 2
100 850
110 1000
125 1400
140 2000
170 1500
180 1900

Mounting
! ATTENTION
Prior to mounting the gaps of the bearings are to be
filled with grease, see page 3. 1
By tightening the groove nut (3/3), the inner ring of the
bearing is expanded by the conical connection (3/1).
This reduces the existing radial bearing clearance. The
radial clearance reduction is the measure for the
interference fit of the bearing.
Measuring the radial bearing clearance

For measuring the radial bearing clearance to be set,
feeler gauges (3/2) are to be used with measuring
blades of different thickness, starting with 0.03 mm.
The bearing clearance is to be measured before, during
and after installation of the bearing, and always
between outer ring and relieved roll.
The bearing is to be turned several times prior to
measuring to allow the rolls to move into correct
position. 3
During measuring, the roll in position of the measuring
point is slightly pressed against the guide ring between
the two lines of rolls. The measured radial clearance
must be the same above both lines of rolls.
The following table shows the reference values for the
radial clearance to be set during the installation of
self−aligning roller bearing with conical bore hole. The
fit resulting from these mounting instructions is of
sufficient tightness.
Specified size of the Radial bearing clear-

bearing bore hole ”d” ance 2
[mm] to be set
[mm]
over up to
80 100 0.05 + 0.01
100 120 0.065 + 0.01
120 140 0.08 + 0.01
Figure 3
140 160 0.09 + 0.01
160 180 0.10 $ 0.01
180 200 0.10 $ 0.01
200 225 0.12 $ 0.01
225 250 0.13 $ 0.01
250 280 0.14 $ 0.01
280 315 0.15 $ 0.01

2 Maintenance
! CAUTION DANGER OF BURNS!

Caution while working on hot parts of the system and
It is unconditionally required to observe the when handling hot oil, there is the danger of burns.
SCHOTTEL Operating, Mounting and Maintenance
Instructions, the “Safety and Environmental Protection
Regulations SV 1”, as well as the regulations regarding
safety and environmental protection in force in the
country of utilisation.
During maintenance- and repair works it is to be
ensured that the driving motor cannot be switched on
inadvertently!
Maintenance interval Works to be carried out
to lubrication schedule, see page * Regreasing

6
every 500 operating hours * Check of all fastening screws for pillow block and shaft line.
every 2500 operating hours * Check of the shaft installation alignment.

Lubricant recommendation
Manufacturer Type of grease
We recommend to use NLGI-lubricants of class 1.5.
Mobil Mobilgrease 28
In case of disregard any and all warranty liabilities of
SCHOTTEL will expire.
Lubrication schedule
The time for regreasing depends on many factors

linked with each other in a complex way, among others ! ATTENTION
of the number of revolutions, operating temperature,
Therefore, the lubrication times stated in the table in
type of grease, free space inside and beside the
operating hours (h) are only reference values.
bearing, as well as the ambient influences.
They are valid for bearing temperatures of 70 C.
Each increase of the bearing temperature of 15 C
demands to halve the lubrication time.
Operation hours “d”

[mm]
r.p.m. d = 70 d = 100 d = 110 d = 125 d = 140 d = 170 d = 180

[min-1] d = 80
d = 90
700 2650 h 2500 h 2350 h 2000 h 1650 h 1350 h 1200 h
800 2350 h 2175 h 2000 h 1650 h 1400 h 1200 h 1100 h
900 2000 h 1825 h 1650 h 1350 h 1200 h 1050 h 950 h
1000 1650 h 1500 h 1350 h 1100 h 1000 h 900 h 800 h
1100 1400 h 1300 h 1200 h 1000 h 800 h −−−− −−−−
1200 1350 h 1200 h 1050 h 950 h 650 h −−−− −−−−
1300 1200 h 1100 h 1000 h 800 h −−−− −−−− −−−−
1400 1050 h 1000 h 950 h 650 h −−−− −−−− −−−−
1500 1000 h 925 h 850 h 600 h −−−− −−−− −−−−
1600 850 h 825 h 800 h 500 h −−−− −−−− −−−−
1700 800 h 775 h 750 h 450 h −−−− −−−− −−−−
1800 650 h 625 h 600 h 300 h −−−− −−−− −−−−

Regreasing
* Regrease the bearing over the lubricating nipple
(4/1) with the prescribed quantity of grease. 1
Diameter of the Grease quantity

bearing seat ”d” new filling
[mm] [g]
70 25
d
80 40
90 55
100 70
110 80
125 110 2
140 150
Figure 4
170 110
180 130
i INFORMATION
After three times of regreasing, the entire grease
quantity in the bearing is to be replaced, see page 3.
* Remove the used grease emerged from the
grease outlet (4/2).

Installation Instructions for Screw and Bolt
Connections and Sealants
These Installation Instructions are to be read and applied carefully to ensure safe operation and
prevent damage occurring to the propulsion system!
en TTD-Ro Installation Instructions for Screw and Bolt Connections and Sealants 14/0208 1180737 1/13
These Installation Instructions have been written
with the utmost care and attention to detail.
However, should you require any further
information, please contact:
SCHOTTEL GmbH
Mainzer Straße 99
56322 Spay, Germany
Phone +49 (0) 2628 610
Fax +49 (0) 2628 61300
2/13 TTD-Ro Installation Instructions for Screw and Bolt Connections and Sealants 14/0208 1180737 en
Table of Contents
1 About these Instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4

1.1 Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
1.2 Means of Representation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
2 Screw and Bolt Connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6

2.1 Tightening Torques . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
2.2 Tightening Order . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
2.3 Securing Screw and Bolt Connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
3 Sealants . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
3.1 Sealing Compounds . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
3.1.1 Preparation of the Sealing Surfaces . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
3.1.2 Applying Sealing Compounds . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
3.2 Thread Sealants . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
3.2.1 Preparation of the Threads . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
3.2.2 Applying Thread Sealants . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
3.3 Filling in of Boreholes and Gaps . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
3.3.1 Conditions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
3.3.2 Applying quick-setting cement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
4 Recommended Products . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
1 About these Instructions
1.1 Introduction
These Instructions provide guidelines for installation, including the handling of screw and bolt connections and
sealants, and relevant recommended products.
The Instructions are part of the Service Manual and are to be kept accessible to all staff at all times in the
immediate vicinity of the propulsion system. Staff are to have read and understood these Instructions
thoroughly before commencing any work. The basic prerequisite for work safety is the observance of all safety
instructions and other instructions provided.
Furthermore, the local accident prevention regulations and general safety provisions apply to the propulsion
system's area of application.
1.2 Means of Representation

Illustrations
number; the second number is the item number in the illustration. For example: (1/3) means figure 1, item 3.
D Items in a list and grouped safety instructions are introduced with a bullet point. The order in which they
Instructions
" This sign is used for an instruction and indicates that an action is to be carried out. Instructions are to
be followed in the order they are stated. They may be followed by additional information for the action
that is to be carried out.
For example:
1. Clean and degrease contact surfaces.
2. Check that the sealing surfaces are level and
rework them, if necessary.
Warning Notices
Warning notices are set apart from the rest of the text in these Instructions. They are marked in colour and
DANGER
WARNING
CAUTION
NOTICE
damage.
Any warning notice within these Instructions for Use

is structured as follows:
KEYWORD
Cause of the danger
i INFORMATION
2 Screw and Bolt Connections
2.1 Tightening Torques
NOTICE i INFORMATION
Damage to the propulsion system due to Thinly applied oil or adhesive (equivalent of having
wrong tightening torques oil thinly applied) has been assumed for the coeffi-
Components may break loose. cients of friction for corrosion-resistant screws and
bolts: Overall coefficient of friction moverall=0.13
▶ Make sure you always use the tightening tor-
ques specified in the installation drawing
when bolting the well and the propulsion
system to the vessel.
The tightening torques specified in the drawings and the Service Manual are to be applied to all other screw
and bolt connections. However, if no tightening torques are specified, the values in the following table apply
in relation to thread size and property class.
Tightening torque MA (Nm)
Size Property class Property class
8.8 10.9 12.9 A4-70 A4-80 C3-80
M4 2,8 4,1 4,8 2,2 2,9 3,1

M5 5,5 8,1 9,5 4,3 5,7 6,1
M6 9,5 14 16,5 7,3 9,8 10,4
M7 15,5 23 27 12 16 17
M8 23 34 40 17 23 25
M10 46 68 79 35 48 51
M12 79 117 135 60 82 87
M14 125 185 215 98 130 140
M16 195 280 330 150 200 215
M18 280 390 460 210 270 300
M20 390 560 650 290 380 430
M22 530 750 880 390 520 580
M24 670 960 1120 490 655 720
M27 1000 1400 1650 730 965 1065
M30 1350 1900 2250 990 1310 1440
M33 1850 2600 3000 1340 1775 1950
M36 2350 3300 3900 1730 2280 2510
M39 3000 4300 5100 2250 3100 3250
2.2 Tightening Order
Screw and bolt connections are to be tightened
gradually in line with the pattern shown in figure 1.
1
i INFORMATION
8 5
Observe tightening torques; see "2.1 Tightening
Torques" section, page 6.
4 3
7
6
Figure 1 Tightening Order
2.3 Securing Screw and Bolt
Connections
Any screw and bolt connections that are not secured
with mechanical components need to be secured
with liquid adhesive. However, make sure these
glued connections can be unscrewed without the
need for heat treatment.
CAUTION
Hazardous substances harmful to health
1
Liquid adhesives may be harmful to health if they
come into direct contact with skin (e. g. caustic
burns, allergic reactions).
▶ Manufacturer safety data sheets are to be
observed.
when handling liquid adhesives.
NOTICE
Damage due to improper use of liquid
adhesives Figure 2 Applying liquid adhesive to bolts
Components may break loose and become
damaged.
▶ When handling liquid adhesives the relevant
manufacturer's specifications are to be
observed.
i INFORMATION
For recommended liquid adhesives, see the
"4 Recommended Products" section, page 13.
D For nut and bolt connections up to M16, apply

liquid adhesive to the first thread turns of the
bolt thread (2/1).
For nut and bolt connections larger than M16,
apply liquid adhesive to both parts being joined.
3 Sealants
3.1 Sealing Compounds
i INFORMATION
Sealing surfaces that need installing with a sealing
compound are identified in the propulsion unit
drawings.
3.1.1 Preparation of the Sealing

Surfaces
Before applying sealing compound, the sealing
surfaces are to be prepared appropriately:
1. Clean and degrease the sealing surfaces.
2. Check that the sealing surfaces are level and
rework them, if necessary.
NOTICE
Damage to the O-rings due to sealing
compounds
O-rings may harden
▶ O-rings must not come into contact with
sealing compounds.
3. Use O-rings or any other specified seals in a dry

state.
3.1.2 Applying Sealing Compounds
CAUTION
Sealing compounds may be harmful to health
(e. g. caustic burns; allergic reactions).
observed.
when handling sealing compounds.
i INFORMATION
For recommended cleaning agents and sealants,
see the "4 Recommended Products" section,
page13.
NOTICE
Damage to the O-rings due to sealing
compounds
O-rings may harden
▶ O-rings must not come into contact with
sealing compounds.
1. Apply a thin and even layer of sealant on one

side.
2. Allow the sealant to air according to the
manufacturer's specifications.
3. Join the components so they fit exactly and do
not move them.
4. Mount the bolts and nuts tightening them
according to specifications; see the drawing or
"2 Screw and Bolt Connections" section,
page 6.
i INFORMATION
Allow the sealant to harden according to the manu-
facturer's specifications before putting any strain
on the joined parts.
3.2 Thread Sealants
i INFORMATION
Threaded pipes that need installing with thread
sealants are identified in the propulsion unit
drawings.
3.2.1 Preparation of the Threads

Before applying thread sealant, the threads are to be
prepared appropriately:
1. Clean and degrease the threads.
2. Check the condition of the threads and rework
them, if necessary.
3.2.2 Applying Thread Sealants
CAUTION
Thread sealants may be harmful to health (e. g.
caustic burns; allergic reactions).
observed.
when handling thread sealants.
i INFORMATION
For recommended cleaning agents and sealants,
see the "4 Recommended Products" section,
page13.
i INFORMATION
For thread sizes up to 1/2" only apply sealant to the
external thread. For larger threads apply sealant to
both parts to be joined.
1. Apply sealant to the first thread turns that are

engaged (first thread turn remains untreated).
2. Mount the screw fittings and tighten them
according to specifications.
i INFORMATION
Allow the sealant to harden according to the manu-
facturer's specifications before putting any strain
on the joined parts.
3.3 Filling in of Boreholes and
Gaps
i INFORMATION
Gaps or boreholes that need to be filled with water-
resistant, quick-setting cement, are identified in
the propulsion unit drawings.
3.3.1 Conditions
D Parts are to be coated.
D Make sure surfaces are clean, dry and

degreased.
3.3.2 Applying Quick-Setting Cement
CAUTION
Quick-setting cement may be harmful to health
(e. g. caustic burns; allergic reactions).
2
observed.
1
when handling quick-setting cement.
i INFORMATION
For recommended quick-setting cement, see the
"4 Recommended Products" section, page13.
1. Insert sealing plugs (3/1) into the hexagonal

socket screw heads.
2. Mix the required amount of quick-setting
cement as specified by the manufacturer.
3. Fill the boreholes/gaps with quick-setting Figure 3
cement (3/2).
4. Allow the quick-setting cement to set according
to the manufacturer's guidelines.
5. Level up the surfaces by sanding and apply a
new coat of paint in line with the relevant
specification.
4 Recommended Products
Application Product Container Part no.:
Thread lockers
Loctite 245 Can 250 ml 1048197
Sealing compounds
DELO ML 5198 Can 200 ml 1058474
Thread sealants
Cleaning agent
Loctite Cleaner 7063 Spray can 150 ml /400 ml 1034072
Quick-setting cement
PCI-Polyfix Sack 15 kg 1127896
Preservation Instructions
Component assemblies are preserved following the SCHOTTEL Hydraulic Systems

trial run/assembly at the manufacturing plant; this
preservation will protect the propulsion systems for
up to 6 months. Internal parts:
Flush the system with ESSO anti−corrosive protec-
If the propulsion systems are not commissioned tion MZ45 to ensure that all internal parts are coated.
within this period of protection, they are to be Also go through the operating functions with no load.
retreated with preservatives as described in the fol- Then drain the preservation oil. Always make sure
lowing: hydraulic cylinders are retracted before being stored.
SCHOTTEL Rudder Propellers/Jets/ General

Transverse Thrusters
Fitting surfaces and untreated parts:
Internal parts: If damage has occurred to preserved fitting surfaces,
Fill the gears with SHELL anti−corrosion oil these have to be washed down with the following
S.7294/SAE 30 and fully rotate all of the power trans- solvent: Petroleum, white spirit diesel, wax remover
mitting parts to ensure that all internal parts are or similar agent.
coated. Then drain the anti−corrosion oil. Next, spray or coat the surfaces with VALVOLINE
TECTYL 846 K−19.
Steering gear:
Fill the steering gear with SHELL anti−corrosion oil For storage in seaworthy packaging, the complete
S.7294/SAE 30 and fully rotate the steering system system and loose parts are shrink−wrapped in plastic
to ensure that all internal parts are coated. film at the manufacturing plant. If this packaging
Then drain the anti−corrosion oil. becomes damaged, the system is to be provided with
desiccant bags and completely repackaged before
being sealed air−tight.
SCHOTTEL Clutches
BMK 80, K 155, K 305 and K 350:

The clutch is to be filled with SHELL preservation oil
! CAUTION
S.7294/SAE 30 and then fully rotated with no load to Before mounting fitting surfaces and untreated parts
ensure that all internal parts are coated. The preser- make sure that the preserved surfaces are washed
vation oil can then be drained. down with the following solvents:
Mechanical clutches: For example:

Coat all of the untreated parts within the clutch − Petroleum
housing with SHELL preservation oil S.7294/SAE − White spirit
30. Make sure the clutch is fully disengaged before − Diesel
application. However, also make sure that the friction − Wax remover
surfaces remain untreated. Always make sure the
clutch is disengaged before being stored.
en TDO−rg Preservation Instructions 3 641/02 1104097 1/ 1

3.2 Hydraulics
BLANK PAGE
Operating Instructions Hydraulic System SST 612
Table of Contents
1 Technical Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Technical Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Weights . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Operating Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Performance Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Ambient Conditions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Test Port Values . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Structure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Hydraulic Pump Unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Hydraulic Tank . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Function . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
2 Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
3 Start-Up, Operation and Monitoring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13

Measures Before Commissioning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
Measures Prior to Start-Up . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
Measures During Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
Measures After Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
Controlling Thrust Direction Using the Manual Operation Device . . . . . . . . . . . . . . . . . . . . . 15
4 Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
Maintenance Schedule . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
Oil Recommendation and Oil Quantities . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
Oil Recommendation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
Oil Quantities . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
Filling/Refilling Oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
Filling the SST with Oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
Refilling the SST with Oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
Draining the Oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
Filling the Hydraulic Pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
Checking and Cleaning the Filler and Breather Filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
Taking an Oil Sample . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
Replacing the Filter Element . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
5 Testing and Adjustment Procedures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23

Checking and Adjusting the V-Belt Tension . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
en STD-Fre Hydraulic System SST 612 12/March 1189950 1/30

6 Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
7 Hydraulic Symbols . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
8 Lifting and Transportation; Storage and Shutdown . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28

Lifting and Transportation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
Hydraulic Pump Unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
Hydraulic Tank . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
Storage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
Shutdown . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
9 Warranty . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
2/30 STD-Fre Hydraulic System SST 612 12/March 1189950 en

Preliminary Notes
These instructions are to provide information and Given that SCHOTTEL propulsion systems are subject
guidance to all persons involved in the initial start-up, to further development, we reserve the right to carry out
operation and maintenance of SCHOTTEL propulsion technical modifications.
systems. Please make sure that these instructions are
read, understood and carefully observed. Important instructions relevant to technical and
operational safety are identified by the following
These instructions are to be made available to all symbols:
persons working on and with the propulsion systems.
We shall not accept liability for any damage or ! WARNING
malfunctions resulting from non-observance of these
instructions. Indicates working and operating methods that are to be
It is a prerequisite that all users are familiar with the strictly observed to prevent any risk to personal safety.
propulsion systems and have been informed about the
possible dangers associated with their use.
Only trained and qualified staff are permitted to carry out
! CAUTION
work on the propulsion systems. Indicates working and operating methods that are to be
strictly observed to prevent damage to or destruction of
References to illustrations are written in brackets in the materials.
text, e.g. (1/3). The first number refers to the illustration
number in the manual; the second number is the item
number in the illustration. NOTE
All illustrations are schematic diagrams and do not Indicates specific features of the working process which
make any claim to completeness. are to be observed.
Any technical modification to SCHOTTEL propulsion
systems to be performed by non-SCHOTTEL
personnel requires written authorisation.
i INFORMATION
However, this does not include any of the modifications Application instructions and information.
or control settings described in our instructions.
When carrying out any work on SCHOTTEL propulsion
systems, always observe the safety and environmental
protection regulations as well as the applicable laws in
force in the respective country they are used.
These instructions have been written with the utmost care and attention to detail.
However, should you require any further information, please contact:
SCHOTTEL GmbH
Mainzer Straße 99
56322 Spay, Germany
Phone +49 (0) 2628 610
Fax +49 (0) 2628 61300
E-mail [email protected]

Technical Data
Dimensions
See the drawing in the Spare Parts Catalogue
Weights
See the drawing in the Spare Parts Catalogue
Operating Data
See the drawing in the Spare Parts Catalogue and
Hydraulic Circuit Diagram
Performance Data
See the drawing in the Spare Parts Catalogue and
Hydraulic Circuit Diagram
Ambient Conditions
D Max. ambient temperature 45 C
D Optimal ambient temperature 20 to 30 C
D Max. water inlet temperature,

Oil/water heat exchanger 38 C
Test Port Values

See the separate Schedule of Measuring Points in this
Service Manual.

Structure
Hydraulic system SST 612, referred to as SST in the Hydraulic Pump Unit
following, comprises a hydraulic pump unit and a
separately installed hydraulic tank. The hydraulic pump and all of the sub-assemblies
attached to it are mounted on the end shield (1/11). One
The hydraulic pump unit comprises the following main side of it is swivel-mounted on the bracket (1/9) and the
assemblies: other side is connected to the bracket by means of the
tensioning device (1/10).
D End shield
D Hydraulic pump The hydraulic pump comprises a variable displacement
D Bracket pump (1/17) and a feed pump (1/18). The hydraulic
pump pulley (1/12) is mounted on the power input shaft
D Pressure filter
of the hydraulic pump. It is connected to the drive shaft
D Tensioning device pulley (1/14), mounted on the drive shaft (1/15), using
D Temperature switch the set of belts (1/13). The pressure filter (1/16) and the
D Hydraulic pump pulley temperature switch (1/8) are mounted on the hydraulic
pump.
The hydraulic tank comprises the following main
assemblies:
Hydraulic Tank
D Oil/water heat exchanger
The hydraulic tank (1/1) is installed separately. It can be
D Oil level switch lifted and transported by means of the two attached
D Temperature indicator lifting eyes (1/4). The oil/water heat exchanger (1/2) is
D Filler and breather filter fastened to the top of the hydraulic tank. The hydraulic
tank is equipped with an oil level switch (1/5), a
temperature indicator (1/6) and a filler and breather filter
(1/7).

1 2 3 4
8 9 10 11
12
4 7 6 5
13
18 17 16
14
15
Figure 1 Overview of the SST

1 Hydraulic tank 10 Tensioning device
2 Oil/water heat exchanger 11 End shield
3 Hydraulic tank type plate 12 Hydraulic pump pulley
4 Lifting eye (2 items) 13 Set of belts
5 Oil level switch 14 Drive shaft pulley
6 Temperature indicator 15 Drive shaft
7 Filler and breather filter 16 Pressure filter
8 Temperature switch 17 Variable displacement pump
9 Bracket 18 Feed pump

1 2 3 4 5 6 7 8 9
10
11
12
25 24 23 22 21 20 19 18 17 16 15
13
14
Figure 2 Schematic Diagram of Hydraulic Pump Unit (Top View)

26 27 28 29
31
30
Figure 3 Schematic Diagram of Hydraulic Tank (Front View)

1 High-pressure line "b" 17 Filter monitoring unit
2 Drain line "h" 18 Test port M5
3 Temperature switch 19 Variable displacement pump
4 Hydraulic pump unit terminal box 20 Test port M2
5 Test port M1 21 Feed pump
6 Manual operation device 22 "Feed pressure min." pressure switch
7 Proportional valve 23 "Working pressure max" pressure switch
8 Test port M4 24 High-pressure line "a"
9 Tensioning device 25 Suction line "c"
10 Hydraulic pump pulley
11 Direction of rotation arrow 26 Filler and breather filter
12 Set of belts 27 Oil/water heat exchanger
13 Drive shaft pulley 28 Oil level switch
14 Drive shaft 29 Hydraulic tank
15 Test port M3 30 Drain screw
16 Pressure filter 31 Temperature indicator

Function
The hydraulic pump unit is driven by the drive shaft Two pressure control valves in the variable
(2/14) using the drive shaft pulley (2/13), the set of belts displacement pump limit the working pressure in high
(2/12) and the hydraulic pump pulley (2/10). pressure lines "a" (2/24) and "b" (2/1) to a maximum of
250 bar.
The feed pump (2/21) draws hydraulic oil from the
hydraulic tank (3/29) via suction line "c" (2/25) thus Test ports M1 to M5 are provided for measuring and
supplying the variable displacement pump (2/19). The testing purposes. The test ports are labelled for clear
variable displacement pump supplies the steering identification. The working pressure of the variable
motors of the SRP and is adjusted hydraulically by the displacement pump can be measured at test ports M1
electrically controlled proportional valve (2/7). If the (2/5) and M2 (2/20). The control pressure supplied to
electric control system fails, the manual operation the adjusting device of the variable displacement pump
device (2/6) can be used to manually operate the can be measured at test ports M3 (2/15) and M4 (2/8).
proportional valve. The feed pressure for the variable displacement pump
can be measured at test port M5 (2/18).
The hydraulic tank is filled through the filler and breather
filter (3/26). The oil temperature is displayed on the The "working pressure max" pressure switch (2/23) can
temperature indicator (3/31) and monitored by the be optionally connected to test ports M1 and M2. The
temperature switch (2/3). If the temperature exceeds "working pressure max" pressure switch is used to
the maximum permitted temperature, the "oil measure the working pressure of the variable
temperature" alarm is issued. displacement pump. If the working pressure rises above
230 bar, a "working pressure max." alarm is activated.
An oil level switch (3/28) enables the remote monitoring
of the oil level in the hydraulic tank. If the oil level falls The direction of rotation arrow (2/11) shows the
below the set switching point, an "oil level" alarm is direction of rotation specified for the hydraulic pump
activated. pulley.
The oil can be drained from the hydraulic tank at the The electric connections for the SST control are located
drain screw (3/30). in the hydraulic pump unit terminal box (2/4).
The leaking oil passes through drain line "h" (2/2) and The hydraulic pump unit type plate and the hydraulic
the oil/water heat exchanger (3/27), before flowing back tank type plate show the type, serial number, year of
into the hydraulic tank. construction and the identification number.
A pressure filter (2/16) filters dirt particles from the
hydraulic oil. It is equipped with a filter monitoring unit
(2/17). A pressure switch electrically monitors the filter
element for contamination. If the differential pressure
reaches 2 bar, a "filter clogged" alarm is issued. If the
pressure rises above 3.5 bar, the bypass valve in the
pressure filter opens and the hydraulic oil is fed to the
actuator without being filtered.
The "feed pressure min." pressure switch (2/22)
measures the feed pressure. If the feed pressure drops
below 10 bar, a "feed pressure min." alarm is activated.
A pressure relief valve in the variable displacement
pump limits the control pressure for the adjustment of
the pump displacement to a maximum of 17.5 bar. A
pressure relief valve in the feed pump acts as a cold start
valve. If the feed pressure rises above 25 bar because
of very cold hydraulic oil, the pressure relief valve shorts
out the feed pump until the hydraulic oil has warmed up
in the bypass circuit and the feed pressure has dropped
to below 25 bar again.

2 Installation
! CAUTION
When mounting the SST, always observe the
installation documents as well as the valid operating,
installation and maintenance instructions.
Proper, professional installation is crucial to the
functionality and operating safety of the SST. For this
reason, always observe SCHOTTEL Instructions
1100933 and 1099237 during installation!
Installation may only be carried out by qualified staff.
To ensure safe and trouble-free operation make sure
the SST is well ventilated.
Mount the SST in an easily accessible position to
enable maintenance and installation work to be carried
out easily.
When connecting hydraulic lines to hydraulic
components and connections, always comply with the
Hydraulic Circuit Diagram and the labels provided.
! CAUTION
Before fitting the set of belts, check that the belts rotate
in the same direction as that specified for the hydraulic
pump pulley.
Connect all electric cables in accordance with the

applicable Wiring Diagram.
The SST is treated with a preservative agent prior to
delivery. If stored in dry ambient air (not sea air), the
preservative provides sufficient protection for
approximately six months.
! CAUTION
Before starting up the SST:
D Fill with oil; see page 18.
D Check the V-belt tension and adjust it if necessary;

see page 23.

3 Start-Up, Operation and Monitoring
ÑÑÑÑÑÑÑÑÑÑ
Measures Prior to Commissioning
D Make sure that the hydraulic pump is filled with oil
(see page 20).
1
D Check the oil level:
Make sure that the oil level is up to the upper mark
on the oil dipstick (4/1).
D Check that all alarm and control systems are

! ÑÑÑÑÑÑÑÑÑÑ
CAUTION
When commissioning the SST, only switch it on for a
brief period initially (< 2 s). Check that the hydraulic
pump pulley (5/3) rotates in the direction indicated by
the direction of rotation arrow (5/4).
D Let the SST run for about two minutes.
D To bleed the hydraulic system actuate the manual

operation devices (5/1 and 5/2) on the hydraulic
pump several times.
D Switch off the SST and check the oil level. Figure 4
If necessary, refill the oil to the specified oil level
(see page 18).
! CAUTION 1
It is essential to check the oil level continually during the

initial operating hours of a new or repaired SST or one
that has been brought back into operation after an oil
change. It may be necessary to refill the oil as a result of
trapped air.
D Check the SST for leaks.

2
Figure 5

Measures Prior to Start-Up
D Check the oil level:
Make sure that the oil level is between the marks on
the oil dipstick (6/1).
1
D
Check that all alarm and control systems are
Measures During Operation
! CAUTION
If any alarms or abnormal noises occur, perform the
tests as described in the Troubleshooting section on
page 24.
Observe the following alarms:
D "Oil level" alarm
D "Oil temperature" alarm
D "Feed pressure min." alarm
D "Working pressure max." alarm Figure 6
D "Filter clogged" alarm
! CAUTION
If an "oil level", "oil temperature", "feed pressure min.",
"working pressure max." or "filter clogged" alarm is 1
activated, the SST is to be switched off and the fault
rectified.
Depending on the viscosity of the oil, a "filter clogged"

alarm may be activated if the oil temperature is v5 C,
even if the filter element is not clogged. If the alarm is
activated during operation of the SST, the filter element
(7/1) is clogged. In this case, switch off the SST and
replace the clogged filter element (see page 22).
D Pay attention to any abnormal noises coming from

the SST.
Measures After Operation

D Check the oil level (see "Measures Prior to
Start-Up" section).
D Check the SST for leaks, damage and loose screw Figure 7
connections.

Controlling Thrust Direction Using the
Manual Operation Device
! WARNING
1
Before using the manual operation device, permission
is to be granted by the navigator over the
intercommunication system (e.g. interphone or
intercom). During manual operation, the vessel is to be
controlled according to the navigator's instructions. The
effect of this control manoeuvre on the vessel's
movement is to be monitored constantly.
! WARNING 2
During and directly after operation, the pump housing

and the valve block can be very hot. Use protective
gloves!
If both full follow-up and non-follow-up control fail, the

manual operation device on the SST can be used to
steer the propulsion unit.
The following conditions are to be fulfilled:
D The proportional valve on the SST is disconnected Figure 8

from the power supply.
1. Switch off the fuses for full follow-up and

non-follow-up control of the thrust direction in the
control system switch cabinet.
2. Use the manual operation device.
To rotate the SRP clockwise:
Use the manual operation device (8/1).
To rotate the SRP anti-clockwise:
Use the manual operation device (8/2).
The SRP will continue to rotate as long as the
manual operation device is used.

4 Maintenance
! WARNING DANGER OF BURNS
It is imperative that the SCHOTTEL operating, Be careful while working on hot parts of the propulsion
installation and maintenance instructions, as well as the system and when handling hot oil.
regulations regarding safety and environmental
protection in force in the relevant country of operation,
are always observed.
Make sure that the SST cannot be started up

unintentionally when performing maintenance and
repair work!
Maintenance Schedule
Maintenance interval Work to be carried out
Daily * Check that all alarm and control systems are functioning properly.
After 50 operating hours * Check the SST for leaks.
* Replace the filter element of the pressure filter
(only after commissioning or repair).
* Check that all fastening screws used for the hydraulic pump unit are tight
and secure.
* Check the V-belt tension and adjust it, if necessary.
Every 1000 operating hours; * Take an oil sample at operating temperature and have it analysed by the
at least every six months oil manufacturer. Change the oil if the oil analysis indicates that this is
necessary.
* Replace the filter element of the pressure filter.
* Check the filler and breather filter and clean it, if necessary.
* Check the V-belt condition and replace it, if necessary.
* Check the V-belt tension and adjust it, if necessary.
Every 5,000 operating hours; * Change the oil.

at least every 5 years
* Check the oil/water heat exchanger for contamination and, if necessary,
clean it according to the manufacturer's documentation.
As required * Replace the filter element of the pressure filter

(only if the filter monitoring unit has activated an alarm).
For further maintenance information regarding individual sub-assemblies, please see the separate oper
ating, installation and maintenance instructions in this Service Manual.

Oil Recommendation and Oil Quantities
Oil Recommendation
i INFORMATION Manufacturer Oil type
The viscosity class depends on the operating ADDINOL Hydraulic oil HLP 32
temperature in the hydraulic tank. In the case of oil ARAL Vitam GF 32
temperatures of up to 60 C, select viscosity class
HLP 32; if they are above 60 C, select viscosity class BP Energol HLP-HM 32
HLP 46 or higher. Bartran 32
It is essential that the hydraulic oil complies with the CASTROL Hybsin AWS 32
following purity levels:
CALTEX Rando HD 32
D 9 according to NAS 1638 DEA Astron HLP 32
D 6 according to SAE CHEVRON Hydraulic Oil AW 32
Mechanism LPS 32
D 18/14 according to ISO 4406
ESSO Nuto 32
This purity level is obtained by using a 10 m hydraulic
oil filter. FUCHS Renolin MR 10 VG 32
Renolin B 10 VG 32
Consult SCHOTTEL if the SST is operated under
extreme conditions, e.g. in very high or very low MOBIL Mobil DTE 24
temperatures. Mobil DTE Excel 32
OMV HLP 32
! CAUTION
Q8 OILS
ZNF 32
Q8 Haydn 32
Only use those hydraulic oils listed in this Oil Q8 holst 32
Recommendation. Q8 Hydraulic S32
Always consult SCHOTTEL before using any biological SHELL Tellus Oil 32
hydraulic oils. Tellus Oil DO 32
Tellus Oil S 32
Never mix hydraulic oils from different manufacturers.
TEXACO Rando 32
subsequently added to the hydraulic oil will change the TRIBOL Tribol 771
oil's properties in an unforeseeable manner. Tribol 1840/32
The use of such additives may negatively affect
performance, the scope of maintenance work and the
service life of the SST.
In case of non-observance of the above, any claims
made under SCHOTTEL's warranty will be void.
Oil Quantities
Reference value: (+ 10% for reserves)
Sub-assembly Oil quantity [L]
Hydraulic tank 44
+ Hydraulic lines

Filling/Refilling Oil
Filling the SST with Oil
! CAUTION 1
Follow the Oil Recommendation.
Use clean oil only.
New oil in sealed drums or barrels often does not meet
the required purity level. Therefore, always use a filter
unit comprising a pump and a  10 m filter when filling 2
or refilling oil.
1. Make sure that the SST cannot be started up

unintentionally.
2. Clean the surrounding area of the filler and 3
breather filter (9/4).
3. Unscrew the breather filter (9/1).
4. Pour oil into the filler filter (9/3) until it is up to the
upper mark on the oil dipstick (9/2).
5. Screw the breather filter back in.
6. Check the propulsion system for leaks.
Refilling the SST with Oil 4
! CAUTION
Use clean oil only.
Always use the same oil used previously.
1. Switch the SST off and make sure it cannot be

started up unintentionally.
2. Clean the surrounding area of the filler and
4. Pour oil into the filler filter (9/3) until it is up to the
upper mark on the oil dipstick (9/2).
5. Screw the breather filter back in.
Figure 9

Draining the Oil
The SST has to be at operating temperature.
2. Have a suitable collecting basin (10/2) at the ready.
3. Unscrew the screw plug (10/1) and completely
drain the used oil into the collecting basin.
4. Screw the screw plug back in with a new seal.
1
! CAUTION
Refill the hydraulic tank with oil in order to prevent
corrosion damage.

2
Figure 10

Filling the Hydraulic Pump
! CAUTION
Follow the Oil Recommendation (see page 17). 1
Use clean oil only.
1. Make sure that the SST cannot be started up

unintentionally.
hydraulic pump to catch any oil leaks.
3. Loosen the screw fitting (11/1) of the drain line
(11/2) and the screw fitting (11/4) of the elbow
union.
4. Unscrew the screw fitting of the drain line (11/3).
5. Turn the drain line 90° to the side (11/A).
6. Turn the drain line with the attached elbow union
upwards until it is in a vertical position (11/B). 4 3 2
7. Slowly pour hydraulic oil into the drain line until it is
filled.
8. Reconnect the overflow oil line.
Figure 11

Checking and Cleaning the Filler and
Breather Filter
ÑÑÑÑÑÑÑÑÑÑÑ
ÑÑÑÑÑÑÑÑÑÑÑ 1
2. Clean the surrounding area of the filler and
4. Check the breather filter for clogging.
Clean it with compressed air from the inside out, if
necessary. Change the breather filter, if necessary.
2
5. Take out the filler filter (12/2), clean it out with
compressed air and, if necessary, clean it with a
suitable cleaning agent.
3
Figure 12
Taking an Oil Sample
! CAUTION
Take the oil sample while the SST is running and at its 1
normal operating temperature.
Tools:
High-pressure hose
1. Have an appropriate container ready to take the

sample.
2. Unscrew the dust cap from test port M5 (13/1).
3. Connect the high-pressure hose to test port M5 and
take an oil sample.
4. Unscrew the high-pressure hose and screw the
dust cap back on.
i INFORMATION
We recommend sending a copy of the oil analysis to the
SCHOTTEL Service Department so that any service
work required can be arranged in good time. Figure 13

Replacing the Filter Element
! WARNING
During operation and directly after being switched off,
the pump housing and the filter element may be very
hot. Use protective gloves!

pressure filter to catch any oil that escapes.
3. Remove the filter element (14/1) by turning it in the
direction of the arrow.
4. Replace the filter element with a new filter element.
5. Thinly apply oil to the O-rings in the filter element.
6. Thoroughly clean the filter head.
1
7. Screw the filter element into the filter head and
tighten it by hand.
Figure 14

5 Testing and Adjustment Procedures
Checking and Adjusting the V-Belt

Tension
Please check and adjust the V-belt tension using the
Optibelt tension testing device included in the tools
provided. A description of how to handle this tool is
included with the testing device.
Please refer to the installation drawing for the required
V-belt tension (static strand force).
1. Switch the system off and and make sure it cannot
be started up unintentionally.
2. Loosen the fastening screws (15/2).
1 1
3. Adjust the V-belt tension using the adjusting
screws (15/1).
4. Retighten the fastening screws.
! CAUTION
2 2
After a run-in period of approx. five hours, check the
V-belt tension again and adjust it, if necessary.
Figure 15

6 Troubleshooting
The following table provides helpful guidance when it Inform the SCHOTTEL Service Department if it is not
comes to locating any possible SST malfunctions, possible to eliminate the fault by taking the following
determining their cause and rectifying them. measures.
Refer to the applicable Hydraulic Circuit Diagram, as it The SCHOTTEL Service Department will need the
is an important aid to troubleshooting. following information:
! CAUTION
D Model, serial number, year of construction and
location of the SST
Always make sure that the malfunction is not due to any D SST identification number
operator errors and that the SST has been installed
correctly. D Identification number of the applicable Hydraulic
Circuit Diagram
D Description of the malfunction and how it affects

the way the system functions.
Malfunction Tests Test result Remedy
Alarm: Check the oil level on the oil Oil level is below lower Add oil.
"oil level" dipstick. mark.
Target value: between the
marks on the oil dipstick
Check the functionality and Oil level switch defective Adjust the oil level switch or
switching point of the oil or switching point set replace it, if necessary.
level switch. incorrectly.
Alarm: Check the oil temperature in Oil temperature  5 C The oil temperature is too low.
"filter clogged" the hydraulic tank If the alarm occurs again after
reaching operating temper-
ature, perform the next test.
Check the filter monitoring Replace the filter element of

unit. the pressure filter.
Alarm: Check the oil temperature in Oil temperature 65 C Check the cooling circuit of the
"oil temperature" the hydraulic tank oil/water heat exchanger.
Clean the oil/water heat
exchanger, if necessary.
Check the temperature Temperature switch Replace the temperature

switch. defective. switch.
Check the viscosity of the oil Oil with incorrect vis- Change the oil.
being used cosity class is being
used

Alarm: Check the feed pressure at Feed pressure < 10 bar Check the V-belt tension.
"feed pressure min." test port M5. Adjust, if necessary.
Target value  10 bar
Check the displacement
volume of the hydraulic pump.
Replace the hydraulic pump, if
necessary.
Feed pressure > 10 bar Replace the pressure switch.
Alarm: Check the working pres- Working pressure Check that the steering motors
"working pressure max." sure at test ports M1 and > 230 bar can move without restriction.
M2. Provide for this, if necessary.
Target value  230 bar
Working pressure Replace the pressure switch.
< 230 bar
Check the oil Oil is too viscous. Change the oil.
Oil is foaming Check the oil Foamy Check the SST for leaks (seals,
screw fittings). Replace seals,
if necessary. Add oil or change
it, if necessary.
Take an oil sample Milky (water in oil) Change the oil.
Steering response Check the feed pressure at Feed pressure < 10 bar Check the V-belt tension.
delayed test port M5. Adjust, if necessary.
Target value  10 bar
Check the displacement
volume of the hydraulic pump.
Replace the hydraulic pump or
pressure switch if necessary.
Feed pressure > 10 bar Bleed the proportional valve

using test ports M3 and M4.
Check the oil Oil is too viscous. Change the oil.

SST not functioning Detach the electrical con Connectors are not live The electric control system for
nectors from the solenoid the solenoid valves is
valves and check their defective.
voltage. Inform the SCHOTTEL Service
Department.
Use the manual operation
device on the SST until this
fault has been rectified.
Connectors are live:
Perform the following tests:
* Check the oil * Oil is gummy * Change the oil.
* Check the proportional * Proportional valve * Clean the proportional

valve. is clogged or valve. Replace, if neces
damaged. sary.
* Check the hydraulic * Hydraulic pump is * Replace the hydraulic

pump. defective. pump.

7 Hydraulic Symbols
Graphic Sym Description Graphic Sym Description

bols bols
Working line Pressure relief valve
Drain line/pilot line
Line connection Directional control valve
High-pressure hose and spe
NW32
NW32
Check valve
cified nominal diameter
Flow control valve
Throttle
Orifice Hydraulic cylinder
M Test port included in Schedule of
2
Measuring Points Pressure switch
M
AC motor
3
Temperature switch
M DC motor
24
V
Oil level switch
Hydraulic motor
Variable displacement pump Sight glass with thermometer
Gear pump Dipstick
Oil/air heat exchanger
Oil/water heat exchanger
Filter
Filler and breather filter with

bleed valve

8 Lifting and Transportation, Storage and Shutdown
Lifting and Transportation
! WARNING
Never stand or walk under suspended loads. Only use
lifting gear which has sufficient lifting capacity. 1
DANGER OF DEATH
Please refer to the shipping documents for the weight of

the SST and the weights of individual packaged units.
Hydraulic Pump Unit

Before lifting, drain the oil from the hydraulic lines.
When lifting, use a crossbar as needed to prevent
damage to any sub-assemblies.
Figure 16
! CAUTION 1 1
Do not put the loop over the pressure filter (16/1).
* The hydraulic pump unit is to be lifted using a

double loop placed under the hydraulic pump.
Hydraulic Tank
Before lifting, make sure the oil is drained from the
hydraulic tank; see page 19.
When lifting, use a crossbar as needed to prevent
damage to any sub-assemblies.
* Attach the lifting gear to the lifting eyes (17/1) of the
hydraulic tank. Figure 17

Storage
! CAUTION
Consult the SCHOTTEL Service Department if the SST
is to be stored for more than six months.
Before storing the SST, carry out all measures required

to equalise pressure in the SST; see SCHOTTEL
Instructions 1099236.
Shutdown
! CAUTION
To prevent corrosion damage to the SST, please
contact the SCHOTTEL Service Department before
shutdown.

9 Warranty
The warranty period is stipulated in the Sales Contract

concluded with SCHOTTEL.
SCHOTTEL will only accept warranty claims if they are
made within the stipulated warranty period and
provided that:
* All installation, safety and operating instructions
have been adhered to.
* All maintenance work has been performed
properly and in due time.
* The SST has been exclusively used for its intended
purpose and according to its scope of supply.
* All relevant terms and regulations contained in the
Sales Contract have been complied with.

HYDRAULIC OIL SPECIFICATIONS FOR SCHOTTEL
PROPULSION UNITS
SCHOTTEL GmbH
Mainzer Straße 99
56322 Spay
GERMANY
Phone: +49 (0)2628 / 61-0
Fax: +49 (0)2628 / 61-300
www.schottel.de
14/0100
Table of Contents
1 About These Oil Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
1.1 Warranty . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
1.2 Hazards . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
1.3 Storage and disposal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
2 Quality requirements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
3 Permissible hydraulic oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9

3.1 HLP hydraulic oils complying with DIN 51524-2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
3.2 HVLP hydraulic oils complying with DIN 51524-3 . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
TTD/Gö Hydraulic Oil Specifications 1196665 14/0100 en 3/10

1 About These Oil Specifications
The operating materials used play a significant role in the service life, operational reliability and functionality
of SCHOTTEL propulsion units. For this very reason, it is absolutely crucial that the right oils are selected.
The oils to be used have been specified in these Oil Specifications.
These Oil Specifications are supplemented by other project-related operating instructions and
specifications in this Service Manual ("Applicable product documents"). These applicable product
documents are supplied with these specifications in the form of a Service Manual.
1.1 Warranty
Failure to comply with these Oil Specifications will render any claims made under SCHOTTEL GmbH's
warranty void. The use of approved oils is an integral part of the warranty conditions.
The oil supplier is responsible for the globally consistent quality of the specified products, and as such is to
declare product conformity with SCHOTTEL GmbH quality requirements. SCHOTTEL GmbH shall reserve
the right to request appropriate evidence of this from the propulsion system operator.
1.2 Hazards
Oils may be hazardous substances. When handling these substances, the relevant manufacturer safety
data sheets are to be observed.
1.3 Storage and disposal

Certain rules and regulations are to be observed for storage and disposal. These are to be derived from the
manufacturers' specifications, statutory provisions and technical rules and regulations in force in the
relevant country of use.
As these concern national specifications, it will not be possible to make a general statement on the
regulations to be observed within these Oil Specifications. Therefore, the propulsion system operator will be
obliged to find out about the applicable provisions. SCHOTTEL GmbH shall not assume any liability for
improper or illegitimate use of the approved oils.

2 Quality requirements
The hydraulic oil supplier is responsible for the globally consistent quality of the specified products, and as
such is to declare product conformity with SCHOTTEL GmbH quality requirements. SCHOTTEL shall
reserve the right to request appropriate evidence of this.
The hydraulic oils are to comply with the following quality requirements:
● Hydraulic oil HLP compliant with DIN 51524-2; ● Compatibility with the internal gearbox coating
hydraulic oil HVLP compliant with DIN 51524-3 used at SCHOTTEL
● The scuffing load capacity must be > 10 ● Compatibility with the elastomer seals used at
according to FZG test A 8.3/90, DIN 51354/2 SCHOTTEL
● Abrasion < 120 μm (ring), and < 30 mm (blade) ● Compatibility with the liquid sealants used at
complying with mechanical test SCHOTTEL
DIN EN ISO 20763
● Compatibility with the lubricating grease used
● Low foaming level with less than 15% foam at SCHOTTEL
formation
● Compatibility with residues of the hydraulic oil
used at SCHOTTEL
For operation in Russian waters, the following applies:

● Hydraulic oils type A compliant with TY 38.1011282

To prevent material damage it is crucial that
the following information is observed:
NOTE
Damage to the propulsion unit due to
contaminated oil being used
damaged.
▶ Use a pump with a filter unit and a ≤ 10 μm
filter when filling or refilling new or recycled
oil.
▶ It is imperative that the specified
maintenance intervals and oil analyses are
complied with.
NOTE
Damage to the propulsion unit due to wrong
oil being used
damaged.
▶ Consult the SCHOTTEL Service
Department before using biological or
synthetic hydraulic oil.
i INFORMATION
Only those oils are permitted for use in
SCHOTTEL propulsion units that contain agents
which increase corrosion protection and
resistance to ageing and decrease wear in mixed
friction conditions.
i INFORMATION
subsequently added to the hydraulic oil will
change its properties in an unforeseeable
manner. Consult the SCHOTTEL Service
Department before using any type of additive.
8/10 TTD/Gö Hydraulic Oil Specifications 1196665 14/0100 en

3 Permissible hydraulic oil
i INFORMATION Manufacturer Oil type
Never mix different hydraulic oils. KLUEBER LAMORA HLP 32
MOBIL Mobil DTE 24

3.1 HLP hydraulic oils Mobil DTE Excel 32
complying with DIN
51524-2 OMV HLP 32
ZNF 32
i INFORMATION PANOLI HLP 32
For applications in Russia, SCHOTTEL GmbH HLP Plus 32
recommends hydraulic oil type A complying with
TY 38.1011282 for light to medium load standard Q8 OILS Q8 Haydn 32
applications.
Q8 Holst 32
Q8 Hydraulic S32
Manufacturer Oil type
SINOPEC L-HM 32 Super
ADDINOL Hydraulic oil HLP 32
SHELL Tellus S2 M 32
ARAL Vitam GF 32 Tellus S2 MA 32
BP Energol HLP-HM 32 Tellus S32
Bartan 32 Tellus S4 ME 32
Autran MBX Tellus SX-Z 32
CASTROL HYSPIN AWS 32 STATOIL HYDRAWAY HMA 32
Paradene 32 AW TQ-D TEXACO Rando HD 32
CHEVRON Hydraulic oil AW 32 TOTAL Total Azolla AF 32

Rykon oil AW ISO 32 Total Azolla ZS 32
Rando HD ISO 32 Total Azolla DUF 32
ENI OSO 32
Precis HLP 32
ESSO Nuto 32
Hydraulic oil HLP 32
FUCHS RENOLIN MR 10 VG 32
RENOLIN B 10 VG 32
RENOLIN ZAF 32 B

3.2 HVLP hydraulic oils Manufacturer Oil type
complying with
STATOIL HYDRAWAY HVXA 32
DIN 51524-3
TEXACO Rando HDZ 32
The use of HVLP oils may have a positive effect on
operations. TOTAL Total Equivis ZS 32
STATOIL Hydraway Bio SE 32

i INFORMATION
Hydraway SE 32 HP
recommends hydraulic oil type A complying with Terresolve Enviro-Logic 3032
TY 38.1011282 for light to medium load standard
applications. Total TOTAL Biohydran TMP 32
TOTAL Biohydran SE 32
Manufacturer Oil type
ADDINOL Hydraulic oil HVLP 32
ARAL Vitam HF 32
BP Bartran HV 32
Bartran HVX 32
CASTROL HYSPIN AWH 32
CHEVRON Mechanism LPS 32
ENI ARNICA 32
ESSO Univis N 32
FUCHS RENOLIN MR 32 MC
RENOLIN B 32 HVI
RENOLIN ZAF 32 MC
MOBIL Mobil DTE 13 M

Mobil DTE 10 Excel 32
OMV HLP-M 32
ZNF 32
PANOLI HLP-Universal 32
Q8 OILS Q8 Händel 32
Q8 Heller 32
SHELL Tellus S2 V 32
Tellus S2 VA 23
Tellus S3 V 32
10/10 TTD/Gö Hydraulic Oil Specifications 1196665 14/0100 en

Flushing Specification for Hydraulic Systems with
Variable Displacement Pump
Preliminary Notes
These instructions are to provide information and Given that SCHOTTEL propulsion systems are subject
guidance to all persons involved in the initial start−up, to further development, we reserve the right to carry out
operation and maintenance of SCHOTTEL propulsion technical modifications.
read, understood and carefully observed. Important instructions relevant to technical and
persons carrying out work on the propulsion systems.
We shall not accept liability for any damages or ! WARNING
malfunctions resulting from non−observance of these
Only trained and qualified personnel are permitted to
! CAUTION
carry out work on the propulsion systems. Indicates working and operating methods that are to be
References to illustrations contained in the text are materials.
written in brackets, e.g. (1/3). The first number refers to
the illustration number in the manual; the second
number is the item number in the illustration. NOTE
All illustrations are schematic diagrams and do not Indicates specific features of the working process
make any claim to completeness. which are to be observed.
systems to be performed by non−SCHOTTEL
i INFORMATION
force in the relevant country of operation.
Should you require any further information, please contact:
SCHOTTEL GmbH
Mainzer Straße 99
56322 Spay, Germany
Phone +49 (0) 2628 610
Fax +49 (0) 2628 61300
E−mail [email protected]
en STD−Ro Flushing Specification for Hydraulic Systems with Variable Displacement Pump 07/3151 1100933 1/ 3
Hydraulic oil used in the operation of a variable
displacement pump in a closed hydraulic system has to ! CAUTION
be absolutely pure. For this reason, the hydraulic
system is to be flushed before commissioning and after The hydraulic system is to be installed according to
maintenance and repair work has been carried out. SCHOTTEL Specification 1099237.
Two flushing procedures are required to attain the
necessary purity level.
Flushing Procedure 1
1
Tools:
D Pressure filter (10m) with check valve (2 x)
D Flushing unit with pump
! CAUTION
Variable displacement pumps and hydraulic motors
must not be rinsed in flushing procedure 1.
2
1. Disconnect the variable displacement pump (1/4)
from the flushing circuit.
2. Connect the flushing unit (1/3).
3. Disconnect the hydraulic motors (1/1) from the
10  10 
flushing circuit.
4. Install the pressure filter with check valve (1/2) in
the flushing circuit in accordance with figure 1.
3
! CAUTION
It is crucial that the minimum flushing time is observed!
The minimum flushing time can be calculated as
follows:
t = V/Q x 5
V = tank volume [ l ], Q = feed quantity of pump [l/min] 4
t = minimum flushing time [ h ]
5. Initiate the flushing procedure with a continuous

volume flow.
NOTE
The results of the oil samples are to be documented.
Figure 1
2/ 3 STD−Ro Flushing Specification for Hydraulic Systems with Variable Displacement Pump 07/3151 1100933 en
6. Take oil samples during the flushing procedure.
7. Continue the flushing procedure until a purity level
complying with ISO 4406 20/18/15 is attained or
better.
8. Remove the flushing unit.
9. Connect the hydraulic motors.
10. Connect the variable displacement pump.
NOTE
Leave the pressure filter in the flushing circuit for
flushing procedure 2.
Once flushing procedure 1 has finished, the entire

hydraulic system is to be flushed in flushing
procedure 2 during commissioning.
2
Flushing Procedure 2
1. Carry out commissioning.

10  10 
! CAUTION
During commissioning, a minimum flushing time of 30
minutes is to be upheld.
2. Remove the pressure filter (2/2) after

commissioning.
3. Reconnect the system according to the Hydraulic

Circuit Diagram.
3
Figure 2
en STD−Ro Flushing Specification for Hydraulic Systems with Variable Displacement Pump 07/3151 1100933 3/ 3
Installation Specifications for Hydraulic Systems
and their Components
These Specifications are to be read and applied carefully to ensure safe operation and prevent damage
occurring to the propulsion system!
en TTD-Wa Installation Specifications for Hydraulic Systems and their Components 12/1810 1099237 1/99
These Specifications have been written with the utmost
care and attention to detail. However, should you
require any further information, please contact:
SCHOTTEL GmbH
Mainzer Straße 99
56322 Spay, Germany
Phone +49 (0) 2628 610
Fax +49 (0) 2628 61300
a).
2/99 TTD-Wa Installation Specifications for Hydraulic Systems and their Components 12/1810 1099237 en
Table of Contents
1 About these Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7

1.1 Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
1.2 Applicable Product Documents . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
1.2.1 SCHOTTEL GmbH: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
1.2.2 Other Applicable Product Documents for Operation of the Hydraulic System . . . . . 7
1.3 Symbols and Diagrams . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
1.4 Restriction on Liability . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
1.5 Warranty . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
1.6 Warranty Conditions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
2 Safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
2.1 Shipyard's Responsibility . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
2.2 Operator's Responsibility . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
2.3 Staff Requirements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
2.3.1 Qualification of Specialist Staff . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
2.3.2 Requirements of Maintenance Staff for the Hydraulic System . . . . . . . . . . . . . . . . . . 12
2.3.3 Requirements of Maintenance Staff for Electrical Components . . . . . . . . . . . . . . . . . 12
2.4 Area of Application . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
2.5 Personal Protective Equipment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
2.6 Intended Use . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
2.7 Foreseeable Misuse . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
2.8 Safety and Monitoring Devices . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
2.9 Switching Off Devices . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
2.9.1 Disconnecting Electrical Components from the Power Supply . . . . . . . . . . . . . . . . . . 14
2.9.2 Deactivating the Activation Signal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
2.10 Safe Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
2.10 Electromagnetic Interference Fields . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
2.12 Ambient Conditions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
2.12 Sound Pressure Level . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
2.14 General Remaining Risks and Protective Measures . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
3 Safety Instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
3.1 Basic Safety Instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
3.2 Special Safety Instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
3.2.1 Prior to Transportation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
3.2.2 Transportation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
3.2.3 Commissioning and Resumption of Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
3.3 Operation and Shutdown . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
3.3.1 Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
3.3.2 Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
3.3.3 Disposal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
4 Technical Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
4.2 Function . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
4.2.1 Hydraulic System Structure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
Open Circulation System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
Closed Circulation System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
Safety Concept . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
5 Transportation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
5.1 Prior to Transportation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
5.2 Transportation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
6 Installation and Preparation for the Trial Run . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26

6.1 Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
6.1.1 Rigid Lines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
6.1.2 Hose Lines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
6.1.3 Couplings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
Connecting the Couplings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
Disconnecting the Couplings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
6.2 Preparation for the Trial Run . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
6.2.1 Initial Fill . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
6.2.2 Flushing and Bleeding the Hydraulic System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
7 Commissioning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34
7.1 Trial Run at the Pier . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35
7.2 Preparation for the Sea Trial . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36
8 Resumption of Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38
9 Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40
9.1 During Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40
9.2 Measures After Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42
10 Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44
10.2 Maintenance Schedule . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47
10.3 Measurement and Control Equipment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48
10.3.1 Prior to Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48
10.3.2 Prior to Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49
10.3.3 During Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49
10.3.4 Following Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50
10.4 Valves . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51
10.4.2 Prior to Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 52
10.5 Couplings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54
10.5.1 Disconnecting and Connecting the Couplings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54
Disconnecting the Couplings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54
Connecting the Couplings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54
10.6 Rigid Lines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55
Rigid Lines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 56
Pipe Clamps . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 57
Pipe Preparation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 58
Cold Bending of Pipes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 59
Screw Fittings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 61
Welded Reducers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 75
Flanged Joints . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 76
10.7 Replacement of Hose Lines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 79
10.7.1 General Points . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 79
Pressure Equipment Directive (14th. GPSGV) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80
Cleaning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 81
Inspection Intervals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 81
Torsion, Traction and Compression . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 83
Permissible Bending Radius . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 83
Abrasion, Chafing and Bending . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 84
Hose Brackets . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 84
Effects of Temperature . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 84
11 Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 86
11.1 Line System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 87
11.1.1 Abnormal Noises . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 87
11.1.2 No or Insufficient Feed Pressure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 88
11.1.3 No or Insufficient Flow Rate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 89
11.1.4 No Oil Fed to Actuator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90
11.2 Fluctuations in the Feed Pressure and Flow Rate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 91
11.3 Measurement and Control Technology . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 91
11.4 Valves . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 92
12 Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 94
13 Storage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 96
13.1 Short-Term Storage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 96
13.2 Long-Term Storage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 97
13.2.1 Hose Lines and Seals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 97
Storage Conditions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 97
14 Disposal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 98
14.1 Scrapping . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 98
14.2 Disposal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 99
BLANK PAGE
1 About These Specifications
1.1 Introduction
These Specifications describe the line systems for hydraulic systems and their components (e.g. hose lines, valves,
and measurement and control equipment). Hydraulic systems are divided into different sub-assemblies; e.g.
hydraulic drive station and hydraulic pump unit.
The hydraulic system and its components, referred to as hydraulic system in the following, is part of the entire
propulsion system supplied by SCHOTTEL GmbH.
The Specifications are part of the Service Manual and are to be kept accessible to all staff at all times in the immediate
vicinity of the hydraulic system. Staff are to have read and understood these Specifications thoroughly before com
mencing any work. The basic prerequisite for work safety is the observance of all safety instructions and other
instructions provided.
Furthermore, the local accident prevention regulations and general safety provisions apply to the hydraulic system's
The following guidelines additionally apply:
VDI 3027 "Initial Operation and Maintenance of Hydraulic Systems"
DIN 24346 "Hydraulic Systems"
ISO 4413 "Hydraulic Fluid Power - General Rules Relating to Systems"
1.2 Applicable Product Documents

1.2.1 SCHOTTEL GmbH:
The designs of hydraulic systems can be very diverse and as part of the overall propulsion system are therefore sub
ject to the most varied of operating instructions. General operating instructions for hydraulic systems may provide
useful information, but are generally supplemented by specific instructions. These Specifications are supplemented
by other project-related operating instructions and specifications in this Service Manual ("Applicable Product Docu
ments").
These applicable product documents are supplied with these Specifications in the Service Manual.
1.2.2 Other Applicable Product Documents for Operation of the Hydraulic System
Shipyard:
● Classification society acceptance report
Operator:
● Instructions on accident prevention, occupational health and safety and environmental protection based on the
regulations applicable in the country of use
1.3 Symbols and Diagrams
Warning Notices
Warning notices are set apart from the rest of the text in these Specifications. They are marked in colour and intro
duced with a symbol and keywords that highlight the extent of the risk or hazard.
DANGER
WARNING
CAUTION
NOTICE
Any warning notice within these Specifications is struc

tured as follows:
KEYWORD
Cause of the danger
i INFORMATION
Instructions and information for efficient and trouble-
free operation.
Diagrams
number; the second number is the item number in the illustration. For example: (1/3) means figure 1, item 3. All illus
trations are schematic diagrams and do not make any claim to completeness.

Instructions
▶ This sign is used for an instruction and indicates that an action is to be carried out. Instructions may be followed
by additional information for the action that is to be carried out.
If instructions consist of several steps to be carried out in a sequence, these steps are numbered and listed chronolo
gically in the specified order.
For example:
1. Switch the hydraulic system off and make sure it cannot be started up unintentionally.

Blank Page
1.4 Restriction on Liability
All information and notices provided in these Specifications have been compiled in consideration of the applicable
standards and regulations, the state of the art and the insights and experience we have gained over many years.
● Failure to comply with these Specifications;
● Using the hydraulic system other than for its intended purpose;
● Using staff that are not trained to deal with the task in question;
● Unauthorised structural, electrical or control-related modifications and repairs;
● Technical modifications;
● Using unapproved spare parts;
1.5 Warranty
a result of failing to comply with these Specifications. Furthermore, any form of warranty granted by SCHOTTEL
GmbH shall become void, and responsibility shall be transferred to the operator.
1.6 Warranty Conditions

The warranty conditions stipulated by contract shall apply, provided that the hydraulic system is used as intended
and the maintenance instructions are observed. SCHOTTEL GmbH may request evidence of the Maintenance
Instructions being observed.
The trial run and sea trial of the hydraulic system are to be carried out by authorised SCHOTTEL GmbH employees.
Original spare parts from SCHOTTEL GmbH are to be used for maintenance and repair work. The full functionality
and safe operation of the propulsion system can only be guaranteed if spare parts supplied by SCHOTTEL GmbH
are used. The warranty shall become void if any parts are used other than original SCHOTTEL parts. SCHOTTEL
GmbH shall not assume any liability or warranty for any damage incurred by using other spare parts and accessories.
SCHOTTEL GmbH's General Terms and Conditions shall expressly apply to all orders placed (www.schottel.de/
agb). Requests for spare parts are to be made in writing.

SCHOTTEL's Customer Service Department is available to provide technical information. For SCHOTTEL GmbH
contact details, see page 2. Furthermore, we are always interested in new information and learning about any new
2 Safety
This section will provide an overview of all of the important safety aspects involved in providing staff with optimal pro
tection and ensuring the safest and smoothest operation possible.
Failure to comply with the safety instructions and other instructions set out in these Specifications may result in ser
ious hazards arising. Therefore, staff are to observe all safety and other instructions set out in this section and in these
Specifications and take the relevant safety measures.
2.1 Shipyard's Responsibility

The shipyard will hand over the hydraulic system to the operator after it has been installed in the respective vessel.
The shipyard is to make sure that the SCHOTTEL GmbH Service Manual is available at the hydraulic system's site
of operation in a legible condition and complete when the vessel is handed over to the operator.
2.2 Operator's Responsibility

The hydraulic system operator is responsible for complying with the applicable legal requirements of occupational
safety.
In addition to the occupational safety instructions within these Specifications, the safety, accident prevention and
environmental protection regulations for the hydraulic system's area of application are to be observed.
the special working conditions at the hydraulic system's site of operation by carrying out a risk assessment.
These are to be implemented in the form of operating instructions for the hydraulic system.
● Check throughout the entire period of hydraulic system use whether the operating instructions he has provided
represent the latest version of rules and regulations, and to amend these, if necessary.
● Designate a large enough danger zone around the hydraulic system. This danger zone must not be accessible
to unauthorised persons during operation; a minimum one metre clearance around the hydraulic system is to
be ensured.
● Ensure that all employees handling the hydraulic system have read and understood the Specifications. Further
more, the operator is to instruct the staff in safety matters at regular intervals and keep them informed about
risks.
● Provide staff with the necessary protective gear.
● Ensure that the hydraulic system is only operated in compliance with its intended use and only if it is in a perfect,
● Ensure that the Specifications are always available at the hydraulic system's site of operation in a legible condi
tion and complete.
● Ensure that all of the safety instructions and warning notices attached to the hydraulic system are never
removed, and are kept clean and easily legible.
2.3 Staff Requirements
2.3.1 Qualification of Specialist Staff
The work described in these Specifications is only to be carried out by qualified specialist staff. Specialist staff are
defined as persons who due to their professional training, knowledge and experience, as well as knowledge of the
pertinent stipulations, are in a position to:
● Carry out the work assigned to them safely, and correctly assess the implications of their work.
● Identify potential hazards independently.
● Take necessary measures to eliminate any hazards, especially those concerning risk of accidents.
Staff are to be trained and instructed regularly in all matters concerning occupational safety and environmental pro
tection.
observed.
2.3.2 Requirements of Maintenance Staff for the Hydraulic System

According to DIN 31051, maintenance covers the individual measures for preventative and corrective maintenance
and inspection. Everyone involved in maintenance needs to be familiar with and adhere to these Specifications.
The preventative maintenance staff (e.g. for replacing filter elements) are to:
● Demonstrate special hydraulic system expertise to be able to carry out preventative maintenance work.
The inspection staff (e.g. for checking the oil level) are to:
● Be aware of the special risks involved in handling the hydraulic system. Special hydraulic system expertise is
not necessary for just inspection work.
The corrective maintenance staff (e.g. for replacing a defective temperature switch) are to:
● Be able to comprehend the function of the hydraulic system and sub-systems, and their interaction with the func
tion of the entire propulsion system.
● Be able to understand technical drawings and the sub-functions of the hydraulic system.
● Have knowledge about the function and structure of the sub-systems (e.g. line systems).
2.3.3 Requirements of Maintenance Staff for Electrical Components

measures.
2.4 Area of Application
The hydraulic system's area of application is determined by the stipulated classification society in its acceptance
procedure. The intended use is to be taken into account when determining the area of application.
2.5 Personal Protective Equipment

The protective gear needed for respective tasks is always to be worn:

Protective workwear
Close-fitting work clothes with little resistance to tearing; close-fitting sleeves with no protrusive parts
Safety footwear
Safety gloves
Safety goggles
Safety helmet
Ear protectors
Protects the ears from excessively loud noises
2.6 Intended Use

The hydraulic system is intended and has been designed for the transfer, control and distribution of energy using a
liquid medium (oil) under pressure. The oil is not only used as a pressure medium, but can also be used as lubrication
oil, anti-corrosion agent and to cool sub-assemblies and components.
The hydraulic system is only to be operated in a perfect technical condition in compliance with its intended use and
these Specifications; furthermore, all operators of the hydraulic system need to be fully aware of all safety issues and
potential risks associated with its use. In particular, malfunctions that may affect safety are to be rectified immedi
ately.
The hydraulic system must not be installed and operated in areas where there is a risk of explosions.
No modifications, additions, or conversions are to be undertaken on the hydraulic system without prior written con
sent from SCHOTTEL GmbH. Such modifications may endanger safety and are not considered to be compliant with
intended use.
The hydraulic system may only be operated on vessels that comply with the applicable specifications of the stipu
lated classification society. Any other procedure is not considered to be compliant with intended use and is not per
mitted.
● Adherence to the directives within these Specifications
● Undertaking the specified maintenance work
2.7 Foreseeable Misuse
Improper use is considered to be any kind of use of the hydraulic system other than that set out under "Intended Use".
This includes:
● Structural modifications to the propulsion unit
● Structural modifications to propulsion unit control components
● Modifications to the software for propulsion unit control
● Modifications to the safety and monitoring devices
● Use of impermissible lubricants
2.8 Safety and Monitoring Devices

Safety and monitoring devices are designed to help rule out personal injuries and material damage.
The hydraulic system may only be operated when all safety and monitoring devices are in place and fully functional.
When a safety and monitoring device has been triggered, the hydraulic system may only be put back into operation,
if:
Safety and monitoring devices may be removed, modified, rendered inoperative or have their effect altered by per
sons in charge or experts for temporary intervention purposes only, as in the case of tests and examinations,
troubleshooting, rectification of damage or defects, and to replace components. Furthermore, these interventions
have to be adequate in terms of safety, or adequate contingency measures have to be taken with regard to safety.
The staff are to be instructed to exercise additional caution in these situations.
2.9 Switching Off Devices

To enable many of the operational sequences described in these Specifications to be carried out safely, the hydraulic
system is to be first switched off, shut down and, if possible, secured by additional precautions. The required switch-
off level depends on the relevant type of operational sequence. The switch-off levels are:
2.9.1 Disconnecting Electrical Components from the Power Supply

Before working on and accessing unprotected wires or connection points, disconnect the relevant electrical com
ponents from all voltage sources.
1. Switch off the electrical components and connected accessories.
2. Make sure that these cannot be switched on unintentionally by locking and labelling the isolators and power
switches used to disconnect the electrical components and optional accessories from the mains.
2.9.2 Deactivating the Activation Signal

Before working on a component which receives an activation signal from a superordinate electrical or mechanical
control unit, the control unit is to be deactivated and measures taken to ensure it cannot be accidentally activated.
1. Switch off the superordinate control unit (e.g. SPS) or disconnect from the mains.
2. Remove the input signal cable from the component.
3. Set the pressure to zero or disconnect the voltage supply; dissipate any residual power.
2.10 Safe Operation
If it can be assumed that safe operation is no longer possible, switch the hydraulic system off immediately and make
● Not all of the safety and monitoring devices are in place and fully functional.
● Persons might be put at risk by operating the hydraulic system.
● The hydraulic system is defective and/or leaking.
● The hydraulic system is visibly damaged.
● The hydraulic system displays malfunctions detected by measurement and control equipment.
● The hydraulic system has been operated, stored or transported in unfavourable ambient conditions (e.g. fumes/
vapours; temperature).
out on the hydraulic system.
The hydraulic system may only be started up again if its safe operation can be guaranteed.
2.11 Electromagnetic Interference Fields

● Mains cables
Protection from electromagnetic interference fields is to be provided for operation of the hydraulic system. The rel
evant specifications in this Service Manual (e.g. applicable product documents; Wiring Diagram) and the specifica
tions of the stipulated classification society are to be observed.
2.12 Ambient Conditions

The respective environmental conditions for using the hydraulic system are dependent on the area of application
designated; see the "2.4 Area of Application" section, page 13.
2.13 Sound Pressure Level

When the hydraulic system is used as intended, a noise level of 85 dB(A) may be exceeded in the hydraulic system
operating area.
2.14 General Remaining Risks and Protective Measures
Despite the hydraulic system's high level of intrinsical safety, risk of injury and/or environmental damage cannot be
ruled out even in the case of correct conduct.
The hydraulic system is part of an entire propulsion system. New, additional hazards may arise as a result of the inter
action between different components.
DANGER WARNING
Hazard to life or risk of serious injuries due to electric Risk of sustaining burn injuries due to surfaces on the
voltage hydraulic system becoming hot during operation
▶ Always observe the special safety provisions ▶ Only commence any work once the hydraulic
when working on any kind of electrical system has sufficiently cooled down.
components.
▶ Work on electrical components is only to be car resistant safety gloves.
unintentionally. WARNING
Hot oil
Risk of sustaining burn injuries due to oil in the
DANGER hydraulic system becoming hot during operation
Oil may spray out under high pressure ▶ Only commence any work once the oil has suffi
necting parts, hoses and lines on hydraulic
components bursting
▶ Switch off the power supply and wait until any
residual power has dissipated.
▶ Do not try and catch hold of lashing hoses. CAUTION
▶ Wear personal protective gear, especially heat- Slipping, falling and tripping over
resistant safety gloves and safety goggles. Head injuries and cuts to limbs due to sharp edges
and pointed corners
Rotating components
DANGER
Malfunctions
Hazard to life or risk of serious injuries due to malfunc
tions or damage to individual components
▶ Any defective components which affect the
safety and function of the hydraulic system are to
safety measures.
It is crucial that the safety instructions and warning notices cited in the following sections of these Specifications are
observed in order to reduce risks to health and prevent hazardous situations.
i INFORMATION
section is not enough to ensure that the hydraulic
system is worked on safely. The safety instructions
and warning notices in the relevant sections need to
be observed in order to understand safety issues
properly and effectively avert danger.
3.1 Basic Safety Instructions

● Before start-up, the operator is to designate an appropriate danger zone. The danger zone must not be access
ible to unauthorised persons.
● The operator is responsible for procuring all current regulations that apply to the operation of the hydraulic
system.
hydraulic system accordingly.
● The hydraulic system is only to be operated if it is in a perfect technical condition.
● All safety instructions and warning notices on the hydraulic system are to be observed and kept in a legible con
dition.
● Personal protective equipment is always to be worn when working on and around the hydraulic system. Always
tie back long hair; never wear loose clothing or jewellery.
● Any malfunctions that may affect the safety of staff or the hydraulic system are to be rectified immediately.
● The hydraulic system is to be shut down immediately in the event of malfunctions. The malfunction is to be recti
fied immediately.
● The maintenance intervals stipulated in these Specifications are to be observed and documented.
● Before any welding, flame cutting and grinding work is carried out, the hydraulic system and its surrounding area
are to be cleaned to remove any combustible substances. There is a risk of fire and explosion by this kind of
a supervisor.
● Safety and monitoring devices that serve to avert danger must not be modified or removed.
3.2 Special Safety Instructions
3.2.1 Prior to Transportation
● Only use lifting gear (e.g. crane or forklift truck) and slings (e.g. chains and ropes) that have been checked and
approved for the weight of the individual components and are in perfect condition.
● At least one other person has to be present when lifting, conveying and setting down the components. The load
is to be constantly watched when being lifted, conveyed or set down.
● Before transportation, the signaller and the slinger are to ensure proper communication by using agreed hand
signals, equipment or by radio.
3.2.2 Transportation
● Transportation of the individual components may only be carried out by a qualified specialist company.
● Only those transport means that comply with the applicable laws, acts and regulations are to be used.
● The individual components are to be attached, fastened and packaged in such a way that damage in transit can
be ruled out.
● The transport vehicle is to be equipped to ensure the safe transportation of the individual components in terms
of weight and dimensions and comply with the requirements for the safe transportation of the individual
components.
● The packaging material is to be disposed of properly.
3.2.3 Commissioning and Resumption of Operation

● The hydraulic system is to be inspected for visible external damage and defects prior to commissioning and
every time operation is resumed. If damage or defects to the hydraulic system are established, switch it off,
make sure it cannot be started up unintentionally and notify the relevant services.
danger when the hydraulic system is started up.
● Prior to commissioning, the operator is to designate an appropriate danger zone around the hydraulic system.
The danger zone must not be accessible to unauthorised persons.
● Prior to commissioning and every time operation is resumed, check the function of all safety and monitoring
devices.
● When working on the hydraulic system when it is switched off, make sure that it cannot be started up unintention
ally.
3.3 Operation and Shutdown
● Only operate the hydraulic system when all safety and monitoring devices are in place and fully functional.
● Ensure that all of the safety instructions and warning notices attached to the hydraulic system are always easily
3.3.1 Maintenance
● The stipulated maintenance intervals are to be complied with and documented.
● Switch off the hydraulic system and make sure it cannot be started up unintentionally before commencing any
maintenance work. Switch off the power to the hydraulic motors and make sure they cannot be started up unin
tentionally.
● Make sure the hydraulic system has cooled down before commencing maintenance work.
● Before commencing any maintenance work, close off access to the work area to any unauthorised persons. Dis
play an information sign to indicate the maintenance work in progress.
● Before carrying out maintenance work depressurise the system sections and pressure lines to be opened and
allow to cool.
● Take special safety precautions for interconnected systems, if individual system parts are still in operation, or
have to be switched on again during maintenance.
of operation.
● Carry out visual inspections of the hydraulic system at regular intervals; see "Maintenance Schedule", page 47.
Rectify and document any defects that arise, e.g. loose screw fittings or scorched cables.
● Regularly clean the floor around the hydraulic system during maintenance work to avert the risk of slipping.
● After completing maintenance work, dismantled safety and monitoring devices are to be reinstalled and bolted
connections tightened according to specifications.
3.3.2 Removal
● Switch off the hydraulic system and make sure it cannot be started up unintentionally before commencing any
removal work.
of operation.
● Regularly clean the floor around the hydraulic system during removal to avert the risk of slipping.
3.3.3 Disposal
always observe the national and international regulations regarding the disposal of operating materials and sup
plies.
i INFORMATION
Refer to the applicable product documents for all
technical data relating to the hydraulic system and
individual sub-assemblies.

Components Rigid line
A single unit (e.g. hose line, valve, and measurement Rigid lines are pipes connected by screw fittings to
and control equipment), which comprises one or more become operational.
parts and is an operational part of the hydraulic system.
Screw fitting
Hose Screw fittings are connection parts for pipes.
Hoses are flexible, tube-shaped, semi-finished
products made up of one or more layers and enclos- Valve
ures. Valves are components for controlling the volume flow
in the line system. Valves can be operated manually
Hose fitting (e.g. hand lever) or by means of an electric or hydraulic
Hose fittings are connection parts for hoses. actuator.
Hose line
Hose lines are hoses connected by hose fittings to
become operational.
Hydraulic drive
Component which transforms the energy of the oil into
mechanical energy (e.g. steering motor).
Hydraulic system
Arrangement of interconnected components that
transfer and control fluid power.
Valve
Valves are components for controlling the volume flow
in the line system. Valves can be operated manually
(e.g. hand lever) or by means of an electric or hydraulic
actuator.
Line System
The line system is made up of pipes, rigid line compon-
ents (e.g. valves), connection parts (e.g. screw fittings,
and flanges) and hose lines.
Measurement and control equipment

Measurement and control equipment includes all com-
ponents that are needed for the hydraulic system's
automatic process to function.
4.2 Function
Hydraulic system components can be divided into dif
ferent functional groups according to their function.
Energy conversion 8 Steering motor (actuator)

7
7 Throttle valve
6 Check valve 6
Energy control
5 Directional control valve
5
4 Pressure relief valve
Energy conversion 3 Hydraulic pump (generator) 4
2 Filter 3
Oil preparation
1 Reservoir
2
Fig. 1 Schematic Diagram of a Hydraulic System
4.2.1 Hydraulic System Structure
The hydraulic system structure depends on the sys Safety Concept

tem's requirements and field of application, and the
extent of the output to be transferred. Functionality and safety make up a whole. All compon
ents installed in the hydraulic system form the basis of
The structure of the individual hydraulic system a comprehensive safety concept for temperature and
depends on: pressure monitoring; e.g. a check valve for load safety,
a pressure relief valve for overload protection, or an oil
● The power output of the individual propulsion units; level indicator for oil level monitoring.
● Where they are installed on the vessel.
● The arrangement of the sub-assemblies and com
ponents (open or closed circulation system).
i INFORMATION
Refer to the applicable product documents in this Ser
i INFORMATION vice Manual for the exact description of the safety
concept and the safety components used.
Refer to the applicable product documents in this Ser
vice Manual for the exact structure and mode of oper
ation of the hydraulic system.
Open Circulation System

The hydraulic pump (generator) draws the oil from a
reservoir and feeds it into the hydraulic system. The
pressurised oil is pumped to the actuators (e. g.
steering motor) via the line system and then fed back
into the reservoir.
The flow direction can be reversed by means of valves
(e.g. directional control valve).
Closed Circulation System

The hydraulic pump (generator) is integrated into the
hydraulic circulation system through the suction and
discharge side. The hydraulic pump is fed directly with
the oil returning from the actuators (e.g. steering
motor). The required driving torque is reduced by the
load pressure at the hydraulic pump suction port.
The normal leakage in the system is compensated for
by an additional hydraulic pump (e.g. feed pump) and
a small reservoir.
The closed circulation system offers a greater level of
efficiency and higher (control) speed at full power.
5 Transportation
5.1 Prior to Transportation
● The individual sub-assemblies may only be lifted, Lifting and conveying in confined spaces
conveyed and set down by specialist staff trained Hazard to life or risk of serious injuries when lifting in
and qualified to do this work. confined spaces as the load may swing and tilt fol
lowing a collision.
▶ Do not go or linger in the danger zone.
● At least one other person has to be present when NOTICE

lifting, conveying and setting down the compon Leaking operating materials
ents. The load is to be constantly watched when
Operating materials may leak out during transit,
being lifted, conveyed or set down.
causing environmental damage.
● It is crucial that proper communication is ensured ▶ Prior to transportation, drain out all operating
between the signaller and the slinger before lifting materials and dispose of them in line with
commences. environmental regulations.
● Observe the dimensions and weights of the indi

vidual sub-assemblies. Please refer to the ship
ping documents and relevant drawings in this Ser NOTICE
vice Manual for the weights and dimensions. Damage to components and lines
● Only use lifting gear (e. g. crane or forklift truck) Components and lines may get damaged by the
and slings (e. g. chains and ropes) that have been slings when lifting the sub-assemblies.
checked and approved for the weight of the indi ▶ Do not attach the slings to superstructures or
vidual sub-assemblies and are in perfect condi lines; if necessary, use a crossbar.
tion.

slings are to be observed. i INFORMATION
● Lifting gear and slings may only be used by per For information on activities that have to be carried out
sons trained and authorised to carry out this type of before transportation of the individual sub-assem
work. blies, please refer to the relevant operating instruc
tions in this Service Manual.
DANGER
Suspended load
Hazard to life or risk of serious injuries due to falling
load
▶ Only attach the sub-assemblies using the desig
nated suspension points.
5.2 Transportation
● The individual sub-assemblies may only be trans

ported by specialist staff trained and qualified to
carry out this task.
● Only use transportation means that comply with
the applicable laws, acts and regulations of the
country where they are used.
● The individual sub-assemblies are to be attached

and fastened in such a way that damage in transit
can be ruled out.
● Observe the dimensions and weights of the indi
vidual sub-assemblies. Please refer to the ship
ping documents and relevant drawings in this Ser
vice Manual for the weights and dimensions.
● Make sure the transport vehicle is designed for the

safe transportation of the propulsion unit in terms
of weight, dimensions and requirements.

● The packaging material is to be disposed of prop

erly.
i INFORMATION
For information on the transportation of the individual
sub-assemblies, please refer to the relevant oper
ating instructions in this Service Manual.
6 Installation and Preparation for the Trial Run
6.1 Installation
i INFORMATION NOTICE
The hydraulic system is treated with a preservative Damage to the hydraulic system due to contam
agent prior to delivery. If stored in dry ambient air (not ination getting into it
sea air), the preservative provides sufficient protec Malfunctions, increased wear and shorter service life
tion for approximately six months. The hydraulic due to contamination in the system
system is to be installed within these six months.
▶ Ensure strict cleanliness when installing the
system.
The hydraulic system is installed by the shipyard. To
prevent material damage and serious or fatal injuries it
▶ Flush rigid and hose lines prior to installation.
is crucial that the following points are observed: ▶ Do not use hemp, Teflon tape or putty as a
sealant.
● The hydraulic system may only be installed by spe
▶ Do not use cleaning wool and fibrous cleaning
cialist staff trained and qualified to carry out this cloths.
task.
▶ Use suitable liquid cleaning agents to remove
● Wear personal protective gear. heavy soiling. Make sure that no cleaning agents
get into the line system.
● The SCHOTTEL installation documents are to be
observed when installing the hydraulic system and
carrying out all flame-cutting, welding and installa
tion work; the shipyard will be provided with these
prior to the installation of the hydraulic system.
● The site where the hydraulic system is installed is

to be adequately ventilated and lit.
● Components (e.g. rigid lines, hose lines, and screw

fittings) which are not included in SCHOTTEL's
scope of delivery, but are provided by the shipyard
during installation, have to comply with all of the
characteristics given in the installation documents
(e.g. material; pressure rating).
● Connect the sub-assemblies according to the
labelling on the connections in line with the
Hydraulic Circuit Diagram (e. g. hydraulic drive
station, and reservoir).
● Connect all electrical cables in accordance with
the Wiring Diagram provided.
i INFORMATION
Rigid and hose lines and any combination of con
nectors, couplings and connection parts fitted to
hoses and pipes are to be checked by an expert to
ensure they are fully safe for operational use.
6.1.1 Rigid Lines
i INFORMATION
The requirements of national and technical regula
tions specific to the application for rigid lines, and the
valid laws, acts and stipulations of the country where
are they used apply without restriction and are to be
fully observed.
● Rigid lines are to comply with all of the character

istics specified in the Hydraulic Circuit Diagram
(e.g. material; nominal pressure).
● The pipe diameters specified in the Hydraulic Cir
cuit Diagram are minimum values to be observed.
● Lay the rigid lines as short as possible.
● To prevent air pockets forming the riser pipe and

vent line are to be installed ascending.
● Ensure there is a minimum of bends in the pipe

routing.
● Make sure rigid lines are installed in an unstrained
condition.
● Do not fix the pipes to each other, but to suitable
attachment points. Metal clamps and cable ties
are not allowed.
● Do not use pipes to hold installed components,

such as filters or valve manifolds.
● Use suitable pipe brackets to ensure vibration is

absorbed.
● Remove protective caps just before commencing

pipework installation.
i INFORMATION
When installing rigid lines, always observe the
"10.6 Rigid Lines" section, page 55.
6.1.2 Hose Lines
i INFORMATION
Only hose lines pre-fabricated by a hose manufac
turer may be used in the hydraulic system.
SCHOTTEL GmbH will void any warranties and
cannot be held liable for any unauthorised structural
modifications, repairs and manipulations to hose
lines.
i INFORMATION
When installing hose lines, always observe the
"10.7 Replacement of Hose Lines" section, page 79.
6.1.3 Couplings
i INFORMATION
The coupling can be connected against a residual
pressure of 50 bar.
1 2
The coupling is a connection piece that locks to both
sides. The valves in the fixed and loose halves open
and close automatically when the coupling is con
nected or disconnected.
Connecting the Couplings
1. Slide the loose half (coupling plug [2/1]) over the
fixed half (coupling sleeve [2/2]) and make sure it 3
is positioned in the axial centre.
2. Screw the screw fitting of the loose half onto the
fixed half.
The valves open automatically. A small amount of
oil leaks out.
3. Continue screwing the screw fitting onto the fixed
half until the red marking ring (2/3) is no longer vis
ible.
The coupling is locked and sealed.
Disconnecting the Coupling Fig. 2 Coupling
1. Hold the loose half and unscrew the screw fitting
from the fixed half by turning it anti-clockwise.
The valves close automatically.
2. The coupling is unlocked and can be separated.
6.2 Preparation for Trial Run
6.2.1 Initial Fill
The hydraulic system has to be prepared for the trial
run. To do this, the measures described in this section
are to be carried out.
● The hydraulic system may only be initially filled by

specialist staff trained and qualified to carry out
this task.

● Make sure the hydraulic system cannot be started
up unintentionally before commencing any work.
safety data sheets.
DANGER
Voltage
voltage
components.
unintentionally.
▶▶
CAUTION
and pointed corners
NOTICE
Damage to seals
Seals may be damaged if exposed to diluting agents
during cleaning.
▶ Do not use any diluting agents when cleaning.
▶ Use petroleum naphtha, white spirit, diesel oil or
a wax remover.
▶ Clean the hydraulic system

Clean any sub-assemblies and components that
have been treated with anti-corrosion agents.
NOTICE
Damage to the hydraulic system due to contam
inated oil
Hydraulic system components may become dam
aged.
▶ Use a pump with a filter unit and a  10 m filter
when filling or refilling the oil.
▶ Fill the hydraulic system with the specified oper

ating materials.
Please refer to the relevant operating instructions
in this Service Manual for the quantities and pro
cedures involved.
i INFORMATION
Once these measures have been taken, the hydraulic
system can be flushed.
6.2.2 Flushing and Bleeding the
Hydraulic System
i INFORMATION
The sub-assemblies (e.g. hydraulic drive station and
hydraulic pump unit) were flushed prior to delivery.
Once installed, the entire hydraulic system is to be
flushed.
The following points are to be observed during flushing:
● The hydraulic system is only to be flushed by an

authorised, trained hydraulics specialist who has
the necessary expertise.

● Before commencing any work, close off access to

the work area to any unauthorised persons. Dis
play an information sign to indicate the work in pro
gress.
● The hydraulic system is fully installed and all of the

connections of the individual sub-assemblies (e.g.
hydraulic drive station and hydraulic pump unit)
have been connected with each other as desig
nated in the Hydraulic Circuit Diagram.
● All electric cables have been wired according to
the Wiring Diagram.
● The hydraulic system has been filled with the spe

cified operating materials.
● The hydraulic system is to be inspected for visible
damage and defects prior to flushing. If damage or
defects to the hydraulic system are established,
make sure it cannot be started up unintentionally
and notify the relevant services.
● Prior to flushing, make sure that no-one can be
exposed to any danger when the hydraulic system
is started up.
● Check any control valves (e.g. ball valve and direc
tional control valve) and, if necessary, move to the
correct position (observe the Hydraulic Circuit Dia
gram).
● Check that all safety and monitoring devices are
▶▶
DANGER
Voltage
voltage
components.
unintentionally.
DANGER
necting parts, hoses and rigid lines on hydraulic com
ponents bursting.
DANGER
Malfunctions
tions
▶ Only commence any work once completely famil
iarised with the function of the hydraulic system
and the components used on the one hand, and
the function of the propulsion unit on the other,
and any risks or dangers have been ascertained
and eliminated.
▶ Full comprehension of the Hydraulic Circuit Dia
gram is absolutely necessary, Furthermore, the
functionality of the installed safety components
is to be fully understood.
NOTICE
Damage to sub-assemblies and components due
to incorrect oil level
Sub-assemblies and components may become dam
aged.
▶ Only check the oil levels when the hydraulic
system is not in operation and the oil temperature
and ambient temperature are the same.
▶ Flush the hydraulic system.
The hydraulic system has been flushed, when the
minimum flushing time and the required purity level
has been achieved according to ISO 4406 class
20/18/15.
▶ Move the control valves (e.g. ball valve and direc
tional control valve) back into the correct position
(observe the Hydraulic Circuit Diagram).
▶ Check that the hydraulic motor of the hydraulic
pumps rotates in the correct direction.
Leave it running for about two minutes at a low
speed. Make sure the direction of rotation is the
same as that of the direction of rotation arrow on
the housing.
▶ Check the hydraulic system for loose screw fittings
and loose flanged joints.
▶ Bleed the hydraulic system.
1. Run the hydraulic system with low pressure at
idling speed.
2. Bleed the hydraulic system at the highest
point (e.g. loosen screw fittings a little).
3. Test all control functions at low pressure.
4. Slowly increase pressure.
Observe the oil levels in the hydraulic system;
if necessary, top up the oil when bleeding the
system.
5. Test all control functions.
The hydraulic system has been completely bled
when the actuators are not displaying any jerky
movements, there are no abnormal noises or foam
occurring (as may be visible in the reservoir or
through the sight glass for example).
▶ Switch off the hydraulic system.
▶ Check the hydraulic system for leaks.
i INFORMATION
Once these measures have been taken, commis
sioning (trial run at the pier) may be carried out by an
authorised SCHOTTEL employee.
7 Commissioning
DANGER CAUTION
Voltage Slipping, falling and tripping over
Hazard to life or risk of serious injuries due to electric Head injuries and cuts to limbs due to sharp edges
voltage and pointed corners
▶ Always observe the special safety provisions ▶ Keep the work area and walked-on areas clean.
components. ▶ Wear personal protective equipment, especially
unintentionally.
DANGER
necting parts, hoses and lines on hydraulic compon
ents bursting
DANGER
Damaged safety devices or components
▶ Prior to start-up, check that the safety and monit
oring devices are functioning properly.
▶ If damage to the hydraulic system occurs, switch
it off and make sure it cannot be started up unin
tentionally; notify the relevant services.
DANGER
Open belt drive
parts being caught or crushed.
▶ Do not reach into the running belt drive.
▶ Do not put any objects into the running belt drive.
▶ Always tie back long hair; never wear loose
clothing, jewellery or similar.
▶ Do not wear protective gloves.
7.1 Trial Run at the Pier
For the trial run at the pier, the measures set out in the
"6 Installation and Preparation for the Trial Run" section
have to have been completed and those described in
this section carried out:
● The hydraulic system is fully installed and all of the

connections of the individual sub-assemblies (e.g.
hydraulic drive station and reservoir) have been
connected to each other as designated in the
Hydraulic Circuit Diagram.
● All electric cables have been wired according to
the Wiring Diagram.
● The hydraulic system has been flushed and bled.
● The hydraulic system has been filled with the spe

cified operating materials.
● The hydraulic system has been checked for leaks,

loose screw fittings and loose flanged joints.
● The hydraulic system has been inspected for vis
ible external damage and defects. If damage or
defects to the hydraulic system are established,
make sure it cannot be started up unintentionally
and notify the relevant services.
● The control valves (e.g. ball valve and directional

control valve) have been moved into the correct
position (observe the Hydraulic Circuit Diagram).
● All safety and monitoring devices have been
checked that they are functioning properly.
NOTICE
aged.
▶ Only check the oil levels when the hydraulic
system is not in operation and the oil temperature
and ambient temperature are the same.
i INFORMATION
Once these preparations have been made, the trial
run at the pier may be carried out by an authorised
SCHOTTEL employee. During the trial run, all control
functions are tested.
7.2 Preparation for the Sea Trial
The hydraulic system has to be prepared for the sea
trial. In this respect, the measures set out in the
"7.1 Trial Run at the Pier" section have to have been
completed and those described in this section carried
out:
● Make sure that no-one can be exposed to any
danger when the hydraulic system is started up.
● The hydraulic system is to be inspected for visible
external damage and defects prior to the sea trial.
If damage or defects to the hydraulic system are
● Prior to the sea trial, the operator is to designate a
danger zone around the hydraulic system. The
danger zone must not be accessible to unauthor
ised persons.
NOTICE
aged.
▶ Only check the oil levels in the hydraulic system
when not in operation and the oil temperature and
▶ Check the oil levels in the hydraulic system.
in this Service Manual for the procedures involved.
▶ Check that all safety and monitoring devices are
tional control valve) into the correct position
▶ Check the hydraulic system is functioning prop
erly.
Leave the hydraulic system running for about two
minutes at low speed and carry out all control func
tions.
▶ Bleed the hydraulic system; see the
"6.2.2 Flushing and Bleeding the Hydraulic
System" section, page 31.
i INFORMATION
hydraulic system or one that has been brought back
into operation, trapped air may escape from the
system. Check the oil level several times in the initial
operating hours and refill the oil, if necessary.

i INFORMATION
Once these measures have been completed, the sea
trial may commence. During the sea trial, the perform
ance of the entire propulsion system is determined by
an authorised SCHOTTEL employee. The results of
the sea trial are documented in an acceptance report
and the required acceptance test is carried out by the
stipulated classification society.
8 Resumption of Operation
The hydraulic system is installed in the vessel ready for
operation. During a sea trial, the performance of the DANGER
entire propulsion system has been determined, an
acceptance report compiled and the required accept
ance test of the stipulated classification society carried Hazard to life or risk of serious injuries due to con
out. necting parts, hoses and lines on hydraulic equip
ment bursting
To prevent material damage and serious or fatal injuries ▶ Wear personal protective gear, especially heat-
it is crucial that the following points are observed: resistant safety gloves and safety goggles.
● The hydraulic system is to be inspected for visible ▶ Switch off the power supply and wait until any
external damage and defects prior to resumimg residual power has dissipated.
operation. If damage to the hydraulic system is ▶ Do not try and catch hold of lashing hoses.
● Wear personal protective gear. DANGER
● Make sure that no-one can be exposed to any Damaged safety devices or components
danger when the hydraulic system is started up. Hazard to life or risk of serious injuries due to inef
● When working on the hydraulic system when it is fective safety devices or damaged components
switched off, make sure that it cannot be started up ▶ Prior to resumption of operation, check that the
unintentionally. safety and monitoring devices are functioning
properly.
DANGER it off and make sure it cannot be started up unin
Voltage
voltage
▶ Always observe the special safety provisions CAUTION
components. Slipping, falling and tripping over
▶ Work on electrical components is only to be car and pointed corners
▶ Switch off the power supply before commencing ▶ Keep the work area and walked-on areas clean.
work and make sure it cannot be switched on ▶ Wear personal protective equipment, especially
unintentionally. protective clothing and a safety helmet.
DANGER
Rotating components
NOTICE
aged.

▶ Check that all safety and monitoring devices are
tional control valve) into the correct position
▶ Check the hydraulic system is functioning prop
erly.
Leave the hydraulic system running for about two
minutes at low speed and carry out all control func
tions.
▶ Bleed the hydraulic system; see the
"6.2.2 Flushing and Bleeding the Hydraulic
System" section, page 31.
i INFORMATION
hydraulic system or one that has been brought back
into operation, trapped air may escape from the
system. Check the oil level several times in the initial
operating hours and refill the oil, if necessary.

i INFORMATION
Once these measures have been taken, the hydraulic
system will be ready for operation.
9 Operation
9.1 During Operation
● Wear personal protective gear. Oil may spray out under high pressure
● The laws, acts and regulations applicable in the necting parts, hoses and lines on hydraulic
country where it is used are to be observed. components bursting
● Make sure that no unauthorised persons are in the ▶ Wear personal protective gear, especially heat-
designated danger zone. resistant safety gloves and safety goggles.
● Ensure that all of the safety instructions and residual power has dissipated.
warning notices attached to the hydraulic system
are always easily legible and never removed. ▶ Do not try and catch hold of lashing hoses.
▶ Depressurise the hydraulic system prior to com
● All safety and monitoring devices are operating. mencing any work and wait until any residual
power has dissipated.
safety data sheets. WARNING
t
DANGER Risk of serious injuries due to the failure of individual
Voltage components as a result of long-term malfunctions
Hazard to life or risk of serious injuries due to electric ▶ Rectify malfunctions immediately.
voltage ▶ Malfunctions are only to be rectified by specialist
when working on any kind of electrical ▶ If damage to the hydraulic system occurs, switch
components. it off and make sure it cannot be started up unin
work and make sure it cannot be switched on WARNING
unintentionally.
Hot surfaces
Risk of sustaining burn injuries due to surfaces on the
DANGER hydraulic system becoming hot
Rotating components resistant safety gloves.
CAUTION
and pointed corners
NOTICE
aged.
The following points are to be observed during opera

tion:
● Observe the malfunction alarms on the vessel's
alarm monitoring system.
Rectify malfunctions immediately. If damage to the
hydraulic system occurs, switch it off and make
sure it cannot be started up unintentionally; notify
the relevant services.
● Listen out for any abnormal noises.

If abnormal noises occur, perform the tests
described in the "11 Troubleshooting" section,
page 87.
● Check the oil condition in the hydraulic system.

● Check the oil levels in the hydraulic system.
● Check the filters in the hydraulic system for clog

ging and, if necessary, replace the filter or filter ele
ment.
9.2 Measures After Operation
● Any work on the hydraulic system may only be car Slipping, falling and tripping over
ried out by specialist staff trained and qualified to Head injuries and cuts to limbs due to sharp edges
carry out these tasks. and pointed corners
● The laws, acts and regulations applicable in the protective clothing and a safety helmet.
● Ensure that all of the safety instructions and
warning notices attached to the hydraulic system NOTICE
are always easily legible and never removed.
● When handling operating materials and supplies, to incorrect oil level
the safety regulations for the product concerned Sub-assemblies and components may become dam
are to be observed. Refer to and observe the aged.
safety data sheets.
DANGER
Voltage
voltage
components.
unintentionally.
WARNING
Hot surfaces
hydraulic system becoming hot
▶ Only commence any work once the hydraulic
system has sufficiently cooled down.
▶ Switch the hydraulic system off and make sure it
▶ Switch off the power to the hydraulic motors and
make sure they cannot be started up unintention
ally.
▶ Inspect the hydraulic system for external visible
damage and defects. If damage or defects to the
hydraulic system are established, make sure it
cannot be started up unintentionally and notify the
relevant services.
▶ Check the oil condition in the hydraulic system.
10 Maintenance
● Maintenance work is only to be carried out by spe
cialist staff trained and qualified to carry out this
task.
● The stipulated maintenance intervals are to be
complied with.
● Switch off the hydraulic system and make sure it
cannot be started up unintentionally before com
mencing any maintenance work.
● Before commencing any maintenance work, close

off access to the work area to any unauthorised
persons. Display an information sign to indicate the
maintenance work in progress.
● Refer to the "5.1 Prior to Transportation" section,

page 24, for components that need slings and
lifting gear to be dismantled.
● Observe the special safety measures for intercon
nected hydraulic systems, if individual sub-assem
blies are still in operation, or have to be switched on
again during maintenance.
● Before carrying out maintenance work depres
surise the line sections and pressure lines to be
opened and allow to cool.

the safety regulations and safety data sheets for
the product concerned are to be observed.
● Carry out visual inspections of the hydraulic

system at regular intervals. Rectify any identified
defects immediately (e.g. loose screw fittings).
● After completing maintenance work, dismantled
safety and monitoring devices are to be reinstalled DANGER
and loose bolted connections tightened. Rotating components
● After completing maintenance work remove any Hazard to life or risk of serious injuries due to body
tools used from the hydraulic system area. parts being caught or pulled into rotating components
DANGER ▶ Do not place objects within the danger zone.
Malfunctions
tions DANGER
▶ Observe the maintenance intervals. Oil may spray out under high pressure
▶ Any defective components which affect the Hazard to life or risk of serious injuries due to sudden
safety and function of the hydraulic system are to relief of oil pressure
be replaced immediately. ▶ Only commence any work once the line system
▶ Only commence any work once completely famil has been depressurised and any existing
iarised with the function of the hydraulic system residual power has dissipated.
and the components used on the one hand, and
the function of the propulsion unit on the other, ▶ Close the shut-off valves on the pressure and
suction side.
and any risks or dangers have been ascertained
and eliminated. ▶ Drain the relevant line section if necessary.
▶ Full comprehension of the Hydraulic Circuit Dia
gram is absolutely necessary.
▶ Furthermore, the functionality of the installed WARNING
safety components is to be fully understood.
Hot surfaces
DANGER hydraulic system becoming hot
▶ Only commence any work once the hydraulic
Voltage system has sufficiently cooled down.
Hazard to life or risk of serious injuries due to electric ▶ Wear personal protective gear, especially heat-
voltage resistant safety gloves.
components.
WARNING
ried out by a qualified electrician. Hot oil
▶ Switch off the power supply before commencing Risk of sustaining burn injuries due to hot oil in the
work and make sure it cannot be switched on hydraulic system
unintentionally.
▶▶
CAUTION
and pointed corners
▶ Keep any walked-on areas clean.
NOTICE
Damage to the hydraulic system due to contami
nation getting into it
Malfunctions, increased wear and shorter service life
due to contamination in the system
▶ Ensure strict cleanliness when installing the
system.
▶ Clean and flush rigid and hose lines prior to
installation.
▶ Do not use hemp, Teflon tape or putty as a
sealant.
▶ Do not use cleaning wool and fibrous cleaning
cloths.
▶ Use suitable liquid cleaning agents to remove
heavy soiling. Make sure that no cleaning agents
get into the line system.
The purpose of maintenance is to uphold or restore the
functional reliability of the hydraulic system. Regular
maintenance of the hydraulic system and individual
components helps to avert malfunctions and unsched
uled downtimes, thus ensuring the availability of the
entire hydraulic system.
The purpose of corrective maintenance is to restore the
propulsion unit's functional reliability following malfunc
tion by replacing defective assemblies or parts.
10.2 Maintenance Schedule
i INFORMATION
Please refer to the relevant operating instructions in
this Service Manual for other maintenance work and
procedures involved.
The hydraulic system is to be checked at regular inter

vals. The following checks are to be carried out:
● Check the oil levels in the hydraulic system.
● Check the condition of the oil (visual inspection,

colour and smell).
● Check the operating pressure in the hydraulic
system.
● Check the operating temperature in the hydraulic
system.
● Check the hydraulic system for leaks.
● Check the filter elements in the hydraulic system.
● Check the hydraulic system for abnormal noises

(e.g. flow sounds).
● Check the condition and age of the hose lines

(observe inspection intervals).

● Check the entire hydraulic system for damage.
● Check that safety instructions and warning notices

attached to and in the hydraulic system are clearly
legible.
10.3 Measurement and Control Equipment
i INFORMATION
If malfunctions and leakages indicate that a measure
ment and control device is damaged or defective, this
is to be replaced. SCHOTTEL GmbH will void any
warrantees and cannot be held liable for any unau
thorised structural modifications, repairs and manip
ulations to measurement and control equipment.
10.3.1 Prior to Installation

Prior to installation the following points are to be
observed:
● Make sure the measurement and control equip

ment is only installed in line with specifications and
used for its intended purpose. The enclosed tech
nical documentation of the respective manufac
turer is to be observed.
● Only remove the protective packaging, caps and
other protective devices from the measurement
and control equipment immediately prior to install
ation.
● Make sure that the accessible interiors of the
adjoining line system are free of foreign bodies.
● Make sure the measurement and control equip
ment is in a perfect and clean condition when
installed.
● The measurement and control equipment is to be

connected to the line system according to stand
ards.
10.3.2 Prior to Removal
Prior to removal the following points are to be observed:
● Any measurement and control equipment which

does not have an intrinsically safe circuit is not to
be opened under voltage.
● Remove the measurement and control equipment
carefully to prevent damaging any adjoining con
nections (e.g. screw fittings).
DANGER
Master control system
Hazard to life or risk of serious injuries due to auto
matic control functions.
▶ Only commence work on electrical measurement
and control equipment once the input signal
cable of the master control system has been dis
connected from the component.
10.3.3 During Installation
i INFORMATION ● Make sure cable glands are fitted correctly and the
necessary seals are in place and undamaged (for
Sealing surfaces that need installing with pipe and electrical measurement and control equipment).
thread sealants are designated in the drawings of the ● To prevent excessive temperatures from occur
respective sub-assembly. Also refer to the Installation ring, live conductors for electrical measurement
Instructions for Bolted Connections and Sealants in and control equipment must not be laid in unper
this Service Manual. mitted wiring bundles.
During installation the following points are to be

observed:
● Do not apply the required tightening torque for

screwing in the measurement and control equip
ment using the housing or cable connection boxes,
but with suitable tools using the spanner flats
intended for this purpose.
● Mount the measurement and control equipment in
an unstrained condition.
● Make sure that sealing surfaces and seals on the
measurement and control equipment and at the
place of installation are undamaged and clean.
● Make sure the cable diameter always matches the

cable gland (for electrical measurement and con
trol equipment).
10.3.4 Following Installation
Following installation the following points are to be
observed:
● Measurement and control equipment has been
installed according to specifications.
● Measurement and control equipment has not been
damaged during installation.
● The measurement and control equipment has
been set to the appropriate nominal value (observe
maximum fuses; see Hydraulic Circuit Diagram).
● All electrical connections have been connected

properly (for electrical measurement and control
equipment).
● Check the line section for loose screw fittings and
loose flanged joints.
● Flush the line section (ISO 4406 class 20/18/15)

and bleed it.
● The control valves (e.g. ball valve and directional

control valve) have been moved into the correct
position (observe the Hydraulic Circuit Diagram).
● Check the line section for leaks by applying
1.5 times the operating pressure.
● Test all control functions at low pressure.

10.4 Valves
i INFORMATION
If malfunctions and leakages indicate that a valve is
damaged or defective, this is to be replaced.
SCHOTTEL GmbH will void any warranties and
modifications, repairs and manipulations to valves.

observed:
● Make sure valves and fittings are only installed in

line with specifications and used for their intended
purpose. The enclosed technical documentation
of the respective manufacturer is to be observed.
● Only remove the protective packaging, caps and

other protective devices from the valve immedi
ately prior to installation.
● Make sure the valve is in a perfect and clean condi
tion when installed.
● Make sure that for valves with direction arrows the
oil flow corresponds to the direction given on the
arrow.
● The valve is to be connected to the line system

according to standards.
10.4.2 Prior to Removal
Prior to removal the following points are to be observed:
● Close the existing shut-off valves down and

upstream of the valve.
● Depressurise the valve prior to removal.
● Place a suitable collecting basin under the valve to

catch any residual oil that may leak out.
● Remove the valve carefully to prevent damaging

any adjoining connections (e.g. mating flange;
screw fittings).
i INFORMATION ● Hand levers on control valves must not protrude

into public areas or emergency escape routes.
Sealing surfaces that need installing with pipe and ● Only use ball valves in the fully open or closed posi
thread sealants are designated in the drawings of the tion. Do not use ball valves to regulate the volume
respective sub-assembly. Also refer to the Installation flow.
Instructions for Bolted Connections and Sealants in
this Service Manual.

observed:
● Replace the existing seals (e.g. O-rings on SAE
flanged fittings) during installation. Only use suit
able seals.
● Do not apply the required tightening torque for

screwing in the valve using the housing, but with
suitable tools using the spanner flats intended for
this purpose.
● Make sure the valve is installed in an unstrained

condition.
● Make sure that sealing surfaces and seals on the

valve and at the place of installation are undam
aged and clean.
● Do not use the valves as fixing points for lines.
● Oil all O-rings in the SAE flanged fittings before

inserting them into the groove ring.
● When tightening the screw fitting (line system) hold

the fitting in the required installation position using
a suitable tool.
● Only install check valves without closing springs in
a vertical position with an ascending direction of
flow. Check valves with closing springs may also
be installed in horizontal and inclined lines.
observed:
● The valve has been installed according to specific
ations.
● Make sure the valve has not been damaged during
installation.
● All control valves have run through one operating

cycle prior to resuming operation (extension lever
must not be used).
● Check the line section for loose screw fittings,

flanged joints and bolted connections.
and bleed it.
● Move the control valves (e.g. ball valve and direc


10.5 Couplings
i INFORMATION
The coupling can be connected against a residual
pressure of 50 bar. 1 2
The following points are to be observed:

surise the line system or line section and allow to
cool.
● Place a suitable collecting basin under the coup 3
ling to catch any residual oil that may leak out.
● Clean the area around the adjoining line system
before disconnecting the coupling.
● To protect the coupling against contamination
close the coupling halves with protective caps after
disconnection.
10.5.1 Disconnecting and Connecting

the Coupling
Fig. 3 Coupling
i INFORMATION
To disconnect and connect couplings, observe the
"6.1.3 Couplings" section, page 28.
Disconnecting the Coupling

1. Hold the loose half (coupling plug [3/1]) and turn
the screw fitting anti-clockwise to the fixed half
(coupling sleeve [3/2]).
The valves close automatically.
2. The coupling is unlocked and can be separated.
Connecting the Couplings

1. Slide the loose half over the fixed half and make
sure it is positioned in the axial centre.
2. Screw the screw fitting of the loose half onto the
fixed half.
The valves open automatically. A small amount of
oil leaks out.
3. Continue screwing the screw fitting onto the fixed
half until the red marking ring (3/3) is no longer vis
ible.
The coupling is locked and sealed.
10.6 Rigid Lines
i INFORMATION
If malfunctions and leakages indicate that pipes or
screw fittings are damaged or defective, the
respective component is to be replaced. SCHOTTEL
GmbH will void any warranties and cannot be held
liable for any unauthorised structural modifications,
repairs and manipulations to pipes or screw fittings.
All components used (pipes and screw fittings) are to

comply with all of the characteristics specified in the
Hydraulic Circuit Diagram (e.g. material; nominal pres
sure).

observed:
cool.
● Before opening the line section concerned,

check that the rigid line has been fully depressur
ised. Open the screw fittings slowly and carefully.
● Place a suitable collecting basin under the rigid line
concerned to catch any residual oil that may leak
out.
● Clean and flush the rigid line to be installed prior to

installation (ISO 4406 class 20/18/15).
● Make sure pipes and screw fittings are only
installed in line with specifications and used for
their intended purpose.

● To protect the premounted rigid lines against con

tamination always close with protective caps.
10.6.2 During Installation 3
i INFORMATION
Sealing surfaces that need installing with pipe and
thread sealants are designated in the drawings of the
respective sub-assembly. Also refer to the Installation
Instructions for Bolted Connections and Sealants in

observed:
● If there is visible damage to pipes and screw fit

tings, these must not be installed.
● Interconnected connecting parts are always to be

mounted in the same combination. Any screw con
nection elements may only be assembled once. 1
2
Rigid Lines
● After installation, rigid lines must not be used as a 3
ladder or climbing support.
● Do not attach any other components to rigid lines.
● Install rigid lines in an unstrained condition (4/3).
● Avoid using short lengths of pipe (4/5).

The minimum length is 2.5 to 3 times the height of
the union nut. Use stud couplings or adapters.
● Make sure that components requiring regular
maintenance are readily accessible (4/1).
● Take account of routing changes to rigid line sec
tions.
● Where possible, mount rigid lines at right angles,
parallel to one another and clearly laid out (4/2).
● Do not use rigid lines as a fixing point for pipe
clamps (4/4). 4
Fig. 4 During installation
Pipe Clamps
● Use pipe clamps with vibration and noise-
absorbing properties, e.g. DIN 3015 T1 and T2
(5/1).
1
● Pipe clamps are not to obstruct changes to rigid
line lengths (5/2).
● Attach pipe clamps directly before and after pipe

bends; but do not mount in the actual bend radius
of the pipe bend.
● Do not use rigid lines as a fixing point for pipe
clamps.
● Observe the specified spacing for rigid line pipe
clamps; see following table and diagram 5.
Outer pipe diameter Space L

(da)
[mm] [m]
6 - 12 1.0
12 - 22 1.2
22 - 32 1.5
32 - 38 2.0 2
38 - 57 2.7
57 - 75 3.0
75 - 90 3.7
90 - 102 4.0
102 - 114 4.5
114 - 168 5.0 da
Fig. 5 During installation
Pipe Preparation
DANGER 1
Malfunctions
tions
▶ The basic prerequisites for the correct installa
tion of screw fittings are to be fulfilled. Improper
installation may affect the safety of the hydraulic
system.
i INFORMATION
The requirements of national and technical regula 0.2 x
tions specific to the application, and the valid laws, 2 455
acts and stipulations apply without restriction and are
to be fully observed (e.g. DIN 3859 T2).
Only use seamless pipes of the following type: 0.2 x

455
● Precision steel tube EN 10305-4, steel P235TR2
(St 37.4), material no. 1.0255
● Seamless and stainless precision steel tube Fig. 6 Pipe Preparation

EN 10305-4, material no. 1.4571
i INFORMATION
Never use pipe cutters or cut-off grinders to shorten
the pipes.
▶ Calculate the pipe lengths. Observe the minimum

lengths of pipes and pipe ends and the length
allowances for flaring; see page 70 and page 71.
▶ Saw off the pipes at a right angle without deforming
using a sawing device; the permissible angular
deviation to the pipe axis is a maximum of 0.5
(6/1).
▶ Lightly debur the inner and outer edges of the cut
pipe sections; bevel up to 0.2 x 45 is permitted
(6/2).
▶ Remove contamination from the pipe ends (e.g.
shavings, dirt and paint). If necessary, clean with
degreaser.
Cold Bending of Pipes
i INFORMATION
Before shortening the pipes, saw off at least 10 mm of
the manufacturer's severance cut (source of error by
delivery).
When preparing the pipes, the following points are to be

observed:
● Always bend cold-drawn pipes with a pipe bending
device (use a manual pipe bending device for outer
pipe diameters of 6 to 8 mm, and a machine for
outer pipe diameters greater than 8 mm).
● The bend radius needs to be at least 3 x the outer
pipe diameter (observe manufacturer's specifica
tions).
● It is essential that there is no cross-section nar

rowing in the bend.
● Make sure that the minimum distance of the

straight pipe end to the pipe bend is upheld; see
page 70.
BLANK PAGE
Screw Fittings
DANGER
Hazard to life or risk of serious injuries due to screw fit
tings bursting
▶ Only screw the same types of threads together.
▶ Make sure the type of seal conforms with the
screw fitting parts.
▶ Where possible, only use connecting ports,
pins and screw fittings from a standard series
on the hydraulic system.
▶ Mark different standard series in the hydraulic
system, e.g. with colour.
Some types of threads can only be differentiated with

difficulty due to their outer geometric similarities and
sizes; some screw fittings with different types of
threads appear to fit together, e.g. screw fittings with
inch threads G!/4" can be screwed into metric M14 x 1.5
boreholes without any difficulty.
General Information
Assembly is carried out using international, standard
screw fitting systems (e.g. solder-free pipe fittings com
plying with DIN EN ISO 8434 T1 and DIN 2353, in con
junction with DIN 3861 and DIN 3870).
1
i INFORMATION
Use reinforcing sleeves for all thin-walled pipes and
soft pipe materials.
● When using different screw fitting and sealant

materials the smallest temperature limits apply in
each case.
● Check the dimensional accuracy of the removed

screw fittings and make sure the fittings are not
damaged; if necessary, replace them.
● Each time a union nut is loosened make sure it is

tightened with the same tightening torque as for Fig. 7 Aligning the screw fittings
final assembly. Observe the maximum tightening
torque; see page 68.
● Make sure the screw fittings are installed in an
unstrained condition (7/1).
Cutting Ring
Installation in the Fitting Device
i INFORMATION
Pipes with outer pipe diameters of 10 mm can be dir
ectly installed in screw fittings that are prefitted to 1
components. For outer pipe diameters greater than 2
12 mm pipes are to be premounted in the fitting
device.
Pipes made of non-rusting materials, connection
pieces for hose fittings and adjustable screw fittings
with shafts must not be fitted in the fitting device.
These are to be installed in the pre-assembly device
(see page 64) or by means of a mounting device.
▶ For pipe preparation, see the "Pipe Preparation"

section, page 58.
i INFORMATION
With non-rusting materials, the cutting ring and the
union nut thread are to be oiled.
Galvanised screw fittings with colourless slide coating
do not have to be oiled.
▶ Slide the union nut (8/1) and cutting ring (8/2) over 3
the end of the pipe.
Make sure the cutting ring collar is facing the union
nut.
▶ Insert the pipe in the fitting device and push firmly
into the inner cone as far as it will go (8/3).
▶ Tighten the union nut by hand until the pipe stops
turning.
As soon as the cutting ring has engaged with the
pipe, there is a noticeable increase in torque.
▶ Mark the position of the union nut (8/4).
Fig. 8 Installation in the fitting device
▶ Tighten the union nut using an open end spanner
by approx. one turn more than the point at which
there is a tangible increase in torque (9/1).
The cutting ring will cut into the pipe evenly.
Hold the fitting device in place.
Use an extension (approx. 15 times the spanner 1
length; e.g. 22-L = 400 mm).
Observe the maximum tightening torque; see
page 68.
▶ Loosen the union nut.
Check the collar projection. Make sure there is a
visible even collar before the first cutting edge
(9/2). The cutting ring can turn on the pipe, but
must not axially slip.
▶ Tighten the union nut without extension.
2
Installation in the Hardened Pre-Assembly Device
section, page 58. 1
1
i INFORMATION
2
Check the pre-assembly device (10/2) with the cone
gauge after about 50 pre-assemblies.
▶ Fix the pre-assembly device in a vice (observe the

outer pipe diameter).
▶ Oil the thread and cone (10/1) on the pre-assembly
device. 3
4
i INFORMATION
▶ Slide the union nut (10/3) and cutting ring (10/4)

over the end of the pipe.
Make sure the cutting ring collar is facing the union
nut.
▶ Insert the pipe in the pre-assembly device and
push in firmly as far as it will go (10/5).
turning.
Hold the pre-assembly device in place with an 5
open end spanner.
As soon as the cutting ring has engaged with the
pipe, there is a noticeable increase in torque.
▶ Tighten the union nut approx. !/2 a turn using an
open end spanner (10/6).
6
The cutting ring will cut into the pipe evenly.
Fig. 10 Installation in the pre-assembly device
▶ Loosen the union nut. 1
visible even collar before the first cutting edge
(11/1).
▶ Insert the pre-assembled pipe into the fitting
device (11/2).
by approx. !/2 a turn more than the point at which
there is a tangible increase in torque.
Hold the fitting device in place with an open end
spanner.
Use an open end spanner extension (approx. 15
times the spanner length; e.g. 22-L = 400 mm).
page 68.
2
▶ Loosen the union nut again.
visible even collar before the first cutting edge. The
cutting ring can turn on the pipe, but must not axi
ally slip.
Fig. 11 Installation in the pre-assembly device
DSW Ring
Installation in the Fitting Device
i INFORMATION
Pipes with outer pipe diameters of 10 mm can be dir 1
ectly installed in screw fittings that are prefitted to 2
components. For outer pipe diameters greater than
12 mm pipes are to be premounted in the fitting
device.
Pipes made of non-rusting materials, connection
pieces for hose fittings and adjustable screw fittings
with shafts must not be fitted in the fitting device.
These are to be installed in the pre-assembly device
(see page 64) or by means of a mounting device.

section, page 58.
i INFORMATION
3
▶ Slide the union nut (12/1) and DSW ring (12/2) over
the end of the pipe.
Make sure the DSW ring collar is facing the union
nut.
▶ Insert the pipe in the fitting device and push firmly
into the inner cone as far as it will go (12/3).
turning.
by approx. 1!/2 a turn more than the point at
4
which there is a tangible increase in torque (12/4).
spanner. 5
Use a spanner extension (approx. 15 times the
spanner length; e.g. 22-L = 400 mm).
page 68.
▶ Loosen the union nut (13/1).
Check the components are sitting properly: Make
sure the DSW ring surface is fitted tightly against
the surface of the fitting device (13/2). 1 2
Final Assembly Tightening Torque By Means Of Torque Wrench For Screw Fittings
Outer pipe diameter L Series

6 8 10 12 15 18 22 28 35 42
Galvanised material 15 15 25 35 45 85 110 130 215 330
[Nm]
Non-rusting material 20 25 30 35 50 130 160 180 275 400
[Nm]
Outer pipe diameter S Series

6 8 10 12 14 16 20 28 30 38
[Nm]
[Nm]
Final Assembly Tightening Torque By Means Of Torque Wrench For Male Connectors
The specified values apply to:
● Male connectors of stud couplings sealed by a
sealing edge form B DIN 3852 or WD seal
● Steel screw fittings with colourless galvanised
slide coating and steel counter piece
Tapered screw-in threads are not self-sealing. Additional sealants are required for sealing.
L Series S Series
Outer pipe Pipe [Nm] Metric ISO [Nm] Outer pipe Pipe [Nm] Metric ISO [Nm]
diameter thread thread diameter thread thread
6 G!/8" A 25 M10 x 1 25 6 G!/4" A 60 M12 x 1.5 35
8 G!/4" A 50 M12 x 1.5 30 8 G!/4" A 60 M14 x 1.5 60
10 G!/4" A 50 M14 x 1.5 50 10 G#/8" A 110 M16 x 1.5 95
12 G#/8" A 80 M16 x 1.5 80 12 G#/8" A 110 M18 x 1.5 120
15 G!/2" A 160 M18 x 1.5 90 14 G!/2" A 170 M20 x 1.5 170
18 G!/2" A 105 M22 x 1.5 160 16 G!/2" A 140 M22 x 1.5 190
22 G#/4" A 220 M26 x 1.5 285 20 G#/4" A 320 M27 x 2 320
28 G1" A 370 M33 x 2 425 25 G1" A 380 M33 x 2 500
35 G1!/4" A 600 M42 x 2 600 30 G1!/4" A 600 M42 x 2 600
42 G1!/2" A 800 M48 x 2 800 38 G1!/2" A 800 M48 x 2 800
Flare Fittings
Flare fittings are used to mount flared pipes on standard
fitting devices conforming to DIN 2353/ISO 8434 T1 1 2
and T4. Flare fittings comprise:
● Fitting device (14/1)
● Adapter (14/4)
● Support ring conforming to DIN 3949 (14/3)
● Union nut conforming to DIN 3949 (14/2)
The adapter creates the transition from the 24 cone of 4
the fitting device to the 37 flare fitting conforming to
SAE.
3
section, page 58.
Observe the length allowances for flaring; see
page 71.
▶ Oil the adapter and thread of the union nut (use a
paste sliding agent for non-rusting materials).
▶ Slide the union nut and support ring over the end of 2
the pipe. 3
▶ Flare the pipe with a suitable device (e.g. flaring
machine).
Check the flared edge and pipe for cracks and
clean. Make sure the inner taper has no grooves
and is clean.
Check the diameter of the pipe collar; see page 70.
▶ Push the adapter completely into the cone of the fit
ting device (14/4).
▶ Place the flared pipe on the adapter.
4
turning.
spanner.
As soon as the adapter has taken hold of the pipe,
there is a noticeable increase in torque.
▶ Tighten the union nut approx. 1 - 1!/2 turns using
the open end spanner (final assembly).
The adapter is pressed into the screw fitting cone
and is connected to the fitting device.
page 72.
Fig. 14 Flared screw fittings
▶ Each time a union nut is loosened make sure it is
tightened with the same tightening torque as for
final assembly.
Minimum Spacing for Straight Pipe Ends with Pipe Bends
Minimum Length for Short Pieces of Pipe
H L
Fig. 15 Minimum Spacing and Lengths
Outer pipe L Series S Series

diameter
6 8 10 12 15 18 22 28 35 42 6 8 10 12 14 16 20 28 30 38
Distance H 31 31 33 33 36 38 42 42 48 48 35 35 37 37 43 43 50 54 58 65
Length L 39 39 42 42 45 48 53 53 60 60 44 44 47 47 54 54 63 68 73 82
Reference Diameter for Pipe Collars

Pipe measurement Reference diameter
D smax Da min Da max
6 1.5 9.1 10.0
8 2 11.3 12.0
10 2 13.1 14.0
12 2 15.3 16.0
14 3 18.6 19.6
15 2.5 19.1 20.0
74
Da
16 3 20.6 22.0
18 2.5 23.2 24.0
smax
20 3.5 25.6 26.8

22 3 26.5 27.5
25 4 31.1 33.0
28 3 32.7 33.3
30 5 37 38.7
35 4 41.8 42.7
38 5 46.0 47.2
42 4 48.8 49.8
Fig. 16 Reference diameter
Determining Pipe Lengths for Flanged Screw Fittings
The pipe length is determined by measuring between the faces of the connection pieces. Measurement X is to be
subtracted from each pipe connection.
L1
Fig. 17 Determining the pipe length
Pipe measure X L1 Pipe measure X L1 Pipe measure X L1

ment ment ment
6x1 1 8 16 x 2.5 1.5 10 30 x 2 -0.5 13
6 x 1.5 2 9 16 x 3 2.5 11 30 x 2.5 0.5 14
8x1 1 8 18 x 1.5 0 7.5 30 x 3 1 14.5
8 x 0.5 2 9 18 x 2 1 8.5 30 x 4 3 16.5
8x2 2.5 9.5 18 x 2.5 1.5 9 30 x 5 4.5 18
10 x 1 1 8 20 x 2 1 11.5 35 x 2 1.5 12
10 x 1.5 2 9 20 x 2.5 2 12.5 35 x 2.5 2 12.5
10 x 2 3 10 20 x 3 3 13.5 35 x 3 3 13.5
12 x 1 1 8 20 x 3.5 4 14.5 35 x 4 4.5 15
12 x 1.5 2 9 22 x 1.5 1 8.5 38 x 2.5 0 16
12 x 2 3 10 22 x 2 2 9.5 38 x 3 0.5 16.5
14 x 1.5 0.5 8.5 22 x 2.5 3 10.5 38 x 4 2 18
14 x 2 1 9 22 x 3 3.5 11 38 x 5 4 20
14 x 2.5 2 10 25 x 2 1 13 42 x 2 1.5 12.5
14 x 3 3 11 25 x 2.5 1.5 13.5 42 x 3 3 14
15 x 1.5 1 8 25 x 3 2.5 14.5
15 x 2 2 9 25 x 4 4 16
15 x 2.5 3 10 28 x 2 1.5 9
16 x 1.5 0 8.5 28 x 2.5 2.5 10
16 x 2 1 9.5 28 x 3 3 10.5
Final Assembly Tightening Torque By Means Of Torque Wrench For Flanged Screw Fittings
Outer pipe diameter L Series

6 8 10 12 15 18 22 28 35 42
Md [Nm]
Md [Nm]
Outer pipe diameter S Series

6 8 10 12 14 16 20 28 30 38
Md [Nm]
Md [Nm]
Correction Table for Face-to-Face Lengths
L2
L3
Fig. 18 Correction Table for Face-to-Face Lengths
Outer pipe L Series

diameter 6x1 8x1 10 x 1.5 12 x 1.5 15 x 1.5 18 x 2 22 x 2 28 x 3 35 x 3 42 x 3
Measurement 17.5 18.5 19.5 20 21.5 23 24 26 30 34
L2
Measurement 20.5 21.5 24 24.5 25.5 27 30.5 31.5 36 40
L3
Outer pipe S Series

diameter 6x1 8x1 10 x 1.5 12 x 1.5 14 x 2 16 x 2 20 x 2 25 x 3 30 x 3 38 x 3
Measurement 17.5 18.5 20 20.5 23 25 27.5 31 33 37.5
L2
Measurement 20.5 21.5 24.5 25 27.5 31 33 38.5 41.5 48
L3
Straight Pipe Sections up to Bending Radius (Flared Fittings)
Bend first - then flare
The union nut can slide on the pipe bend.
Outer pipe dia Measurement L1

meter
6 43
8 44
10 46
12 47
14 50
15 50
16 52
18 58
20 58
22 60
25 60
28 60 L1
30 62
35 62
38 70
42 70 Fig. 19 Bend first - then flare
Flare first - then bend

If the pipe end is shorter than that specified in the table
due to difficulties in installation, the pipe is to be bent
after flaring.
Outer pipe dia Measurement L2 L2

meter
10 15
12 15
15 17
16 21
18 18
Fig. 20 Flare first - then bend
Taper Couplings Complying with DIN 3865
The following points are to be observed for taper coup
lings:
● The union nuts on the screw fittings cannot be
removed.
● Screw fittings with sealing cones are to be fitted in

the relevant screw fitting pieces in the final
assembly.
i INFORMATION
With non-rusting materials, the thread and the
tapered end are to be oiled. 1 2
▶ Insert the sealing cone (21/2) in the cone of the fit 3

ting device (21/3).
▶ Screw on the union nut (21/1) by hand until it tan
gibly reaches the stop on the fitting device.
▶ Tighten the union nut a maximum of !/2 a turn using
an open end spanner (final assembly).
Ready Assembled Screw Fittings with Shafts Fig. 21 Taper coupling

● Screw fittings with shafts are to be fitted in the rel
evant screw fitting pieces in the final assembly.
i INFORMATION
With non-rusting materials, the thread and the
tapered end are to be oiled.
▶ Firmly tighten the straight stud coupling.

▶ Screw on the union nut (22/1) by hand until it tan 2
gibly reaches the stop on the fitting device.
1 3
▶ Mark the position of the union nut.
▶ Tighten the union nut by turning approx. 30 using
an open end spanner (final assembly).
Use an extension (approx. 15 times the spanner
length; e.g. 22-L = 400 mm).
Fig. 22 Screw fitting with shaft
Welded Reducers
By using international, standard screw fitting systems
reducers can be used in a wide range of combinations.
If there are no standard reducers available, pipe ends 1
with different outer pipe diameters can be welded dir
ectly.
The following points are to be observed in the process:
● The volume flow must not be affected by the cross-
section narrowing.
● Observe the flow rate.
● Only create tapered reducers.
i INFORMATION
Never use pipe cutters or cut-off grinders to shorten 2 3
the pipes.
▶ Calculate the pipe lengths. Observe the minimum

lengths.
ÇÇÇÇÇÇÇÇÇ
D
▶ Saw off the pipes at a right angle without deforming
using a sawing device; the permissible angular
ÉÉÉÉÉÉÉÉ
ÇÇÇÇÇÇÇÇÇ
deviation to the pipe axis is a maximum of 0.5
(23/1). ÉÉÉÉÉÉÉÉ 1xD
4
▶ Remove contamination from the pipe ends (e.g.

shavings, dirt and paint). If necessary, clean with
degreaser.
▶ Bevel the inside of pipe ends with smaller outer
pipe diameters (23/2). Fig. 23 Welded reducers
▶ Bevel the outside of pipe ends with larger outer
pipe diameters (preparation for welding [23/3]).
▶ Without forcing it, insert the smaller pipe end in the
larger pipe end by hand. Observe the minimum
insertion depth (23/4).
▶ Weld the entire circumference of the pipes so they
are sealed.
▶ Clean the weld joint both inside and out. Pickle the
weld joint and remove any scale.
Flanged Joints
i INFORMATION 1
Hose lines are equipped with a pair of flanges (flange
and mating flange fittings).
Components
By using international, standard 4-hole flanged joints
(ISO 6162 T1 [SAE J518 Code 61] and ISO 6162 T2
[SAE J518 Code 62]) flanged fittings, mating flange fit
tings and flange halves can be used in a wide range of
combinations. Flanged joints comprise:
● Flanged fittings (4-hole full face flange and flange 2

adapter) have an O-ring groove and bolt holes.
● Mating flange fittings do not have an O-ring groove,

but have a tapped bore (e.g. metric). Mating
flanges are always used in conjunction with a
flanged fitting (flange with O-ring). Connecting
faces on components are always designed as
mating flanges.
● Flange halves (two flange halves or whole flange

half) are used in conjunction with flange adapters.
Connection Methods
3
● Flanged joints with weld joints offer the option of
connecting pipes with flanges by means of
welding. Flanged joints are designed as a welded
on connection (24/1) or welded in connection
(24/2).
● Full face flanges with threaded connections allow

a 4-hole flanged joint to be connected to an existing
threaded connection. Full face flanges are
designed with an inner thread (24/3) or external
thread (24/4).
● Flange adapters always have an internal thread,
allowing pipes and hoses with 4-hole flanged joints 4
to be connected by means of a threaded connec
tion piece (e.g. flare fitting).
Fig. 24 Flanged joints
▶ Mount the flanged fitting on the pipe. 1
For welded on flanges:
1. Bevel the outside of the pipe end (preparation
for welding).
2. Weld the entire circumference of the pipe to 1 4
seal it.
3. Clean the weld joint both inside and out (scale-
free and pickled).
3 2
For welded in flanges:
1. Insert the pipe end into the flanged fitting and
push in firmly as far as it will go.
2. Weld the entire circumference of the pipe to
seal it.
Fig. 25 Tightening order
3. Clean the weld joint both inside and out (scale-
free and pickled).
For internal or external threads:
1. Prepare the thread surfaces observing the
separate SCHOTTEL Installation Instructions
for Bolted Connections and Sealants in this
Service Manual.
2. Screw the pipe to the flanged fitting; see
"Screw Fittings" section, page 61.
Observe the maximum tightening torque;
see pagee 68.
▶ Check the surface of the O-ring. Make sure there
are no burrs, notches, scratches or foreign bodies
present.
▶ Lubricate the O-ring with oil.
▶ Position the flange.
▶ Tighten up the bolts by hand.
▶ Tighten the bolted connections gradually in line
with the pattern shown in figure 25.
Observe the maximum tightening torque, see sep
arate SCHOTTEL Installation Instructions for
Bolted Connections and Sealants in this Service
Manual.
DANGER
Hazard to life or risk of serious injuries due to sudden
expansion of the oil.
▶ Depressurise the line system and/or line section
before tightening screw fittings and parts.
After installation the following points are to be

observed:
● Check the line system and/or line section for loose
screw fittings, flanged joints and bolted connec
tions.
● Flush the line system and/or line section (ISO 4406

class 20/18/15) and bleed.

● Check the line system and/or line section for leaks

by applying 1.5 times the operating pressure.

10.7 Replacement of Hose Lines
The hose lines used must comply with all of the charac
teristics specified in the Hydraulic Circuit Diagram (e.g.
material; nominal pressure).
10.7.1 General Points
i INFORMATION
The requirements of national and technical regula
tions specific to the application of hose lines, and the
valid laws, acts and stipulations of the country where
they are used apply without restriction and are to be
fully observed (e.g. DIN 20066 T4).
Every hose line is designed with features specified by

SCHOTTEL. Use in other conditions (also for other
media) requires the materials used for hose lines and
hose fittings to be checked with regard to the changed
conditions. This is to be organised by the operator and
documented, or SCHOTTEL is to be commissioned to
carry this out. During this examination, the design of the
hose lines is checked and the relevant documents
reviewed. As a rule, an "Examination as to Safe Prepar
ation and Use" then needs to be carried out for the hose
line.
It is crucial that the following points are always
observed when using hose lines:
● Never exceed the maximum permitted operating
pressure for the hose line.
● Never exceed the maximum permitted temper
ature in terms of the oil used.
● In operating conditions, the hose line materials
must be resistant to the oil used.
● Hose line wear in terms of potential abrasion is to
be calculated and checked.
Pressure Equipment Directive (14th. GPSGV)
i INFORMATION
Only hose lines pre-fabricated by a hose manufac
turer may be used in the hydraulic system.
SCHOTTEL GmbH will void any warrantees and
modifications, repairs and manipulations to hose
lines.
The fabricated hose line is designed, manufactured

and certified as a rigid line according to the Pressure
Equipment Directive (14th GPSGV "Equipment and
Product Safety Act'). The hose line forms a unit com
prising the relevant hose, both sides of the hose fittings
and the two identification tapes.
When selecting the hose lines the following points are
to be observed:
● Only use standard hose lines.
● The requirement of identification tapes for the hose

line is to be fulfilled.
● The operating pressure, nominal diameter and

hose fittings of the new hose line must correspond
with those of the old hose line.
● The usage and storage period is to be observed for

the period of use starting from the date of manufac
ture of the hose line; (maximum period of use for
hose lines is five years, including a maximum
storage period of two years).
Cleaning
DANGER
necting parts and hose lines bursting.
▶ Do not use steam lances for cleaning purposes.
Clean hose lines after use and before each inspection

with suitable agents and flush (ISO 4406 class
20/18/15). When cleaning with steam or chemical
additives pay attention to the resistance of hose com
ponents.
Inspection Intervals
The condition of the hose lines used is to be checked by
a competent person authorised to do so by the operator
to ensure they are safe for operational use:
● After installation and prior to using a hose line
● After accidents, modifications (conversions) to the

hydraulic system and longer periods of non-use
(extraordinary inspection)
● After corrective maintenance work on the

hydraulic system, which may result in safety being
affected
● Repeatedly, at stipulated, regular intervals
observed:
cool.
● Before opening the line section concerned, check

that the hose line has been fully depressurised.
Always open the hose line fittings slowly and care
fully.
● Place a suitable collecting basin under the hose

line concerned to catch any residual oil that may
leak out.
● Clean and flush the hose line to be installed prior to
installation (ISO 4406 class 20/18/15).
● Make sure hose lines are only installed in line with
specifications and used for their intended purpose.
● Hose lines must not be used for longer than the

maximum period of use, including the maximum
storage period.

observed:
● Hose lines are to be protected against damage

caused by the effects of external mechanical,
thermal or chemical factors.
● If there is visible damage to the hose line, it must

not be installed.
● The hose lines need to be accessible at all times
following installation.
● After installation, hose lines must not be used as a
ladder or climbing support.
● Hose lines must never be painted over.
Torsion, Traction and Compression
i INFORMATION
1
When installing a hose line with an elbow fitting,
always mount the elbow fitting first.
● Prevent torsion (26/2).

Hose lines must not be obstructed from taking up
their natural position or moving. 2
● Prevent traction and compression (26/1).

Take account of potential shortening or extension
under pressure. Install hose lines so they sag.
● Do not bundle together hose lines with different 3
operating pressures (different linear expansion).
● Use suitable hose fittings (e.g. elbow fitting of 30,
45 or 90) or connection pieces to prevent addi
tional strain on the hose line (26/3).
Permissible Bending Radius

● Observe the permissible bending radius.
Make sure the bending radius for the hose line is
not smaller than that specified by the manufac
turer.
The permissible bending radius is specified in line
with the relevant standards for each type of hose in
relation to the nominal width (e.g. DIN EN 853 bis
DIN EN 857 and DIN 20021).
● The length of any hose line bend inserted after a

straight section needs to be at least 1.5 times the
external diameter da (26/4).
● Avoid bending the hose directly after the connec
tion (26/5).
4
1.5 x da
Fig. 26 During Installation
Abrasion, Chafing and Bending
● Protect hose lines from external damage, such as
abrasion caused by chafing (27/2) or mechanical-
related nicks (27/1).
● Protect loosely laid hose lines from damage, abra

sion and deformation (use hose protection ramps).
Hose Brackets
● Use hose clamps to hold the hose that do not 1

clamp it and have a smooth inner surface (27/3).
● Mount hose brackets on the straightest sections

possible (27/4).
● Hose brackets must not obstruct the natural move

ment of the hose line or changes to its length (27/5).
● If hose lines are directly connected to a rigid line, a 2

pipe clamp is to be mounted immediately after the
screw fitting (27/6).
3
Effects of Temperature
● Protect hose lines from the damaging effects of
temperature both inside and out.
● Do not install hose lines near sources of heat.
Fig. 27 During Installation
observed:
and bleed it.
● Check the line section for loose screw fittings,
flanged joints and bolted connections.



11 Troubleshooting
The following points are to be observed during Successful troubleshooting requires precise know
troubleshooting: ledge of the hydraulic system structure and mode of
operation, and of the individual components.
cannot be started up unintentionally before The combination of hydraulics and electrics/elec
troubleshooting. Switch off the power to the tronics can complicate troubleshooting; therefore,
hydraulic motors and make sure they cannot be cooperation between hydraulics and electrical engin
started up unintentionally. eers is paramount.
● Observe the special safety measures for intercon Always proceed systematically and purposefully even
nected hydraulic systems, if individual sub-assem under time pressure. In the worst case scenario, ran
blies are still in operation, or have to be switched on domly and rashly changing the settings and removing
again during troubleshooting. components may mean that the original cause of the
fault can no longer be established.
WARNING
it off and make sure it cannot be started up unin
Any deviations from the hydraulic system's usual oper

ating conditions indicate malfunctions and are to be
remedied immediately.
The table does not make any claim to completeness.
During operation, malfunctions may occur that are not
listed in the table.
table, please notify the SCHOTTEL Customer Service
Department. For SCHOTTEL GmbH contact details,
see page 2.
● Suspected cause
11.1 Line System
11.1.1 Abnormal Noises
Cavitation in the hydraulic system Filter clogged Replace the filter
Foreign bodies in the suction line Flush the line system
Suction line leaking; air is being Seal the leaks

drawn in
Too many bends in the suction line Reinstall the suction line or use a
larger nominal diameter
Suction line too long Shorten the suction line; improve

the rigid line routing
Damaged rigid line or bent hose line Repair or replace the rigid line,
in the suction line replace the hose line and, if neces
sary, improve the rigid and hose
line routing
Partially closed valve in the suction Make sure the oil can flow through
line the valve (e. g. check position;
clean the valve)
Wrong oil Check the oil used; observe the Oil

Specifications
Hydraulic pump speed is too high Check the hydraulic motor speed
(observe the Hydraulic Circuit Dia
gram)
Foam formation or trapped air in oil Oil level too low Check the oil level and fill it up, if
necessary.
Reservoir has been installed in the Check the reservoir's place of

wrong place installation and change if necessary

Specifications
Inadequate bleeding Lay the vent line properly and bleed

the line system
Mechanical vibration Imbalance between hydraulic motor Check the alignment and coupling;
and hydraulic pump check for wear and repair or
replace, if necessary
Vibration in the rigid line Check the fastening parts and

tighten, or improve the installation
situation
Mechanical vibration (continuation) Rigid line installed wrongly Improve the rigid line routing
Hydraulic pump damaged or Repair or replace the hydraulic

defective pump
Hydraulic motor damaged or Repair or replace the hydraulic

defective motor
Pressure relief valve unstable (flap Check the setting and adjust, if
ping) necessary, or replace the pressure
relief valve
Check valve damaged or defective Replace the check valve
Fastening bolts on motor bracket Tighten the fastening bolts

loose
Inflow and outflow rates too high/too Filter clogged Replace the filter
low
11.1.2 No or Insufficient Feed Pressure

Hydraulic pump not pumping or Foam formation or trapped air in oil See "foam formation or trapped air
only inadequately in oil" malfunction

Specifications
Filter clogged Replace the filter
Valve in ine system clogged (e.g. Clean the valve, or replace

foreign bodies in housing) or dam
aged
Inadequate rigid line routing Improve the rigid line routing

defective pump
Excessive vacuum in suction line Filter clogged Clean the filter

due to high flow friction
Nominal diameter of suction line too Enlarge the nominal diameter of the
small suction line
Too many bends in the suction line Reinstall the suction line or use a
larger nominal diameter
Suction line too long Shorten the suction line; improve

the rigid line routing
Hydraulic pump overheated Wrong oil Check the oil used; observe the Oil
Specifications

defective pump
Insufficient cooling Improve the rigid cooling line

routing
Oil cooler damaged or defective (if Repair or replace the oil cooler
present)
Hydraulic pump speed is too high Check the hydraulic motor speed
Operating pressure not reached; Pressure relief valve damaged or Replace the pressure relief valve
constant drop in pressure defective
Wrong setting on the pressure relief Check the setting and adjust, if
valve necessary
Oil level too low Check the oil level and fill up, if
necessary
Hydraulic motor rotating in wrong Wire up the electrical connections

direction (electrical connections properly
wired up wrongly)
11.1.3 No or Insufficient Flow Rate

Hydraulic pump is pumping against Shut-off valve is closed on the pres Open the shut-off valve on the pres
excessive pressure sure side sure side
Insufficient cross-section ratios Filter clogged Replace the filter
Line system leaking Seal the leaks
Foam formation or trapped air in oil See "foam formation or trapped air
in oil" malfunction
Line system clogged (e.g. valve; Flush the line system

rigid line)
Insufficient speed transmission Imbalance between hydraulic motor Check the alignment; check for
between hydraulic motor and and hydraulic pump wear and repair or replace, if
hydraulic pump necessary
Pressure relief valve defective Wrong setting Check the setting and adjust, if
necessary
Pressure relief valve clogged or Replace the pressure relief valve

defective
11.1.4 No Oil Fed to Actuator
Power supply switched off Maintenance work being carried out Finish maintenance work
on hydraulic system
Emergency stop triggered Emergency stop triggered in entire Remedy the cause and malfunction
propulsion system
Hydraulic motor is not in operation Electrical connections not right Wire up the electrical connections
properly
Power supply switched off (main Finish maintenance work

tenance work being carried out on
hydraulic system)
Hydraulic motor damaged or Repair or replace the hydraulic

defective motor
Motor circuit breaker switches off See "motor circuit breaker switches
off" section
Hydraulic motor is working; Coupling is damaged or defective Repair or replace the coupling
hydraulic pump is not
Motor circuit breaker switches off Electrical connections not right Wire up the electrical connections
properly
Wrong supply voltage or frequency Compare to rating plate
Line system clogged (e.g. valve; Flush the line system

rigid line)
Motor circuit breaker is switched off Maintenance work being carried out Finish maintenance work
on hydraulic system
11.2 Fluctuations in the Feed Pressure and Flow Rate
Trapped air in the line system, Line system not bled properly Bleed the line system
causing an uneven or slackening
movement Electric control defective; e.g . Check the function of the hydraulic
valves are constantly switching system according to the Wiring Dia
gram and Hydraulic Circuit Diagram
11.3 Measurement and Control Technology

Absent output signal on the meas Signal line interrupted or defective Check the signal line
urement and control equipment
Electrical connections not right Wire up the electrical connections
properly
Measurement and control equip Replace the measurement and con

ment damaged or defective trol equipment
Same output signal when pressure Mechanical overload Replace the measurement and con
changes trol equipment

Signal voltage insufficient Supply voltage too low or absent Check the supply voltage
Working resistance too high or too Adjust the working resistance or

low supply voltage
Mechanical overload Replace the measurement and con

trol equipment
Zero point signal too high or too low Mechanical overload Replace the measurement and con
trol equipment
Signal characteristic curve non Mechanical overload Recalibrate the measurement and
linear control equipment
Absent input signal on the measure Signal line interrupted or defective Check the signal line
ment and control equipment
Measurement and control equip Electrical connections not right Wire up the electrical connections
ment not switching properly
Supply voltage too low or absent Check the supply voltage

Sporadic faulty control of measure Extreme radio interference Shield the supply voltage
ment and control equipment
Extreme vibration Eliminate vibration; if necessary,
relocate the measurement and con
trol equipment

Specifications
11.4 Valves
Safety valve (e.g. pressure relief Sealing surfaces, sealing elements, Clean the safety valve or replace, if
valve; overflow valve) constantly valve seat or similar contaminated necessary
discharges or damaged in the valve
Pressure spring broken Replace the safety valve
Response pressure set wrongly Check the setting and adjust, if

necessary
Differential pressure too low Check the operating pressure and

adjust, if necessary
Safety valve (e.g. pressure relief Response pressure set wrongly Check the setting and adjust, if
valve; overflow valve) responds at necessary
low pressure
Differential pressure too low Check the operating pressure and
adjust, if necessary
Safety valve (e.g. pressure relief Sealing surfaces, sealing elements, Clean the safety valve or replace, if
valve; overflow valve) not valve seat or similar contaminated necessary
responding or damaged in the valve
Response pressure set wrongly Check the setting and adjust, if

necessary
Connections mixed up Check connections and correct
Valve leaking Differential pressure too high Check the line system
Sealing surfaces, sealing elements, Open the valve and repeat the
valve seat or similar contaminated closing process
or damaged in the valve
Clean the valve, or replace, if

necessary
Valve cannot be operated Valve contaminated or clogged Clean the valve, or replace, if
(e.g. foreign bodies in the housing) necessary
Valve cannot be operated (continu Power supply has failed Check the power supply
ation)
Power supply switched off (main Finish maintenance work
tenance work being carried out on
hydraulic system)
Leak between valve and connection Connection device not installed Mount the connection device prop
device tightly (e.g. screw fitting not erly
tightened properly)
Valve fitted improperly Loosen the connection device and

remount
Seal, flange seal, etc. defective Remove the valve and reseal
Interruptive opening and closing of Sealing surfaces, sealing elements, Open the valve and repeat the
valve valve seat or similar contaminated closing process
or damaged in the valve
Valve contaminated or clogged Clean the valve, or replace, if

(e.g. foreign bodies in the housing) necessary
12 Removal
The following points are to be observed prior during
removal: CAUTION
● The hydraulic system may only be removed by Slipping, falling and tripping over
specialist staff trained and qualified to carry out Head injuries and cuts to limbs due to sharp edges
this task. and pointed corners
● The laws, acts and regulations applicable in the protective clothing and a safety helmet.
cannot be started up unintentionally before com NOTICE
mencing any removal work.
● Before commencing any removal work, close off Environmental damage caused by the improper dis
access to the work area to any unauthorised per posal of materials harmful to the environment
sons. Display an information sign to indicate the ▶ Observe the safety data sheets.
removal work in progress.
● When handling operating materials and supplies, mentally friendly way.
the safety regulations for the product concerned ▶ Always observe the national and international
are to be observed. Refer to and observe the regulations regarding the disposal of materials.
safety data sheets in this Service Manual.
DANGER
Voltage
voltage
when working on any kind of electrical compon
ents.
unintentionally.
WARNING
The following tasks are to be carried out during removal:
▶ Switch the hydraulic system off and make sure it
▶ Drain out all operating materials.
▶ Remove all electric cables properly.
▶ Dismantle rigid and hose lines properly.
WARNING
Risk of injury due to thermal and mechanical cut
ting work
Burns and cuts to limbs
NOTICE
Damage to the hydraulic system
Hydraulic system sub-assemblies and components
may become damaged during thermal or mechanical
cutting work.
▶ Only perform cutting work properly as set out in
▶ Separate the welded joints by flame cutting or

grinding.
▶ Separate all bolted connections between the sub-
assemblies and the vessel structure.
i INFORMATION
Once these measures have been carried out,
hydraulic system sub-assemblies and components
are separated and can be lifted. For lifting the sub-
assemblies and components, see the "5 Transporta
tion" section, page 24.
13 Storage
13.1 Short-Term Storage
i INFORMATION
For information on activities that have to be carried out
on the individual sub-assemblies, please refer to the
relevant operating instructions in this Service Manual.
For short-term storage, the hydraulic system sub-

assemblies and components are removed from the
vessel and put into storage for a period of up to six
weeks.
i INFORMATION
To prevent corrosion damage to the hydraulic system
sub-assemblies and components, contact the
SCHOTTEL Customer Service Department before
placing them in short-term or long-term storage. For
SCHOTTEL GmbH contact details, see page 2. The
SCHOTTEL Customer Service Department will draw
up an individual storage procedure schedule.
● The storage area has to be clean and dry (relative

humidity < 65%).
● Make sure there is no exposure to direct sunlight or
high UV radiation from a light source.
● Make sure there is no vibration in the near vicinity
of the sub-assemblies and components.
● Do not operate any ozone generating equipment in
the storage area (electric motors, high-voltage
equipment, neon tubes).
● Make sure that hydraulic system sub-assemblies
and components are accessible for inspections.
● The valid laws, acts and stipulations of the country
where components with elastomers are used (e.g.
hoses, hose lines, and seals) are to be observed
(e.g. DIN 7716 and DIN EN 982).
13.2 Long-Term Storage
i INFORMATION
For information on activities that have to be carried out
on the individual sub-assemblies, please refer to the
relevant operating instructions in this Service Manual.
For long-term storage, the hydraulic system sub-

assemblies and components are removed from the
vessel and put into storage for a period of over six
weeks.
i INFORMATION
To prevent corrosion damage to the hydraulic system
sub-assemblies and components, contact the
SCHOTTEL Customer Service Department before
placing them in short-term or long-term storage. For
SCHOTTEL GmbH contact details, see page 2. The
SCHOTTEL Customer Service Department will draw
up an individual storage procedure schedule.
13.2.1 Hose Lines and Seals

The maximum storage periods for hose lines and seals:
● Hose Lines: 2 years

● Hoses: 4 years
● NBR seals: 4 years
● FKM seals: 10 years
Storage Conditions
● Store hose lines, hoses and seals free from strain

and in a horizontal position. When storing hose
lines or hoses in coils ensure that the bending
radius is not smaller than that specified by the man
ufacturer.
● Do not stack hose lines.
● Where possible, store seals in their original pack

aging; prevent air circulation.
14 Disposal
WARNING
NOTICE
Environmental damage caused by the improper dis
posal of materials harmful to the environment
▶ Observe the safety data sheets.
mentally friendly way.
▶ Always observe the national and international
regulations regarding the disposal of materials.
14.1 Scrapping
If the hydraulic system or its sub-assemblies are no
longer operational, the operator is to ensure that these
are properly scrapped; this means a state in which the
hydraulic system or its sub-assemblies can no longer
be used for their intended purpose.
SCHOTTEL GmbH shall not assume any responsibility
for any personal injuries or material damage that may
occur as a result of a hydraulic system sub-assembly
being reused for a purpose other than its intended use.
The following points are to be carried out during the
scrapping process:
● Disassemble the sub-assembly into individual
parts.
● Lock movable parts.
● Dispose of individual parts properly.
14.2 Disposal
The operator is to ensure that materials are disposed of
in an environmentally sound process. When doing this,
the regulations regarding the disposal of operating
materials and supplies applicable at the site of opera
tion are to be observed.
The disposal process is to include the recovery of basic
materials from the hydraulic system. These materials
might be able to be reused in a recycling process.
Materials harmful to the environment need to be dis
posed off with extra care; these include:
● Plastic parts
● Rubber parts
● Electric parts
● Metal parts
● Operating materials and supplies
3.3 Electrics
BLANK PAGE
Control and Electrical System
Table of Contents
Overview of the propulsion systems . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Control desks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
At the port side and starboard stern propulsion systems . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
Main control desk . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
Operating controls and indicators . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
Control system switch cabinet . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
Operating controls and indicators . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
Additional engine control room indicator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
Indicator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
Control and operating modes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
Control modes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
Full follow-up (FFU) control mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
At the main control desk . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
Non-follow-up (NFU) control mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
Operating modes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
Clutch mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
Manual mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
Automatic mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
Fire fighting mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
At the main control desk of the starboard stern propulsion system . . . . . . . . . . . . . 28
2 Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
Starting up the propulsion systems . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
Switch on the power supply at the control system switch cabinet . . . . . . . . . . . . . . . . . . 29
Control system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
Manual operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
Switching the propulsion system on . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
Switching the propulsion system off with no load . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
Switching the propulsion system back on . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
Selecting the control desk . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32
Taking command at the control system switch cabinet . . . . . . . . . . . . . . . . . . . . . . . . . . 32
Transferring command from the control system switch cabinet to the main
control desk . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34
Selecting the control mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36
Activating full follow-up (FFU) control mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36
At the main control desk . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36
Activating non-follow-up (NFU) control mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37
At the main control desk . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37
Selecting the operating mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38
en TTD-Kt Control and Electrical System 2014/10 1207405 1/52

Clutch mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38
Manual mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38
In full follow-up (FFU) speed control mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38
In non-follow-up (NFU) speed control mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40
Automatic mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41
Activating automatic mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41
In full follow-up (FFU) speed control mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42
In non-follow-up (NFU) speed control mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43
Deactivating automatic mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44
Manually disengaging the clutch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45
Fire fighting mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46
Activating fire fighting mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46
Deactivating fire fighting mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47
Controlling thrust direction and speed . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48
At the main control desk . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48
Controlling thrust direction using the thrust direction handle . . . . . . . . . . . . . . . . . . . . 48
Controlling thrust direction using the illuminated buttons . . . . . . . . . . . . . . . . . . . . . . . 49
Controlling speed using the speed control lever . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50
Increasing speed . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50
Decreasing speed . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50
Controlling speed using the illuminated buttons . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51
Increasing speed . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51
Decreasing speed . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51
Emergency operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 52
Controlling thrust direction using the manual operation device . . . . . . . . . . . . . . . . . . . . 52
2/52 TTD-Kt Control and Electrical System 2014/10 1207405 en

Preliminary notes
These Instructions provide information and guidance to Given that SCHOTTEL propulsion systems are subject
all persons involved in the initial start-up, operation and to further development, we reserve the right to carry out
maintenance of SCHOTTEL propulsion systems. They technical modifications.
are to be read, understood, and observed at all times.
Important instructions relevant to technical and
These Instructions are to be made available to all operational safety are identified by the following
persons working on and with the propulsion systems. symbols:
We shall not accept liability for any damage or
malfunctions resulting from non-observance of these ! WARNING
Instructions.
It is a prerequisite that all users are familiar with the Indicates working and operating methods that are to be
propulsion systems and have been informed about the strictly observed to prevent any risk to personal safety.
Only trained and qualified staff are permitted to carry out
work on the propulsion systems.
! CAUTION
Indicates working and operating methods that are to be
References to illustrations are written in brackets in the strictly observed to prevent damage to or destruction of
text, e.g. (1/3). The first number refers to the illustration materials.
number in the illustration.
NOTICE
All illustrations are schematic diagrams and do not
make any claim to completeness. Indicates specific features of the working process which
Any technical modification to SCHOTTEL propulsion are to be observed.
systems to be performed by non-SCHOTTEL staff
requires written authorisation.
i INFORMATION
However, this does not include any of the modifications
or control settings described in our Instructions. Application instructions and information.

force in the respective country they are used.
These Instructions have been written with the utmost care and attention to detail.
However, should you require any further information, please contact:
SCHOTTEL GmbH
Mainzer Straße 99
56322 Spay
Germany
Phone +49 (0)2628 610
Fax +49 (0)2628 61300
E-mail [email protected]

Overview of the propulsion systems
The vessel is equipped with the following propulsion
units:
D Two SCHOTTEL RUDDER PROPELLERS 1515

FP (referred to as port side stern propulsion
system and starboard stern propulsion system
in the following) used as the main propulsion units
in the stern.
Refer to the Technical Specification and the Spare
Parts Catalogue for all technical data and for the design
of your propulsion systems.
Each propulsion system includes:
D SRP 1515 FP
D Hydraulic system SST 612 (mechanical pump unit
HPV 135 and oil expansion tank)
D Control system switch cabinet
D Main control desk
D Warning system
D Additional engine control room indicator

i INFORMATION
Port side and starboard stern propulsion systems
For a description of the SRP 1515 FP propulsion unit,
see the SCHOTTEL Operating Instructions in this
Service Manual.
For a description of hydraulic system SST 612, see the
SCHOTTEL Operating Instructions in this Service
Manual.
For a description of the S-ODS system display, see the
SCHOTTEL User Documentation in this Service
Manual.
For a description of the warning system, see the
SCHOTTEL Operating Instructions in this Service
Manual.

Stern propulsion Stern propulsion
system system
Port side Starboard
Fig. 1 Overview of all propulsion units

Port side and starboard stern propulsion systems
Key for figure 2:
1 Warning system of port side stern propulsion
system
2 Main control desk of port side stern propulsion
system
3 Main control desk of starboard stern propulsion
system
4 Warning system of starboard stern propulsion
system
5 Control system switch cabinet of starboard stern
propulsion system
6 Additional engine control room indicator of
starboard stern propulsion system
7 Mechanical pump unit HPV 135 of starboard stern
propulsion system
8 Oil expansion tank of starboard stern propulsion
system
9 SRP 1515 FP of starboard stern propulsion system
10 SRP 1515 FP of port side stern propulsion system
11 Oil expansion tank of port side stern propulsion
system
12 Mechanical pump unit HPV 135 of port side stern
propulsion system
13 Additional engine control room indicator of port
side stern propulsion system
14 Control system switch cabinet of port side stern
propulsion system

Bridge deck
Bow
1 2 3 4
Engine
control room
14 5
13 6
12 7
11 8
10 9
Fig. 2 Overview of the propulsion systems

Control desks
At the port side and starboard stern propulsion systems
Main control desk
The main control desk is equipped with the following types of illuminated buttons and indicator lights:
D Illuminated buttons D Indicator lights
The edges of the illuminated buttons are marked by The edges of the indicator lights are marked by a
a thick blue frame and are slightly raised (finger thin blue frame.
guidance). The illuminated buttons have a clearly
defined pressure point and a non-lock design.
The front cover of the control desk is covered by a film printed with the necessary functions. Each of the illuminated
buttons and indicator lights has a coloured LED (Light Emitting Diode).
During system configuration, it is specified which illuminated buttons or indicator lights are parametrised in the
software and which illuminated buttons are provided with background illumination. None of the status indicators have
background illumination; the lettering is only illuminated when a malfunction alarm has been activated.
When the illuminated buttons or indicator lights are activated or selected during operation, the illumination intensity
(brightness) increases. Depending on the function, either the whole surface of the illuminated button or indicator light
lights up (lettering is black), or just the lettering is illuminated.
i INFORMATION
The arrangement of the operating controls and indicators on the main control desk of the port side and starboard stern
propulsion systems is almost identical. Differences in functions are indicated in a footnote. Some of the operating
controls and indicators on the main control desk of the port side and starboard stern propulsion systems are the
reverse order of each other (mirror image).
Controls and indicators
Pos. Controls and indicators Function
1 Thrust direction indicator The red pointer on the indicator displays the current thrust direction
of the propulsion unit, regardless of the active control desk and the
selected control and operating mode.
2 Speed indicator Displays the current speed of the propeller in revolutions per minute
regardless of the active control desk and the selected control and
operating mode.
3 Illuminated Ô "turn propulsion When non-follow-up thrust direction control mode is activated, the
unit" button (yellow) propulsion unit will rotate anti-clockwise as long as the illuminated
button is pressed.
Lights up when non-follow-up thrust direction control mode is activ
ated for the propulsion unit.
The illuminated button has no background illumination. The illumina
tion intensity cannot be adjusted.

1 2
BACKUP CONTROL
AZIMUTH RPM
6 NFU LOCAL
RPM RPM RPM
ON/OFF
3 4 5 7 8 9 10
EXTERNAL SYSTEMS DESK SELECTION CLUTCH CONTROL
MAIN
RPM
14 13 12 11
TAKE FAULT
ON OVER UNIT
15 16 17 18
LOCKED
DIMMER DIMMER LAMP
DISPLAY PANEL CHECK
23 22 21 20 19
MODES LIGHT CONTROL STATUS
24
25
26
Fig. 3

4 "Azimuth" indicator light (green) Lights up when full follow-up thrust direction control mode is activ
5 Illuminated Õ "turn propulsion When non-follow-up thrust direction control mode is activated, the
unit" button (yellow) propulsion unit will rotate clockwise as long as the illuminated button
is pressed.
Lights up when non-follow-up thrust direction control mode is activ
6 Illuminated NFU ON/OFF button Activates and deactivates non-follow-up control mode for thrust dir
(yellow) with protective frame ection and speed.
Lights up when non-follow-up control mode is activated for thrust dir
ection and speed.
7 LOCAL indicator light (yellow) Lights up during local manual operation of the control system switch
cabinet.
8 Illuminated RPM ↓ button (yellow) When non-follow-up speed control mode is activated, the engine
speed will decrease as long as the illuminated button is pressed.
Lights up when non-follow-up speed control mode is activated for the
engine.
9 RPM indicator light (green) Lights up when full follow-up speed control mode is activated for the
engine.
10 Illuminated RPM ↑ button (yellow) When non-follow-up speed control mode is activated, the engine
speed will increase as long as the illuminated button is pressed.
Lights up when non-follow-up speed control mode is activated for the
engine.
11 "Clutch engaged" indicator light Lights up when the clutch is engaged, regardless of the active control
(green) desk or selected control and operating mode.

1 2
BACKUP CONTROL
AZIMUTH RPM
6 NFU LOCAL
RPM RPM RPM
ON/OFF
3 4 5 7 8 9 10
MAIN
RPM
14 13 12 11
TAKE FAULT
ON OVER UNIT
15 16 17 18
LOCKED
DIMMER DIMMER LAMP
DISPLAY PANEL CHECK
23 22 21 20 19
24
25
26
Fig. 4

12 Illuminated RPM "automatic clutch Activates automatic clutch mode.

mode" button (orange) The clutch is engaged or disengaged using the speed control lever
(5/25) or illuminated RPM ↑ (5/10) and RPM ↓ buttons (5/8)
depending on which control mode has been activated.
Lights up when automatic clutch mode is activated, regardless of
which control desk is active or which control and operating mode is
selected.
13 Illuminated "clutch disengaged" Deactivates automatic clutch mode.

button (blue) During operation, this disengages the clutch in emergency situ
ations.
Lights up when the clutch is disengaged, regardless of which control
desk is active or which control and operating mode is selected.
14 Illuminated MAIN button (yellow) Lights up when the main control desk is active.
15 Illuminated "fire fighting mode" ON Activates and deactivates fire fighting mode.
button (green) 1* Lights up when fire fighting mode is activated.
Flashes when the fire fighting system has been activated, the fire
pump clutch is engaged, and the pipes are filled.
16 Illuminated TAKE OVER button Flashes when a transfer of command from the control system switch
(white) with imprinted button face cabinet is pending.
17 FAULT UNIT indicator light (red) Lights up when a common alarm activated by the propulsion system
is signalled by the vessel's alarm monitoring system and goes out
once the fault has been rectified (serves only as a status indicator and
does not supersede the vessel's alarm monitoring system).
18 "Power supply" indicator light (red) Lights up when there is a malfunction in the propulsion system's
power supply and goes out once the fault has been rectified (serves
only as a status indicator and does not supersede the vessel's alarm
monitoring system).
19 LOCKED indicator light: "propul Lights up when the propulsion unit feedback fails to correspond with
sion unit locked" (red) the setpoint and goes out once the fault has been rectified (serves
only as a status indicator and does not supersede the vessel's alarm
monitoring system).
20 "Azimuth" indicator light (propul Lights up when the propulsion unit's full follow-up thrust direction
sion system does not follow up control mode is blocked due to a mechanical or electrical fault and
[red]) goes out once the fault has been rectified (only serves as a status
indicator and does not supersede the vessel's alarm monitoring
system).
1* Only on the main control desk of the starboard stern propulsion system

1 2
BACKUP CONTROL
AZIMUTH RPM
6 NFU LOCAL
RPM RPM RPM
ON/OFF
3 4 5 7 8 9 10
MAIN
RPM
14 13 12 11
TAKE FAULT
ON OVER UNIT
15 16 17 18
LOCKED
DIMMER DIMMER LAMP
DISPLAY PANEL CHECK
23 22 21 20 19
24
25
26
Fig. 5

21 Illuminated LAMP CHECK button Carries out a lamp test on the illuminated buttons and indicator lights.
(orange) Verifies that all illuminated buttons and indicator lights light up.
The buzzer will sound while this button is being pressed.
22 Illuminated DIMMER PANEL Adjusts the brightness of the illuminated buttons and indicator lights.
button (orange) The illuminated button is pressed to adjust the brightness to max
imum and again to attain minimum brightness.
Flashes while the brightness of the illuminated buttons and indicator
lights is being set.
Lights up when maximum or minimum brightness has been attained.
23 Illuminated DIMMER DISPLAY Adjusts the brightness of the indicators (thrust direction indicator and
button (orange) speed indicator).
The illuminated button is pressed to adjust the brightness to max
imum and again to attain minimum brightness.
Flashes while the brightness of the indicators is being set.
Lights up when maximum or minimum brightness has been attained.
24 Copilot Controls the thrust direction of the propulsion unit and the engine
speed.
25 Speed control lever Controls the engine speed when full follow-up speed control mode is
activated.
26 Thrust direction handle Controls the thrust direction of the propulsion unit when full follow-up
thrust direction control mode is activated.
The thrust direction is indicated by the pointer of the thrust direction
handle on a scale of 0 to 360° in divisions of 10°.

1 2
BACKUP CONTROL
AZIMUTH RPM
6 NFU LOCAL
RPM RPM RPM
ON/OFF
3 4 5 7 8 9 10
MAIN
RPM
14 13 12 11
TAKE FAULT
ON OVER UNIT
15 16 17 18
LOCKED
DIMMER DIMMER LAMP
DISPLAY PANEL CHECK
23 22 21 20 19
24
25
26
Fig. 6

Control system switch cabinet
i INFORMATION
The arrangement of the operating controls and indicators on the switch cabinet door of the port side and starboard
stern propulsion systems is identical.
Controls and indicators
1 Illuminated LOCAL button (green) Switches the hydraulic system to local manual operation (e.g. for
with protective cover maintenance work).
Lights up during local manual operation of the hydraulic system.
2 Illuminated REMOTE button Switches the hydraulic system to control system operation.
(yellow) Lights up when the hydraulic system is operated using the control
system.
Flashes when a transfer of command from the control system switch
cabinet is pending.
3 Illuminated FAULT UNIT button Acknowledges incoming alarms activated by the control system and
(red) resets it.
Lights up if an alarm is set off by the control system, and goes out
once the fault has been rectified.
4 System display For a description of the S-ODS system display, see the SCHOTTEL
User Documentation in this Service Manual.

1 2 3
FAULT
LOCAL REMOTE UNIT
Fig. 7

Additional engine control room indicator
Indicator
1 Thrust direction indicator The red pointer on the indicator displays the current thrust direction
of the propulsion unit, regardless of the active control desk and the
selected control and operating mode.
Fig. 8

Control and operating modes
At the port side and starboard stern
propulsion systems
The control and operating modes can be divided into
two areas:
D Control modes
D Operating modes
Control modes
The propulsion system can be run in the following
control modes:
D Full follow-up control mode

The thrust direction of the propulsion unit is
controlled using the Copilot.
The engine speed is controlled using the Copilot.
The clutch is engaged and disengaged using the
speed control lever.
Automatic follow-up of the propulsion system.
(Full follow-up [FFU])
D Non-follow-up control mode

The thrust direction of the propulsion unit is
controlled using the illuminated buttons.
The engine speed is controlled using the
illuminated buttons.
illuminated buttons.
No automatic follow-up of the propulsion system.
(Non-follow-up [NFU])

Full follow-up (FFU) control mode
i INFORMATION
If a full-follow up control mode fails (thrust direction
control or speed control [FFU]), this will automatically
switch over to non-follow-up (NFU) control mode. This
failure is signalled both visually and acoustically by the
vessel's alarm monitoring system.
At the main control desk

BACKUP CONTROL
RPM AZIMUTH
RPM
The status of the full follow-up (FFU) thrust direction

control mode of the propulsion unit is indicated by the 1 2
"azimuth indicator light (9/2) on the main control desk. CLUTCH CONTROL DESK SELECTION EXTERNAL SYSTEMS
The status of the full follow-up (FFU) speed control

mode for the engine is indicated by the RPM indicator
light (9/1) on the main control desk.
The thrust direction of the propulsion unit is controlled at
STATUS MODES
the main control desk using the thrust direction LIGHT CONTROL
handle (9/4).
The engine speed is controlled at the main control desk 3
using the speed control lever (9/3).
The clutch is automatically engaged and disengaged
using the speed control lever when automatic mode is
activated.
Fig. 9

Non-follow-up (NFU) control mode
Non-follow-up (NFU) control mode is superordinate to
full follow-up control mode (e.g. synchronous mode and
tiller control system), or the external control systems.

Non-follow-up (NFU) control mode is activated at the
main control desk by pressing the illuminated NFU
ON/OFF button (10/3). When the button is pressed RPM
BACKUP CONTROL
AZIMUTH
RPM RPM
again, the propulsion system will switch back to the NFU
ON/OFF
available full follow-up (FFU) control mode.

1 2 3 4 5
The thrust direction of the propulsion unit is controlled at
the main control desk using the illuminated Ô "turn CLUTCH CONTROL DESK SELECTION EXTERNAL SYSTEMS
propulsion unit (10/4) and Õ "turn propulsion unit

buttons (10/5).
The engine speed is controlled at the main control desk
using the illuminated RPM ↓ (10/1) and RPM ↑ (10/2)
STATUS LIGHT CONTROL MODES
buttons.
When automatic mode is activated, the clutch is
engaged when the engaging speed is reached by using
the illuminated RPM ↑ button and disengaged by using
the RPM ↓ button as soon as the engine is idling.
Fig. 10

Operating modes
The propulsion system can be run in the following
operating modes:
D Clutch mode
D Fire fighting mode (starbord stern propulsion
system)
Clutch mode
To extend the operational capability of the propulsion RPM
BACKUP CONTROL
AZIMUTH
system it is recommended that during normal operation RPM RPM
it is operated with automatic clutch mode and full

follow-up (FFU) speed control mode activated.
1 2
CLUTCH CONTROL DESK SELECTION EXTERNAL SYSTEMS
Manual mode
NOTICE
Manual mode is automatically activated when STATUS LIGHT CONTROL MODES
automatic mode is deactivated.
At the main control desk 3

If automatic clutch mode is not activated, using the
speed control lever (11/3) or the illuminated
RPM ↑ (11/2) or RPM ↓ buttons (11/1) on the main
control desk will only increase or reduce the engine
speed (e.g. for service and maintenance work). The
clutch is not engaged.
Fig. 11

Automatic mode
! CAUTION
In emergency situations, automatic mode may be
deactivated at any speed during operation.
NOTICE RPM
BACKUP CONTROL
AZIMUTH
RPM RPM
If full follow-up (FFU) speed control mode fails, the

propulsion system will automatically switch to
non-follow-up (NFU) speed control mode. The engine 1 2
speed is controlled at the main control desk using the
illuminated RPM ↓ (12/1) and RPM ↑ (12/2) buttons. Full RPM
follow-up speed control mode failure is signalled by the

vessel's alarm monitoring system. 5 4 3
During normal operation, automatic clutch mode is

activated and the clutch operates in full follow-up (FFU)
speed control mode. The clutch is engaged and
disengaged in relation to the engine speed.
Automatic mode is activated at the main control desk
using the illuminated RPM "automatic clutch mode"
button (12/4) and deactivated using the illuminated
"clutch disengaged" button (12/5).
The status of the clutch is indicated at the main control
desk by the "clutch engaged" indicator light (12/3) and
illuminated "clutch disengaged" button.
The clutch can be disengaged during operation by
pressing the illuminated "clutch disengaged" button,
e.g. to warm up the engine and in emergency situations.
Fig. 12

In full follow-up (FFU) speed control mode
The clutch operates in three stages and is engaged and
disengaged at the main control desk using the speed
control lever (13/1).
D Stage 0:
The speed control lever is set to the 0° position
(neutral position).
The engine is idling. BACKUP CONTROL
RPM AZIMUTH
The clutch is disengaged.
D Stage 1:
The angle of the speed control lever is ≥ 10°.
The engine speed increases slightly.
The clutch engages.
D Stage 2:
MODES
STATUS LIGHT CONTROL
The angle of the speed control lever is > 10 to 90°.
The engine speed will increase in relation to the +
speed control lever setting until top speed is
reached.
1
05 -
105
905
Fig. 13

In non-follow-up (NFU) speed control mode
The clutch operates without any transitional stages and
is engaged at the main control desk using the
illuminated RPM ↑ button (14/2) as soon as the
engaging speed is reached and disengaged using the
RPM ↓ button (14/1) as soon as the engine is idling.
BACKUP CONTROL
RPM AZIMUTH
RPM RPM
1 2
Fig. 14

Fire fighting mode
i INFORMATION
The fire fighting system is not included in SCHOTTEL
GmbH's scope of delivery.
NOTICE
Fire fighting mode can only be activated at the starboard
stern propulsion system. When fire fighting mode is AZIMUTH
BACKUP CONTROL
RPM
activated, the propulsion unit cannot be used for

steering manoeuvres.
At the main control desk of the starboard stern

propulsion system ON
In fire fighting mode, a fire fighting system can be

activated to help fight fire or combat oil. 1
Fire fighting mode can only be enabled when the main MODES LIGHT CONTROL STATUS
control desk of the starboard stern propulsion system is
active, the engine is idling and automatic clutch mode is
deactivated. Fire fighting mode is enabled using the fire
fighting system interfaces.
The fire fighting system is activated at the main control
desk of the starboard stern propulsion system using the
illuminated "fire fighting mode" ON button (15/1).
The engine speed is automatically increased to the
speed of the fire fighting system. The propulsion unit
speed cannot be controlled when fire fighting mode is
activated and the clutch remains disengaged.
Fig. 15

2 Operation
Starting up the propulsion systems
1 2
propulsion systems
The following condition is to be fulfilled:
D The power supply needed for operating the control

and drive systems is available. S1 S2
1. Switch on the power supply at the control system

switch cabinet.
4 3
2. Switch the propulsion system on.
Switching on the power supply at the control

system switch cabinet.
i
LOCAL REMOTE
INFORMATION
Once the power supply has been switched on, the
operating mode that was last activated before the
propulsion system was switched off will be resumed
(control system or manual operation).
Fig. 16
1. Open the door of the switch cabinet.
2. Set switches S1 (16/1) and S2 (16/2) to the "I"
position.
3. Close the door of the switch cabinet.
Control system
1. Press the illuminated REMOTE button (16/3).
The illuminated REMOTE button lights up as soon
as the propulsion system control system is
switched on.
Manual operation
1. Press the illuminated LOCAL button (16/4).
The illuminated LOCAL button lights up.

Switching the propulsion system on
i INFORMATION
If there are no malfunction alarms after the power supply
is switched on at the control system switch cabinet:
D The control desk that was last activated before the
propulsion system was switched off will be
reactivated.
D The control mode that was last activated before the
RPM
BACKUP CONTROL
AZIMUTH
propulsion system was switched off will be RPM
resumed.
D The operating mode that was last activated before 1 2
the propulsion system was switched off will be CLUTCH CONTROL DESK SELECTION EXTERNAL SYSTEMS
resumed.
By way of example, this section describes how to switch 3

on the port side stern propulsion system in full follow-up
(FFU) control mode at the main control desk.
LAMP
CHECK

4
D The engine is ready for operation. STATUS LIGHT CONTROL MODES
D The illuminated REMOTE button is lit up on the +

5
1. Set the speed control lever (17/5) to the 0° position
(neutral position).
The propulsion system is switched on with no load.
2. Press the illuminated LAMP CHECK button (17/4).
All illuminated buttons and indicator lights must
light up when this button is pressed and the buzzer -
sounds.
The "azimuth" indicator light (17/2) lights up.
The RPM indicator light (17/1) lights up.
The illuminated "clutch disengaged" button (17/3) 05 -
lights up. 105
905
Fig. 17

! CAUTION
To switch on the engine the automatic clutch mode has
to be deactivated, and the start function enabled for the
engine (start interlock).
3. Switch on the engine.

4. Press the illuminated RPM "automatic clutch
mode"button (18/2).
The illuminated RPM "automatic clutch mode" RPM
BACKUP CONTROL
AZIMUTH
button lights up.

The thrust direction of the propulsion unit is CLUTCH CONTROL DESK SELECTION EXTERNAL SYSTEMS
controlled using the thrust direction handle (18/4). RPM
The engine speed is controlled using the speed

control lever (18/3). 1 2
speed control lever.
The propulsion system is ready for operation.
Switching the propulsion system off with no load +

By way of example, this section describes how to switch
off the starboard stern propulsion system at the main 3
control desk.
1. Set the speed control lever to the 0° position
(neutral position).
The propulsion system is switched off with no load.
2. Press the illuminated "clutch disengaged" button -
(18/1).
The illuminated RPM "automatic clutch mode" 4
button goes out.
3. Switch off the engine.
4. Switch off the control system switch cabinet.
* Set switches S1 and S2 to the "0" position; see 05 -

page 29. 105
The control system is switched off.

+
Switching the propulsion system back on
905
After the propulsion system has been switched off, or if
a system failure has occurred, the propulsion system is
to be switched back on with no load.
D The speed control lever on the main control desk is

in the 0° position (neutral position).
Fig. 18

Selecting the control desk
propulsion systems
Taking command at the control system switch
cabinet
! WARNING
Before activating the control system switch cabinet,
permission is to be granted by the navigator. During
local manual operation, the vessel is to be controlled
according to the navigator's instructions. The effect of
this control manoeuvre on the vessel's movement is to
be monitored constantly.
NOTICE
A takeover of command without its prior deactivation at
the active control desk is only possible at the control
system switch cabinet. The takeover of command is
independent of which control or operating mode is
activated.
NOTICE
If command is taken over for manual operation at the
control system switch cabinet of the starboard stern
propulsion system during fire fighting mode, this mode
will be deactivated.

By way of example, this section describes the take over
of command of the port side stern propulsion system
from the main control desk.
1. Press the illuminated LOCAL button (19/1) on the 1
The illuminated LOCAL button on the control LOCAL
system switch cabinet lights up.

The buzzer sounds at the main control desk.
The LOCAL indicator light (19/2) on the main
control desk lights up.
The illuminated MAIN button (19/3) on the main
control desk goes out.
BACKUP CONTROL
RPM AZIMUTH
LOCAL
2
MAIN
Fig. 19

Transferring command from the control system
switch cabinet to the main control desk
NOTICE 1
REMOTE
Command will remain in local manual operation mode
until the transfer of command has been concluded.
When taking over command from the control system 2
switch cabinet and desk selection has been activated:
D The control mode that was last activated before the

takeover of command will be resumed.
D The operating mode that was last activated before
the takeover of command will be resumed.
By way of example, this section describes how to

transfer command of the port side stern propulsion
system to the main control desk in full follow-up (FFU)
control mode while automatic clutch mode is activated.
D The start screen appears on the system display.
D The speed indicator (20/2) shows a value of 0.

D
BACKUP CONTROL
RPM AZIMUTH
The speed control lever (20/8) is in the 0° position RPM
(neutral position).
3 4
1. Press the illuminated REMOTE button (20/1) on CLUTCH CONTROL DESK SELECTION EXTERNAL SYSTEMS
the control system switch cabinet.
The illuminated REMOTE button on the control RPM
system switch cabinet flashes.

6 5
The illuminated TAKE OVER button (20/7) on the TAKE
OVER
main control desk flashes.

The buzzer sounds at the main control desk. 7
2. Press the illuminated TAKE OVER button on the
main control desk. STATUS LIGHT CONTROL MODES
The illuminated TAKE OVER button on the main

The "azimuth" indicator light (20/4) on the main 8
The RPM indicator light (20/3) on the main control
desk lights up.
The illuminated RPM "automatic clutch mode"
button (20/5) on the main control desk lights up.
The illuminated "clutch disengaged" button (20/6)
on the main control desk lights up.
Fig. 20

The illuminated MAIN button (21/4) on the main
The LOCAL indicator light (21/3) on the main 1 2
LOCAL REMOTE
The illuminated REMOTE button (21/2) on the
control system switch cabinet lights up.
The illuminated LOCAL button (21/1) on the control
system switch cabinet goes out.
BACKUP CONTROL
RPM AZIMUTH
LOCAL
3
MAIN
Fig. 21

Selecting the control mode
At the port side and starboard stern 1 2
propulsion systems
Activating full follow-up (FFU) control mode
i INFORMATION
If there are no malfunction alarms after the propulsion
system has been switched on, full follow-up (FFU)
control mode will be activated. If a full-follow up control BACKUP CONTROL
RPM AZIMUTH
mode fails (thrust direction control or speed control), RPM RPM RPM
NFU
ON/OFF
this will automatically switch over to non-follow-up
(NFU) control mode. The failure is signalled by the
vessel's alarm monitoring system. If the propulsion 3 4 5 6 7 8 9
system is switched off and then on again at the control
system switch cabinet following the failure:
D The control desk that was last active before the

failure will be reactivated.
D
The control mode that was last activated before the
failure will be resumed.
D The operating mode that was last activated before 10

the failure will be resumed.

11
D The required control desk is active.
D Non-follow-up (NFU) control mode has been
activated manually.
D The position of the thrust direction handle (22/11)
corresponds to the current value on the thrust
direction indicator (22/2).
D The position of the speed control lever (22/10)
corresponds to the current value on the speed
indicator (22/1).
Fig. 22
1. Press the illuminated NFU ON/OFF button (22/6).
The illuminated NFU ON/OFF button goes out.
The illuminated Ô "turn propulsion unit" (22/7) and
Õ "turn propulsion unit" buttons (22/9) go out.
The illuminated RPM ↓ (22/3) and RPM ↑
buttons (22/5) go out.
The "azimuth" indicator light (22/8) lights up.
The RPM indicator light (22/4) lights up.

Activating non-follow-up (NFU) control mode
NOTICE
If non-follow-up (NFU) control mode is activated during
fire fighting mode at the starboard stern propulsion
system manually or due to a malfunction, fire fighting
mode will be deactivated.

The following conditions are to be fulfilled: RPM
BACKUP CONTROL
AZIMUTH
RPM RPM RPM
D
NFU
The required control desk is active. ON/OFF
D Full follow-up (FFU) control mode is activated. 1 2 3 4 5 6 7

1. Press the illuminated NFU ON/OFF button (23/4).

The illuminated NFU ON/OFF button lights up.
The illuminated Ô "turn propulsion unit (23/5) and
Õ "turn propulsion unit buttons (23/7) light up.
The illuminated RPM ↓ (23/1) and RPM ↑ STATUS LIGHT CONTROL MODES
buttons (23/3) light up.

The "azimuth indicator light (23/6) goes out.
The RPM indicator light (23/2) goes out.
Fig. 23

Selecting the operating mode
1
propulsion systems
Clutch mode
Manual mode
NOTICE
Manual mode is automatically activated when RPM
BACKUP CONTROL
AZIMUTH
automatic mode is deactivated.
CLUTCH CONTROL EXTERNAL SYSTEMS
i
DESK SELECTION
INFORMATION RPM
The clutch is not engaged in manual mode. 2 3

At the main control desk STATUS LIGHT CONTROL MODES

+
D Full follow-up (FFU) speed control mode is 4
activated.
D The speed control lever (24/4) is in the 0° position
(neutral position).
-
D The illuminated RPM "automatic clutch mode"
button (24/3) is not lit up.
D The illuminated "clutch disengaged" button (24/2)
is lit up.
D Fire fighting mode is deactivated (starboard stern
propulsion system) 05 -
105
Increasing speed
1. Push the speed control lever forward [+] and +
monitor the change on the speed indicator.
905
The engine speed will continue to increase in line
with the speed control lever setting until top speed
is reached.
The clutch remains disengaged.
Fig. 24

Decreasing speed
1
2. Pull the speed control lever (25/2) back [-] and
monitor the change on the speed indicator (25/1).
The engine speed will continue to decrease in line
with the speed control lever setting until idling
speed is reached.
BACKUP CONTROL
RPM AZIMUTH
05 -
105
905
Fig. 25

In non-follow-up (NFU) speed control mode 1
D Non-follow-up (NFU) speed control mode is
activated.
BACKUP CONTROL
D
RPM AZIMUTH
The illuminated RPM "automatic clutch mode" RPM RPM
button (26/4) is not lit up.

D The illuminated "clutch disengaged" button (26/5) 2 3
is lit up. CLUTCH CONTROL DESK SELECTION EXTERNAL SYSTEMS
RPM
Increasing speed
5 4
1. Press the illuminated RPM ↑ button (26/3) and
The engine speed will continue to increase as long STATUS LIGHT CONTROL MODES
as the illuminated RPM ↑ button is pressed until top
speed is reached.
Decreasing speed
2. Press the illuminated RPM ↓ button (26/2) and
The engine motor speed will continue to decrease
as long as the illuminated RPM ↓ button is pressed
until idling speed is reached.
Fig. 26

Automatic mode
Activating automatic mode 1
NOTICE
Automatic clutch mode can only be activated for the
starboard stern propulsion system when fire fighting
mode is deactivated.
BACKUP CONTROL
RPM AZIMUTH

D The required control desk is active. CLUTCH CONTROL DESK SELECTION EXTERNAL SYSTEMS
D The required speed control is activated. RPM
D The speed indicator (27/1) shows a value of 0. 2 3

is lit up.
1. Press the illuminated RPM "automatic clutch

mode"button (27/3).
button lights up.
Fig. 27

1
D Full follow-up (FFU) speed control mode is
activated.
button (28/3) is lit up.
D The illuminated "clutch disengaged" button (28/2) RPM
BACKUP CONTROL
AZIMUTH
is lit up.
D Fire fighting mode is deactivated (starboard stern CLUTCH CONTROL DESK SELECTION EXTERNAL SYSTEMS
propulsion system) RPM
Engaging the clutch 2 3 4
1. Push the speed control lever (28/5) forward [+] to

an angle of > 0 to < 10°.
The engine speed increases slightly.
2. Push the speed control lever further forward [+] to +
an angle of ≥ 10° (stop position).
The clutch engages. 5
The "clutch engaged" indicator light (28/4) lights
up.
The illuminated "clutch disengaged" button goes
out.
3. Push the speed control lever further forward [+] to -
an angle of > 10 to 90° and monitor the change on
the speed indicator (28/1).
The engine speed will continue to increase in line
is reached.
Disengaging the clutch 05 -

105
4. Pull back [-] the speed control lever to an angle less
than 10° and monitor the change on the speed
indicator. +
The clutch disengages. 905
The illuminated "clutch disengaged" button lights
up.
The "clutch engaged" indicator light goes out.
with the speed control lever setting until idling
speed is reached.
Fig. 28

In non-follow-up (NFU) speed control mode
At the main control desk 1
activated.
D
BACKUP CONTROL
RPM AZIMUTH
The illuminated "clutch disengaged" button (29/6) RPM RPM
is lit up.
2 3
Engaging the clutch CLUTCH CONTROL DESK SELECTION EXTERNAL SYSTEMS
1. Briefly tap the illuminated RPM ↑ button (29/3). RPM
The engine speed increases slightly. 6 5 4

The clutch engages.
The "clutch engaged" indicator light (29/4) is lit up.
The illuminated "clutch disengaged" button goes
out. STATUS LIGHT CONTROL MODES
2. Press the illuminated RPM ↑ button and monitor the

change on the speed indicator (29/1).
The engine speed will continue to increase as long
speed is reached.
Disengaging the clutch

The illuminated "clutch disengaged" button lights
up.
Fig. 29

Deactivating automatic mode
1
! CAUTION
In emergency situations, automatic mode may be
deactivated at any speed during operation.

BACKUP CONTROL
D
RPM AZIMUTH
The required control desk is active.
D The required speed control is activated.
CLUTCH CONTROL EXTERNAL SYSTEMS
DESK SELECTION
D The speed indicator (30/1) shows a value of 0. RPM

2 3
is lit up.
1. Press the illuminated "clutch disengaged" button.

button goes out.
Fig. 30

Manually disengaging the clutch
NOTICE
In emergency situations the clutch may be disengaged
during operation using the illuminated "clutch
disengaged" button (31/1).
The following conditions are to be fulfilled: BACKUP CONTROL

RPM AZIMUTH

D The required speed control is activated. CLUTCH CONTROL DESK SELECTION EXTERNAL SYSTEMS
D The illuminated RPM "automatic clutch mode" RPM
button (31/2) is lit up. 2 3

1
D The "clutch engaged" indicator light (31/3) is lit up.
1. Press the illuminated "clutch disengaged" button.

The illuminated "clutch disengaged" button lights STATUS LIGHT CONTROL MODES
up.
button goes out.
Fig. 31

Fire fighting mode
Activating fire fighting mode 1
propulsion system
NOTICE
If non-follow-up (NFU) control mode is activated during
fire fighting mode at the starboard stern propulsion
system manually or due to a malfunction, fire fighting BACKUP CONTROL
mode will be deactivated. AZIMUTH RPM
NOTICE
Before fire fighting mode can be activated, automatic ON
clutch mode must be deactivated at the starboard stern

propulsion system. 2
The following conditions are to be fulfilled: MODES LIGHT CONTROL STATUS
D The fire fighting system is switched on at the +

external control system preselection device.
D The main control desk of the starboard stern

propulsion system is active. 3
D Full follow-up (FFU) control mode is activated.
D The speed control lever (32/3) is in the 0° position -

(neutral position).
D Automatic clutch mode is deactivated.
D The clutch is disengaged.
1. Activate fire fighting mode at the fire fighting

system. 05 -
105
The fire fighting system clutch is engaged.
The illuminated "fire fighting mode" ON
button (32/2) flashes. +
The engine speed is limited to idling speed. 905
2. Press the illuminated "fire fighting mode" ON
button.
The illuminated "fire fighting mode" ON button
lights up.
The engine automatically increases to the speed of
the fire fighting system.
Fig. 32

Deactivating fire fighting mode
propulsion system
NOTICE
After fire fighting mode has been deactivated,
automatic clutch mode must be resumed at the
starboard stern propulsion system.
The following conditions are to be fulfilled: AZIMUTH

BACKUP CONTROL
RPM
D The main control desk of the starboard stern

propulsion system is active. EXTERNAL SYSTEMS DESK SELECTION CLUTCH CONTROL

(neutral position). ON
1. Press the illuminated "fire fighting mode" ON 1

button (33/1).
The illuminated "fire fighting mode" ON button
flashes. +
The engine speed is limited to idling speed.
2. Deactivate fire fighting operation on the fire fighting
2
system.
The fire fighting system clutch is disengaged.
The illuminated "fire fighting mode" ON button goes
out.
05 -
105
905
Fig. 33

Controlling thrust direction and speed
At the port side and starboard stern 1
propulsion systems
Controlling thrust direction using the thrust
direction handle
! CAUTION
BACKUP CONTROL
To avert dangerous sailing manoeuvres the propulsion AZIMUTH RPM
unit is only to be rotated by 180° when the engine is idle.


D Full follow-up (FFU) thrust direction control mode is
activated.

propulsion system).
2
1. Control the thrust direction of the propulsion unit
using the thrust direction handle (34/3).
The scale ring (34/2) on the thrust direction handle
is provided for orientation.
3
To rotate the propulsion unit clockwise:
Turn the thrust direction handle clockwise.
To rotate the propulsion unit anti-clockwise:
Turn the thrust direction handle anti-clockwise.
The propulsion unit will continue to rotate until the
set thrust direction has been reached.
2. Monitor the thrust direction on the thrust direction
indicator (34/1).
Fig. 34

Controlling thrust direction using the illuminated
buttons
1
D Non-follow-up (NFU) thrust direction control mode
is activated.
1. Press the illuminated Ô "turn propulsion

unit (35/2) or Õ "turn propulsion unit
button (35/3). BACKUP CONTROL
AZIMUTH RPM

Press the illuminated Õ "turn propulsion unit
button. 2 3
Press the illuminated Ô "turn propulsion unit
button.
The propulsion unit will continue to turn either
clockwise or anti-clockwise as long as the relevant MODES LIGHT CONTROL STATUS
illuminated button is pressed.

indicator (35/1).
Fig. 35

Controlling speed using the speed control lever
The following conditions are to be fulfilled: 1
D Full follow-up (FFU) speed control mode is
activated.
(neutral position).
D
BACKUP CONTROL
Automatic clutch mode is activated. AZIMUTH RPM

CLUTCH CONTROL
EXTERNAL SYSTEMS DESK SELECTION
propulsion system)
Increasing speed
1. Push the speed control lever forward [+] and
monitor the change on the speed indicator. MODES LIGHT CONTROL STATUS
The engine speed will continue to increase in line +

is reached.
2
Decreasing speed
2. Pull the speed control lever back [-] and monitor the
change on the speed indicator.
with the speed control lever setting until idling -
speed is reached.
05 -
105
905
Fig. 36

Controlling speed using the illuminated buttons
The following conditions are to be fulfilled: 1
activated.
D Automatic clutch mode is activated.
D The clutch is engaged.
Increasing speed AZIMUTH

BACKUP CONTROL
RPM
RPM RPM
1. Press the illuminated RPM ↑ button (37/3) and

monitor the change on the speed indicator (37/1).
2 3
The engine speed will continue to increase as long EXTERNAL SYSTEMS DESK SELECTION CLUTCH CONTROL

speed is reached.
Decreasing speed
Fig. 37

Emergency operation
1
propulsion systems
Controlling thrust direction using the manual
operation device
2
! WARNING
Before engaging in manual operation, permission is to 3
be granted by the navigator. During manual operation,
the vessel is to be controlled according to the
navigator's instructions. The effect of this control
manoeuvre on the vessel's movement is to be
monitored constantly.
Fig. 38
! WARNING
1
During and directly following operation, the pump
housing and the valve block may be very hot. Use
protective gloves!
NOTICE
During emergency operation, the engine speed is
controlled manually on the engine itself.
In the event of a failure of both full follow-up and

non-follow-up thrust direction control mode, the
propulsion unit can be rotated using the manual
operation device.
Fig. 39
D Mechanical pump unit HPV 135 (38/3) is in

operation.
1. Take over command at the control system switch

cabinet; see page 32.
2. Use the manual operation device on mechanical
pump unit HPV 135.
Press the pressure pin (38/2) on the proportional
valve.
Press the pressure pin (38/1) on the proportional
valve.
The propulsion unit will continue to rotate as long as
the corresponding pressure pin is pressed.
feedback unit (39/1).

Examples of Steering Manoeuvres
en TTD-Gm Example of Steering Manoeuvres 13/April 1196570 1/9

These Examples of Steering Manoeuvres have been
written with the utmost care and attention to detail.
However, should you require any further information,
please contact:
SCHOTTEL GmbH
Mainzer Straße 99
D-56322 Spay, Germany
Telefon +49 (0) 2628 / 61-0
Fax +49 (0) 2628 / 61-300
E- Mail [email protected]
a).
2/9 TTD-Gm Example of Steering Manoeuvres 13/April 1196570 en

Table of Contents
1 Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
1.1 Key for individual symbols . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
2 Examples of Steering Manoeuvres . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5

2.1 Moving ahead and moving astern . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
2.2 Turning to port side . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
2.3 Turning to starboard . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
2.4 Turning on the spot . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
2.5 Moving sideways . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9

1 Introduction
In the Examples of Steering Manoeuvres shown below the vessel is equipped with the following propulsion units:
● Two azimuth propulsion units in the stern
The steering manoeuvres shown are for information purposes. Whether or not a given steering manoeuvre can be
used in individual cases depends on:
● The number of available propulsion units
● The power output of the individual propulsion units
● The availability of the individual propulsion units
● The distribution of power among the propulsion units
● Where they are installed on the vessel
All illustrations are schematic diagrams and do not make any claim to completeness.
These Examples of Steering Manoeuvres are aimed at the ship's navigator.
The Examples of Steering Manoeuvres are part of the Service Manual. The basic prerequisite for work safety ist the
observance of all safety instructions and other instructions provided in the Service Manual.
1.1 Key for individual symbols
Symbol Description
Vessel's heading
Azimuth propulsion unit thrust direction

handle
Azimuth propulsion unit thrust direction

handle (not used)
Azimuth propulsion unit
Azimuth propulsion unit (not used)
Ship's hull

2 Examples of Steering Manoeuvres
2.1 Moving ahead and moving astern
Moving ahead Moving astern

Figure 1 Moving ahead and moving astern

2.2 Turning to port side
Turning to port side moving ahead Turning to port side moving astern
Figure 2 Turning to port side

2.3 Turning to starboard
Turning to starboard moving ahead Turning to starboard moving astern

Figure 3 Turning to starboard

2.4 Turning on the spot
Turning the stern to port side Turning the stern to starboard

Figure 4 Turning on the spot

2.5 Moving sideways
Moving sideways to port side Moving sideways to starboard

Figure 5 Moving sideways

User Documentation
for System Display S-ODS V2.00.10
This User Documentation is to be read and applied carefully to ensure safe operation and prevent damage
occurring to the propulsion system!
en TTD-Kt User Documentation for System Display S-ODS V2.00.10 13/Feb 1187801 1/105
This User Documentation has been written with the
utmost care and attention to detail. However, should
you require any further information, please contact:
SCHOTTEL GmbH
Mainzer Straße 99
56322 Spay
GERMANY
Phone: +49 (0)2628 610
Fax: +49 (0)2628 61300
e-Mail: [email protected]
www.schottel.de
2/105 TTD-Kt User Documentation for System Display S-ODS V2.00.10 13/Feb 1187801 en
Table of Contents
1 About this User Documentation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
1.1 Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
1.2 Applicable product documents . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
1.2.1 SCHOTTEL GmbH: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
1.3 Symbols and diagrams . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
1.4 Restriction on liability . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
1.5 Warranty . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
1.6 Warranty conditions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
1.7 Customer Service . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
2 Safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
2.1 Shipyard's responsibility . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
2.2 Operator's responsibility . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
2.3 Staff requirements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
2.3.1 Qualification of specialist staff . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
2.3.2 Requirements of maintenance staff for electrical components . . . . . . . . . . . . . . . . 12
2.4 Intended use . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
2.5 Foreseeable misuse . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
2.6 Safety devices . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
2.7 Safe operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
2.8 Electromagnetic interference fields . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
2.9 Ambient conditions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
2.10 General remaining risks and protective measures . . . . . . . . . . . . . . . . . . . . . . . . . . 15
3 Safety Instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
3.1 Basic safety instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
3.2 Special safety instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
3.2.1 Commissioning and resumption of operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
3.3 Operation and shutdown . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
3.3.1 Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
4 List of Abbreviations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
5 Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
5.1 Hardware . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
5.1.1 Technical Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
5.1.2 Assignment of connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
5.1.3 Removable media . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
5.2 Software . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
5.2.1 System description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
5.2.2 Log files . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
5.3 Menu structure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
5.4 Indicators and operating controls . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
5.4.1 Used cell types . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
5.4.2 Used buttons and display screens . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
5.4.3 Keyboard . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
5.4.4 Numeric keypad . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
5.5 Start screen . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
5.6 Main menu . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37
5.6.1 Easy main menu . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38
5.6.2 Advanced main menu . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40
6 Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44
6.1 System display operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44
6.1.1 Switching on the system display . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45
6.1.2 Switching off the system display . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45
6.1.3 Using removable media . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46
Memory card . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46
USB stick . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48
6.2 Login . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49
6.3 Logout . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51
6.4 Changing a password . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51
6.5 Basic settings on the system display . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 52
6.5.1 Setting the thrust direction indicator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 52
Adjusting the heading . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 52
Setting the scale division of the thrust direction indicator . . . . . . . . . . . . . . . . . . . 53
Setting the direction of rotation of the thrust direction indicator . . . . . . . . . . . . . 53
6.5.2 Setting the speed indicator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54
Setting the scale division of the speed indicator . . . . . . . . . . . . . . . . . . . . . . . . . . 54
6.5.3 Setting the pitch indicator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54
6.5.4 Setting the IP address and background illumination . . . . . . . . . . . . . . . . . . . . . . . . . 55
Setting the IP address . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55
Setting the background illumination . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 57
6.6 Working with the log files . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 59
6.6.1 Displaying, copying or hiding the error memory file . . . . . . . . . . . . . . . . . . . . . . . . . . 59
Displaying the error memory file . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 59
Selecting events according to the type of error . . . . . . . . . . . . . . . . . . . . . . . . . . . 60
Copying a single, selected event . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 61
Copying all displayed events . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 63
Hiding a single, selected event . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 65
Hiding all displayed events . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 66
6.6.2 Copying log files . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 67
6.6.3 Importing parameter files . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 69
6.6.4 Copying or activating a parameter file . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70
Copying a single, selected parameter file . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 71
Copying all displayed parameter files . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 72
Activating the selected parameter file . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 73
Hiding the selected parameter file . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 73
Hiding all displayed parameter files . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 73
6.6.5 Displaying the operating data of control modules . . . . . . . . . . . . . . . . . . . . . . . . . . . 74
6.7 Displaying and changing settings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 75
6.7.1 Displaying and changing memory addresses . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 75
6.7.2 Making a backup copy of the parameter file . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 78
6.7.3 Calibrating the rotation angle encoder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 79
6.8 Control system diagnostics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80
6.8.1 Displaying the system overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80
Displaying the system inputs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 81
Allocating the existing system inputs according to type . . . . . . . . . . . . . . . . . . . . 82
Selecting the existing system inputs as required . . . . . . . . . . . . . . . . . . . . . . . . . . 83
Redisplaying the overview of the existing system inputs . . . . . . . . . . . . . . . . . . . 84
6.8.2 Displaying the available main subassemblies . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 85
Displaying the control module of the thrust direction control . . . . . . . . . . . . . . . . 86
Displaying the control module of the speed control . . . . . . . . . . . . . . . . . . . . . . . 87
Displaying the control module of the pitch control . . . . . . . . . . . . . . . . . . . . . . . . . 88
Displaying the valve control module of the thrust direction control . . . . . . . . . . . 89
Displaying the valve control module of the pitch control . . . . . . . . . . . . . . . . . . . . 90
6.8.3 Displaying the availability of the automatic control . . . . . . . . . . . . . . . . . . . . . . . . . . 91
6.8.4 Displaying the availability of the control system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 92
6.8.5 Displaying the available control desks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 92
6.8.6 Displaying the overview of available subassemblies . . . . . . . . . . . . . . . . . . . . . . . . . 93
6.9 Displaying general information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 94
6.9.1 Displaying information about the system display . . . . . . . . . . . . . . . . . . . . . . . . . . . . 94
6.9.2 Displaying project information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 95
6.10 Installing new software . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 96
6.11 Remote access to the system display . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 98
7 Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 99
7.1 Error states . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 100
8 Cleaning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 105
BLANK PAGE
1 About This User Documentation
1.1 Introduction
The SCHOTTEL Operation Diagnosis System (S-ODS) is a display and monitoring system for the SCHOTTEL
control system.
The S-ODS, referred to as “system display” in the following, is part of the whole system supplied by SCHOTTEL
GmbH.
The User Documentation only provides information about the system display. The User Documentation does not
include information about operation of the whole system in which the system display is installed.
This User Documentation contains information about the following topics:
● Operation
● Troubleshooting
● Maintenance
The User Documentation is part of the Service Manual and is to be kept accessible to all staff at all times in the
immediate vicinity of the system display. Staff are to have read and understood this User Documentation thoroughly
before commencing any work. The basic prerequisite for work safety is the observance of all safety instructions and
other instructions provided.
Furthermore, the local accident prevention regulations and general safety provisions apply to the system display's
1.2 Applicable product documents
1.2.1 SCHOTTEL GmbH

The system display is to be operated in compliance with this User Documentation. This User Documentation is
supplemented by other project-related instructions and specifications in this Service Manual ("Applicable product
documents").
These applicable product documents are supplied with this User Documentation in the Service Manual.
Warning notices
Warning notices are set apart from the rest of the text in this User Documentation. They are marked in colour and
DANGER
WARNING
CAUTION
NOTICE
Any warning notice within this User Documentation is

structured as follows:
KEYWORD
Cause of the danger
Tips and recommendations
i INFORMATION
Diagrams
number; the second number is the item number in the illustration. For example: (1/3) means figure 1, item 3. All
illustrations are schematic diagrams and do not make any claim to completeness.

Instructions
For example:
2. Place a suitable collecting basin underneath the pressure filter unit.

Blank page
Used styles
Bold
Bold marks program text (menus, text in dialogues boxes, buttons and message fields).
For example:
Touch the Display Settings button.
Menu structure for the menus

At the beginning of every section, the structure for the individual menus is indicated using arrows and the button label.
For example:
Start screen Login Display Settings
1.4 Restriction on liability
All information and notices provided in this User Documentation have been compiled in consideration of the
applicable standards and regulations, the state of the art and the insights and experience we have gained over many
years.
● Failure to comply with this User Documentation
● Using the system display for anything other than its intended purpose
● Using staff that are not trained to deal with the task in question
● Unauthorised structural, electrical or control-related modifications and repairs
● Technical modifications
● Using unapproved spare parts
1.5 Warranty
a result of failing to comply with this User Documentation. Furthermore, any form of warranty granted by SCHOTTEL
GmbH shall become void, and responsibility shall be transferred to the operator.
1.6 Warranty conditions

The warranty conditions stipulated by contract shall apply, provided that the system display is used as intended and
the applicable product documents are observed.

SCHOTTEL's Service Department is available to provide technical information. For SCHOTTEL GmbH contact
details, see page 2. Furthermore, we are always interested in new information and learning about any new
2 Safety
This section will provide an overview of all of the important safety aspects involved in providing staff with optimal
protection and ensuring the safest and smoothest operation possible.
Failure to comply with the safety instructions and other instructions set out in this User Documentation may result
in serious hazards arising. Therefore, staff are to observe all safety and other instructions set out in this section and
in this User Documentation and take the relevant safety measures.
2.1 Shipyard's responsibility

The shipyard will hand over the system display to the operator after it has been installed in the vessel.
The shipyard is to make sure that a legible and complete SCHOTTEL GmbH Service Manual is available at the site
where the whole propulsion system is operated when the vessel is handed over to the operator.
2.2 Operator's responsibility

The system display operator is responsible for complying with the applicable legal requirements of occupational
safety.
In addition to the occupational safety instructions within this User Documentation, the safety, accident prevention
and environmental protection regulations for the system display's area of application are to be observed.
the special working conditions at the system display's site of operation by carrying out a risk assessment. These
are to be implemented in the form of operating instructions for the system display.
● Check throughout the entire period of system display use whether the operating instructions provided represent
the latest version of rules and regulations, and to amend these, if necessary.
● Ensure that all employees handling the system display have read and understood the User Documentation.
Furthermore, the operator is to instruct the staff in safety matters at regular intervals and keep them informed
about risks.
● Ensure that the system display is only operated in compliance with intended use and only if in a perfect,
● Ensure that the User Documentation is always available at the system display's site of operation in a legible
condition and complete.
● Ensure that all of the safety instructions and warning notices attached to the system display are never removed,
and are kept clean and easily legible.
2.3 Staff requirements
2.3.1 Qualification of specialist staff

The work described in this User Documentation is only to be carried out by qualified specialist staff. Specialist staff
are defined as persons who due to their professional training, knowledge and experience, as well as knowledge of
the pertinent stipulations, are in a position to:
● Carry out the work assigned to them safely, and correctly assess the implications of their work;
● Identify potential hazards independently;
● Take necessary measures to eliminate any hazards, especially those concerning risk of accidents;
Staff are to be trained and instructed regularly in all matters concerning occupational safety and environmental
protection.
observed.
2.3.2 Requirements of maintenance staff for electrical components

measures.
2.4 Intended use

The system display is used as a display and monitoring system for the SCHOTTEL control system.
The system display is only to be operated in a perfect technical condition in compliance with its intended use and
this User Documentation; furthermore, all operators need to be fully aware of all safety issues and potential risks
associated with its use. In particular, malfunctions that may affect safety are to be resolved immediately.
The system display must not be installed and operated in areas where there is a risk of explosions.
The system display may only be operated on vessels that comply with the applicable specifications of the stipulated
classification society. Any other procedure is not considered to be compliant with intended use and is not permitted.
● Adherence to the directives within this User Documentation
2.5 Foreseeable misuse
Improper use is considered to be any kind of use of the system display other than that set out under "Intended use".
This includes:
● Structural modifications to the system display
● Software modifications
● Modifications to safety devices
2.6 Safety devices

Safety devices are to help ensure that personal injuries or material damage can be ruled out.
The system display may only be operated if all safety devices are in place and fully functional, e.g. fuses, and earth
cables.
When a safety device has been triggered, the system display may only be put back into operation, if:
Safety devices may be removed, modified, rendered inoperative or have their effect altered by persons in charge
or experts for temporary intervention purposes only, as in the case of tests and examinations, troubleshooting,
rectification of damage or defects, and to replace components. Furthermore, these interventions have to be
adequate in terms of safety, or adequate contingency measures have to be taken with regard to safety. The staff are
to be instructed to exercise additional caution in these situations.
2.7 Safe operation

If it can be assumed that safe operation is no longer possible, switch the system display off immediately and make
● Not all of the safety devices are in place and fully functional.
● Persons might be put at risk by operating the system display.
● The system display is defective.
● The system display is visibly damaged.
● The system display has been operated, stored or transported in unfavourable ambient conditions (e.g.
fumes/vapours; temperature).
out on the system display.
The system display may only be started up again if its safe operation can be guaranteed.
2.8 Electromagnetic interference fields
● Mains cables
Protection from electromagnetic interference fields is to be provided for operation of the system display. The relevant
specifications in this Service Manual (e.g. applicable product documents; Wiring Diagram) and the specifications
of the stipulated ship classification society are to be observed.
2.9 Ambient conditions

The respective ambient conditions for using the system display are dependent on the area of application designated.
2.10 General remaining risks and protective measures
Despite the system display's high level of integral safety, risk of injury and/or environmental damage cannot be ruled
out even in the case of correct conduct.
The system display is part of a whole propulsion system. New, additional hazards may arise as a result of the
interaction between different components.
DANGER NOTICE
Voltage Damage to the system display
Hazard to life or risk of serious injuries due to electric Direct, constant sunlight, strong magnetic fields and
voltage sudden extreme fluctuations in temperature may
▶ Always observe the special safety provisions damage the system display.
when working on any kind of electrical compo ▶ Protect the system display from direct sunlight.
nents.
▶ Never operate strong magnetic fields in its
▶ Work on electrical components is only to be car vicinity.
▶ Keep temperatures in the operation area con
▶ Switch off the power supply before commencing stant.
unintentionally.
NOTICE
DANGER Damage to the system display
Malfunctions Pointed or sharp objects, such as pens or fingernails
may cause irreparable damage to the display screen.
tions or damage to individual components ▶ Only use fingertips when operating the touch
screen.
▶ Any defective components which affect the
safety and function of the electrical system are to
safety measures.
NOTICE
Damage to the system display
The system display may be damaged by using
WARNING aggressive cleaning agents to clean it.
Risk of short circuiting; fire hazard ▶ Do not use cleaning solutions.
A short circuit or fire may occur by fluids or solid sub ▶ Never use scrubbing sponges, scouring agents
stances getting into ports and openings on the system or solvents, such as alcohol or benzine.
display.
▶ Only use cloths made of microfibre, cotton or
▶ Before cleaning, makes sure all ports and open linen.
ings are covered and that these covers are prop
erly closed. ▶ Do not spray cleaning agents directly onto the
system display.
NOTICE
When operating above +60 °C or below -10 °C the
liquid crystals change their order which may damage
the system display.
▶ Only operate the system display within the per
missible temperature range.
It is crucial that the safety Instructions and warning notices cited in the following sections of this User Documentation
are observed in order to reduce risks to health and prevent hazardous situations.
i INFORMATION
section is not enough to ensure that the system dis
play is worked on safely. The safety instructions and
warning notices in the relevant sections need to be
observed in order to understand safety issues prop
erly and effectively avert danger.
3.1 Basic safety instructions

● Before start-up, the operator is to designate an appropriate danger zone. The danger zone must not be
accessible to unauthorised persons.
● The operator is responsible for procuring all current regulations that apply to the operation of the system display.
system display accordingly.
● The system display is only to be operated if it is in a perfect technical condition.
● All safety instructions and warning notices on the system display are to be observed and kept in a legible
condition.
● Any malfunctions that may affect the safety of staff or the system display are to be rectified immediately.
● The system display is to be taken out of service immediately in the event of malfunctions. The malfunction is to
be rectified immediately.
● Before any welding, flame cutting and grinding work is carried out, the system display and its surrounding area
are to be cleaned to remove any combustible substances. There is a risk of fire and explosion with this kind of
a supervisor.
● Safety devices that serve to avert danger must not be modified or removed.
3.2 Special safety instructions
3.2.1 Commissioning and resumption of operation
● The system display is to be inspected for visible external damage and defects prior to commissioning and every
time operation is resumed. If damage to the system display is established, make sure it cannot be started up
danger when the system display is started up.
● Prior to commissioning and every time operation is resumed, check the function of all safety devices.
● When working on the system display when switched off, make sure it cannot be started up unintentionally.
3.3 Operation and shutdown

● Only operate the system display when all safety devices are in place and fully functional.
● Ensure that all of the safety instructions and warning notices attached to the system display are always easily
3.3.1 Removal
● Switch off the system display and make sure it cannot be started up unintentionally before commencing any
removal work.
BLANK PAGE
4 List of Abbreviations
Alt Gr Alternate Graphic IP Ingress Protection

CAL Calibration IP address Internet Protocol Address
CAN Controller Area Network LCD Liquid Crystal Display
CP propulsion Controllable Pitch propulsion LED Light Emitting Diode
system system
MTBF Mean Time Between Failure
Crtl Control
NFU Non Follow Up
DCM Digital Control Module
NTFS New Technology File System
Del Delete
RPM Revolutions Per Minute
DHCP Dynamic Host Configuration
Protocol S-ODS SCHOTTEL Operation Dia
gnosis System
DIO Digital Input Output
SPS Programmable Logic Control
DIP Dual Inline Package
Tab Tabulator
DPV Digital Proportional Valve
TFT Thin Film Transistor
DWord Double word
UMTS Universal Mobile Communica
EEPROM Electrically Erasable Program tion System
mable Read Only Memory
USB Universal Serial Bus
Esc Escape
V. Version
FAT File Allocation Table
VNC Virtual Network Computing
FFU Full Follow Up
FSP Control Desk Panel
ID NO. Identification Number
5 Description
5.1 Hardware
Item Controls and indicators Function
1 power light Displays the status of the system display.

Lights up blue when the system display is connected to the power
supply.
Flashes red when log files are being backed up.
2 Display By pressing an area (e.g. button) on the touchscreen (touch-sen-

sitive screen) menus are opened or closed. Required text or num
bers are entered using the on-screen keyboard.
1 2
Fig. 1 SCHOTTEL Operation Diagnosis System (S-ODS), front view
5.1.1 Technical data
General
Front panel Aluminium
Housing material Aluminium
Film Acid-resistant polyester film
Weight 1.5 kg
Front panel
Screen format 7”
Display LCD display with LED background illumination
Operation (input) Resistive touchscreen
Resolution 800 x 480 px (W x H)
Protection class (front) IP 65
Protection class (rear side) IP 20
Background illumination service life 20,000 h MTBF
LED 1 x blue/red
System
Processor ARM 9, 400 MHz
Operating system Windows CE®
Internal memory (application memory) 80 MB
External storage medium SD card
Interfaces
Serial 2 x RS232 (not used)
2 x RS422/RS485 (not used)
Ethernet 10/100 Mbit/s RJ45
USB USB 2.0 port
Ambient conditions
Operation temperature range -10 to +60 °C
Storage temperature range -20 to +70 °C
Relative humidity (operation and storage) 5 to 85%; no condensation
Operational area Closed areas
Electrical data
Power supply 24 V DC
Power input for rated voltage 6W
Fuse Internal fuse, 2.0 AT
5.1.2 Connection layout
● CAN bus (galvanically isolated [2/1])
● CAN bus (galvanically isolated [2/2])
1 2
● USB 2.0 port (under the cover [2/3]) 3.4
● Memory card slot (under the cover [2/4])

● Serial RS232/485 (not used [2/5])
● Ethernet RJ 45 (2/6)
● Serial RS232/485 (not used [2/7])
● Power supply 24 V DC (2/8) 8 7 6 5
Fig. 2 Connection layout, side view

5.1.3 Removable media
i INFORMATION
Removable media is only supported in the file format
FAT16/32. 1 2
● Memory card, max. 2 GB (included in the scope of

delivery [3/1])
● Standard USB stick (not included in the scope of
delivery [3/2])
Fig. 3 Removable media
5.2 Software
5.2.1 System description
The system display is a display and monitoring system
for the SCHOTTEL control system. All system and
operating data, parameters and statuses relevant for
the operator are displayed here.
● The touchscreen is used for intuitive operation.

● Settings can be adjusted directly on the system
display for optimum operational status of the
control system.
● Maintenance-related information for the whole
propulsion system can be directly read on the
system display.
● The system display shows a detailed error analysis
for the control system.
● Log files are saved in the internal memory and on
the memory card.
● Log files can be exported (copied) via the USB
connection for further system analysis.
● Parameter files can be imported via a USB
connection.
5.2.2 Log files

All events are recorded in log files for system analysis,
to optimise system processes and for system
diagnosis.
The following log files are available:
● Error memory file (failure memory)
● Event file (log file)
● Parameter file (parameter list)
5.3 Menu structure
Start screen Page 31
Main menu Page 37
Display Settings Page 52
Azimuth Page 52
CP Page 54
RPM Page 54
System from page 55
IP-Settings from page 55
Backlight from page 57
Service from page 59
Failure Memory from page 59
Copy Selected from page 61
Copy All from page 63
Clear Selected Page 65
Clear All Page 66
EEPROM Page 69
from file
load File Page 69
Save Files from page 67
Save Log-File from page 67
Parameter List from page 70
Copy Selected Page 71
Copy All Page 72
Activate Selected Page 73
Clear Selected Page 73
Clear All Page 73
See figure 5, Operating Data Page 74

Part 2
Available at the "Crew" user level
Available at the "Service" user level (not part of this User Documentation)
Fig. 4 Menu structure, part 1
See figure 4,
Part 1
SCHOTTEL from page 75
Settings
EEPROM from page 75
read from page 75
write from page 75
Create Page 78
Parameter Backup
Encoder CAL Page 79
SCHOTTEL from page 80

Diagnosis
System Overview from page 80
System Inputs Page 81
expert mode from page 82
System Hardware from page 85
DCM from page 86
DPV from page 89
System availability Page 92
FSP Page 92
State Wago Page 91
Hardware Page 93
Overview
Info from page 94
System Display Page 94
Project Data Page 95
Available at the "Crew" user level
Available after release by SCHOTTEL
Available after release by SCHOTTEL at the "Crew" user level
Fig. 5 Menu structure, part 2
5.4 Indicators and operating
controls
5.4.1 Cell types used
The system display has the following types of cells:
● Button
A button is used to open a menu or initiate a
function.
● Display screen
The display screen indicates a status.
● Control box
Only two values are entered using the control box
(YES or NO).
● Dialogue box
Information is displayed using a dialogue box
(plain text).
● Edit box
Numerical or alphanumerical values are entered
manually using the edit box.
● Drop down menu
A value can be selected from the list of available
values presented in a drop down menu.
● Tab
Other individual elements are displayed in a tab.
5.4.2 Buttons and display screens
Various buttons and display screens with different symbols are used to operate the menus. The symbols on the
buttons and display screens indicate the function of the available menus.
The colours of the buttons and display screens have the following meaning:
Diagram Colour Function
Dark shading Available menus
Menus which are only available with a login (password-protected area),

Light shading
or still have no function.
The symbols have the following meaning:
Diagram Colour Function
Black Menus which only indicate a status.
Blue Menus in which settings can be made.
Green Menus which only show general information.
1.
5.4.3 Keyboard
The keyboard is automatically displayed if alphanumeric figures need entering in an edit box. The keyboard can be
shifted to the edge by touching and dragging it.
1 Alphanumeric character block Letters, numbers and characters enable data changes (value) in the
edit box.
2 u button Deletes the character before the cursor in the edit box.
3 Del button Deletes the character after the cursor in the edit box.
4 o button Acknowledges and saves the entered value, and closes the edit box.
5 Home button Moves the cursor in the edit box to the beginning of the line.
6 End button Moves the cursor in the edit box to the end of the line.
7 u, ", =, O button Moves the cursor in the edit box by a position in the relevant direction.
8 AltGr button Opens the special symbols keyboard (special symbols keyboard
has no function).
9 "Space" button Enables a space to be entered in the edit box.
10 Alt button Opens the special symbols keyboard (special symbols keyboard
has no function).
11 Ctrl button Has no function.
12 Shift button Enables a capital letter to be entered once in the edit box.
13 Caps button Enables only capital letters to be entered in the edit box.
14 Tab button Moves the cursor a specified space in the edit box.
15 ESC button Clears the input value, closes the edit box and reloads the last value
saved.
1 2
15 3
14
13 4
5
12 6
11 10 9 8
Fig. 6 Keyboard
2.
5.4.4 Numeric keypad
The numeric keypad is automatically displayed if alphanumeric figures need entering in an edit box. The keypad can
be shifted by touching and dragging the edge.
1 Numeric keys The numbers enable data changes (value) in the edit box.
2 ESC button Clears the input value, closes the edit box and reloads the last value
saved.
3 u button Deletes the character before the cursor in the edit box.
4 Del button Deletes the character after the cursor in the edit box.
5 o button Acknowledges and saves the entered value, and closes the edit box.
6 " button Moves the cursor one position to the right in the edit box.
7 u button Moves the cursor one position to the left in the edit box.
8 – button Enables a negative value to be entered in the edit box.
7 6 5
Fig. 7 Numeric keypad
5.5 Start screen
The start screen is adapted to the specific project and
is displayed following start-up.
Propulsion unit with fixed-pitch propeller

● Thrust Direction (thrust direction indicator [8/1])
1 2
● RPM (speed indicator [8/2])
Fig. 8 Propulsion unit with fixed-pitch propeller
Propulsion unit with pitch control

● Pitch % (pitch indicator [9/1])
1 2 3
● Thrust Direction (thrust direction indicator [9/2])
● RPM (speed indicator [9/3])
Fig. 9 Propulsion unit with pitch control
i INFORMATION
The start screen of a propulsion unit with fixed-pitch
propeller and one with pitch control are arranged
almost identically. Differences in the display are indi
cated in a footnote. The following illustrates the start
screen of a propulsion unit with pitch control.
1 Pitch % "pitch indicator" 1* Displays the current propeller pitch as a percentage [%].
The pitch is displayed on a scale of - 100 to 0 to + 100% in divisions
of 4%.
The positive scale represents the positions of "ahead" pitch; the neg
ative scale the positions of "astern" pitch.
2 SCHOTTEL button Opens the main menu; see the “5.6 Main menu” section, page 37.
3 Thrust Direction " thrust direction Indicates the actual thrust direction of the propulsion unit.
indicator" The thrust direction is displayed on a scale of 360° (± 180°).
The thrust direction indicator's “ahead” position, its scale division
and direction of rotation can be adjusted; see the
“6.5.1 Setting the thrust direction indicator” section, page 52.
4 RPM “speed indicator” Displays the current speed of the propeller in revolutions per minute
[RPM].
The scale division can be adjusted; see the
“6.5.2 Setting the speed indicator” section, page 54.
5 "Control mode" status indicator Indicates the activated control mode.
- (no indicator) Full follow-up control mode (FFU) is activated.
NFU active Non-follow-up control (NFU) is activated.
6 "Active control desk" Indicates the active control desk.
Main-Desk The main control desk is active.
Desk 1 to desk 5 The secondary control desk is active (adjusted to specific project).
ECR The engine control desk is active.
LOCAL The local control panel or control system switch cabinet is active.
1* Only for propulsion units with pitch control
1 2 3 4
7 6 5
7 "External control system" status Indicates operation using an external control system
indicator (e.g. DP system).
- (no indicator) No external control system is activated.
ext.Sys1 45 External control system with a thrust direction control of ± 45° is

activated.
activated.

activated.
activated.
Masterstick The masterstick system is activated.
1 2 3 4
7 6 5
BLANK PAGE
5.6 Main menu
The system display is available in two versions.
● Easy main menu ● Advanced main menu
This function is available ex works (optional) or on
request from the SCHOTTEL Service Department.
Functions: Functions:
The thrust direction indicator scale division The thrust direction indicator scale division
can be changed. can be changed.
The speed indicator scale division can be The speed indicator scale division can be
changed. changed.
The pitch indicator can be activated. The pitch indicator can be activated.
The log files can be displayed and exported The log files can be displayed and exported
(copied). (copied).
The background illumination can be The background illumination can be
changed. changed.
The Internet address can be adapted to the The Internet address can be adapted to the
network environment. network environment.
Different information about the system Different information about the system
display and other project data can be display and other project data can be
displayed. displayed.
The system and operational data can be
displayed.
The existing system devices can be
displayed.
The availability of system devices can be
displayed.
5.6.1 Easy main menu
i INFORMATION
The following illustrates the easy menu of a propulsion
unit with fixed-pitch propeller.
Status bar (displayed on all menu levels)
1 "User profile" status indicator Shows the active user profile.
- (no indicator) No user is logged on.
Crew The Crew user profile is logged on; see “login area” button [12/8]).
2 Thrust direction indicator Indicates the actual thrust direction of the propulsion unit.
The thrust direction is displayed on a scale of 360° (± 180°).
[RPM].
Menu bar
4 Display Settings button Opens the Display Settings menu; see page 52.
In the Display Settings menu, different basic settings can be made
for the system display.
5 Service button Opens the Service menu; see page 59.

In the Service menu, different log files (error memory file, event file,
and parameter file) can be displayed and copied.
6 Info button Opens the Info menu; see page 94.

In the Info menu, different information can be displayed for the
system display and project data.
Navigation bar (displayed on all menu levels)
7 “Browse menu” button Navigation aid for browsing menus
“backward ” Goes back to the previously opened superordinate menu

"forward" Goes back to the previously opened subordinate menu
8 “Login area” button Displays the status of the user level and opens the login area;
see page 49.
“Logout” No user is logged on (logout).
“Login” A user is logged on (login).
1 2 3
7 8
Fig. 12 Easy main menu
5.6.2 Advanced main menu
This function is available ex works (optional) or on request from the SCHOTTEL Service Department.
i INFORMATION
The following illustrates the advanced menu of a
propulsion unit with fixed-pitch propeller.
Status bar (displayed on all menu levels)
1 "User profile" status indicator Shows the active user profile.
- (no indicator) No user is logged on.
Crew The Crew user profile is logged on; see “login area” button [14/8]).
2 Thrust direction indicator Indicates the actual thrust direction of the propulsion unit.
The thrust direction is displayed on a scale of 360° (± 180°).
[RPM].
Menu bar
4 Display Settings button Opens the Display Settings menu; see page 52.
In the Display Settings menu, different basic settings can be made
for the system display.
5 Service button Opens the Service menu; see page 59.

In the Service menu, different log files (error memory file, event file,
and parameter file) can be displayed and copied.
6 Button Opens the SCHOTTEL Settings menu; see page 75.

SCHOTTEL Settings In the SCHOTTEL Settings menu, memory addresses can be dis
played and changed.
7 Button Opens the SCHOTTEL Diagnosis menu; see page 80.

SCHOTTEL Diagnosis In the SCHOTTEL Diagnosis menu, information about the existing
hardware and its availability can be displayed.
8 Info button Opens the Info menu; see page 94.

In the Info menu, different information can be displayed for the
system display and general project data.
1 2 3
8
6
10 7 9
Fig. 13 Advanced main menu
Navigation bar (displayed on all menu levels)
9 “Login area” button Displays the status of the user level and opens the login area;
see page 49.
“Logout” No user is logged on (logout).
“Login” A user is logged on (login).
10 “Browse menu” button Navigation aid for browsing menus
“backward ” Goes back to the previously opened superordinate menu

"forward" Goes back to the previously opened subordinate menu
1 2 3
8
6
10 7 9
6 Operation
6.1 System display operation
NOTICE
When operating above +60 °C or below -10 °C the
liquid crystals change their order which may damage
the system display.
▶ Only operate the system display within the per
missible temperature range.
NOTICE
Direct, constant sunlight, strong magnetic fields and
sudden extreme fluctuations in temperature may
damage the system display.
▶ Protect the system display from direct sunlight.
▶ Never operate strong magnetic fields in its
vicinity.
▶ Keep temperatures in the operation area con
stant.
NOTICE
Pointed or sharp objects, such as pens or fingernails
may cause irreparable damage to the display screen.
▶ Only use fingertips when operating the touch
screen.
6.1.1 Switching on the system display
1. Switch on the power supply at the control system
switch cabinet; see the SCHOTTEL Instructions in 1 2
The system display is automatically switched on
when the control system switch cabinet is switched
on.
The power light (15/1) lights up blue.
After start-up, the start screen (15/2) appears.
The system display is ready for operation.
6.1.2 Switching off the system display

1. Switch off the power supply at the control system
switch cabinet; see the SCHOTTEL Instructions in
The system display saves all settings and Fig. 15 Start screen (example: propulsion unit with
automatically switches off. pitch control)
The power light (15/1) goes out.
6.1.3 Using removable media
Memory card
Using a memory card
i INFORMATION 1
A missing or faulty memory card is indicated by a
flashing symbol (16/1; 17/1).
1. Open the cover (18/1) .
NOTICE
Malfunctions
By using an incompatible memory card, both the card
and the system display may be damaged. In addition,
data saved on the memory card may be corrupted.
▶ Only use the memory card provided.
▶ Never use the provided memory card for any
other purpose, e.g. for a camera. Fig. 16 Missing or faulty memory card
1
i INFORMATION
The contact area of the memory card must point right
wards (direction of the switch cabinet door)
2. Insert the memory card (18/2) into the memory

card slot and push until it clicks into place.
3. Close the cover.
Fig. 17 Missing or faulty memory card
1 2
Fig. 18 Using a memory card
Ejecting a memory card
i INFORMATION
Make sure the provided memory card is inserted
when recording the log files.
i INFORMATION
Never remove the memory card when saving data.
This may damage the memory card and the system
display, as well as the data saved on the card. 1 2

2. Push the memory card (19/2) further into the
memory card slot.
The memory card is ejected from the memory card Fig. 19 Ejecting a memory card
slot when released.
3. Remove the memory card.
4. Close the cover.
USB stick
Inserting the USB stick
i INFORMATION
If the USB stick is too wide, the memory card may be
released from the memory card slot. Reinsert the
memory card or use a different USB stick.
1
NOTICE
Malfunctions 2
By using an incompatible USB stick, both the stick
data saved on the USB stick may be corrupted.
▶ Only use a USB stick that conforms to general
industrial standards. Fig. 20 Inserting and removing the USB stick
▶ The USB stick must be formatted in the file format
FAT16/32.
2. Insert the USB stick (20/1) in the USB port.
Removing the USB stick
i INFORMATION
Never remove the USB stick when saving data. This
may damage the USB stick and the system display,
as well as the data saved on the stick.
1. Open the cover.

2. Remove the USB stick from the USB port.
3. Close the cover.
6.2 Login
Menu structure:
Start screen Easy main menu or advanced menu
1
i INFORMATION
Login is required, if:
● Values or settings are to be changed.
● Events in the error memory file are to be hidden.
● Parameter files are to be exported/imported.
● A backup copy is to be made of the log files. 3
● The control module parameters are to be

changed. 2
Fig. 21 Login
i INFORMATION
Login can be cancelled using the Cancel button
(21/3).
1. Touch the “login area” button (21/2).

The Login dialogue box is displayed.
1
i INFORMATION
The Developer and Service user levels are not part
of this User Documentation.
2. Touch the drop down User menu (21/1).

3. Select the Crew option (22/1).
The selection is adopted (23/1). Fig. 22 Login dialogue box
4. Touch the edit box for the Password check box
(23/2).
▶▶
1
2
Fig. 23 Entering the password
i INFORMATION
An invalid password is indicated by the Login failure 1
dialogue box (24/1). The message disappears after a
short period, or can be acknowledged with the OK
button (24/2).
2
5. Enter the Crew password using the keyboard and
confirm; see page 28.
The User Crew is logged in dialogue box (24/3) 3
is displayed.
The message disappears after a short period, or
can be acknowledged with the OK button (24/2).
2
6. Confirm with the OK button (25/1).
The “login area” button indicates the “login” status Fig. 24 Dialogue box for entering the password
(26/2).
The Crew user level (26/1) is indicated by the “user
profile” status indicator.
i INFORMATION
If the system display is not used for ten minutes, the
user will be automatically timed out (auto logout) and
the start screen will appear.
Fig. 25 Confirming the password
Fig. 26 Login successful
6.3 Logout
i INFORMATION 1
If the system display is not used for ten minutes, the

user will be automatically timed out (auto logout) and
the start screen will appear.
Menu structure:
Start screen Easy main menu or advanced main
menu User level Crew (27/1) is displayed in the “user
profile” status indicator.
1. Touch the “login area” button (27/2).

The User Crew is logged out dialogue box (28/1)
is displayed; the message disappears soon after.
2
The Crew user level disappears from the “user
profile” status indicator. Fig. 27 Logout
6.4 Changing the password

Menu structure:
Login
1
i INFORMATION
The factory-set password may only be changed fol
lowing consultation with the SCHOTTEL Service
Department.
Fig. 28 Logout successful
6.5 Basic settings on the system
display
i INFORMATION
The menu is only available after login.
Menu structure:
Display Settings 1
In the Display Settings menu (29/1), different basic

settings can be made:
● Setting the thrust direction indicator (Azimuth
button [30/1])
● Setting the pitch indicator (CP button [30/2])
● Setting the speed indicator (RPM button [30/3])
● Setting the IP address and background Fig. 29 Easy main menu
illumination (System button [30/4])
6.5.1 Setting the thrust direction

indicator
i INFORMATION 1 4
2
Menu structure: 3
Display Settings
1. Touch the Azimuth button (30/1).

The Systemsettings dialogue box is displayed.
Adjusting the heading Fig. 30 Display Settings menu

Depending on the installation position of the system
display, the thrust direction indicator (31/1) 0° "ahead"
1 2
position is to be set.
1. Touch the required push button (31/3, 31/4, 31/5,
or 31/6). 3
The thrust direction indicator (31/2) indicates the
0° "ahead" position.
For example:
The push button (31/6) has been selected. 6 4
The white arrow (31/1) on the thrust direction 5
indicator shows the 0° "ahead" position.
Fig. 31 Azimuth menu
Adjusting the scale division of the thrust direction
indicator
The following scale divisions are available:
● No scale division (show no marks [32/1])
● Scale divisions of 45° (show 45° marks [32/2])
● Scale divisions of 90° (show 90° marks [32/3])
1
1. Touch the required scale division. 2
Selection is indicated by a green spot.
3
For example:
The scale division show no marks (32/1) has
been selected.
The thrust direction indicator on the start screen
(34/1) is displayed with the selected scale division.
Setting the direction of rotation of the thrust

direction indicator Fig. 32 Thrust direction indicator scale division
i INFORMATION 1
Activation is determined by the SCHOTTEL Service
Department during commissioning.
The direction of rotation of the thrust direction indicator

(33/1) must correspond with that of the propulsion unit.
For example:
The propulsion unit rotates anti-clockwise. 2
The thrust direction indicator rotates clockwise.
1. Touch the Change turn direction check box
(33/2).
Selection is indicated by a green tick.
The propulsion unit rotates anti-clockwise.
The thrust direction indicator (33/1) rotates
anti-clockwise. Fig. 33 Thrust direction indicator direction of
rotation
Fig. 34 For example: Thrust direction indicator

scale division
6.5.2 Setting the speed indicator
i INFORMATION
Menu structure:
Display Settings RPM
1. Touch the RPM button (35/1).

The settings RPM dialogue box is displayed. 1
Setting the scale division of the speed indicator

There are several scale divisions available to represent
the maximum propeller speed (scale end value).
1. Touch the required scale division.

Fig. 35 Settings menu
For example:
The scale division 0 - 300 RPM (36/1) is selected.
The speed indicator on the start screen (37/1) is
displayed with the selected scale division.
1
6.5.3 Setting the pitch indicator
Menu structure:
Display Settings CP
i INFORMATION
Activation is determined by the SCHOTTEL Service
Fig. 36 Setting the speed indicator
Fig. 37 For example: Speed indicator scale division
6.5.4 Setting the IP address and
background illumination
i INFORMATION
Menu structure:
1
Display Settings System
In the System menu (38/1), the following settings can

be made:
● Setting the IP address (IP-Settings button [39/1])
● Setting the background illumination (Backlight
button [39/2])
Setting the IP address

Fig. 38 Settings menu
i INFORMATION
Menu structure:
Display Settings System IP-Settings
1
1. Touch the IP-Settings button (39/1).
2
The IP-Settings dialogue box is displayed.
i INFORMATION
The IP address must be set to the network environ
ment. The standard system display address is
192.168.1.1.
Fig. 39 Systemsettings menu
Obtaining an IP address from the server
i INFORMATION
The Cancel button (40/2) is used to close the dialogue 1
box without making any changes.
1. Touch the Obtain an IP address via DHCP

check box (40/1).
The IP address is obtained from the server.
The IP-Settings dialogue box closes. 3 2
Fig. 40 Obtaining an IP address from the server
Specifying your own IP address
Menu structure:
Display Settings System IP-Settings
1
i INFORMATION
The Cancel button (41/5) is used to close the dialogue
box without making any changes. 2
3
4
i INFORMATION
6 5
Any queries concerning specification of the Internet
address are to be resolved with the network adminis
trator in charge.
1. Touch the Specify an IP address check box Fig. 41 Specifying the IP address
(41/1).
2. Touch the IP address edit box (41/2).
3. Enter the required IP address using the numeric
keypad and confirm; see page 30.
4. Touch the Subnet mask edit box (41/3).
6. Touch the Default Gateway edit box (41/4).
The IP-Settings dialogue box closes.
Setting the background illumination
i INFORMATION
The dialogue box is only available after login.
Menu structure:
Display Settings System Backlight
1
1. Touch the Backlight button (42/1).
The Backlight Settings dialogue box is
displayed.
Switching off the background illumination

automatically
i INFORMATION Fig. 42 Systemsettings menu

1. Touch the Automatically turn off backlight

check box (43/2). 1 2
The background illumination goes out after the set
delay time.
Keeping the background illumination on

4 3
i INFORMATION
Fig. 43 Switching the background illumination on
1. Touch the Keep backlight on if the notifier and off
window is visible check box (43/1).
The background illumination is kept on for as long
as a dialogue box is displayed.
Setting the background illumination delay time
i INFORMATION
1. Touch the edit box (44/1) for the Idle time before
turn off (Seconds) check box.
1
2. Enter the required delay time (0 - 999) using the
numeric keypad and confirm; see page 30.
3 2
Setting the background illumination brightness
i INFORMATION
The Cancel button (45/2) is used to close the dialogue Fig. 44 Setting the delay time
Setting the brightness using the scale

1. Set the required brightness (0 to 100%) using the
slide adjustment (45/1).
The set brightness is displayed in the edit box
(45/4).
Setting the brightness using the edit box 4 1

1. Touch the edit box (45/4).
3 2
2. Enter the required brightness (0 - 100%) using the
numeric keypad and confirm; see page 30.
Fig. 45 Setting the brightness
6.6 Working with log files
Menu structure:
Service
In the Service menu (46/1), various display and

copying functions can be used:
● Display, copy and hide the error memory file
(Failure Memory button [47/1]) 1
● Import parameter files (EEPROM from File button
[47/2])
● Copy log files (Save Files button [47/3])
● Copy and activate parameter files (Parameter
List button [47/4])
● Display the control module operating data
Fig. 46 Easy main menu
(Operating Data button [47/5])
1. Touch the Service button.

The Service menu is displayed.
6.6.1 Displaying, copying or hiding the

error memory file
1 4
i INFORMATION 2 5
Any events defined as errors are saved in the error
memory file. The events are ordered chronologically 3
according to date and time, starting with the commis
sioning of the propulsion system.
Displaying the error memory file

Menu structure: Fig. 47 Service menu
menu Service Failure Memory Trigger Events
1. Touch the Failure Memory button (47/1).

The Trigger Events menu is displayed. 1
The error memory file is displayed.
The event is displayed in plain text (48/1) with the
date and time of occurrence (for error status, see
section 7).
▶▶
Fig. 48 Trigger Events menu
In the Trigger Events menu, there are various options
available for working with the error memory file:
● Select events according to the type of error (Sort
By [49/1])
1
● Copy single displayed event (Copy Selected
[49/2]) 2
● Copy all displayed events (Copy All [49/3]) 3
● Hide single displayed event (Clear Selected
[49/4]) 4
● Hide all displayed events (Clear All [49/5]) 5
Selecting events according to the type of error

Menu structure:
Start screen Easy main menu or advanced main Fig. 49 Trigger Events menu
1. Touch the Drop down menu Sort By (50/2).

2. Select the required error type.
1 2
For example:
All events of error type DPV1 Azi - open circuit
valve (50/1) are displayed.
A single, displayed event can be copied (see page
61) or hidden (see page 65).
All displayed events can be copied (see page 63)
or hidden (see page 66).
Fig. 50 Selecting according to the type of error
Copying a single, selected event
i INFORMATION 1
A missing USB stick is reported via the No USB drive
found dialogue box (51/1). Close the dialogue box by
touching the OK button (51/2). 2
The Unable to copy dialogue box (51/3) shows that
the copying process cannot be completed, e. g. due
to insufficient memory or activated write protection on
the USB stick. Close the dialogue box by touching the 3
ESC button (51/4).
Menu structure:
4

5
● The USB stick is inserted; see the “Inserting the
USB stick” page 48 6
7
i INFORMATION
Preselection via type of error is possible; see page 60.
1. Select the required event. 8

For example:
DCM extSys1 - SetpointAI2 (52/1) is selected.
2. Touch the Copy Selected button (52/2).
i INFORMATION Fig. 51 Dialogue box

The copying process is cancelled using the ESC
button (51/7).
Do not remove the USB stick during copying.
1
The Copying… dialogue box (51/5) is displayed.
The progress bar (51/6) indicates the progress of 2
the copying process.
Once copying is complete, the done dialogue box
(51/8) is displayed.
▶▶
Fig. 52 Copying a single, selected event
i INFORMATION
The error memory file is copied to the USB stick in the
.csv format and opened in an external editor.
Fig. 53 Dialogue box
Copying all displayed events
i INFORMATION 1
ESC button (54/4).
Menu structure:
4

5
● There is no event marked in the error memory file
7
(55/1)
i INFORMATION
8
All displayed events are copied. Preselection via type
of error is possible; see page 60.
1. Touch the Copy All button (55/2).
i INFORMATION Fig. 54 Dialogue box

button (54/7).
The Copying… dialogue box (54/5) is displayed.

1
The progress bar (54/6) indicates the progress of
Once copying is complete, the done dialogue box 2
▶▶
Fig. 55 Copying all displayed events
i INFORMATION
The error memory files are copied to the USB stick in
the .csv format and opened in an external editor.
Hiding a single, selected event
i INFORMATION
This action is only available after login.
1
Menu structure:
2
i INFORMATION
Preselection via type of error is possible; see page 60.
1. Select the required event.

For example:
DCM extSys1 - SetpointAI2 (57/1) is selected.
Fig. 57 Hiding a single, selected event
2. Touch the Clear Selected button (57/2).
The selected event is hidden.
i INFORMATION
The event is retained in the error memory file.
Hiding all displayed events
i INFORMATION
Menu structure: 1
i INFORMATION
All displayed events are hidden. Preselection via type 2
of error is possible; see page 60.

● There is no event marked in the error memory file
Fig. 58 Hiding all displayed events
(58/1)
1. Touch the Clear All button (58/2).

All events are hidden.
i INFORMATION
The events are retained in the error memory file.
6.6.2 Copying log files
1
i INFORMATION
A missing USB stick is reported via the No USB drive 2
touching the OK button (59/2).
the copying process cannot be completed, e. g. due 3
the USB stick. Close the dialogue box by touching the
ESC button (59/4).
4
Menu structure:
Service Save Files 5
The following condition is to be fulfilled: 6
1. Touch the Save Files button (60/1).

The Copy files menu is displayed.
i INFORMATION
button (59/7).
1. Touch the Save Log-File button (61/1).

Log files (error memory file, event file and 1
parameter file) are copied to the USB stick
sequentially.
The Copying... dialogue box (59/5) is displayed
for every log file.
The progress bar (59/6) indicates the progress of Fig. 60 Service menu
the respective copying process.
▶▶
Fig. 61 Copying log files
i INFORMATION
1
The error memory file is copied to the USB stick in the
.csv format, the event file in .txt and the parameter file
in .csv format.
2
6.6.3 Importing the parameter files
i INFORMATION
Menu structure:
Start screen Easy main menu or advanced menu 1
Service EEPROM from File
USB stick“ page 48
1. Touch the EEPROM from File button (63/1).

Fig. 63 Service menu
The EEPROM from File menu is displayed.
1
NOTICE
The parameter file with new settings is provided by the
2
SCHOTTEL Service Department. The parameter file
must be on the USB stick in the root directory.
(File name: SCHOTTELEEPROM.csv) 3
i INFORMATION 4
found dialogue box (64/1). Close the dialogue box by 5
touching the OK button (64/2).
The No files found dialogue box (64/3) shows that no
parameter file can be found on the USB stick. 6
1. Touch the load File button (65/1). 7
i INFORMATION
The importing process is cancelled using the ESC 8
button (64/6).
Do not remove the USB stick while importing. Fig. 64 Dialogue box
The in progress… dialogue box (64/5) is

displayed.
The parameter file is imported.
Once importing is complete, the done dialogue
box (64/7) is displayed. 1
Fig. 65 Importing the parameter files
6.6.4 Copying or activating parameter
files
i INFORMATION
All control system settings are saved in a parameter
file Any setting changes made after commissioning
are recorded.
1
Menu structure:
Service Parameter List
1. Touch the Parameter List button (66/1).

The ParameterLists menu is displayed.
Parameter files (67/1) are shown with the change
date and time.
In the ParameterLists menu, there are various options
available for working with the parameter files: Fig. 66 Service menu
● Activating the selected parameter file (Activate

Selected [67/4])
● Copying single parameter file (Copy Selected
[67/2]) 1
● Copying all displayed parameter files (Copy All 2
[67/3]) 3
● Hiding single displayed parameter file (Clear
Selected [67/5]) 4
● Hiding all displayed parameter files (Clear All 5
[67/6]) 6
Fig. 67 ParameterLists menu
Copying a single, selected parameter file
i INFORMATION 1
ESC button (68/4).
Menu structure:
4
Service Parameter List ParameterLists

5
1. Select the required parameter file. 7

For example:
para1203051446.csv (69/1) is selected.
2. Touch the Copy Selected button (69/2).
8
i INFORMATION
The copying process is cancelled using the ESC 9
button (68/7).
The Copying... dialogue box (68/5) is displayed.
(68/8) is displayed. 1
3. Confirm with the OK button (68/9). 2
i INFORMATION
The parameter file is copied to the USB stick in the
.csv format and can be opened in an external editor.
Fig. 69 Copying a single, selected parameter file
Copying all displayed parameter files
i INFORMATION 1
ESC button (70/4).
Menu structure:
4
Service Parameter list Parameter lists

5
● There is no parameter file marked (71/1)
7
i INFORMATION
All displayed parameter files are copied.
8
1. Touch the Copy All button (71/2).
i INFORMATION 9

button (70/7). Fig. 70 Dialogue box
The Copying... dialogue box (70/5) is displayed.

1
2
i INFORMATION
The parameter files are copied to the USB stick in the
.csv format and opened in an external editor.
Fig. 71 Copying all displayed parameter files
Activating the selected parameter file
i INFORMATION
Menu structure: 1
Service Parameter List ParameterLists
1. Select the required parameter file. 2

For example:
Para1203051446.csv (72/1) is selected. 3
2. Touch the Activate Selected button (72/2). 4
The selected parameter file is loaded into the
control module.
Hiding the selected parameter file Fig. 72 Activating the selected parameter file
i INFORMATION
The Clear Selected (72/3) action is only available at
the Developer and Service user levels. The
Developer and Service user levels are not part of this
User Documentation.
Hiding all displayed parameter files
i INFORMATION
The Clear All (72/4) action is only available at the
Developer and Service user levels. The Developer
and Service user levels are not part of this User Docu
mentation.
6.6.5 Displaying the operating data of
control modules
Menu structure:
Service Operating Data
1. Touch the Operating Data button (73/2).

2. Touch the tab for the required control module.
● Thrust direction control (Azimuth tab [74/1])

1
● Speed control (Speed tab [74/2])
● Pitch control (Pitch tab [74/3])
The operating data of the selected control module
is shown on the display screen (74/4).
Fig. 73 Service menu
1 2 3 4
Fig. 74 Displaying the control module operating

data
6.7 Displaying and changing
settings
i INFORMATION
Menu structure:
Start screen Advanced main menu
SCHOTTEL Settings
1. Touch the SCHOTTEL Settings button (75/1).

1
The SCHOTTEL Settings menu is displayed.
6.7.1 Displaying and changing memory

addresses
i INFORMATION
Menu structure:
SCHOTTEL Settings EEPROM
1. Touch the EEPROM button (76/1).

The EEPROM menu is displayed. 1
In the EEPROM menu, memory addresses can be

displayed and changed.
● Enter the memory address to be read (EEPROM
adr. [77/1])
● Select the CAN bus interface (Select CAN
interface [77/2])
● Read the memory address (read [77/3])
Fig. 76 SCHOTTEL Settings menu
● Create parameter file (Create
Parameter-Backup [77/4])
● Adopt new memory address value (write [77/5])
● Display the memory address value or enter new
value (Value [77/6]) 1 2 3
● Enter checksum to safeguard data integrity

(Checksum [77/7])
9
● Select the input and output format (hexadecimal
[77/8])
8
● Select the size of addressed memory (Byte, Word
or DWord [77/9])
7 6 5 4
Fig. 77 EEPROM menu
i INFORMATION
1 2 3
Menu structure:
7
1. Touch the Select CAN interface drop down menu
(78/2).
6
2. Touch the required CAN bus.
The selection is adopted.
3. Touch the EEPROM addr. edit box (78/1).
5 4
4. Enter the required memory address using the
numeric keypad and confirm; see page 30. Fig. 78 Displaying and changing memory
5. Touch the required check box (78/7) for Byte, addresses
Word or DWord.
6. Touch the read button (78/3).
The selected memory address value is displayed
in the edit box Value (78/4).
i INFORMATION
The input and output format of the memory address
can be decimal or hexadecimal. The required input
and output format is selected with the hexadecimal
check box (78/6). If the selection is marked with a
green tick, the input and output format will be hexa
decimal.
7. Enter the new memory address value in the Value

edit box.
NOTICE
SCHOTTEL Service Department will provide a
checksum to safeguard the data integrity. To save a
new value enter the checksum in the Checksum edit
box (78/5).
8. Touch the Checksum edit box.

▶▶
i INFORMATION
1
An invalid checksum is indicated by the Checksum
incorrect dialogue box (79/1). The message is
acknowledged with the OK button (79/2).
2
9. Enter the checksum using the numeric keypad and
confirm; see page 30.
10. Touch the write button (80/1). 3
The Value changed dialogue box (79/3) is
displayed.
11. Confirm with the OK button (79/4). 4
Fig. 80 Changing the memory address
6.7.2 Creating a backup copy of the
parameter file
i INFORMATION
Menu structure:
1. Touch the Create Parameter-Backup button

(81/1).
The In Progress.. Please Wait.. dialogue box
the saving process.
Fig. 81 Creating a backup copy of the parameter
file
i INFORMATION
The parameter file is created in the .csv format and
can be copied to a USB stick via the Parameter- 1
Lists menu (83/1);
see the “6.6.4 Copying or activating parameter files” 2
section, page 70.
Fig. 83 ParameterLists menu
6.7.3 Calibrating rotation angle
encoders
Menu structure:
SCHOTTEL Settings
i INFORMATION
The Encoder CAL menu (84/1) is still being
developed and is not yet available.
1
Fig. 84 Encoder Cal menu
6.8 Diagnosing the control
system
Menu structure:
SCHOTTEL Diagnosis
1. Touch the SCHOTTEL Diagnosis button (85/1).

The SCHOTTEL Diagnosis menu is displayed.
6.8.1 Displaying the system overview

Menu structure:
Start screen Advanced main menu 1
SCHOTTEL Diagnosis System Overview
1. Touch the System Overview button (86/1).

The System Overview menu is displayed.
In the System Overview menu, various diagnosis

functions can be displayed:
● Display existing system inputs (System Inputs
[87/1])
● Display available main subassemblies (System
Hardware [87/2])
● Display control system availability (System
1
availability [87/3])
● Display available control desks (FSP [87/4])
● Display availability of automatic control (State
Wago [87/5])
Fig. 86 SCHOTTEL Diagnosis menu
2 4
3 5
Fig. 87 System Overview menu
Displaying the existing system inputs
Menu structure:
SCHOTTEL Diagnosis System Inputs
1. Touch the System Inputs button (88/1).

The System Inputs menu is displayed.
1
The System Inputs dialogue box displays the
switching states of the main subassemblies:
● Digital inputs of the SPS CoDeSys1 (89/1)
● Digital inputs of the control module DCM-Azimuth
(89/4)
● Digital inputs of the control module
DCM-Speed(89/3) 1 2 3 4 5
● Digital inputs of the control module
DCM-Pitch(89/9)
● Digital inputs of the control module DCM-ext.
Sys 1 (89/5)
● Digital inputs of the control module DCM-ext.
Sys 2 (89/6)
● Digital inputs of the input and output module DIO-
Adr.52 (89/7)
● Digital inputs of the input and output module DIO-
Adr.32 (89/9)
10 9 8 7 6
i INFORMATION Fig. 89 System Inputs dialogue box

The text colours have the following significance:
● Green text = connected (24 V)
● Black text = not connected (0 V)
For unavailable main subassemblies the message
not available is displayed.
Allocating the existing system inputs according to
type
Menu structure:
The tabs can be used to display the system inputs for

the following main subassemblies:
● Digital inputs of the control modules (DCM tab
([91/1])
● Digital inputs of the SPS (CoDeSys tab ([91/2])
● Digital inputs of the output and input modules (DIO
tab [91/3])
1. Touch the expert mode check box (90/1).

Selection is indicated by a green tick. 1
The Digital Inputs menu is displayed. Fig. 90 Changing the display setting
i INFORMATION 1 2 3
Within a tab, the “scroll forward” button (91/4) can be
used to display the next main subassemblies.
i INFORMATION
For unavailable main subassemblies the message
not available is displayed.
4
Fig. 91 Sorting main subassemblies according to

type
Selecting the existing system inputs as required
Menu structure:
1
The display of main subassemblies and their system
inputs can be individually selected by means of the
customize tab (92/1).
1. Touch the customize tab.

2. Touch the edit customise button (92/2).
The custom menu is displayed.
3. Touch the required drop down menu list.
4. Select the required main subassembly.
2
For example:
The DCM-extSys1 control module (93/1) is
Fig. 92 Selecting the main subassemblies as
selected.
required
The DCM-extSys2 control module (93/2) is
selected.
The DCM-Speed control module (93/3) is
selected.
The digital input assembly of the SPS CoDeSys 3
(93/4) is selected.
5. Touch the “confirm ” button (93/5).
The Custom menu closes.
Main subassemblies are shown in the required
order; see figure 94. 1 2 3 4
Fig. 93 Selecting the main subassemblies
Fig. 94 Display of the selected main subassemblies
Redisplaying the overview of the existing system
inputs
Menu structure:
1
1. Touch the overview tab (95/1).
The display returns to the overview; see the
“System Inputs dialogue box” section, page 81.
Fig. 95 Selected modules
Fig. 96 System Inputs menu
6.8.2 Displaying available main
subassemblies
Menu structure:
SCHOTTEL Diagnosis System Hardware
1. Touch the System Hardware button (97/1).

1
The System Hardware menu is displayed.
In the System Hardware menu, the following main

subassemblies can be displayed:
● Displaying the control modules of the thrust
direction control, speed control and pitch control
(DCM button [98/1])
● Displaying the valve control modules of the thrust Fig. 97 System Overview menu
direction control and pitch control (DPV button
[98/2])
● No function (98/3)
Fig. 98 System Hardware menu
Displaying the control module of the thrust
direction control
Menu structure:
SCHOTTEL Diagnosis System Hardware DCM
1. Touch the DCM button (99/1).

The System Hardware-DCM menu is displayed.
1
2. Touch the Azimuth button (100/1).
In the DCM-Azimuth dialogue box, the following
information is displayed:
● Digital inputs of the hardware components

(Digital Inputs [101/6])
● Digital outputs of the hardware components
(Digital outputs [101/5])
● Voltage values of the analogue inputs and Fig. 99 System Hardware menu
outputs of the hardware component
(Analogue Values [101/4)
● DIP switch 3 position (DIP3 [101/1])
● Software identification (101/3)
1
i INFORMATION
Fig. 100 DCM menu
1
2
6 5 4 3
Fig. 101 DCM-Azimuth dialogue box
Displaying the control module of the speed
control
Menu structure:

1
2. Touch the Speed button (103/1).
In the DCM-Speed dialogue box, the following

(Digital outputs [104/5])
● Voltage values of the analogue inputs and Fig. 102 System Hardware menu
outputs of the hardware component
(Analogue Values [104/4])
i INFORMATION 1

Fig. 103 DCM menu
1
2
6 5 4 3
Fig. 104 DCM-Speed dialogue box
Displaying the control module of the pitch control
Menu structure:

1
2. Touch the Pitch button (106/1).
In the DCM-Pitch dialogue box, the following

(Digital Outputs [107/5])
● In not displayed (Analogue Values [107/4]) Fig. 105 System Hardware menu
i INFORMATION
1
Fig. 106 DCM menu
1
2
6 5 4 3
Fig. 107 DCM-Pitch dialogue box
Displaying the valve control module of the thrust
direction control
i INFORMATION
Activation of the Azimuth2 button (109/2) is deter-
mined by the SCHOTTEL Service Department during
commissioning.
Menu structure:
SCHOTTEL Diagnosis System Hardware DPV
1. Touch the DPV button (108/1).

The System Hardware DPV menu is displayed.
2. Touch the Azimuth1 button (109/1).
In the DPV1_Azimuth dialogue box, the following
● Actual current [mA] at valves A and B (Valves
[110/2])
● Voltage values of the analogue inputs of the
hardware components (Analogue Values
1
[110/3])
● Software identification (110/4) 2
i INFORMATION
● Black text = not connected (0 V) Fig. 109 DPV menu
1 2 3 4
Fig. 110 DPV1_Azimuth dialogue box
Displaying the valve control module of the pitch
control
i INFORMATION
Activation of the Pitch1 (112/2) and Pitch2 buttons
(112/2) is determined by the SCHOTTEL Service
Menu structure:
SCHOTTEL Diagnosis System Hardware DPV
1. Touch the DPV button (111/1).

The System Hardware DPV menu is displayed.
2. Touch the Pitch1 button.
In the DPV1_CP dialogue box, the following
● Actual current [mA] at valves A and B (Valves
[113/2])
● Voltage values of the analogue inputs of the
hardware components (Analogue Values
2
[113/3])
Fig. 112 DPV menu
1 2 3 4
Fig. 113 DPV1_CP dialogue box
6.8.3 Displaying availability of the
automatic control
Menu structure:
SCHOTTEL Diagnosis System Overview State
Wago
1. Touch the State Wago button (114/1).

The State Wago dialogue box (115/1) is
displayed.
The State Wago dialogue box displays the
operating data of the automatic control. 1
i INFORMATION
If the automatic control is not connected, the No
Wago System found message (116/1) is displayed
in the dialogue box.
Fig. 115 Wago status
Fig. 116 'No Wago System found' message
6.8.4 Displaying control system
availability
Menu structure:
SCHOTTEL Diagnosis System Overview System
availability
i INFORMATION
The System availability menu (117/1) is still being 2
developed and is not yet available.
1
6.8.5 Displaying available control desks

Menu structure:
SCHOTTEL Diagnosis System Overview FSP
i INFORMATION
The FSP menu (117/2) is still being developed and is
not yet available.
6.8.6 Displaying the overview of
available assemblies
Menu structure:
SCHOTTEL Diagnosis Hardware Overview
1. Touch the Hardware Overview button (118/1).

In the Hardware Overview dialogue box, a
schematic overview of available assemblies is
displayed.
1
For example:
● Control module assembly
DCM-ext.Sys1 (119/1)
DCM-ext.Sys2 (119/2)
DPV-Azimuth1 (119/3) Fig. 118 SCHOTTEL Diagnosis menu
● Main control desk assembly

FSP-Main [119/4)
● Engine control desk assembly
FSP-ECR [119/5) 1
● Data bus cable CAN-Bus (119/6) 9
2 4
● Control module assembly 8
DCM-Speed (119/7) 7 3
DCM-Azimuth (119/8) 6
5
WAGO (119/9)
Fig. 119 Hardware Overview dialogue box
6.9 Displaying general
Information
Menu structure:
Info
1. Touch the Info button (120/1).

The Info menu is displayed.
6.9.1 Displaying information about the

system display
Menu structure: 1
Info System Display
1. Touch the System Display button (121/1).

In the Info-Display dialogue box, the following
information is displayed: Fig. 120 Easy main menu
● Software name Projectname (122/1)

● Software version of the operating system
WinCE Ver (122/2)
● Runtime version of the operating system
Runtime Vers. (122/3)
● Available RAM [byte] 1
physical RAM (122/4)
● Application memory [MB] available Storage
(122/5)
● Current date and time
Date/Time (122/6)
● Software version of CAN bus system
CAN Firmware (122/7)
Fig. 121 Info menu
● Software version of the system display
Version (122/8)
● Running time of the system display in hours
[h] and minutes [min] Running Hours
(122/9)
1 7
2 8
3
4 9
5
6
Fig. 122 Info-Display dialogue box
6.9.2 Displaying information about the
project
i INFORMATION
The project number Project No. (124/3) and serial
number of the propulsion unit BuildingNo. of
Thruster (124/4) are provided by the SCHOTTEL
Service Department for commissioning.
Menu structure:
1
Info Project Data
1. Touch the Project Data button (123/1).

In the Info-Project dialogue box, the following
● Order number Order No. (124/1)

Fig. 123 Info menu
● Password Codeword (124/2)
● Project number Project No. (124/3)
● Propulsion unit serial number
BuildingNo. of Thruster (124/4)
1
2
3
4
Fig. 124 Info-Project dialogue box
6.10 Installing new software
NOTICE
Malfunctions
By using an incompatible USB stick, both the stick
data saved on the USB stick may be corrupted.
▶ Only use a USB stick that conforms to general
industrial standards.
▶ The USB stick must be formatted in the file format
FAT16/32.
i INFORMATION
The directory structure on the USB stick must be
maintained; do not rename folders or files; see figure Fig. 125 Directory structure on the USB stick
125.
1. Copy new software into the USB stick root

directory.
1
2. Insert the USB stick; see the “Inserting the USB
stick” section, page 48. 2
3. Switch on the system display; see the
“6.1.1 Switching on the system display” section,
page 45.
3
i INFORMATION
Installation is automatically cancelled, if the software 4
version on the USB stick is the same as the version
installed.
4. Copy project from USB memory? dialogue box Fig. 126 Dialogue box
Confirm with the Yes button (126/2).
i INFORMATION
Do not remove the USB stick during installation.
5. Backup existing project? dialogue box (126/3) is

displayed.
Confirm with the Yes button (126/4).
▶▶
A backup copy of the software is saved on the USB
stick.
1
The Backing up project dialogue box (127/1) is
displayed.
the saving process.
A new software version is installed.

The Copying project dialogue box (127/3) is 3
displayed.
installation. 4
The Copying project dialogue box closes as soon

as installation is complete.
6. Remove the USB stick; see the “Removing the
USB stick” section, page 48.
7. The system display is ready for operation.
i INFORMATION
All settings made (basic settings, log files, and
memory addresses, etc.) are automatically reloaded
following installation.
6.11 Remote access to the system
display
i INFORMATION
Remote access (e.g. via UMTS, and satellite) to the
system display is still being developed and is not yet
available.
7 Troubleshooting
WARNING
Any deviations from the whole propulsion system's

usual operating states indicate malfunctions and are to
be remedied immediately.
The following table does not make any claim to
completeness. During operation, malfunctions may
occur that are not listed in the table.
table, please notify the SCHOTTEL Service
Department.

● Suspected cause
Successful troubleshooting requires precise

knowledge of the whole propulsion system structure
and mode of operation, and of the individual
components.
Always proceed systematically and purposefully even
under time pressure. Randomly and rashly changing
the settings and removing components may mean that
the original cause of the fault can no longer be
established.
7.1 Error states
Fault Cause Remedy
DCM azi setpoint No setpoint at the azimuth control module

(4A1)
DCM azi feedback No feedback at the azimuth control

module (4A1)
DCM azi high voltage Overvoltage at the azimuth control

module (4A1)
DCM azi low voltage Low voltage at the azimuth control module
(4A1)
DCM azi CAN bus CAN bus error at the azimuth control
module (4A1)
DPV1 azi short circuit valve Short circuit in valve A (4Y1) or valve B
(4Y2) of the thrust direction control (DPV
control module [4A2])
DPV1 azi open circuit valve Fault or wire break in valve A (4Y1) or valve
B (4Y2) of the thrust direction control (DPV Check the error indication in the con
control module [4A2]) trol cabinet. Replace the defective
component if required.
DPV1 azi high voltage Overvoltage at the DPV control module
(4A1)
DPV1 azi low voltage Low voltage at the DPV control module
(4A1)
DPV1 azi CAN bus CAN bus error at the DPV control module
(4A1)
DPV2 azi short circuit valve Short circuit in valve A (4Y1) or valve B
(4Y2) of the thrust direction control (DPV
DPV2 azi open circuit valve Fault or wire break in valve A (4Y1) or valve
B (4Y2) of the thrust direction control (DPV
DPV2 azi high voltage Overvoltage at the DPV control module

(4A4)
Fault Cause Remedy
DPV2 Azi-LowVoltage Low voltage at the DPV control module

(4A4)
DPV2 Azi-CAN Bus CAN bus error at the DPV control module
(4A4)
DPV1 CP-short circuit valve Short circuit in valve (9Y1) of the pitch con
trol (DPV control module [9A2])
DPV1 CP-open circuit valve Valve fault or wire break in valve (9Y1) of
the pitch control (DPV control module
[9A2])
DPV1 CP-HighVoltage Overvoltage at the DPV control module

(9A2)
DPV1 CP-LowVoltage Low voltage at the DPV control module

(9A2)
DPV1 CP-CAN Bus CAN bus error at the DPV control module
(9A2)
DPV2 CP-short circuit valve Short circuit in valve (9Y1) of the pitch con Check the error indication in the con
trol cabinet. Replace the defective
trol (DPV control module [9A3])
component if required.
DPV2 CP-open circuit valve Valve fault or wire break in valve (9Y1) of
the pitch control (DPV control module
[9A3])
DPV2 CP-HighVoltage Overvoltage at the DPV control module

(9A3)
DPV2 CP-LowVoltage Low voltage at the DPV control module

(9A3)
DPV2 CP-CAN Bus CAN bus error at the DPV control module
(9A3)
DCM Speed-Setpoint No setpoint at the Speed control module

(3A1)
DCM Speed-Feedback No feedback at the Speed control module

(3A1)
DCM Speed-HighVoltage Overvoltage at the Speed control module

(3A1)
Fault Cause Remedy
DCM Speed-LowVoltage Low voltage at the Speed control module

(3A1)
DCM Speed-CAN Bus CAN bus error at the Speed control

module (3A1)
DCM Speed-Feedback RPM No actual output Speed feedback value

Lost (N2) at the Speed control module (3A1)
(only with SCHOTTEL slip clutches).
DCM Speed-unit locked No adjustment between input Speed feed

back setpoint (N1) and actual output
Speed feedback value (N2); only with
SCHOTTEL slip clutches, Speed control
module (3A4).
DCM Speed-clutch sliding in Slip clutch slips in the speed range (only
RPM-area with SCHOTTEL slip clutches, Speed
DCM Pitch-Setpoint No setpoint at the CP control module (9A1) Check the error indication in the con
DCM Pitch-Feedback No feedback at the CP control module component if required.
(9A1)
DCM Pitch-HighVoltage Overvoltage at the CP control module

(9A1)
DCM Pitch-LowVoltage Low voltage at the CP control module

(9A1)
DCM Pitch-CAN Bus CAN bus error at the CP control module

(9A1)
DCM Pitch-unit locked Setpoint and feedback for the pitch control
do not correspond (CP control module
[9A1]).
DCM Pitch-Loadsignals No load signal from the engine/propulsion

motor; propeller blades cannot be
adjusted in relation to speed (CP control
module [9A1]).
Fault Cause Remedy
DCM extSys1-SetpointAI1 No setpoint for the thrust direction control

of external control systems 1 (autopilot
and tiller) at the external systems (A81).
DCM extSys1-SetpointAI2 No setpoint for the speed control of

external control systems 2 (DP system,
joystick system, and masterstick) at the
external systems (A81).
DCM extSys1-HighVoltage Overvoltage at the external systems con

trol module (A81)
DCM extSys1-LowVoltage Low voltage at the external systems con

trol module (A81)
DCM extSys1-CAN Bus CAN bus error at the external systems

control module (A81)

of external control systems 2 (DP system,
external systems (A81). Check the error indication in the con
DCM extSys1-SetpointAI4 No setpoint for the pitch control of external component if required.
control systems 2 (DP system, joystick
system, and masterstick) at the external
systems (A81).

of external control systems 1 (autopilot
and tiller) at the external systems (A82).
DCM extSys2-SetpointAI2 No setpoint for the speed control of

external control systems 2 (DP system,
external systems (A82).
DCM extSys2-HighVoltage Overvoltage at the external systems con

trol module (A82)
DCM extSys2-LowVoltage Low voltage at the external systems con

trol module (A82)
DCM extSys2-CAN Bus CAN bus error at the external systems

control module (A82)
Fault Cause Remedy

of external control systems 2 (DP system,
external systems (A82). Check the error indication in the con
trol desk. Replace the defective
DCM extSys2-SetpointAI4 No setpoint for the pitch control of external component if required.
control systems 2 (DP system, joystick
system, and masterstick) at the external
systems (A82).
8 Cleaning
WARNING
Risk of short circuiting; fire hazard
A short circuit or fire may occur by fluids or solid sub
stances getting into connections and openings on the
system display.
▶ Do not open the system display housing when
cleaning.
▶ Before cleaning, makes sure all connections and
openings are covered and that these covers are
properly closed.
NOTICE
The system display may be damaged by using
aggressive cleaning agents to clean it.
▶ Do not use cleaning solutions.
▶ Never use scrubbing sponges, scouring agents
or solvents, such as alcohol or benzine.
▶ Only use cloths made of microfibre, cotton or
linen.
▶ Do not spray cleaning agents directly onto the
system display.
1. Wet a cloth with a mild cleaning agent and wipe the

display clean.
2. Wipe with a dry cloth.
Warning System
Table of Contents
System Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
DIO Module . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Types . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Switching Logic . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
OUT LED Operating States . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
DIO Module Operating Elements and Indicators . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Technical Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
Display Unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
Types of Illuminated Buttons and Indicator Lights . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
Operating States of the Illuminated Buttons and Indicator Lights . . . . . . . . . . . . . . . . . . . 11
Operating Elements and Indicators on the Display Unit . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
Technical Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
Types of Connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
Standard . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
Types . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
System Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
CAN Bus . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
Types . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
System Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
2 Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
Preparing the System for Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
Setting the Time Delay (Special Function) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
en STD−Kt Warning System 10/Feb 1176151 1/25

2/25 STD−Kt Warning System 10/Feb 1176151 en
Preliminary Notes
These instructions are to provide information and Given that SCHOTTEL systems are subject to further
guidance to all persons involved in the initial start−up, development, we reserve the right to carry out technical
operation and maintenance of SCHOTTEL systems. modifications.
Please make sure that you have read and understood
these instructions and that you observe them carefully. Important instructions relevant to technical and
persons carrying out work on the system.
We do not accept any liability for damages and ! WARNING
systems and have been informed about the possible
dangers associated with their use.
Only trained and qualified personnel are permitted to
! CAUTION
carry out work on the system. Indicates working and operating methods that are to be
References to illustrations are written in brackets in the materials.
text, e. g. (1/3). The first number refers to the illustration
number in the illustration. NOTE
All illustrations are schematic diagrams and do not Indicates specific features of the working process
make any claim to completeness. which are to be observed.
Any technical modification to SCHOTTEL systems to
be performed by non−SCHOTTEL personnel requires
written authorisation.
i INFORMATION
When carrying out any work on SCHOTTEL systems,
always observe the safety and environmental
force in the relevant country of operation.
SCHOTTEL GmbH
Mainzer Straße 99
56322 Spay, Germany
Phone +49 (0) 2628 610
Fax +49 (0) 2628 61300
E−mail [email protected]

System Overview
The warning system constantly monitors the state of
the propulsion system and recognises any operating
states deviating from the norm. Different measuring
devices (e.g. sensors) measure the actual value at
various measuring points on the system. If there is a
discrepancy between the actual value and the nominal
value (e.g the set hydraulic oil temperature is
exceeded), the warning message is read by the
warning system and shown on the display unit with a
time delay. This is signalled accoustically by the buzzer
and visually by the relevant indicator light. The nominal
value is defined as a fixed value (e.g. hydraulic oil
temperature too high) or as a range value (e.g.
feedback follow−up time).
Please refer to the Technical Specification and the
Spare Parts Catalogue for all technical data and type of
warning system concerned.
The warning system includes:
D Display unit
D DIO Master module
D DIO Slave module (optional)
Key for figure 1

1 Bridge display unit for main control desk 6 DIO Master module
2 Bridge display unit for port side wing control desk 7 DIO Slave module
3 Bridge display unit for starboard wing control desk 8 Main propulsion unit control cabinet
4 Slave display unit for stern control desk 9 Main propulsion unit
5 Master display unit for engine control desk

Bridge deck
Bow
1
Bridge wing Bridge wing

Port side Starboard
2 3
Bridge deck
Stern
5 6 7 Engine
control room
8
Figure 1 System Overview (Example)

DIO Module
Types
The warning system may be equipped with the
following DIO modules (Digital In Out module):
D Master
6x inputs for warning messages
6x outputs for warning messages
1x input for illuminated ”buzzer off” button
1x input for illuminated LAMP CHECK button
1x output for buzzer
1x output for common alarm
D Slave (optional)
8x inputs for warning messages
8x outputs for warning messages
The DIO module to be parameterised as the DIO
Master module or DIO Slave module is specified during
system configuration in relation to the existing warning
messages on the display unit. In Master mode, only the
DIO Master module is needed (individual warning
system). In Master/Slave mode, the DIO Master
module can be combined with a maximum of four DIO
Slave modules (network warning system). The number
of DIO modules needed is determined by the number
of warning messages to be processed.
Switching Logic
Each DIO module used in the system can be operated
independently from the others, using either the closed
circuit current principle or the open circuit current
principle. However, the individual inputs on the DIO
module cannot be activated separately.
D Open circuit current principle
The inputs are activated when there is an incoming
warning message (IN LEDs do not light up).
D Closed circuit current principle
The inputs are not activated when there is an
incoming warning message (IN LEDs light up).

OUT LED Operating States
The following operating states are signalled by the OUT
LED (LED = Light Emitting Diode) on the DIO module:
D Flashes quickly if the incoming warning message
has not been acknowledged.
D Lights up when the incoming message has been
acknowledged.
D Flashes slowly if the warning message has been
remedied, but not acknowledged (buzzer is off;
common alarm still active).
D Goes out when the incoming message has been
acknowledged and cleared.

DIO Module Operating Elements and
Indicators
i INFORMATION
Please refer to the propulsion system’s current Wiring
Diagram for the exact configuration of the inputs and
outputs on the DIO module.
Item Operating elements and indica- Function

tors
1 PWR LED (green) Lights up when the DIO module is ready for operation.
2 RUN LED (yellow) Lights up when the DIO module is operational.
3 IN LED 0 ... 7 (yellow) Lights up when the relevant input is activated.
4 OUT LEDs 0 to 7 (yellow) Lights up when the relevant output is activated.
5 Configuration switch Switches the DIO module to operating or programming mode.
D Left position Operating mode is enabled.
D Right position Programming mode is enabled (e.g. for software version update).
6 DIP switch S1
D ON position Closed circuit current principle
D OFF position Open circuit current principle
7 DIP switch S2
D ON position Time delay can be set.
D OFF position Time delay cannot be set.
8 DIP switch S3
D ON position Common alarm is issued constantly.
D OFF position Common alarm is issued in cycles.

1 2 3 4 5 6 7 8
9 10 11 12 13 14 15 16
CAN−DIO 3
IN OUT
0 0
1 1
2 2
1 PWR RUN
2 3 3
4
4 4
5 5
5 6 6
7 7
17 18 19 20 21 22 23 24
25 26 27 28 29 30 31 32
6 7 8
ON
1 2 3 4 5 6 7 8
Figure 2

Technical Data
Operating Data
Temperature range (operation) 0 ... +70 C
Temperature range (storage) −20 ... +50 C
Relative humidity (operation and storage) 10 ... 90%; no condensation
Permissible voltage deviation, incl. ripple +30 %
−20 %
Ripple t 1.5 V AC
PWM outputs 2 items; TTL level
Indicators
LED operation indicator 1 item
LED function indicator 1 item
LED digital input status 8 items; 8 ... 36 V, static
LED digital output status 8 items; 500 mA @ 24 V DC; short circuit
proof
Connections
Interface 1 item; D−SUB 9, galvanically isolated

Display Unit
Types of Illuminated Buttons and Indicator
Lights
The display unit is equipped with the following types of
illuminated buttons and indicator lights:
D Illuminated buttons
The edges of the buttons are marked by a thick
blue frame and are slightly raised (finger
guidance). The illuminated buttons have a clearly
defined pressure point and a non−lock design.
D Indicator lights
The edges of the buttons are marked by a thin blue
frame.
The front cover of the display unit is covered by a film
printed with the necessary functions. Each illuminated
button and indicator light is equipped with a coloured
LED.
Which system warning messages are to be issued on
the warning system and/or the display unit is specified
during system configuration. None of the indicator
lights have background illumination; the lettering is only
illuminated (to the edges) when a warning message
occurs.
Operating States of the Illuminated Buttons

and Indicator Lights
The following operating states are signalled by the
illuminated buttons and indicator lights on the display
unit:
D Flashes quickly if the incoming warning message
has not been acknowledged.
D Lights up when the incoming message has been
acknowledged.
D Flashes slowly if the incoming warning message
has been remedied, but not acknowledged.
D Goes out when the incoming message has been
acknowledged and cleared.

Operating Elements and Indicators on the Display Unit

tors
1 “Available for allocation” indicator Project−related allocation (optional).

light (red)
2 “Power supply” indicator light (red) Flashes if there is a fault in the system’s power supply.
3 “Additional power supply” indi- Flashes if there is a fault in the system’s additional power supply
cator light (supply line [red]) (supply line).
4 “RPM FFU” indicator light (speed Lights up if the full follow−up speed control of the engine/propulsion
control not responding [red]) motor is blocked due to a mechanical or electrical fault.
The warning message is triggered by the speed control’s electronic
circuit board.
5 “RPM NFU” indicator light (speed Lights up if the non−follow−up speed control of the engine/propul-
control not responding [red]) sion motor is blocked due to a mechanical or electrical fault.
The warning message is triggered by the fuse monitoring relay.
6 “Azimuth FFU” indicator light (pro- Lights up if the full follow−up thrust direction control of the propulsion
pulsion unit not responding [red]) unit is blocked due to a mechanical or electrical fault.
The warning message is triggered by the thrust direction control’s
electronic circuit board.
7 “Azimuth NFU” indicator light (pro- Lights up if the non−follow−up thrust direction control of the propul-
pulsion unit not responding [red]) sion unit is blocked due to a mechanical or electrical fault.
The warning message is triggered by the fuse monitoring relay.
8 “Water ingress, flexible bearing” Lights up if the flexible bearing seal is no longer watertight.
indicator light (red) The warning message is triggered by the moisture sensor in the well
flange.
9 ”Insufficient oil flow” indicator light Lights up if the oil flow in the lubrication oil circulation system is
(red) insufficient.
The warning message is triggered by the flow control device.
10 ”Filter element 2 in changeover Lights up if filter element 2 in the changeover duplex filter is clogged.
duplex filter clogged” indicator Lights up if the lubrication oil becomes too viscous at extremely low
light (red) temperatures.
The warning message is triggered by the pressure switch in the
lubrication oil line (differential pressure w 2.2 bar). When the differ-
ential pressure is w 3.5 bar, the bypass valve on the duplex filter
opens.

1
RPM
RPM
2 3 4 5 6 7
1 2
13 12 11 10 9 8
HY HY HY HY HY
bar bar
14 15 16 17 18 19
CLUTCH
LAMP
PRESS
CHECK
OFF
24 23 22 21 20
CAN Bus circuit board
25
ON
1 2 3 4 5 6 7 8
Figure 3

tors
11 ”Filter element 1 in changeover Lights up if filter element 1 in the changeover duplex filter is clogged.
duplex filter clogged” indicator Lights up if the lubrication oil becomes too viscous at extremely low
light (red) temperatures.
lubrication oil line (differential pressure w 2.2 bar). When the differ-
ential pressure is w 3.5 bar, the bypass valve on the duplex filter
opens.
12 ”Lubrication oil temperature too Lights up if the lubrication oil temperature in the above−water
high” indicator light (red) gearbox of the propulsion system is too high.
The warning message is triggered by the temperature switch in the
lubrication oil line (lubrication oil temperature w 90 C).
13 ”Lubrication oil level too low” indi- Lights up if the lubrication oil level in the above−water gearbox of the
cator light (red) propulsion unit is too low.
The warning message is triggered by the oil level switch in the pro-
pulsion unit.
14 HY ”hydraulic oil level too low” Lights up if the hydraulic oil level in the hydraulic system is too low.
indicator light (red) The warning message is triggered by the oil level switch in the
hydraulic tank.
15 HY ”hydraulic oil pressure too low” Lights up if the hydraulic oil pressure in the hydraulic system is too
indicator light (red) low.
hydraulic oil line (operating pressure v 10 bar).
16 HY ”hydraulic oil filter element Lights up if the filter element in the pressure filter is clogged.
clogged” indicator light (red) Lights up if the hydraulic oil becomes too viscous at extremely low
temperatures.
hydraulic oil line (differential pressure w 2.0 bar). When the differen-
tial pressure is w3.5 bar, the bypass valve on the pressure filter
opens.
17 HY ”hydraulic oil temperature too Lights up if the hydraulic oil temperature in the hydraulic system is
high” indicator light (red) too low.
The warning message is triggered by the temperature switch in the
hydraulic tank (hydraulic oil temperature w 65 C).
18 HY ”hydraulic oil pressure too Lights up if the hydraulic oil pressure in the hydraulic system is too
high” indicator light (red) high.
hydraulic oil line (operating pressure w 250 bar).
19 LOCKED “propulsion unit locked” Lights up if the propulsion unit feedback does not follow up.
indicator light (red)

1
RPM
RPM
2 3 4 5 6 7
1 2
13 12 11 10 9 8
HY HY HY HY HY
bar bar
14 15 16 17 18 19
CLUTCH
LAMP
PRESS
CHECK
OFF
24 23 22 21 20
25
ON
1 2 3 4 5 6 7 8
Figure 4

tors
20 Illuminated “Buzzer off” button Deactivates the buzzer when there are incoming warning messages
(orange) for the propulsion system.
Flashes to signal an incoming warning message and goes out once
it has been acknowledged.
The buzzer sounds if a warning message is issued.
Once the illuminated LAMP CHECK button (5/21) is pressed, the
buzzer will sound for four seconds.
21 Illuminated LAMP CHECK button Carries out a lamp test for the illuminated buttons and indicator
(orange) lights.
Tests the buzzer (5/20) and common alarm functions.
Once pressed, all illuminated buttons, indicator lights, the buzzer
and common alarm will be activated for four seconds.
All indicator lights and illuminated buttons have to light up and the
buzzer has to sound.
22 CLUTCH OFF ”Clutch automati- Lights up if the clutch operating pressure is too low.
cally disengaged” indicator light The warning message is triggered by the pressure switch in the
(red) clutch hydraulic system (operating pressure v 35 bar); at the same
time, the clutch is disengaged.
23 ”Clutch temperature too high” indi- Lights up if the clutch temperature is too high.
cator light (red) The warning message is triggered by the temperature switch in the
clutch hydraulic system (hydraulic oil temperature w80 C).
24 PRESS ”Clutch operating pres- Lights up if the operating pressure for the pneumatic clutch is too
sure too low” indicator light (red) low.
The warning message is triggered by the pressure switch for the
pneumatic clutch (operating pressure v 8 bar).
25 DIP switch S1 and The switch positions determine allocation to the relevant functional
DIP switch S2 groups (see page 20).

1
RPM
RPM
2 3 4 5 6 7
1 2
13 12 11 10 9 8
HY HY HY HY HY
bar bar
14 15 16 17 18 19
CLUTCH
LAMP
PRESS
CHECK
OFF
24 23 22 21 20
25
ON
1 2 3 4 5 6 7 8
Figure 5

Technical Data
Casing and front board
Front board Aluminium, black anodised
Seal None
Protection class (front) IP 65
Protection class (on rear side) IP 20
Environmental Conditions
Temperature range (operation) 0 ... +55 C
Temperature range (storage) −20 ... +70 C
Relative humidity (operation and storage) 10 ... 90%; no condensation
Operational area Closed areas
Electrical Data
Connected load 24 V DC 450 mA
Fuse 3.15 A, delay
Inverse polarity protection Yes

Types of Connections
Standard
Types
An incoming warning message is directly transmitted via the relevant DIO module and indicated accoustically by
the buzzer and visually by the relevant indicator light at all display units. The warning message acknowledgement
applies to all display units.
System Overview
LAMP
CHECK
1 2 3 4 5 6 7 8 1 2 3 4 5 6 7 8
9 10 11 12 13 14 15 16 9 10 11 12 13 14 15 16
CAN−DIO CAN−DIO
IN OUT IN OUT
0 0 0 0
1 1 1 1
PWRRUN 2 2 PWRRUN 2 2
3 3 3 3
4 4 4 4
5 5 5 5
6 6 6 6
7 7 7 7
MASTER SLAVE
17 18 19 20 21 22 23 24 17 18 19 20 21 22 23 24
25 26 27 28 29 30 31 32 25 26 27 28 29 30 31 32
Figure 6 Overview of Standard System

CAN Bus
Types
The display units can be divided into three functional groups:
D Master
D Bridge
D Slave
In all three groups, the incoming warning message is transmitted via the CAN Bus telegram and indicated
accoustically by the buzzer and visually by the relevant indicator light at all display units. If the various functional
groups are combined with one another within the CAN Bus system, at least one of these is designated as the Master
display unit. The functional groups differ from one another in the way that warning messages are acknowledged.
Allocation to the relevant functional groups is set by means of the DIP switches (see page 17).
Functional Group Functional Group Functional Group Slave

Master Bridge
Acknowledging warning mess- Yes No No

ages
(indicator light status changes)
Acknowledging buzzer Yes Yes Yes

(deactivating accoustic signal)
Acknowledgement of warning all functional groups and all of the Bridge functional only to its own functional
message or buzzer applies to the DIO Master module group group
DIP switch settings S1 S2 S1 S2 S1 S2
ON OFF OFF ON ON ON

System Overview
CAN Bus
LAMP LAMP
CHECK CHECK
CAN Bus
CAN Bus
LAMP
CHECK
1 2 3 4 5 6 7 8 1 2 3 4 5 6 7 8
9 10 11 12 13 14 15 16 9 10 11 12 13 14 15 16
CAN−DIO CAN−DIO
IN OUT INOUT
0 0 0 0
1 1 1 1
PWR RUN 2 2 PWR RUN 2 2
3 3 3 3
4 4 4 4
5 5 5 5
6 6 6 6
7 7 7 7
MASTER SLAVE
17 18 19 20 21 22 23 24 17 18 19 20 21 22 23 24
25 26 27 28 29 30 31 32 25 26 27 28 29 30 31 32
Figure 7 CAN Bus System Overview

2 Operation
Preparing the System for Operation
D The configuration switch on the DIO module(s) is
switched to the left position (8/4). 0
IN OUT
0
1 1
1. Switch on the power supply for the DIO module(s); 1 PWR RUN 2 2 2 3
3 3
(e.g. at the main propulsion unit control cabinet). 4 4
5 5
The PWR LED (8/1) on the DIO module(s) lights

1 2 3 4 5 6 7 8
4 6 6
9 10 11 12 13 14 15 16
7 7
up.
The RUN LED (8/2) on the DIO module(s) lights
CAN−DIO
up.
The parameterised IN/OUT LEDs 0 to 7 (8/3) on
IN OUT
0 0
1 1
the DIO module(s) light up.

2 2
PWR RUN
3 3
4 4
5 5
6 6
If there are no internal malfunctions in the warning 7 7
system (DIO module(s) and display unit), it is ready

for operation.
An internal malfunction in the warning system is
transmitted to the master warning system (e.g. 17 18 19 20 21 22 23 24
ship’s warning system) via the alarm relay in the 25 26 27 28 29 30 31 32
DIO Master module (RUN LED does not light up).
All display units are activated.
Figure 8
2. Press the illuminated LAMP CHECK button (9/1)
on each display unit.
Once pressed, all illuminated buttons and indicator
lights are to light up, and the buzzer is to sound for
four seconds.
LAMP
CHECK
Figure 9

Setting the Time Delay 1
(Special Function) 1 2 3 4 5 6 7 8 1 2 3 4 5 6 7 8 1 2 3 4 5 6 7 8
9 10 11 12 13 14 15 16 9 10 11 12 13 14 15 16 9 10 11 12 13 14 15 16
NOTE −2A1 −2A2 −2A3

CAN−DIO CAN−DIO CAN−DIO
If power is lost whilst setting the time delay, the IN OUT IN OUT IN OUT
procedure is to be repeated. The setting is to be

0 0 0 0 0 0
1 1 1 1 1 1
2 2 2 2 2 2
PWR RUN PWR RUN PWR RUN
documented on a record sheet to be filled out by hand

3 3 3 3 3 3
4 4 4 4 4 4
5 5 5 5 5 5
and sent to the TEK Department at SCHOTTEL.

6 6 6 6 6 6
7 7 7 7 7 7
i INFORMATION
The time delay determines how long a preset nominal 17 18 19 20 21 22 23 24 17 18 19 20 21 22 23 24 17 18 19 20 21 22 23 24
value can be fallen short of or exceeded, before an 25 26 27 28 29 30 31 32 25 26 27 28 29 30 31 32 25 26 27 28 29 30 31 32
alarm signal is generated and indicated by the relevant

indicator light on the display unit.
1 2 3 4 5 6 7 8
1. Switch off the warning system fuse, e.g in the main 2 3 3 2
propulsion unit control cabinet (component label:
−2F1), and make sure it cannot be switched on
inadvertently. 9 10 11 12 13 14 15 16
2 2
2. Remove all terminal blocks (10/2) on the −2A1
DIO Master module (component label: −2A1 CAN−DIO
[10/1]) from the casing with a screwdriver. IN OUT
4
0 0
1 1
2 2
PWR RUN
3. Push in the detents (10/3) on the casing with a

3 3
5
4 4
5 5
screwdriver and remove the cover with the circuit

6 6
7 7
6
boards (10/7) from the casing.
4. Switch DIP switch S2 on the circuit board to the ON
position (10/8). 2 2
5. Insert the cover into the casing and click into place. 17 18 19 20 21 22 23 24
! CAUTION 2
25 26 27 28
3 3 29 30 31 32
2
All terminal blocks have to match up with the terminal

numbers on the casing.
8
7
6. Connect the terminal blocks to the DIO Master
module casing.
ON
7. Switch on the warning system fuse, e.g in the main

propulsion unit control cabinet. 1 2 3 4 5 6 7 8
OUT LED 6 (buzzer [10/5]) and OUT LED 7

(common alarm [10/6]) flash alternately on the DIO
Master module.
OUT LEDs 0 to 5 (warning outputs [10/4]) flash on
the DIO Master module.
Figure 10

8. Press the illuminated LAMP CHECK button (12/1)
on the Master display unit.
The DIO Master module is selected via the Master
display unit.
All illuminated buttons and indicator lights
controlled by the DIO Master module flash on all of
the display units present. Bridge Slave
9. Press the illuminated ”Buzzer off” button (12/2).

The Master display unit is acknowledged.
All illuminated buttons and indicator lights
controlled by the DIO Master module flash on the
Master display unit (see figure 11).
NOTE Master
Once the special function has been enabled, the DIO

Master module is automatically activated. If the time
delay for a warning message controlled via a DIO Slave
CAN−DIO
module is to be set, the DIO Slave module concerned
is to be selected using the illuminated LAMP CHECK
button.
Master
10. Press the illuminated LAMP CHECK button and
select the required warning message.
11. Press the illuminated ”Buzzer off” button.
The selected warning message is acknowledged. Figure 11
The selected warning message indicator light

flashes and displays the time delay currently set.
Input value: 0 ... 15; unit of measurement in
seconds [s]
Example:
Interval Time delay [s]

Non−stop flashing 0
Flashes x 3 − stops − flashes x 3 3
12. Tap the illuminated LAMP CHECK button and set

the time delay to 0 s (basic setting).
13. Release the illuminated LAMP CHECK button.
LAMP
CHECK
1 2
Figure 12

14. Tap the illuminated LAMP CHECK button (13/1)
and set the required time delay (1 tap ¢ 1 s).
15. Press the illuminated ”Buzzer off” button (13/2).
The entry is acknowledged.
NOTE
If the time delay for a warning message controlled via
a DIO Slave module has been set, control automatically
returns to the DIO Master module, once the setting has LAMP
been acknowledged using the illuminated ”Buzzer off” CHECK
button.
1 2
All indicator lights controlled by the DIO Master
module flash on the Master display unit.
Figure 13
16. Set the next time delay; see procedural steps 10 to

15. 2 2
1 2 3 4 5 6 7 8
17. Switch off the warning system fuse, e.g in the main 1 1
propulsion unit control cabinet (component label:
−2F1), and make sure it cannot be switched on
9 10 11 12 13 14 15 16
inadvertently.
1 −2A1
1
18. Remove all terminal blocks (14/1) on the DIO CAN−DIO
Master module (component label: −2A1 [14/3]) 3 0
IN OUT
0
from the casing with a screwdriver.

1 1
2 2
PWR RUN
3 3
4 4
5 5
19. Push in the detents (14/2) on the casing with a 6

7
6
7
screwdriver and remove the cover with the circuit

boards (14/5) from the casing.
20. Switch DIP switch S2 on the circuit board to the 1 1
OFF position (14/4).
17 18 19 20 21 22 23 24
21. Insert the cover into the casing and click into place.
1 1
! CAUTION 25 26 27 28
2 2 29 30 31 32
All terminal blocks have to match up with the terminal

numbers on the casing. 4 5
22. Connect the terminal blocks to the DIO Master ON

module casing.
1 2 3 4 5 6 7 8
23. Switch on the warning system fuse, e.g in the main
propulsion unit control cabinet.
The warning system is ready for operation.
Figure 14

Speedronic Motor Control Unit MSV Id. No. 1115903
The motor control unit is mainly composed of:
D Voltage stabiliser Inputs

D Digital control unit
The motor control unit has two galvanically
D Short−circuit proof MOS−FET output separated digital 18V to 32V inputs which are used
D LEDs to make the Speedronic motor turn clockwise or
anti−clockwise.
1
Outputs
The motor control unit has two analogue 18V to
32V/5A outputs to control the Speedronic motor. In
case of a short circuit on the motor side, the current
2 is limited.
Technical Data
Permissible voltage deviation, + 30%
incl. ripple − 25 %
1 2 3 4 5 6
Ripple t 1.5 V /AC
Permissible ambient tempera-
ture 0 . . . 70 C
Figure 1
Power off at approx. 5A
Description
The MSV motor control unit is a MOS−FET power
amplifier which controls the SCHOTTEL Speedronic
Terminal Assignment of the MSV
used for the speed control system.
The control signals are received via digital inputs X1 : +24V DC −25%..+30%
which cause the DC motor in the Speedronic to turn
clockwise or anti−clockwise. X2 : GND
In addition, the module is provided with a number of
LEDs: X3 : Digital input 1, set input 1
The yellow LEDs (1/2) indicate which digital X4 : Digital input 2, set input 2
inputs are active.
X5 : Analogue output for
The green LED (1/1) is lit up when the module is Speedronic motor
energised.
X6 : Analogue output for
If the module fails, the external superordinate logic Speedronic motor
module (DCM) detects the error and transfers it.
en TEL−SCH−ge Speedronic Motor Control Unit MSV Id. No. 1115903 0 July/00 1128284 1/ 1
Operating Instructions DCM Module
Table of Contents
Preliminary Notes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
1 Technical Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Application . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Full Follow−Up Steering of SCHOTTEL Propulsion Systems . . . . . . . . . . . . . . . . . . . 5
Full Follow−Up Speed Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Further Applications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Structure and Functions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
LEDs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Operating Mode Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
System Diagnosis . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Software Configuration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Hardware Configuration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Adjustments . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Analogue Output Signals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Alarm Relay . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Battery . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
DCM Module: Front View and Left and Right Boards . . . . . . . . . . . . . . . . . . . . . . . . . . 9
2 Configuration, Installation and Adjustments . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10

Configuration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
Overview of Jumper Configurations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
Removing the Terminal Strips . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
Inserting the Terminal Strips . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
Removing the DCM Module from the Casing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
Inserting the DCM Module into the Casing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
General Tests . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
Checking the Proper Functioning of the Full Follow−Up Steering . . . . . . . . . . . . . . . . . 14
Checking the Proper Functioning of the Full Follow−Up Speed Control . . . . . . . . . . . . 15
Parameterising the CAN Sensors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
Full Follow−Up Steering . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
Full Follow−Up Speed Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
3 Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
4 Measuring Points and Nominal Values . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24

Supply . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
Alarm Relay . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
CAN Bus . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
Inputs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
Analogue Inputs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
Digital Inputs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
Outputs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
Analogue Outputs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
Digital Outputs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
en STD−Ka Operating Instructions DCM Module 2.x 10/1597 1162900 1 / 31

5 Terminal Assignment and Technical Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
Terminal Assignment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
Technical Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
2 / 31 STD−Ka Operating Instructions DCM Module 2.x 10/1597 1162900 en

Preliminary Notes
These instructions are to provide information and Important instructions relevant to technical and
guidance to all persons involved in the initial start−up, operational safety are identified by the following
operation and maintenance of SCHOTTEL propulsion symbols:
read, understood and carefully observed.
! WARNING
These instructions are to be made available to all
We do not accept any liability for damages and strictly observed to prevent any risk to personal safety.
instructions.
It is a prerequisite that all users are familiar with the
! CAUTION
materials.
Only skilled and qualified electricians are permitted to
carry out work on the propulsion systems.
NOTICE
References to illustrations contained in the text are
written in brackets, e.g. (1/3). The first number refers to Indicates specific features of the working process
the illustration number in the manual; the second which are to be observed.
number is the item number in the illustration.
All illustrations are schematic diagrams and do not i INFORMATION
make any claim to completeness. Application instructions and information.
systems, always observe the ”Safety and
However, this does not include any of the modifications Environmental Protection Regulation SV 1” as well
or control settings described in our instructions. as the applicable laws in force in the relevant country
of operation.
Given that SCHOTTEL propulsion systems are subject
to further development, we reserve the right to carry out
technical modifications.
SCHOTTEL GmbH
Mainzer Straße 99
56322 Spay, Germany
Phone +49 (0) 2628 / 61−0
Fax: +49 (0) 2628 / 61−300
E−mail: [email protected]

Application
The DCM Module (1/2) is an electronic module which
reads, processes and outputs control signals. It is
basically used to:
D steer SCHOTTEL propulsion systems in full
follow−up mode;
D to control the engine speed.
Full Follow−Up Steering of SCHOTTEL

Propulsion Systems
Figure 1 provides a schematic diagram of how the DCM
Module is used for the steering of SCHOTTEL 1
propulsion systems (1/4).
D When full follow−up steering is activated, the DCM

module compares the current steering command
(i. e. the ”setpoint”) from the control desk (1/1) to
the current feedback value (1/5). The difference
between the setpoint and feedback value is 2
calcuted by the DCM module and transmitted to
the amplifier (1/3) (e.g. a DPV module).
D Depending on the difference value transmitted by

the DCM module, the amplifier actuates the
SCHOTTEL propulsion system until the feedback
and setpoint values are identical (difference
value = 0).
5
3
Full Follow−Up Speed Control
In full follow−up speed control mode, the DCM module
also receives a control command (”setpoint”) from the
control desk. Depending on this setpoint value, an
output signal is provided by the DCM module.
Further Applications
4
This document addresses both full follow−up steering
of SCHOTTEL propulsion systems and full follow−up
speed control.
Further applications of the DCM module are described
in the relevant specifications.
Figure 1

Structure and Functions
The DCM module is mainly composed of:
1
D 2 boards with the main electronic components,
DIP switches and jumpers for the hardware
configuration of the module, see figure 5 on
page 9.
D 8 digital inputs (2/2)
D 4 digital outputs (2/1)
2
D 4 analogue inputs (2/3) (0 ... 10 V / 0 ... 20 mA,
depending on the configuration of jumpers J7 and
J8)
2 analogue inputs which, depending on the jumper
configuration, are either provided on the 3
potentiometers AI3 (3/1) and AI4 (3/2) or on the
2
terminals 23 (3/3) and 24 (3/4)
D 2 analogue outputs (2/4) (0 ... 10 V / 0 ... 20 mA)
D LEDs to display the operating states and status,
see section ”LEDs”.
4
Figure 2
3
4
Figure 3

LEDs
18 LEDs signal the following operating states:

1
LED Operating state CAN DPV 1
F 100 is lit in case of a CAN bus failure
is lit when a failure in the
F 101 DCM DPV 2
voltage supply occurs
F 102 is lit in case of a setpoint error
F 103 is lit in case of a feedback error
F 104 is lit in case of a programmed error 2
F 105 is lit in case of a programmed error
SF 1 flashes/is lit during parameterisation
SF 2 special function
PWR is lit when the module is energised
is lit when the module is operational
RUN
and goes out when a failure occurs
IN 0 is lit when digital input 0.0 is active
OUT 0 is lit when digital output 0 is active
When a failure or error occurs, one of the LEDs F100

... F105 lights up. When operational, the PWR and RUN
LEDs and, depending on the situation, the LEDs
IN 0 ... IN 3, OUT 0 ... OUT 3 or SF 1/SF 2 are lit up.
Operating Mode Switch

The operating mode switch (4/3) is used to select the
ON and LD operating modes. In the LD operating mode
a software update can be uploaded to the DCM
module.
During operation on a ship, the switch must always be
in the ON position.
3
System Diagnosis
Using the interfaces (4/1) and (4/2), a hardware Figure 4
diagnosis can be made by a SCHOTTEL service
engineer.

Software Configuration Analogue Input Signals
Depending on the intended use, the DCM module is The DCM module can be used with analogue input
programmed with a system software before delivery. signals (0 ... 10 V or 0 ... 20 mA) − depending on the
The system software is adapted to each application (full jumper configuration.
follow−up steering, full follow−up speed control etc.)
The operating mode switch (5/4) must be in the LD Optionally, both inputs can be adjusted using the
position when the system software is to be transferred potentiometers AI3 and AI4.
to the DCM module. During operation, the operating
mode switch must always be in the ON positon. Analogue Output Signals
Normally, the analogue output signal of 0 ... 10 V is
Hardware Configuration provided to an isolation amplifier (5/3) in SCHOTTEL
systems. The isolation amplifier controls the required
If the DCM module is defetive, it can easily be replaced component using an output signal of 4 mA to 20 mA.
within the SCHOTTEL electrical system by specialist
staff. Owing to the various possible applications, the Depending on the configuration of the jumpers, the
identification number of the DCM module is to be DCM module can optionally also provide a current
considered. The hardware of the DCM module must signal of 4 to 20 mA as output signal.
first be configured according to the intended use
before it can be installed in the switch cabinet and
adjusted accordingly. Alarm Relay
Before configuration, the DCM module is removed from The DCM module is equipped with an alarm relay with
the casing. After that, the DIP switches (5/13) and CAN a potential−free NO contact provided on the terminal
terminator (5/3) on the left board (5/12) must be strips which is generally used to switch from full
adjusted. The jumpers on both boards are to be follow−up to non−follow−up operation when the DCM
plugged depending on the particular application. module is no longer ready for operation. In addition, the
NO contact is used to transmit a message to the ship’s
The left board (5/12) has 8 jumper blocks while the right warning system.
board (5/11) has 14 jumper blocks. The jumper blocks
with two connectors (5/1) can either be plugged with a
jumper or they remain unplugged. The jumper blocks Battery
with three connectors (5/2) either have a jumper
plugged into pins 1 and 2 or 2 and 3 or they remain The DCM module is equipped with a battery (5/10) to
unplugged. The connector numbers 1, 2 and 3 (5/9) are save the date and time. The battery has no effect on the
printed on the boards. system software. The battery cannot be replaced.
An overview of the jumper configurations J1 to J12 is

provided on page 10.
Using the DIP switches (5/13), the module can be
adapted to the SCHOTTEL propulsion system.
During installation, the DCM module casing is installed
on the mounting rail. During electrical installation, the
terminal strips (5/6) can be removed from a defective
module and inserted into a replacement module.

6
7
5
2 2
3 9 10
1 1 1
2 2
6
1
1
OFF 123
ON
3
3 1
1
321
321
12 11 1
13 2 9 2 2 2
9
Figure 5 DCM Module: Front View and Left and Right Boards
1 Jumper block with two connectors 11 DCM module, right board

2 Jumper block with three connectors 12 DCM module, left board
3 CAN bus terminator 13 DIP switch
4 Operating mode switch upper row: S4
5 LEDs for operating states, lower row: S3
see page 7 (marked on the board)
6 Terminal strips
7 LEDs of digital inputs and outputs, see page 7
8 AI 3 and AI 4 potentiometers
9 Connector numbers 1, 2 and 3
for jumper blocks with 3 connectors
10 Battery CR2032

2 Configuration, Installation and Adjustments
! CAUTION
Overview of Jumper Configurations
The DCM module is to be configured according to its Item Function

intended use before being installed and adjusted.
Terminal 31
Analogue output AO 0
Pin 1−2: AO 0: voltage output
! CAUTION J1 Pin 2−3: AO 0: current output
Make sure you carefully observe the following
instructions in order to ensure the safe operation of the
J2 Pin 2−3: AO 0: current output
entire propulsion system after replacing a DCM
module.
Terminal 32
Configuration Analogue output AO 1
1. Switch off the electrical system and secure it J4 Pin 2−3: AO 1: current output
against unintended start−up.
2. Pull out the terminal strips from the defective DCM Pin 1−2: AO 1: voltage output
module, see page 12. J5 Pin 2−3: AO 1: current output
Do not disconnect any electrical equipment from
the terminal strips. Pin 1−2: AO 1: voltage output
3. Remove the defective and new DCM modules
from the casing, see figure 8 on page 12. Terminal 24
Connection of AI4
4. Transfer all DIP switch (6/3) positions from the
J7 Pin 1−2: 0 − 10 V / 0 − 20 mA
defective module to the new DCM module.
Pin 2−3: Potentiometer AI 4
5. Transfer all jumper (6/1) positions from the
defective module to the new DCM module. For an Terminal 23
overview of the jumper configurations, see right Connection of AI3
column. Jumpers J13 and J14 must always be J8 Pin 1−2: 0 − 10 V / 0 − 20 mA
plugged onto pins 2 and 3. Pin 2−3: Potentiometer AI 3
6. Transfer the terminator (6/2) position from the Input connection

defective module to the new DCM module. Open: AI 2 voltage input
J9 Plugged: AI 2 current input
! CAUTION
J 10
Open: AI 1 voltage input
Plugged: AI 1 current input
The terminator (7/1), as the last CAN bus device, must
always be in the ON position, see schematic diagram
in figure 7 and the Wiring Diagram.
J 11 Plugged: AI 3 current input
7. Insert the new DCM module into the casing in the
switch cabinet and slide the terminal strips into the
module. J 12 Plugged: AI 4 current input

1 1 2 1 1
1
J13 1
J14
ON OFF
J10 J8
J9
1
J11 J7 1
J1
J12 J2
J3
1
J4
J5
J6
Figure 6
CAN
1
OFF OFF ON
Figure 7

Installation
Removing the Terminal Strips
D Pull out the terminal strips (8/1) from a defective

DCM module (8/4) using a screwdriver. 1
2
Inserting the Terminal Strips
D After configuration, slide the terminal strips (8/1) 3

into the new DCM module.
4
! CAUTION
1
Make sure that all terminal numbers (8/3) match when
sliding in the terminal strips (8/1). The DCM module
may be destroyed due to an incorrect position.
Check that all terminal strips in the DCM module are
tight.
Removing the DCM Module from the Casing 1
D Push down the detents (8/2) with a screwdriver

Figure 8
and pull out the DCM module (8/4). The DCM
module must be removed from the casing before
it can be configured.
1 2 1 2
Inserting the DCM Module into the Casing
D Slide the DCM module into the casing until it snaps

into place.
3 3
General Tests
The following tests are to be performed when
configuration and installation are completed:
D Check the position of all operating mode switches

(9/3). All switches must be in the ON position
before the electrical system is switched on.
1 2
D Start up the electrical system. The PWR (9/1) and

RUN (9/2) LEDs of all modules must light up. If not 3
all LEDs on all modules light up, the electrical
system or the DCM module is not operational, see
the ”Troubleshooting” section on page 20.
Figure 9

NOTICE
For further information on the functional test of the full

follow−up steering, see page 14.
For further information on the functional test of the full
follow−up speed control, see page 15.
en STD−Ka Operating Instructions DCM Module 2.x 10/1597 1162900 13 /31

Checking the Proper Functioning of the Full Follow−Up Steering
follow−up thrust direction is changed using the control
i INFORMATION device (10/2). The drive units (10/4) controlling the
thrust direction are actuated until the setpoint and
feedback values are identical.
If the DCM module (10/5) is used for full follow−up
steering, no further adjustments are required once If the control and feedback devices (10/1) are equipped
configuration and installation are completed. After the with CAN sensors as shown in figure 10, the CAN
start−up of the entire propulsion system, the DCM sensors can be parameterised using the DCM module
module activates the amplifier (10/3) as soon as the full when required, see page 16.
3 4
1 2
M
24 V GND
Figure 10

Checking the Proper Functioning of the Full Follow−Up Speed Control
i INFORMATION
If the DCM module is used for full follow−up speed The output signal can be checked using a universal
control, no further adjustments are required once meter (11/2) (measuring range: 0 ... 20 V or 0 ... 25 mA,
configuration and installation are completed. After the depending on the configuration).
start−up of the entire propulsion system, the DCM
module activates the amplifier (11/3) as soon as the full Figure 11 shows an example with analogue output
follow−up speed is changed using the control device signals of 0 .. 10 V.
(11/1). If the control device is equipped with a CAN sensor (no
Figure 11 shows an example of how the DCM module illustration), the CAN sensor can be parameterised
can be used for Full Follow−Up Speed Control (11/1) using the DCM module when required, see page 18.
with the analogue outputs AO1 and AGND. Depending
on the configuration of jumpers J7 and J8, the following
adjustments are required after configuration and
installation:
D Starting point from which the engine (11/5) speed
is to be increased − adjustable on potentiometer
AI3 (11/3) (position of the control lever (11/6)
D Maximum engine speed − adjustable on
potentiometer AI4 (11/4)
2
6
1
000.0
min 0 GND
max
V DC
3 U
I
4
5
24 V GND
AO1
AGND
Figure 11

Parameterising the CAN Sensors
Full Follow−Up Steering
6. Switch on the DCM module for full follow−up
i INFORMATION steering. The PWR and RUN LEDs light up,
If a CAN sensor (12/1) in the full follow−up control the SF 1 LED (13/7) flashes.
device (12/4) or feedback device (12/2) is replaced, the
new CAN sensor can be parameterised using the DCM
module (12/3). 7. Supply two short 24 V pulses to terminal 17 on
terminal strip (13/4) within 10 seconds after
switching the module on. The SF 1 LED lights up.
NOTICE
The installation of the new CAN sensors must be fully
completed.
The DCM module for full follow−up steering must be NOTICE
ready for operation.
Make sure you do not change the ahead position (0o)
during parameterisation.
1. For parameterisation (adjustment of zero position)
of the full follow−up steering, manually turn the After 10 seconds the DCM module disables the
SCHOTTEL propulsion unit (13/3) into the ahead parameterisation of the zero position. The SF 1 LED
position (0o). Switch off the electric control flashes slowly.
systems on the full follow−up drive units (13/2).
If the zero position adjustment needs to be repeated,
first switch off the DCM module for full follow−up
2. Turn the full follow−up control device (13/1) into the steering. Then repeat items 6. and 7.
ahead position (0o).
8. When parameterisation is completed, switch off
3. Switch off the DCM module for full follow−up the DCM module for full follow−up steering.
steering (13/5). The PWR (13/8) and RUN LEDs The PWR AND RUN LEDs are not lit up.
(13/6) are not lit up.
9. Pull out the terminal strips from the DCM module

4. Pull out the terminal strips (13/4) from the DCM and open the module, see page 12.
module and open the module, see page 12.
5. Set the S 3.8 DIP switch (13/10) in row S3 (13/9) 10. Set the S 3.8 DIP switch in row S 3 to the OFF
to the ON position. Insert the DCM module into the position. Insert the DCM module into the casing
casing and slide the terminal strips into the DCM and slide the terminal strips into the DCM module,
module, see page 12. see page 12.

1 1
4 3
Figure 12
1 2 2
0o
0o
M
3
8 6
4
S4
S3
5 24 V GND
10
Figure 13

Full Follow−Up Speed Control
i INFORMATION 5. Switch on the DCM module for full follow−up speed

control. The PWR and RUN LEDs light up. The
If a CAN sensor (14/1) in the full follow−up speed
SF 1 LED (15/2) flashes.
control device (14/2) is replaced, the new CAN sensor
can be parameterised using the DCM module (14/3). 6. Supply two short 24 V pulses to terminal 17 on
terminal strip (15/5) within 10 seconds after
switching the module on. The SF 1 LED lights up.
NOTICE
The installation of the new CAN sensor must be fully
completed. NOTICE
The DCM module for full follow−up speed control must Make sure you do not change the zero position of the
be ready for operation. speed control lever during parameterisation.
After 10 seconds the DCM module disables
1. Set the full follow−up speed control device (15/1) parameterisation. The SF 1 LED flashes slowly.
to the zero position.
If parameterisation needs to be repeated, first switch off
the DCM module for full follow−up speed control. Then
2. Switch off the DCM module for full follow−up speed repeat items 5. and 6.
control (15/6). The PWR (15/3) and RUN LEDs
(15/4) are not lit up. 7. When parameterisation is completed, switch off
the DCM module for full follow−up speed control.
The PWR AND RUN LEDs are not lit up.
and open the module, see page 12.
and open the module, see page 12.
4. Set the S 3.8 DIP switch (15/7) in row S3 (15/8) to
the ON position. Insert the DCM module into the 9. Set the S 3.8 DIP switch to the OFF position. Insert
casing and slide the terminal strips into the DCM the DCM module into the casing and slide the
module, see page 12. terminal strips into the DCM module, see page 12.

1 2 3
Figure 14
3 4
S4
S3
6 24 V GND
7
Figure 15

3 Troubleshooting
NOTICE 1
Note that the following table only addresses possible

failures as may be caused by a faulty configuration,
installation or adjustment of the DCM module.
It does not cover any faults which are due to the
on−board power supply (e.g. faulty supply voltages, 13 14 15 16 17 18 19 20
4A1
damaged cables etc.).
Inform the SCHOTTEL Service Department if it is not
possible to eliminate the fault by taking the following
measures.
The SCHOTTEL Service Department will need the

following information: 1410XXXX 115XXXX
=
+B
Bl.
D SCHOTTEL code word, order number (16/2) and

part number from the Wiring Diagram (16/3) 2
D Name (16/1) of the DCM module as per the Wiring
Diagram 3
D Description of the fault and how it affects the

functioning of the propulsion system
Figure 16
i INFORMATION
To ensure a trouble−free operation of the DCM module,

the following conditions are to be fulfilled:
1. The operating mode switch (17/1) must be in the

ON position.
1
2. All jumpers must be plugged onto the
corresponding pins according to the intended use,
see item 1 in figure 6 on page 11.
3. All DIP switches must be set according to the

intended use, see item 3 in figure 6 on page 11. 2
4. The terminator must be in the ON position if the

module is the last device in the CAN chain. Within
the CAN chain, the terminators in all modules must
be in the OFF positions, see item 2 in figure 6 on
page 11 und figure 12 on page 17.
If one of these conditions is not fulfilled, the DCM

module is not operational. Figure 17

Failure/error Possible causes Tests/remedy
SCHOTTEL propulsion unit Control or feedback device: Parameterise CAN sensor, see
rotates continuously CAN sensor not parameterised page 16
(continuous rotation of full fol-
low−up steering)
Signals on the potentiometer of Check connections and correct, if
the control or feedback device necessary.
interchanged.
Information on rotational direction Check information on rotational

to amplifier interchanged. direction and correct, if required.
For hydraulic systems: Swap
valves.
For frequency converters:
Change information on rotational
direction, e.g. cw (=clockwise) for
ccw (=counterclockwise).
SCHOTTEL propulsion unit DIP switch 1 in row S 3 in wrong Correct position of DIP switch 1
rotates in opposite direction position in row S3 and parameterise CAN
(wrong direction of rotation of full sensors of control and feedback
follow−up steering) devices, see page 16
Signals on the potentiometer of Check signals from feedback

the control or feedback device device AI3 and AI4 and swap, if
interchanged. necessary.
Correct position of the potentio-
meter on the feedback device.
Information on rotational direction
to amplifier interchanged. Check information on rotational
direction and correct, if required.
For hydraulic systems: Swap
valves.
For frequency converters:
Change information on rotational
direction, e.g. cw (=clockwise) for
ccw (=counterclockwise).
PWR LED does not light up when No voltage supplied to the Check voltage supply on the
the electrical system is switched module. DCM module, see page 24.
on.
Provide the voltage supply to the
DCM module; e.g. check proper
function of automatic cutouts and
connections etc.
DCM module defective Replace DCM module
RUN LED does not light up when Module is not ready for operation. Check if one of the F100, F101,
the electrical system is switched F102, F103, F104 or F105 LEDs
on. is lit up, see following entries in
(Failure alarm) this table.

LED F100 is lit up. Failure of CAN bus system. Make sure that all cables of the
CAN bus system are connected
properly and no wires are dam-
aged.
Replace damaged lines, if neces-

sary.
Make sure lines are connected
properly.
Check position of terminator, see

item 6. on page 10 and 20
Measure the resistance between

CAN High and CAN Low: 60 
LED F101 is lit up. Failure of voltage supply Check voltage supply on the
DCM module, see page 24.
Check the supply voltage.

Observe the specifications in the
Wiring Diagram.
LED F102 is lit up. Set point error

(Failure of control device):
If CAN sensors are used Check if LED F 100 is lit up.

Check supply to CAN sensor;
check CAN address (see Wiring
Diagram) and replace CAN
sensor, if necessary.
(see also entry ”Failure/Error
LED F100 is lit up”)
If potentiometers are used Make sure that cables of the

potentiometers are not damaged.
Replace damaged lines, if neces-
sary.
properly.
Check supply to potentiometers;
check signals and replace poten-
tiometers, if necessary.

LED F103 is lit up. Feedback error

(Failure of feedback device):
If CAN sensors are used Check if LED F 100 is lit up.
Check supply to CAN sensor;
check CAN address (see Wiring
Diagram) and replace CAN
sensor, if necessary.
(see also entry ”Failure/Error
LED F100 is lit up”)
If potentiometers are used Make sure that cables of the

potentiometers are not damaged.
Replace damaged lines, if
necessary.
properly.
Check supply to potentiometers;
check signals and replace poten-
tiometers, if necessary.
LED F104 is lit up. Currently not used Consult SCHOTTEL

4 Measuring Points and Nominal Values
Supply
D Terminal 25 (18/1): GND

D Terminal 26 (18/2): 24 V DC
24 V
1
2
Figure 18
9 10
Alarm Relay
D Terminal 9 (19/9): Potential−free
Figure 19

CAN Bus
D Terminal 1 (20/1): 5 V CAN−VCC
5V
D Terminal 4 (20/4): CAN−GND
D Terminal 2 (20/2): CAN−H 1
2
D Terminal 3 (20/3): CAN−L
3
4
Figure 20

Inputs
Analogue inputs
D Terminal 21 (21/21): AI 1
0 ... 10 V DC 0 ... 10 V
21
D Terminal 22 (21/22): AI 2 22
0 ... 10 V DC 23
0 ... 10 V DC / 0 ... 20 mA
depending on the configuration of the J8 jumpers
0 ... 10 V DC / 0 ... 20 mA
depending on the configuration of the J7 jumpers
D Terminal 29 (21/29): AGND

AGND for analogue inputs AI 1, AI 2, AI 3 and AI 4
24
29
i INFORMATION
Optionally, all analogue inputs can also be used as Figure 21

current inputs. Each input processes a current signal
of 0 ... 20 mA. Each analogue input can be configured
using the corresponding jumper.

Digital Inputs

13
D Terminal 13 (22/13): DI 0.0 High: 24 V 14
High: 24 V / Low: 0 V Low: 0 V
15
D Terminal 14 (22/14): DI 0.1
High: 24 V / Low: 0 V 16
D Terminal 15 (22/15): DI 0.2

High: 24 V / Low: 0 V
D Terminal 16 (22/16): DI 0.3

25
Figure 22
17
High: 24 V
D Terminal 17 (23/17): DI 1.0
High: 24 V / Low: 0 V Low: 0 V
D Terminal 18 (23/18): DI 1.1

D Terminal 19 (23/19): DI 1.2 18

19
D Terminal 20 (23/20): DI 1.3
20
25
Figure 23

Outputs
Analogue Outputs

GND for analogue outputs 30, 31 and 32
reference voltage
D Terminal 31 (24/31): 0 ... 10 V DC
D Terminal 32 (24/32): 0 ... 10 V DC
0 ... 10 V DC
32
i INFORMATION
31
Optionally, all analogue outputs can also be used as 10 V DC
30
current outputs. Each output provides a current signal 29
of 0 ... 20 mA. Each analogue output can be configured
using the corresponding jumper.
Figure 24
Digital Outputs
5
D Terminal 5 (25/5): DO 0 High: 6
24 V 7
D Terminal 6 (25/6): DO 1 8
High: 24 V / Low: 0 V Low:
0V
D Terminal 7 (25/7): DO 2
D Terminal 8 (25/8): DO 3
28
Figure 25

5 Terminal Assignment and Technical Data
Terminal Assignment
Terminal assignment
Contact Description
Voltage output CAN

1
(+ 5 V DC VCC)
2 CAN bus CAN−H
3 CAN bus CAN−L
Reference potential CAN

4
(CAN−GND)
5 Digital output 0 DO 0
9 Alarm relay
10 Alarm relay
11 RS 232 TXD
12 RS 232 RXD
13 Digital input 0 DI 0.0
Figure 26

Terminal assignment
Contact Description
21 Analogue input AI 1
25 Voltage supply GND
26 Voltage supply 24 V
29 Analogue reference potential AGND
Reference voltage output 10 V

30
10 V REF
31 Analogue output AO 0
32 Analogue output AO 1
Figure 27

Technical Data
General data
Type approval by GL
Operating Data
Power supply 24 V DC / 100 mA
Permissible voltage deviation, incl. ripple − 25 % . . . +50 %
Power consumption when idle < 200 mA
Permissible ambient temperature during operation 0 . . . 70C
(Standard)
Permissible ambient temperature during storage and trans- −10 . . . 70C
portation
(Standard)
Permissible ambient temperature during operation −25 . . . 70C
(Extended temperature range)
portation
Galvanic isolation −−
Digital Inputs
Digital outputs DI0.0 ... DI 0.3 24 V DC
Low: 0 ... 5 V, High: 15 ... 36 V
Digital inputs DI1.0 ... DI 1.3 24 V DC
Low: 0 ... 5 V, High: 15 ... 36 V
Digital Outputs
Digital outputs DI0.0 ... DI 0.3 500 mA @ 24 V DC
Analogue inputs
Analogue input AI1 ... AI4 0 ... 10 V DC or 0 ... 20 mA
depending on the jumper position
for a 10−bit resolution
Reference voltage output 10 V DC ( IRef < 10 mA)
Analogue outputs
Analogue output AO0 ... AO1 0 ... 10 V DC or
0 ... 20 mA
for a 12−bit resolution
Alarm relay switching contact
Switching contact 1,000 mA @ 30 V DC

Operating Instructions DPV Module
Table of Contents
Preliminary Notes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
1 Technical Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Application . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Structure and Functions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Potentiometers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
LEDs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Operating Mode Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
System Diagnosis . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Input and Output Signals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Software Configuration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Hardware Configuration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Adjustments . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
PWM Outputs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Speed Override . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Alarm Relay . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
2 Configuration, Installation and Adjustments . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10

Configuration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
Removing the Terminal Strips . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
Inserting the Terminal Strips . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
Removing the DPV Module from the Casing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
Inserting the DPV Module into the Casing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
Initialisation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
Adjusting the Thrust Direction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
Adjusting Imin and Imax . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
Optimising the Adjustments . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
Speed Override . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
Characteristic . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
Adjusting the Pitch Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
Adjusting Imin and Imax . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
Optimising the Adjustments . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
3 Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
en STD−Ka Operating Instructions DPV Module 10/1598 1162901 1 / 30

4 Measuring Points and Nominal Values . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
Supply . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
Supply to the Module . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
Supply to Valve A . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
Supply to Valve B . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
PWM Outputs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
Valve A . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
Valve B . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
CAN Bus . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
Inputs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
Analogue Inputs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
Digital Inputs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
Alarm Relay . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
5 Terminal Assignment and Technical Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28

Terminal Assignment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
Technical Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
2 / 30 STD−Ka Operating Instructions DPV Module 10/1598 1162901 en

Preliminary Notes
These instructions are to provide information and Important instructions relevant to technical and
guidance to all persons involved in the initial start−up, operational safety are identified by the following
operation and maintenance of SCHOTTEL propulsion symbols:
read, understood and carefully observed.
! WARNING
These instructions are to be made available to all
We do not accept any liability for damages and strictly observed to prevent any risk to personal safety.
instructions.
It is a prerequisite that all users are familiar with the
! CAUTION
propulsion systems and have been informed about the Indicates working and operating methods that are to be
possible dangers associated with their use. strictly observed to prevent damage to or destruction of
Only skilled and qualified electricians are permitted to materials.
carry out work on the propulsion systems.
References to illustrations contained in the text are NOTICE
written in brackets, e.g. (1/3). The first number refers to
the illustration number in the manual; the second Indicates specific features of the working process
number is the item number in the illustration. which are to be observed.
All illustrations are schematic diagrams and do not
make any claim to completeness. i INFORMATION
Any technical modification to SCHOTTEL propulsion Application instructions and information.
However, this does not include any of the modifications systems, always observe the ”Safety and
or control settings described in our instructions. Environmental Protection Regulation SV 1” as well
as the applicable laws in force in the relevant country
of operation.
Given that SCHOTTEL propulsion systems are subject
to further development, we reserve the right to carry out
technical modifications.
SCHOTTEL GmbH
Mainzer Straße 99
56322 Spay, Germany
Phone +49 (0) 2628 / 61−0
Fax: +49 (0) 2628 / 61−300
E−mail: [email protected]

Application
The DPV module (1/3) is an amplifier module used for
the steering of SCHOTTEL propulsion systems (1/5). It
controls directional hydraulic valves on hydraulic
components according to a setpoint value received
from the electronic control system (1/2).
Figure 1 shows the most common application of the
DPV module:
1
D A setpoint value (thrust direction command) from
the control desk (1/1) is received by the electronic
control system (1/2) and compared to the
feedback value.
D The calculated difference is transmitted to the DPV

module. ELECTRONIC
CONTROL
SYSTEM 2
D Depending on the provided difference value, the
DPV module activates the hydraulic valves (1/4)
using a PWM signal until the setpoint and feedback
values of the SCHOTTEL propulsion system are
identical (difference value = 0).
D Owing to the eight potentiometers, individual

adjustments can be made, such as:
3
− Threshold of a steering action
− Velocity of a steering action
− Acceleration of a steering action,
see section ”Potentiometers”, page 6.
All adjustments are adapted by the DPV module if a

hydraulic pump with a variable operating speed is used.
The steering behaviour and manoeuvrability of a
SCHOTTEL propulsion system and hence that of a ship 4
can be individually adjusted and optimised using the
DPV module.
In addition, the DPV module can be used to control the

hydraulic pitch control system, i. e. the thrust force and
thrust direction. Depending on the information from the
electronic control system, the DPV module controls the
hydraulic components which in turn control the 5
propeller blades of a CP propeller to achieve the
required thrust force and thrust direction.
Figure 1

Structure and Functions
The DPV module is mainly composed of:
D Two boards with the main electronic components, 1

DIP switches and jumpers for the hardware
configuration of the module, see figure 5
D Digital inputs (2/5) (4 items)
D Analogue input (+/− 10 V) for control commands

from external systems (2/3)
D Analogue input (0 ... 10 V) for speed override (2/4)
D PWM outputs for valve control (2/1) (2 items)
D CAN bus interface 5 2
D Eight potentiometers for adaptations to the 3

propulsion system. The settings can be read using
the test port, see section ”Potentiometers” 4
D Ten LEDs to display the operating states and

status, see section ”LEDs”
D Test port for a universal meter (2/2)

Figure 2
Potentiometers
The potentiometers are used to make adjustments for
the hydraulic components which are to be controlled.
Each of the following potentiometers has a dual design,
i. e. their outputs (valves A and B) can be adjusted
separately:
1
Pot Function
Imax to adjust the steering velocity of the 2
(3/1) SCHOTTEL propulsion system.
Imin to adjust the steering accuracy of
(3/2) the SCHOTTEL propulsion system. 3
to adjust the acceleration and
amp 4
braking time of the SCHOTTEL pro-
(3/3)
pulsion system’s steering action.
to adjust the responsiveness to
sens
steering commands from the
(3/4)
SCHOTTEL control desk.
The characteristics of these adjustments are shown in

figure 13.
Figure 3

LEDs
Ten LEDs signal the following operating states:
1 2
LED Operating state
CAN DPV 1
F 200 is lit in case of a CAN bus failure
is lit when a fault in the
F 201
voltage supply occurs
DCM DPV 2
F 202 is lit in case of an internal error
is lit in case of a short circuit, valve
VALVE failure or a broken wire on valve A
or B.
Valve A is lit when valve A is active.
Valve B is lit when valve B is active.
is lit when the DPV module is ener-
PWR
gised
is lit when the DPV module is oper-
RUN ational and goes out when a failure
of the DPV module occurs
Operating Mode Switch

The operating mode switch (4/3) is used to select the
ON and LD operating modes. In the LD operating mode
a software update can be uploaded to the DPV module.
During operation on a ship, the switch must always be

in the ON position.
System Diagnosis
Using the interfaces (4/1) and (4/2), a quick hardware
diagnosis can be made by a SCHOTTEL service
engineer.
Figure 4

Input and Output Signals Adjustments
The DPV module can read, process and output A number of initial adjustments are to be made for each
analogue and digital signals. The analogue inputs are particular application of the DPV module. These
used to receive analogue signals such as speed adjustments are made using the Imax, Imin, amp and
signals from a hydraulic pump, see section ”Speed sens potentiometers (5/7).
Override”. The digital inputs are used for the control
process within the electronic control system. A CAN For adjustment, a universal meter is connected to the
bus is provided for the communication within the entire test port (5/8) to read the Imin and Imax values. The
system. The hydraulic valves are controlled using the value is displayed in mV and corresponds to the output
PWM outputs. current in mA provided on the PWM outputs (e.g. 1000
mV = 1000 mA).
Software Configuration PWM Outputs

The DPV module is programmed with a system The hydraulic valves are controlled via the PWM
software before delivery. The operating mode switch outputs of the DPV module. The outputs are adjusted
(5/4) must be in the LD position when the system using four potentiometers, each for valves A and B.
software is transferred to the DPV module. During
operation, the operating mode switch must always be The maximum valve current can be adjusted on the
in the ON position. Imax potentiometer. The minimum valve current can
be adjusted on the Imin potentiometer. The
responsiveness can be adjusted on the sens
Hardware Configuration
potentiometer.
If a DPV module is defective, it can easily be replaced The difference value, from which the maximum valve
with a replacement module by specialist staff. current is reached, can be adjusted on the amp
potentiometer.
The DIP switches (5/12) and CAN terminator (5/3) on
the left board (5/11) are adjusted during configuration. The reference values of the maximum valve current
Jumpers can be plugged on both boards. Imax and the minimum valve current Imin depend on
the relevant manufacturer of the hydraulic components
The left board has eight jumper blocks while the right and must be considered when making the initial
board (5/10) has two jumper blocks. The jumper blocks adjustments.
with two connectors can either be plugged with a
jumper or they remain unplugged. The jumper blocks Speed Override
with three connectors (5/2) either have a jumper
plugged into pins 1 and 2 or 2 and 3 or they remain When hydraulic pumps with a variable operating speed
unplugged. The connector numbers 1, 2 and 3 (5/9) are are used, the current operating speed of the hydraulic
printed on the boards. pump is detected by a speed sensor before being
evaluated by the electronic control system and
Using the DIP switches, the hardware can be processed as an analogue input signal (1 ... 9 V) in the
configured, thus adjusting it to the electronic control DPV module.
system, e.g. for the feedback evaluation by the
electronic control system or the inversion of input Alarm Relay
signals etc.
The DPV module is equipped with an alarm relay with
If the module is the last device in the CAN bus chain, the a potential−free NO contact provided on the terminal
CAN terminator must be in the ON position, see strips. The NO contact is used to transmit a message
schematic diagram in figure 9. to the ship’s warning system.

6
5
7
4 8
1 2 2 9
3
1 1 2
ON OFF 123
3
1
11 10
12 2
9
Figure 5 DPV Module, Front View and Left and Right Boards
1 Jumper block with two connectors 7 Imax, Imin, amp and sens potentiometers
2 Jumper block with three connectors 8 Test port
3 CAN bus terminator 9 Connector numbers 1, 2 and 3
4 Operating mode switch 10 DPV module, right board
5 LEDs 11 DPV module, left board
6 Terminal strips 12 DIP switch

2 Configuration, Installation and Adjustments
Configuration
! CAUTION
1. Switch off the electrical system and secure it
against unintended start−up.
The DPV module is to be configured according to its 2. Pull out the terminal strips from the defective DPV
intended use before being installed and adjusted for module, see page 11. Do not disconnect any lines
its particular application. from the terminal strips.
3. Remove the defective and replacement DPV
!
modules from the casings, see figure 8.
CAUTION
4. Transfer all DIP switch (6/3) positions from the
Make sure you carefully observe the following defective DPV module to the replacement DPV
instructions in order to ensure the safe operation of the module, see valve characteristics in figure 7.
entire propulsion system after replacing a DPV module. 5. Transfer all jumper (6/1) positions from the
defective DPV module to the replacement DPV
module.
1 1 2 1
ON OFF
4.4
4.2
4.1
4.3
S4
3 S3
Figure 6

6. Transfer the terminator (6/2) position from the
S4.1
S4.3
S4.4
S4.2
defective to the replacement DPV module.
OFF OFF OFF OFF OFF OFF OFF ON ON ON ON ON ON ON ON

ON OFF ON OFF ON OFF ON OFF ON OFF ON OFF ON OFF ON
OFF ON ON OFF OFF ON ON OFF OFF ON ON OFF OFF ON ON
OFF OFF OFF ON ON ON ON OFF OFF OFF OFF ON ON ON ON

F
! CAUTION
E
The terminator (9/4), as the last CAN bus component, PSL/PSV
D
must always be in the ON position.
C
7. Insert the replacement DPV module into the
casing in the switch cabinet and slide the terminal
B
strips into the DPV module.
A
9
Installation LINDE
8
7
Removing the Terminal Strips
6
D Pull out the terminal strips (8/1) from a defective
DPV module (8/3) using a screwdriver.
5
HYDROMATIC
Inserting the Terminal Strips REXROTH 4

3
D After configuration, slide the terminal strips (8/1)

2
into the replacement DPV module (8/3). HYDROMATIC

1
! CAUTION
Figure 7
Make sure that all terminal numbers match when

sliding in the terminal strips (8/1). The DPV module may 1
be destroyed due to an incorrect position. 2
Check that all terminal strips in the DPV module are
tight.
3
Removing the DPV Module from the Casing
D Push down the detents (8/2) with a screwdriver 1

and pull out the DPV module (8/3).
Inserting the DPV Module into the Casing
D Slide the DPV module into the casing until it snaps

into place. 1
Figure 8

Initialisation
Configuration and installation in the switch cabinet
must be fully completed before initialisation can be
started, see pages 10 and 11.
All adjustments must be made for both PWM outputs,
i. e. for valves A and B each.
1. Check the position of all operating mode switches

(9/3). They must be in the ON position on all
modules before the electrical system is switched
on.
2. The hydraulic component that is to be controlled

must be idle when the reference values on the DPV
module (10/3) are adjusted. Switch off the
hydraulic pump (10/1) for this process.
3. Switch on the electrical system. The PWR (9/1)

and RUN (9/2) LEDs of all modules must light up.
If these LEDs do not light up on any of the modules,
the electrical system or the DPV module is not
operational, see the ”Troubleshooting” section on
page 20.
4. To initialise the thrust direction, turn the Copilot

(10/4) until the valve A (10/7) and valve B (10/6)
LEDs go out.
To initialise the pitch control, move the speed

control lever (10/5) until the valve A (10/7) and
valve B (10/6) LEDs go out.
5. Connect a universal meter (10/2) with a set

measuring range of approx. 1500 mV to 3000
mV/DC to the test ports (”measure points”).
i INFORMATION
The mV value displayed on the universal meter
corresponds to the respective output current (in mA) of
the relevant PWM output on the terminal strips (e.g.
1000 mV = 1000 mA).
NOTICE
The Imin, amp und sens settings must be optimised

during the sea trial.

CAN
1 2 1 2 1 2
3 3 3
4
OFF OFF ON
Figure 9
7 6
3 000.0
5
GND
V DC
ELECTRONIC
CONTROL 24 V GND
SYSTEM
Figure 10
en STD−Ka Operating Instructions DPV Module 10/1598 1162901 13 /30

Adjusting the Thrust Direction
Adjusting Imin and Imax Optimising the Adjustments
i
! CAUTION INFORMATION
For the following adjustments see also figure 13 and
Initialisation must be fully completed, see page 12. the Imax, Imin, amp and sens characteristics.
i INFORMATION 1. Adjust the minimum valve current on the Imin

potentiometer (11/10).
The following adjustments must be made for both
When the DPV module (11/5) activates a valve, the
outputs, i. e. for valves A and B each.
minimum valve current must flow at this valve. If
the Imin value is too high it can cause the
1. Gently turn the Copilot (11/1) until the valve A propulsion unit to sway during operation. The
(11/9) or valve B (11/8) LED lights up. Adjust the propulsion unit must move as soon as a valve is
Imin (11/10) potentiometer to the minimum valve activated.
current reference value, as is specified for the
relevant hydraulic component in the table below. 2. Adjust the steering velocity of the thrust direction
The output current is increased by turning the Imin control using the Imax (11/11) potentiometer.
potentiometer clockwise.
Refer to the Hydraulic Circuit Diagram for the
appropriate steering velocity. The acceleration
2. Turn the Copilot by approx. 180o . Adjust the Imax
and braking times are not included in the specified
(11/11) potentiometer to the maximum valve
steering velocity.
current reference value, as is specified for the
relevant hydraulic component in the table below.
3. Adjust the steering responsiveness using the sens
The output current is increased by turning the Imax
(11/6) potentiometer.
potentiometer clockwise.
The lower the responsiveness is set the more
accurate is the steering action of the propulsion
Hydraulic Imin [mA] Imax [mA] unit. The accuracy of the propulsion unit’s steering
component action is increased by turning the sens
potentiometer anti−clockwise.
Hydromatic approx. 270 approx. 630
If the propulsion unit starts swaying during
Rexroth approx. 250 approx. 500 operation, the responsiveness is set too low. It can
be increased by turning the sens potentiometer
Linde approx. 175 approx. 350 clockwise.
PSL/PSV approx. 300 approx. 600 4. Adjust the execution time for the maximum
steering velocity using the amp potentiometer
Reference values (11/7).
The execution time for the maximum steering

velocity and the propulsion unit’s responsiveness
3. The hydraulic component which is to be controlled to small to medium changes in thrust direction is
must be operational when the adjustments of the increased by turning the potentiometer clockwise.
DPV module are optimised. Switch on the
hydraulic pump for this process.

2
1
000.0
GND
11
V DC
10 1000 mV 5 1000 mA
8
Command (Setpoint)
6
Feedback
ELECTRONIC Difference
CONTROL
SYSTEM 24 V GND
Difference = Difference between setpoint and feedback values
Figure 11

Speed override
When using a hydraulic pump (12/2) with variable (12/3) according to the current speed of the hydraulic
speeds, the speed is detected by a speed sensor (12/1) pump. Thus, the steering velocity of the propulsion unit
before it is evaluated and read as an analogue signal remains constant in spite of variable speeds of the
( 1 ... 9 V) by the DPV module (12/4). The DPV module hydraulic pump.
adapts the output signal set on the Imax potentiometer
Speed evaluation
3
3 2
1 .. . 9 V
ELECTRONIC
CONTROL
SYSTEM 24 V GND
Figure 12

Characteristics
The following characteristics show the possible speeds, the Imax output signal of the DPV module is
adjustments for the Imax, Imin, amp and sens adapted by means of an analogue input signal
potentiometers. transmitted from an electronic module (13/2).
When using a hydraulic pump (13/1) with variable
1
Imax
1 .. . 9 V
amp
Valve current
Imin
Difference
sens
Feedback
CONTROL
SYSTEM
Command
(Setpoint)
Figure 13

Adjusting the Pitch Control
Adjusting Imin and Imax Optimising the Adjustments
! CAUTION i INFORMATION
The initialisation of the DPV module must be fully For the following adjustments see also figure 13 and
completed, see page 12. the Imax, Imin, amp and sens characteristics.
The following adjustments must be made for both
outputs, i. e. for valves A and B each. 1. Adjust the minimum valve current on the Imin
potentiometer (14/10).
1. Gently move the speed control lever (14/1) to
”ahead” or ”astern” until the valve A or valve B LED When the DPV module (14/5) activates a valve, the
lights up. Adjust the Imin (14/10) potentiometer to minimum valve current must flow at this valve. The
the minimum valve current reference value, as is pitch control mechanism must move as soon as a
specified for the relevant hydraulic component in valve is activated.
the table below. The output current is increased by
turning the Imin potentiometer clockwise. 2. Adjust the pitch control velocity using the Imax
(14/11) potentiometer.
2. Set the speed control lever (14/1) to maximum
thrust. Adjust the Imax (14/11) potentiometer to Refer to the Hydraulic Circuit Diagram for the
the maximum valve current reference value, as is appropriate pitch control velocity. The
specified for the relevant hydraulic component in acceleration and braking times are not included in
the table below. The output current is increased by the specified pitch control velocity.
turning the Imax potentiometer clockwise.
3. Adjust the responsiveness of the pitch control
using the sens (14/6) potentiometer.
Hydraulic Imin [mA] Imax [mA]
component
The lower the responsiveness is set the more
accurate is the control action of the pitch control
Hydromatic approx. 270 approx. 630
mechanism. The accuracy of the pitch control
action is increased by turning the sens
Rexroth approx. 250 approx. 500 potentiometer anti−clockwise.
Linde approx. 175 approx. 350
4. Adjust the execution time for the maximum pitch
PSL/PSV approx. 300 approx. 600 control velocity using the amp potentiometer
(14/7).
Reference values
The execution time for the maximum pitch control
velocity and the responsiveness to small to
3. The hydraulic component which is to be controlled medium changes in propeller pitch is increased by
must be operational when the adjustments of the turning the potentiometer clockwise.
DPV module are optimised. Switch on the
hydraulic pump for this process.

1 2
max
0 astern
3
max
ahead
000.0
4
GND
V DC
11
10 1000 mV 5 1000 mA
8
Command (Setpoint)
6
Feedback
CONTROL
SYSTEM 24 V GND
Difference = Difference between setpoint and feedback values
Figure 14

3 Troubleshooting
NOTICE 1
Note that the following table only addresses possible

failures as may be caused by a faulty configuration,
installation or adjustment of the DPV module.
13 14 15 16 17 18 19 20
It does not cover any faults which are due to the 4A1
on−board power supply (e.g. faulty supply voltages,
damaged cables etc.).
Inform the SCHOTTEL Service Department if it is not
possible to eliminate the fault by taking the following
measures.
=
The SCHOTTEL Service Department will need the 1410XXXX 115XXXX +B
Bl.
following information:
D SCHOTTEL code word, order number (15/2) and 2
part number from the Wiring Diagram (15/3)
3
D Name (15/1) of the DPV module as per the Wiring
Diagram
D Description of the fault and how it affects the Figure 15

functioning of the propulsion system
i INFORMATION
To ensure a trouble−free operation of the DPV module,

the following conditions are to be fulfilled:
1. The operating mode switch (16/1) must be in the

ON position.
2. All jumpers must be plugged according to the 1

intended use, see figure 6, item 1.
3. All DIP switches must be set according to the

intended use, see figure 6, item 3.
4. The CAN bus terminator must be set correctly, see

figure 6, item 2. The CAN bus position for each
module is indicated in the Wiring Diagram.
If one of these conditions is not fulfilled, the DPV

module is not operational. Figure 16

Propulsion unit is too fast when Speed sensing process not func- Check proper function of speed
hydraulic pump operates at high tioning sensing devices and correct set-
speed. tings or replace defective parts, if
required.
No analogue input signal Check analogue input signal on

received by the DPV module the DPV module, see page 26
Propulsion unit swaying when Setting on the Imin potentiometer Correct settings on the Imin and
Copilot on the control desk is not too high sens potentiometers, see
in use page 14
Responsiveness set too high on

the sens potentiometer
PWR LED does not light up when No voltage supplied to the Check voltage supply on the DPV
the electrical system is switched module. module, see page 23.
on.
Provide the voltage supply to the
DPV module; e.g. check proper
function of automatic cutouts and
connections etc.
DPV module defective Replace DPV module
RUN LED does not light up when DPV module has detected a fault Check if one of the F200, F201,
the electrical system is switched and cannot perform any functions F202, F203, F204 or VALVE
on. LEDs is lit up
(Failure alarm)
LED F200 is lit up. Failure of CAN bus system Make sure that all cables of the
CAN bus system are connected
properly and no wires are dam-
aged.
Replace damaged lines, if

necessary
properly
Check position of terminator, see

item 4. on page 20
Measure the resistance between

CAN High and CAN Low: 60 
LED F201 is lit up. Failure of voltage supply Check voltage supply on the DPV
module, see page 23.
Check the supply voltage.

Observe the specifications in the
Wiring Diagram.
LED F202 is lit up. Failure of DPV module Replace DPV module

VALVE LED is lit up. Electrical fault in the supply to the Check the cables to the hydraulic
hydraulic component, e.g. a component for damage.
broken wire etc. Replace damaged lines, if
necessary
Check terminal assignment
Electrical fault in the hydraulic Check that valve coil of hydraulic

component, e.g. a short circuit component is functioning cor-
etc. rectly
Replace defective hydraulic com-
ponent, if required

4 Measuring Points and Nominal Values
Supply
Supply to the Module
Supply to Valve A
24 V
1
2
Supply to Valve B Figure 17

PWM Outputs
Valve A
D Terminal 5 (18/5):
feedback PWM−GND (A/B−COM)
D Terminal 6 (18/6): PWM signal 5

(valve A) 6
Figure 18
Valve B
D Terminal 7 (19/7): PWM signal

(valve B)
D Terminal 8 (19/8): 7
feedback PWM−GND (A/B−COM)
8
Figure 19

CAN Bus
D Terminal 1 (20/1): 5 V CAN−VCC
5V
D Terminal 4 (20/4): CAN−GND
D Terminal 2 (20/2): CAN−H 1
2
D Terminal 3 (20/3): CAN−L
3
4
Figure 20

Inputs
Analogue Inputs

for analogue inputs 23 and 24
reference voltage
D Terminal 23 (21/23): −10 V ... 10 V DC 24
AI 1
0 ... 10 V
D Terminal 24 (21/24): 0 V ... 10 V DC 23
AI2
−10 V ... +10 V

10 V
22
21
Figure 21
Digital Inputs
17
D Terminal 17 (22/17): DI 1.0
High: 24 V / Low: 0 V High: 24 V
Low: 0V
D Terminal 18 (22/18): DI 1.1
D Terminal 19 (22/19): DI 1.2
High: 24 V / Low: 0 V 20
D Terminal 20 (22/20): DI 1.3 19
18
25
Figure 22

Alarm Relay
D Terminal 10 (23/10): Potential−free 10
Figure 23

5 Terminal Assignment and Technical Data
Terminal Assignment
Terminal assignment
Contact Description
Voltage output CAN

1
(+ 5 V DC VCC)
2 CAN bus CAN−H
3 CAN bus CAN−L
Reference potential CAN

4
(CAN−GND)
Feedback PWM output

5
(A/B−COM)
PWM output
6
Coil A
PWM output
7
Coil B
Feedback PWM output

8
(A/B−COM)
9 Alarm relay
10 Alarm relay
11 RS 232 TXD
12 RS 232 RXD
13 Not existing
14 Not existing
15 Not existing
16 Not existing
Figure 24

Terminal assignment
Contact Description
Reference potential for analogue

21
inputs AGND
Reference voltage output 10 V

22
10 V REF
Voltage supply GND

29
(VALVE A)
Voltage supply 24 V
30
(VALVE A)
Voltage supply GND

31
(VALVE B)
Voltage supply 24 V
32
(VALVE B)
Figure 25

Technical Data
General data
Type approval by GL (no installation on bridge)
Operating Data
Power supply 24 V DC / 100 mA
Permissible voltage deviation, incl. ripple − 25 % . . . +50 %
Power consumption when idle < 200 mA
Permissible ambient temperature during operation 0 . . . 70C
(Standard)
portation
(Standard)
Permissible ambient temperature during operation −25 . . . 70C
portation
Galvanic isolation −−
Digital Inputs
Digital inputs DI1.0 ... DI 1.3 24 V DC
Low: 0 ... 5 V, High: 15 ... 36 V
Analogue inputs
Analogue input AI1 −10 V ... +10 V DC / 10−bit resolution
Analogue input AI2 0 V ... +10 V DC / 10−bit resolution
Reference voltage output 10 V DC ( IRef < 10 mA)
PWM outputs
Valve A / valve B 0 ... 1,000 mA @ 24 V DC
short−circuit proof
Alarm relay switching contact
Switching contact 1 A @ 30 V DC
Test port for universal meter
Range of adjustment approx. 1500 mV DC 0 ... 1000 mV / 10−bit resolution

YOUR PROPULSION EXPERTS
Projectcode
TUG-110244-05
Code word
BONNY 38
Order number
14338678
Thruster
SRP 1515 FP
Ship classification society

ABS
Language
English
SPARE PARTS CATALOGUE
SCHOTTEL
Version 2015/05/18
Table of contents
2
SCHOTTEL SPARE PARTS CATALOGUE 2015/05/18 Order number: 14338678
1 Ordering Spare Parts 5
2 Overview 8

3 Rudder-Propeller -SRP 1515-R/R 12


4 Upper gear box I=2,238 16
5 Lower gear-box 21
6 propeller-shaft-sealing 25
7 Cover plate assy, cpl. 28
8 Lubrication system cpl. 30
9 Change-Over Inline Filter 36
10 Heat Exchanger 38
11 Steam-Section sealing 40
12 Propeller components 42
13 Hy-steering connection cpl. 44
14 Level Switch cpl. 46
15 Rudder-Propeller -SRP 1515-R/L 48
16 Upper Gear Box I=2,238 52
17 Lower gear-box 57
18 propeller-shaft-sealing 61
19 Cover plate assy, cpl. 64

20 Lubrication system cpl. 66
3
21 Change-Over Inline Filter 72
22 Heat Exchanger 74
23 Steam-Section sealing 76 
24 Propeller components 78 
25 Hy-steering connection cpl. 80
26 Level Switch cpl. 82
27 Intermediate shaft cpl. 84
28 Cardan Shaft, cpl. 41-90 86
29 counter shaft 88
30 Hydro Measuring KIT 90
31 Hydro-Aggregate 91
32 Level switch cpl. 95
33 Hy-Pump HPV135 cpl. -cw 97
34 Temperature Switch cpl. 102
35 Tools for SRP1515 N=1600 104
36 Oil pump cpl. 105
37 Inductive proximity switch cpl 107
38 Spare Parts SRP+HY 109
39 Switch box cpl. 112
40 panel,main cab 117



SCHOTTEL SPARE PARTS CATALOGUE 2015/05/18 Order number: 14338678 4
43
42
41
Panel
panel,main cab
Spare parts, electric system

122
121
119
1. Ordering Spare Parts
5
We would like to draw express attention to the fact that only those
spare parts and accessories supplied by SCHOTTEL GmbH have
been checked and released. The full functionality and safe operation
of the propulsion system can only be guaranteed if spare parts sup-
plied by SCHOTTEL GmbH are used. 
The warranty shall become void if any parts are used other than orig-
inal SCHOTTEL parts. SCHOTTEL GmbH shall not assume any li-
ability or warranty for any damages incurred by using non−original

spare parts and accessories.
SCHOTTEL GmbH’s General Terms and Conditions shall expressly

apply to all orders placed (www.schottel.de/agb).
Requests for spare parts are to be made in writing. Orders received

and given on the telephone shall be expressly at the customer’s own
risk and account.
Ordering Please always send your spare parts requests and orders to the
SCHOTTEL Service Department in writing. Please use the enclosed
order form or copy the pages from the spare parts catalogue adding
any missing details or information in your covering letter.
To enable clear identification please provide the following information

on your propulsion system:
Service Manual number (1/1)
Key word (1/2)
Order number (1/3)
Type of product (1/4)
Serial number (1/5)
Classification society (1/6)

6
Figure 1: Service Manual Cover Sheet
We will require the following information to be able to process your

spare parts order:
Assembly number
Assembly drawing
Quantity
Denomination
Parts number
Position number
Shipping (post, forwarders, train, etc...)
Customer’s address
Dispatch address
Figure 2: Excerpt of Assembly Parts List

Telefax
SCHOTTEL Agency SCHOTTEL GmbH
Mainzer Straße 99
or 56322 Spay/Rhein
Germany
Dept.: SET
Telefax No.: +49 2628 61---433
SPARE PARTS REQUEST
Order No. :
Serial Number :
Type of Product :
Manual No. :
Name of Ship :
Ship Owner :
Part No. Part Name Item No. of Sub-- Name of Sub--Assembly Quantity
No. Assembly
* Tick where applicable
Spare Parts with Approval : Yes No Delivery Address :
Dispatch by : Mail Road Rail
Other
Invoice Address :
Stamp / Signature of Customer Place and Date

2. Overview
8
Position Part Designation Quantity Instructions
1 1187004 Rudder-Propeller -SRP 1515- 1 piece 1191501


R/R
1181209 Upper gear box I=2,238 1 piece


1170929 Lower gear-box 1 piece
1170923 propeller-shaft-sealing 1 piece
1169887 Cover plate assy, cpl. 1 piece
1187003 Lubrication system cpl. 1 piece
1185977 Change-Over Inline Filter 1 piece
1143017 Heat Exchanger 1 piece
1173246 Steam-Section sealing 1 piece
1173061 Propeller components 1 piece
1174074 Hy-steering connection cpl. 1 piece
1095792 Level Switch cpl. 1 piece
2 1187005 Rudder-Propeller -SRP 1515- 1 piece 1191501

R/L
1181246 Upper Gear Box I=2,238 1 piece
1170930 Lower gear-box 1 piece
1170923 propeller-shaft-sealing 1 piece
1169887 Cover plate assy, cpl. 1 piece
1187003 Lubrication system cpl. 1 piece
1185977 Change-Over Inline Filter 1 piece

9

1143017 Heat Exchanger 1 piece
1173246 Steam-Section sealing 1 piece


1173061 Propeller components 1 piece
1174074 Hy-steering connection cpl. 1 piece 
1095792 Level Switch cpl. 1 piece
3 1188944 Intermediate shaft cpl. 2 piece 1167641
4 1189030 Cardan Shaft, cpl. 41-90 2 piece
5 1129697 counter shaft 2 piece 1167641
6 1073430 Hydro Measuring KIT 1 piece
7 1183366 Hydro-Aggregate 2 piece
1089883 Level switch cpl. 1 piece
8 1160796 Hy-Pump HPV135 cpl. -cw 2 piece
1106219 Temperature Switch cpl. 1 piece
9 1154883 Tools for SRP1515 N=1600 1 piece
1113864 Oil pump cpl. 3 piece
10 1201109 Inductive proximity switch 2 piece

cpl
11 1189406 Spare Parts SRP+HY 1 piece
12 1201904 Switch box cpl. 2 piece
13 1187218 panel,main cab 1 piece
14 1187219 panel,main cab 1 piece
15 1182230 Panel 2 piece 1176151

10

16 1190438 Spare parts, electric system 1 piece
17 1129696 cardan shaft 41-90 2 piece 1129696_GEWES see

chapter: Documents from

Suppliers
18 1146427 Control Unit, Airflex 9-11 bar 2 piece 1146427_KENDRION see


Suppliers
19 1105027 Emergency Control Bolt 8 piece
20 1124319 Preloading Measuring Gauge 1 piece
21 1185979 Filter insert 2 piece
22 1055379 Filter 2 piece
23 1156410 support for 1 indicator 96x96 2 piece
24 1156514 Thrust direction indicator 2 piece
25 1143989 V-Belt Pulley 2 piece
26 1140579 Endless Narrow V-Belts 10 piece
27 1104097 Preservation Instructions 2 piece 1104097
28 1104096 Signboard -Attention!-D,GB.F,E 2 piece
29 1104095 Signboard -Attention!-D,GB.F,E 2 piece
30 1098729 Hexagon head screw M22X 50 16 piece
31 1055386 Hexagon head bolt M22X 80 32 piece
32 1074322 Hexagon head bolt M22X100 16 piece
33 1001027 Hexagon nut M 22 48 piece
34 1188111 Schedule of measuring points 1 piece
35 1108411 Pointer 1 piece

11

36 1201784 Center of gravity 2 piece
37 1149617 Pneumatic Diagram 1 piece


38 1151373 Hydro-Diagram 1 piece
39 1201903 E.-Diagram 1 piece 1207405 

3. Rudder-Propeller -SRP 1515-R/
12
R
Part: 1187004

Drawing number: 1187004
 Änderungsnummer: 14/2625
1154676 Path cable,Radox 1 meter
1175174 cover 1 piece
1202657 Cable with plug 3m P12 1 piece
001 1181209 Upper gear box I=2,238 1 piece
002 1170929 Lower gear-box 1 piece
003 1200767 Power transmission shaft 1 piece
004 1197109 Nozzle D2625X1300 m.Y-Ab- 1 piece

stuetz
005 1201751 Propeller,right,push 1 piece 1197744
006 1186949 Steering gear compl. 1 piece
007 1187003 Lubrication system cpl. 1 piece
008 1173246 Steam-Section sealing 1 piece
009 1173061 Propeller components 1 piece
010 1132923 Coupling,Airflex 1 piece
011 1174074 Hy-steering connection cpl. 1 piece
012 1187531 Cone support tube 1 piece

13

014 1194791 Console 1 piece
015 1180572 Inductive Proximity Switch 2 piece


016 1179731 Cable with plug M12 2 piece
018 1002224 Sealing Ring A 48,0X 55,0 8 piece 
019 1095792 Level Switch cpl. 1 piece
020 1101848 Hexagon socket head cap 26 piece

screw
021 1104985 Name Plate 1 piece
022 1010473 Round and head grooved pin 4 piece

screw
025 1096188 Double nipple 280-2 1 piece
026 1095911 Ball valve 1 piece
027 1034755 Sealing Ring A 60,0X 68,0 1 piece
028 1125717 Hexagon Head Screw Plug 1 piece
029 1001356 O-ring 65,00x 3,00 1 piece
030 1001433 O-ring 192,00x 4,00 1 piece
031 1001324 O-ring 30,00x 3,00 1 piece
032 1173306 Cover 1 piece

14

037 1037190 Hexagon head screw M 8X 20 3 piece
040 1002213 Sealing ring A 21,0X 26,0 7 piece


041 1002236 Hexagon head screw plug 7 piece

042 1002221 Sealing Rings A 36,0X 42,0 2 piece
049 1002707 Seamless precision steel tube 1 meter
050 1026987 Pipe clamp D42 8 piece
051 1017599 Double nipple 280-1 1/2 1 piece
052 1114012 Ball valve, spring return 1 piece
053 1012653 Oil gauge R1 1/2 Z SK 33L 1 piece

16 15 14 13 12 11 10 9 8 7 6 5 4 3 2 1
Achtung:
DIN EN ISO 4017 - M20x55

Flansch nur warm aufziehen.
Nicht mit Öldruck montieren. 40,41 32,29 33MA=68Nm 45,46 36,31 37MA=34Nm B
A-A MA=560Nm Aufschubweg = 9 +1
Schrumpftemperatur 180°C B
M
18 Attention:
M
flange chadt only warm

44
ca.1300
don't use oil pressure
length of mounting = 9 +1
shrink temperature 180°C
315
290
7
1
L L

D
MA=34Nm
480
22
18 2896
-2
-5
1
K 21 F E K
80
185
50
12 F
19 DIN EN ISO 4762 - M20x70
A A
42 MA=560Nm
34,30 D
35
MA=117Nm Einfüllhöhe gekennzeichnet
durch Schild IDNR 1131503.
J J
fill leve marked with
18,44 signeboard IDNO 1131503.
42,43
47,48
18,44 40,41
3200
Einfüllhöhe 775
MA=82Nm 2
50
H
8 H
40,41
2625
2600
3 4
42,43 18,44
6 C
5 18,44 18,44
G G
9
E
Kühlwasseraustritt G1 1/2"
cooling water outlet G1 1/2"
C Kühlwassereintritt G1 1/2"
51 - 53 cooling water intlet G1 1/2"
DIN EN ISO 4029 - M20x25 1415

F F
MA=300Nm
25,26,27,28 10
ca.820
Aufschubweg
4,5mm bei 20°C
280
length of mounting
11 2
4,5mm at 20°C
E
2 E
6
175 h6
280
1633
20 MA=1400Nm
G G
1:5
14 3
D 16 D
4 15
1700 1228
Abstand 3-5mm Leerrohre für Verkabelung, Pos. 49, 50 sind bei der
distance 3-5mm SRP-Montage nach Absprache mit TEL zu befestigen.
C Pipes for cable-protection, Pos. 49, 50 have to C
A:A be installed in acception with TEL.
(Ausführung R/L) MA=2450Nm 23 Montagehinweis:

Alle Flanschflaechen mit Fluessigdichtung Ident-Nr. 1058474 montieren.
Alle Schraubenverbindungen durch Ident-Nr. 1048197 sichern.
F-F Assembly instructions:
Mount all flange surfaces using liquid sealant, ID no. 1058474.
1:5 Secure all screw and bolt connections using ID no. 1048197.
Abnahmepruefzeugnis DIN EN 10204:2005-01 - 3.2
B 41 nach den gueltigen Vorschriften der geforderten

Schiffsklassifikationsgesellschaft B
40 Inspection certificate DIN EN 10204:2005-01 - 3.2

acc. to the rules of the demanded ship' classification society
0 175
L
175 h6
I A
-0,025 174,975
EN T
Maß Passung
NFID
Dieser Entwurf ist geistiges Eigentum Schutzvermerk CAD-ZEICHNUNG Typ: SRP 1515
CO
der SCHOTTEL GmbH DIN ISO 16016 beachten Manuelle Aenderung verboten !
Fügetemperatur 115°C Ausfüllen von Nischen nach Ident-Nr. 1079919 Werkstueckkanten Projektionsmethode 1 Allgemeintoleranz DIN ISO 2768-mK Massstab: 1:10 Gewicht: 26.000 kg
shrink temperature 115°C filling of recess see Ident-No. 1079919 DIN ISO 13715
-0.3
DIN ISO 128 Schweisskonstr. DIN EN ISO 13920-C
Tolerierung DIN ISO 8015 Werkstoff:
+0.8
Oberflaechenangaben DIN EN ISO 1302 Rohteil-Nr.:
Datum Name Modell-Nr.:
Bearb. 07.11.2011 ErbarH Benennung:
A A
Gepr. 06.02.2012
AV 07.02.2012
FaerberJ
KensyC
Ruderpropeller SRP1515 R/R
Ident-Nr Ausführung 004 14/2625 22.09.2014 HoerschD Norm 29.09.2014 MalewskiD
DIN EN ISO 4762 - M30x80 Ident-No Version 003 14/2618 19.09.2014 HoerschD Abt. TKG Rudder-Propeller -SRP 1515-R/R
MA=1400Nm 002 12/1198 11.05.2012 RossmannB SCHOTTEL GmbH Zeichnungs-Nr. Index: 004 Format
1187004
1187005
R/R
R/L
001
000
12/0985
0000
Zust. Aenderung Datum
13.04.2012 RossmannB
07.11.2011 ErbarH
Name
Mainzer Strasse 99
D-56322 Spay/Rhein
Urspr.: 1183277
1187004
Ers. f.: Ers. d.:
Bl.Nr.: 1
von 1 0
16 15 14 13 12 11 10 9 8 7 6 5 4 3 2 1
4. Upper gear box I=2,238
16
Part: 1181209
Drawing number: 1181209_TD
Änderungsnummer: 0000

001 1181204 SET OF Bevel Gears cpl.2,238 1 piece
002 1173341 housing, upper gear 1 piece
003 1133055 Housing, power input 1 piece
004 1154953 Bearing Housing 1 piece
005 1133061 Bearing cover 1 piece
006 1099952 Tapered Roller Bearing 2 piece
007 1132882 Cylindrical Roller Bearings 1 piece
008 1061006 Thrust Roller Bearing 1 piece
009 1079355 Tapered roller bearing 1 piece
011 1146169 Liner 1 piece
012 1133106 Disk 1 piece
013 1133094 Flange 1 piece
016 1133096 Segment 4 piece

17

018 1133114 Slotted Nut 1 piece

screw




screw
026 1064014 Hexagon socket set screw 4 piece
027 1133116 Retaining Rings for Bores 1 piece
028 1003734 Spring 8 piece
029 1141163 Cylindrical pin 1 piece
030 1146341 Rotary Shaft Seal 1 piece
031 1001458 O-ring 290,00x 3,00 1 piece
032 1159744 O-ring 350,00x 6,00 1 piece
033 1043303 O-ring 485,00x 6,00 1 piece
034 1001316 O-ring 16,00x 3,00 2 piece
035 1001409 O-ring 150,00x 4,00 1 piece
036 1001357 O-ring 65,00x 5,00 1 piece
037 1154952 Internal Rotorseal C2 1 piece
038 1181168 Disk 1 piece

18

039 1042505 Banjo coupling 1 piece
040 1181218 hose assembly, in oil 1 piece


041 1058629 Straight Male Stud Fitting 1 piece

042 1007106 Straight coupling 2 piece
043 1025656 Male stud coupling 1 piece
045 1029221 Hexagon socket pipe plug 2 piece
046 1001406 O-ring 144,30x 3,00 1 piece
049 1154947 Disk 1 piece

screw
051 1154951 Circlip for Bore SB 290 1 piece

screw
053 1131628 O-ring 810,00x 6,00 1 piece
054 1119548 Screw plug M24X1,5 1 piece

19

061 1108159 Spring pin SM 22,0X 70 M16 1 piece


062 1008084 Hose assembly 1 piece
063 1007106 Straight coupling 1 piece 
064 1018148 Blanking plug 1 piece
065 1064377 Plate, Connection 1 piece

16 15 14 13 12 11 10 9 8 7 6 5 4 3 2 1
Ausführung "Tellerrad obenliegend für Anbau KE-Flansch"

version "top crown gear for mounting KE-flange"
M M
L L
2
Ausführung "Tellerrad untenliegend für Anbau Kupplung"
47 version "crown gear for mounting clutch" 24
48 14
K 19 K
5
16
6
35
25
15
J J
1
52
61
56 2
H H
39
53
36 20
24
42
62 50
G 63 49 G
43
58
57
66 44
F
66 F
37 22
40 46
42
60
14
41 6 45
65 23 55
54
E
64 13 33
E
17
27
7
3
32
D D
12
51
M 1 :10 8
29
28
C
4 C
34
21
9
18
30
31
10
26 I A L
B
11 EN T B
N F ID
CO
Getriebe Oberwasser Kegel-Tellerrad-Paar kpl. Ausführung Kegel-Tellerrad-Paar Drehrichtung KE Dieser Entwurf ist geistiges Eigentum Schutzvermerk CAD-ZEICHNUNG Typ: SRP 1515
upper gear box set of bevel gears compl. version set of bevel gears direction of rotation KE der SCHOTTEL GmbH DIN ISO 16016 beachten Manuelle Aenderung verboten !
Werkstueckkanten Projektionsmethode 1 Allgemeintoleranz DIN ISO 2768-mK Massstab: 1:10 Gewicht: 2418.67 kg
Tellerrad untenliegend DIN ISO 13715 DIN ISO 128 Schweisskonstr. DIN EN ISO 13920-C
1181209 1181204 1180881 rechts -0.3 Tolerierung DIN ISO 8015 Werkstoff:
für Anbau Kupplung +0.8
Tellerrad obenliegend
1181246 1181207 1180881 rechts Bearb. 22.05.2014 KaulmannB Benennung:
A für Anbau Kupplung A
Gepr. 27.05.2014 HoerschD
AV
Getriebe,Oberwasser I=2,238
Tellerrad untenliegend Norm 28.05.2014 LauerI Untenliegendes Tellerrad
1181247 1181204 1180881 rechts Upper gear box I=2,238
für Anbau KE-Flansch Abt. TKG
SCHOTTEL GmbH Zeichnungs-Nr. Index: 000 Format
1181248 1181207
für Anbau KE-Flansch
1180881 rechts 000 0000 22.05.2014 KaulmannB
Zust. Aenderung Datum Name Urspr.:
Mainzer Strasse 99
D-56322 Spay/Rhein 1181209_TD
Ers. f.: Ers. d.:
Bl.Nr.: 1
von 1 0
16 15 14 13 12 11 10 9 8 7 6 5 4 3 2 1
5. Lower gear-box
21
Part: 1170929

001 1150415 Housing,Lower Gear-Box 1 piece
002 1170916 SET OF Bevel Gears 41:14 cpl. 1 piece
005 1116470 Cap 1 piece
007 1116460 Bearing hanger 1 piece
012 1125380 Disk 1 piece
013 1116756 Self-Aligning Roller Bearing 1 piece
014 1117413 bearing spacer 1 piece
017 1117213 Disk 1 piece

22


screw




screw

screw

screw
026 1011618 Usit-Ring U26,7X35,0X2,0 1 piece
029 1170923 propeller-shaft-sealing 1 piece
030 1169887 Cover plate assy, cpl. 1 piece
033 1112440 Cylindrical Roller Bearing 1 piece

screw

23

038 1117418 Spacer 1 piece


041 1117424 Spacerring 1 piece 
042 1112342 Slotted Nut M190X3,0 1 piece
047 1066042 O-ring 916,50x 8,00 2 piece
048 1148768 O-ring 590,00x 6,00 1 piece
049 1001494 O-ring 100,00x 4,00 2 piece
050 1001331 O-ring 38,00x 4,00 3 piece
056 1001340 O-ring 48,00x 4,00 1 piece
105 1195182 Distance disc 1 piece

16 15 14 13 12 11 10 9 8 7 6 5 4 3 2 1
44 Ausführung "LEACON" und "LEACON+Ölabsaugung"

42 version "LEACON" and "LEACON+Oil scavenging"
M M
43
53 54 111 110
41
39 49
9 56
40
48
L
Ausführung Standard 38 L
version "Standard"
8 51,52
50
45
37 1
K
7 K
33
46
J J
36 51,52
34 55
35
H H
30
29
G 28 31,32 G
22
F 18 F
16
21
19
47
20
E
25 E
24
D 2 D
105
12
13
1 : 10 23
3 T I A L
IDEN
C C
F
47 CON
14 27,26
Ident-Nr.
17 Ident-Nr.
Ident-No.
Kegel-Tellerad-Paar kpl
Ident-No.
Ausführung
Version
Propellerdrehrichtung
direction of rotation
set of bevel gears compl. of the propeller
4 1199532 1170916 Leacon+Ölabsaug. rechts / right

1199533 1170917 Leacon+Ölabsaug. links / left
B 1188815 1188812 Eisklasse rechts / right B
1188816 1188814 Eisklasse links / left

15 1170929
1170930
1170916
1170917
Standard
Standard
rechts / right
links / left
1170931 1170916 Leacon rechts / right
1170932 1170917 Leacon links / left
DIN ISO 13715 DIN ISO 128 Schweisskonstr. DIN EN ISO 13920-C
10
-0.3 Tolerierung DIN ISO 8015 Werkstoff:
+0.8
Bearb. 25.10.2013 KaulmannB Benennung:
A A
Getriebe,Unterwasser
11
AV
Norm 25.11.2013 MalewskiD Propeller Rechtsdrehend
Abt. TKG Lower gear-box
5
000 0000 25.10.2013

KaulmannB
Name Urspr.:
Mainzer Strasse 99
Ers. f.: Ers. d.:
Bl.Nr.: 1
von 1 0
16 15 14 13 12 11 10 9 8 7 6 5 4 3 2 1
6. propeller-shaft-sealing
25
Part: 1170923
Änderungsnummer: 10/2281

001 1157144 Housing, for Radial Sealing 1 piece
004 1153724 Disk 1 piece
005 1154150 net protection ring 1 piece
006 1153725 Disk 1 piece
007 1150407 Disk 1 piece

screw

screw

screw
015 1148408 Indicator Plug G 1/4 A 2 piece
016 1020517 O-ring 480,00x 4,00 1 piece

26

017 1062416 O-ring 14,00x 3,00 2 piece
018 1020514 O-ring 350,00x 4,00 1 piece


019 1001460 O-ring 297,00x 4,00 1 piece

020 1001447 O-ring 240,00x 4,00 1 piece
8 7 6 5 4 3 2 1
B-B A-A A
1 3
6 5 4 3 1 7
MA=68Nm
9 B
19 20 8 14 15 17
F F
13
E E
R7
240
207,50
D D
H7
240
C C
18
H6
360
12
557 g6
MA=405Nm
16
10 T I A L
11
N FI DEN
MA=48Nm MA=48Nm
C O
B
C A B 360
557
H6
g6
+0,036
0
-0,022
360,036
360
556,978
B
-0,066 556,934
C-C 2 vorgespannt min 0,3mm

prestressed 240 R7 -0,067
-0,113
+0,046
239,933
239,887
240,046
240 H7
0 240
MAßSTAB 1 : 5 Zwischenraum der Radialwellendichtringe mit
Maß Passung
2vorgespannt min 0,6mm Fett "AMBLYGON TA 15/2" (Ident-Nr. 1096549)

gefüllt
Dieser Entwurf ist geistiges Eigentum
der SCHOTTEL GmbH
Schutzvermerk
DIN ISO 16016 beachten
CAD-ZEICHNUNG
Manuelle Aenderung verboten !
Typ: SRP 1515
prestressed DIN ISO 13715 DIN ISO 128 Schweisskonstr. DIN EN ISO 13920-C
Werkstoff:
space of the shaft sealing rings filled -0.3
+0.8
Tolerierung DIN ISO 8015
with "AMBLYGON TA 15/2" grease Datum Name Modell-Nr.:
Bearb. 29.10.2008 ChristD Benennung:
A Schraubenverbindungen durch EFK gesichert A
alle Flanschflächen mit Flüssigdichtung screw connection secured with EFK
Gepr. 31.10.2008 KaemmerlingR
AV 30.10.2008 Lang
Propellerwellendichtung kpl.
2 DELO-ML 5198 Ident-Nr. 1058474 montiert Norm 09.09.2010 MalewskiD Leacon
Ident-Nr. Produkt Kenn-Nr. Eigenschaft 003 10/2281 08.09.2010 BartelC Abt. TKG propeller-shaft-sealing
all surfaces of flanges are mounted by using id-no. product no. quality
14 15
002 09/0950 23.04.2009 NoskeJ SCHOTTEL GmbH Zeichnungs-Nr. Index: 003 Format
fluid sealing DELO-ML 5198 Ident-No. 1058474

1048197 LOCTITE 245
normal lösbar
normally detachable
001
000
09/0586
Neuanlage
12.03.2009 ChristD
31.10.2008 ChristD
Name Urspr.:
Mainzer Strasse 99
D-56322 Spay/Rhein 1170923
Ers. f.: Ers. d.:
Bl.Nr.: 1
von 1 2
8 7 6 5 4 3 2 1
7. Cover plate assy, cpl.
28
Part: 1169887

001 1101447 Cover Plate 1 piece

screw
005 1099996 Housing 1 piece
006 1100000 Shaft 1 piece
007 1100103 Tension spring 1 piece
008 1002348 Retaining rings for bores 1 piece
009 1099998 Disk 1 piece
010 1001348 O-ring 55,00x 3,00 1 piece
014 1001514 O-ring 285,00x 4,00 1 piece

8 7 6 5 4 3 2 1
F F
358
E 3 E
MA=48Nm
MA=48Nm
13
2 2 11 12 5 4 3
1
D A A D
91
14
Ident-Nr. signiert
ident-no. marked
10 6 7 8 9
C C
TI A L
F ID EN
CO N
B B
2
1184734 GGG NiCr202
1169887 GGG
Ident-Nr. Ausführung
Dieser Entwurf ist geistiges Eigentum Schutzvermerk
CAD-ZEICHNUNG Typ: SRP 1010
der SCHOTTEL GmbH Manuelle Aenderung verboten !
Montagehinweis:
Werkstoff:
Alle Schraubenverbindungen durch -0.3
+0.8
ID-Nr. 1048197 gesichert. Datum Name Modell-Nr.:
Bearb. 14.08.2008 ErdleiA Benennung:
A A
Mounting instruction: Gepr. 04.08.2008 ChristD
AV 04.08.2008 LangF
Abschlussplatte kpl.
Norm 17.04.2013 MalewskiD
All screw connections safeted by 003 13/1000 15.04.2013 KaulmannB Abt. TKG Cover plate assy, cpl.
ID-no. 1048197. 002 11/1101 11.05.2011 RossmannB SCHOTTEL GmbH Zeichnungs-Nr. Index: 003 Format
001
000
08/2525
Neuanlage
28.10.2008 ErdleiA
04.09.2008 ErdleiA
Name
Mainzer Strasse 99
D-56322 Spay/Rhein
Urspr.: 1130612
1169887
Ers. f.: Ers. d.:
Bl.Nr.: 1
von 1 2
8 7 6 5 4 3 2 1
8. Lubrication system cpl.
30
Part: 1187003

001 1122487 Hydro pipe cpl. 1 piece
002 1010956 Gasket 1 piece
004 1026798 Adjustable elbow coupling 3 piece
005 1130158 Electro LUB Oil Pump 1 piece 1130158_KRACHT see

Suppliers
008 1007332 Washer 8 8 piece

screw
011 1073218 Cutting ring DS42-L 2 piece
012 1073217 Cap nut M 42-L 2 piece
014 1185977 Change-Over Inline Filter 1 piece
016 1007336 Washer 12 6 piece

31

018 1026149 Stud standpipe coupling 2 piece


019 1135648 Equal cross 1 piece
020 1025879 Reducing connection 1 piece 
021 1095864 Test coupling with screw lock 1 piece
023 1030668 Straight reducing coupling 1 piece
024 1064005 Reducing connection 2 piece
026 1194295 Flow switches 15-45 l/min 1 piece
027 1030666 Adjustable barrel tee coupling 1 piece
028 1094039 Lengthening 2 piece
029 1137923 Temperature switch 1 piece
030 1097385 Glass Thermometer 0-160 C 1 piece
031 1063242 Equal elbow 3 piece
037 1143017 Heat Exchanger 1 piece 1143017_GEA BLOKS-

MA see chapter: Docu-
ments from Suppliers

32

042 1174043 Oil tank 1 piece



044 1053426 Round cord seal 6,00 1 meter
046 1007334 Washer 10 56 piece
048 1175158 cover 2 piece
051 1157767 Orifice 1 piece
053 1064006 Adjustable branch tee coupling 1 piece

33

062 1096117 Male Stud Coupling 1 piece


065 1029244 Reducing adaptor 1 piece 
066 1108051 Air filter G3/4 1 piece
068 1129459 Level Indicator 1 piece
069 1131503 Signboard 1 piece
070 1064355 Equal tee 2 piece
081 1150218 Pipe 1 piece
082 1150219 Pipe 1 piece

34




087 1007334 Washer 10 4 piece

16 15 14 13 12 11 10 9 8 7 6 5 4 3 2 1
22 55 67 66 B 65 67 55 31 70,84 46 47 MA=68Nm 45 82 81 D
55 A
M M
Anordnung der Füllstandsanzeige
31 35
und Einfüllhöhe
siehe Zeichnung Ruderpropeller.
Position of the level-indicator
42 1
22 and fill level
see drawing Rudder-Propeller. 43
MA=560Nm
44
315
290
L L
285
68,69
85, 4 22
35,36 MA=68Nm 86, 3 18
87
30
34
°
K
9,10,11,12 4
K
MA=117Nm 28,30
1
4 5 55
70,84 56 54 53 55 77,78
35 13
23
MA=117Nm 3 22
6,7,8
J J
MA=34Nm
67 67
8,83 22 19 20,21 18 14 18 25 26 25 27,28,29 22 31

H H
MA=34Nm 2 2 2 2 2
1,2
Ausfuehrung: "Verrohrung KE"
version: " piping for KE"
G 77,78 77,78 50,51,52 G
D
C
73,74
F
22 24 41 40 37 41 40 24 F
22
22 Ausfuehrung: "Verrohrung Schlupfkupplung"

39 MA=68Nm version: " piping for slipping clutch" 5
60
61 22 48
35
E E
64
22
18
56
79,80
63 46,49
MA=68Nm
B C I A L
T
35
EN
22
ID
D D
N F
CO
56 Montagehinweis:
62 48 Alle Flanschflaechen mit Fluessigdichtung

Ident-Nr. 1058474 montiert.
75,76 Alle Schraubenverbindungen durch
Ident-Nr. 1048197 gesichert.
46,49 Mounting instruction:
C
22 79,80 All flange surfaces fitted using liquid sealant
C
MA=68Nm
ID no. 1058474.
All screw connections are to be secured using
59 ID no. 1048197.
1,5kW/480V-
1152678
57,58 60Hz/1710UPM
1,5kW/1,8kW-
B 1187003 1130158 B
50Hz/60Hz
Id.-Nr.
Schmierölssystem Id.-Nr. Pumpe Bezeichnung Pumpe
Id.-Nr. Id.-Nr. pump discription pump
lubrication system
+0.8
A A
Gepr. 05.01.2012 RossmannB
Schmieroelsystem kpl.
15 16,17 71,72 75,76 005 15/0170
004 14/1890
003 14/0564
16.01.2015 KaulmannB
AV 06.01.2012
Norm 19.01.2015
Abt. TKG
KensyC
DioufM
Lubrication system cpl.
MA=117Nm
A
002 13/0125 15.01.2013 KollmannK SCHOTTEL GmbH Zeichnungs-Nr. Index: 005 Format
001
000
12/2749
0000

07.11.2011 ErbarH
Name Urspr.:
Mainzer Strasse 99
D-56322 Spay/Rhein 1187003
Ers. f.: Ers. d.:
Bl.Nr.: 1
von 1 0
16 15 14 13 12 11 10 9 8 7 6 5 4 3 2 1
9. Change-Over Inline Filter
36
Part: 1185977

1181916 Servicing indicator 1 piece
1182087 Sealing KIT 1 piece
1185979 Filter insert 1 piece

8 7 6 5 4 3 2 1
F F
Bezeichnung Filterfeinheit Abmessung A Teile Nr.

Denomination Filter-fineness Dimension A Part No.
Dichtungssatz 1182087
Sealink kit
E Leitungsfilter, umschaltbar 538 mm 1182463 E
Change-over, inline filter
Filterelement
25 µm 1177558
Filter insert
Leitungsfilter, umschaltbar
Change-over, inline filter 538 mm 1186972
Filterelement 10 µm 1187231
Filter insert
D Leitungsfilter, umschaltbar 388 mm 1181388
D
A Filterelement
Filter insert 25 µm 1177755
Leitungsfilter, umschaltbar 388 mm 1186971
Filterelement
C C
Filter insert
Filterelement
10 µm 1187232
B Filter insert B
CAD-ZEICHNUNG Typ: SRP 1212 CP
DIN ISO 13715 DIN ISO 128-30 Schweisskonstr. DIN EN ISO 13920-CF
-0.3 Tolerierung DIN EN ISO 8015 Werkstoff:
+0.8
I AL
E NT
ID
Bearb. 05.02.2015 SchulzF Benennung:
ONF Leitungsfilter, umschaltbar

Gepr. 09.02.2015 ScherrW
C AV
A Norm 10.02.2015 LauerI A
Abt. TTD Change-Over Inline Filter
000 0000 05.02.2015

SchulzF
Name Urspr.:
Mainzer Strasse 99
Ers. f.: Ers. d.:
Bl.Nr.: 1
von 1 3
8 7 6 5 4 3 2 1
10. Heat Exchanger
38
Part: 1143017

1143535 Zinc Protector ROD 1 piece
1143536 Cover 2 piece
1143604 O-ring 82,22x 2,62 1 piece
1203968 Pass partition 1 set

1 2 3 4
Bezeichnung Denomination Teile Nr.

Part No.
Enddeckel Cover 1143536
E NTIAL Zinkschutzstab Zinc protector ROD 1143535
F ID
CON O-Ring 82,22x2,62 O-ring 82,22x2,62 1143604
Trennwand Pass partition 1203968
E
CAD-ZEICHNUNG Typ: H 0
+0.8
Gepr. 09.02.2015 FaerberJ
AV
Waermetauscher, seewasserfest
Norm 10.02.2015 LauerI
F Heat Exchanger
Abt. TTD
000 0000 05.02.2015

SchulzF
Name Urspr.:
Mainzer Strasse 99
Ers. f.: Ers. d.:
Bl.Nr.: 1
von 1 4
11. Steam-Section sealing
40
Part: 1173246

001 1172929 Bushing 1 piece
004 1119319 Disk 2 piece
005 1138419 Ring 1 piece
012 1165864 O-ring 760,00x 5,00 1 piece
013 1122219 O-ring 610,00x 4,00 2 piece
014 1001478 O-ring 12,00x 3,00 1 piece
015 1093016 Gland Packing, Aramid 10X10 1 meter
016 1013858 Washer 10 4 piece

8 7 6 5 4 3 2 1
A
F
A-A F
177 ±0,1 7
E 9,10 25
B-B
96 5 C-C
56
6
15 MA= 82 Nm
11
B Z 13 2 1
E 16 3
E
E 2 2
B
890 E-E
D-D 8
780 f6 E
E
R7
20 MA= 82 Nm
605
D D
D
4
C
3
vorgspannt
14
prestressed
C
min. 0,9 mm Z C
D
Fügetemperatur 115°C
12 shrink temperature 115°C
C
KE signiert 1
A KE marked
T IA L
F ID EN
N
B B
C O
605 R7 -0,155 604,845
Montagehinweis: -0,225 604,775
780 f6 -0,080 779,920
-0,130 779,870
Alle Flanschflaechen mit Fluessigdichtung Ident-Nr. 1058474 montiert. Maß Passung
Alle Schraubenverbindungen durch Ident-Nr. 1048197 gesichert. der SCHOTTEL GmbH DIN ISO 16016 beachten
Zwischenraeume der Wellendichtringe mit Fett Ident-Nr. 1096549 gefuellt. DIN ISO 13715 DIN ISO 128 Schweisskonstr. DIN EN ISO 13920-C
Werkstoff:
-0.3
+0.8
A
Mounting instruction: Bearb. 14.04.2009 MudersS Benennung:
A
Gepr. 22.06.2009 BaldusM
AV 22.06.2009 PechD
Trag-Steuerrohr-Abdichtung
All flange surfaces fitted with fluid sealing ID-No. 1058474 Norm 22.01.2015 DioufM Standard
003 15/0183 20.01.2015 KaulmannB Abt. TKG Steam-Section sealing complete
All screwed connections safeted by ID-No. 1048197 002 12/1121 14.05.2012 RossmannB SCHOTTEL GmbH Zeichnungs-Nr. Index: 003 Format
Spaces between rotary shaft seals filled with ID-no. 1096549 grease.
001
000
10/2364
Neuanlage
16.09.2010 ForsterF
20.07.2009 ChristD
Zust. Aenderung Datum Name
Mainzer Strasse 99
D-56322 Spay/Rhein
Urspr.: 1171179
1173246
Ers. f.: Ers. d.:
Bl.Nr.: 1
von 1 2
8 7 6 5 4 3 2 1
12. Propeller components
42
Part: 1173061

001 1156622 Propeller Hub 1 piece
003 1017324 Hexagon socket screw plug 4 piece
005 1001454 O-ring 270,00x 4,00 1 piece
010 1137238 Net-cutter 2 piece
011 1013859 Washer 12 4 piece

8 7 6 5 4 3 2 1
12 A
MA=60Nm
11 2 A-A
660,50 5 4
F F
3 9
10
MA=300Nm 6,7
E E
705
D D
8 1 5
C 2,3 C
A N TIAL
FID E
C O N
IDENT-Nr. / IDENT-No. Bezeichnung / description
1190607 Propeller Anbauteile / Edelstahl
3
B 1173061 Propeller Anbauteile B
der SCHOTTEL GmbH
4 Montagehinweis/Mounting instruction: Manuelle Aenderung verboten !
Alle Flanschflächen mit Flüssigdichtung -0.3
+0.8
ID-Nr 1058474 montiert. Datum Name Modell-Nr.:
All flangs surfaces fitted with fluid sealing Bearb. 25.06.2009 ChristD Benennung:
ID-No 1058474. Gepr. 26.06.2009 BaldusM
Propeller Anbauteile
005 13/1587 12.06.2013 HoerschD AV 29.06.2009 PechD
A Alle Schraubenverbindungen durch 004 12/2880 07.11.2012 HoerschD Norm 14.06.2013 MalewskiD
Propeller components
A
003 12/2277 31.08.2012 BlassD Abt. TKG
ID-Nr 1048197 gesichert. 002 12/1006 17.04.2012 HoerschD Zeichnungs-Nr. Index: 005 Format
All screw connections safeted by SCHOTTEL GmbH
ID-No 1048197.
001
000
12/0388
Neuanlage
06.02.2012 HoerschD
29.06.2009 ChristD
Name
Mainzer Strasse 99
D-56322 Spay/Rhein
Urspr.: 1173060
1173061
Ers. f.: Ers. d.:
Bl.Nr.: 1
von 1 3
8 7 6 5 4 3 2 1
13. Hy-steering connection cpl.
44
Part: 1174074
Änderungsnummer: Neuanlage

007 1007505 Plate, Connection, Small -E- 1 piece
008 1007504 Plate, Connection, Small -D- 1 piece
009 1007506 Plate, Connection, Small -F- 1 piece
010 1007832 Cabel Strap 3 piece

8 7 6 5 4 3 2 1
F
4 3 7,10 1 F
30
E E
853,50
30
8,10 782
18
18
D D
6 5 9,10 2
C C
B B
+0.8
AV 23.06.2009 PechD
HY-Steuerungsanschluss kpl.
A Norm 26.06.2009 MalewskiD A
Abt. TKG Hydro-Steering Connection
000 Neuanlage
23.06.2009 ChristD
Name Urspr.:
Mainzer Strasse 99
D-56322 Spay/Rhein 1174074
Ers. f.: Ers. d.:
Bl.Nr.: 1
von 1 3
8 7 6 5 4 3 2 1
14. Level Switch cpl.
46
Part: 1095792

001 1081657 Screw Plug G 1 1/2Z-3/8 1 piece
003 1089884 Terminalbox 1 piece
004 1012099 Float Switch 1 piece
005 1078130 cable clamp 1 piece
006 1069293 END Sleeve Strand H 0,50/14 2 piece
007 1015691 Cheese head screw M 3X 25 1 piece
008 1129221 Cable Glemmt D= 4-10 PG11 1 piece
009 1030820 Threaded piece 1 piece
013 1000975 Hexagon Nut M 3 1 piece

8 7 6 5 4 3 2 1
Version A
17
Mit DELO gedichtet
F
Mit EFK-A gedichtet
Tightened with EFK-A
tightened with DELO
ID-NRS: 1040106
13 Bei Montage abschneiden
F
switch point
Schaltpunkt
ID-NRS: 1029100 Cut off when assembling
20
G
E E
38 101
4 9 10 1 2 7 5 3 8
17
Bei Montage abschneiden

Version B Cut off when assembling
D 17 D
4 9 11 12 10 1 2 13 7 17
switch point
Schaltpunkt
1209304 200 B 1 1/2" 25
1209243 170 A 1 1/2" 24

C C
1209231 970 B 1" 24 17
G
1204084 530 B 1 1/2" 23
38 Mit EFK-A gedichtet
1169091 250 B 1" 21 Tightened with EFK-A
ID-NRS: 1029100 16
1168750 700 B 1" 20 101
1166204 250 B 1 1/2" 19 A
Mit DELO gedichtet
1155662 410 B 1 1/2" tightened with DELO
1130898 311 B 1 1/2"
15
ID-NRS: 1040106 5 3 8
B
1115800 280 B 1 1/2" B
1115070 466 B 1 1/2"
1113535 150 A 1 1/2" TIA L
ID E N
1113534 320 B 1 1/2" C ONF
1113533 348 B 1 1/2"
1111652 368 B 1 1/2" Dieser Entwurf ist geistiges Eigentum Schutzvermerk
1110445 133 A 1 1/2" Pos.4 um 180° gedreht Werkstueckkanten Projektionsmethode 1 Allgemeintoleranz DIN ISO 2768-mK Massstab: 1:1 Gewicht: 0.63 kg
1096421 133 A 1 1/2" +0.8
1096696 185 A 1 1/2" 025 15/0486 18.02.2015 KaulmannB Bearb. 10.01.1990 KraemerE Benennung:
A A
1095792 231 B 1 1/2" 019 07/3056 11.12.2008 KaemmerlingR
024 15/0449
023 14/1346
13.02.2015 AntonB
08.05.2014 KollmannK
Gepr. 24.05.1993 Wahl
AV 24.05.1996 Pech
Niveauschalter kpl.
018 07/1820 09.08.2007 GerstnerH 022 09/0524 13.03.2009 BartelC Norm 19.02.2015 MalewskiD
1089883 223 B 1 1/2" 017 07/1017 23.04.2007 LembkeJ 021 08/1616 01.07.2008 LembkeJ Abt. TBM / N Level switch cpl.
016 07/0655 14.03.2007 LembkeJ 020 08/1352 04.06.2008 LembkeJ Zeichnungs-Nr. Index: 025
ID-NRS A Version G 20 Bemerkung / note SCHOTTEL GmbH Format
Versionstabelle
015 06/0181 18.01.2006 ScherrW
013 01/0445KG 19.11.2002 DUE
019
018
07/3056
07/1820
11.12.2007 KaemmerlingR
09.08.2007 GerstnerH
Mainzer Strasse 99
D-56322 Spay/Rhein 1089883
Ers. f.: Ers. d.:
Bl.Nr.: 1
von 1 2
8 7 6 5 4 3 2 1
15. Rudder-Propeller -SRP 1515-R/
48
L
Part: 1187005

 Änderungsnummer: 14/2625
1154676 Path cable,Radox 1 meter
1175174 cover 1 piece
1202657 Cable with plug 3m P12 1 piece
001 1181246 Upper Gear Box I=2,238 1 piece
002 1170930 Lower gear-box 1 piece
003 1200766 Power transmission shaft 1 piece
004 1197109 Nozzle D2625X1300 m.Y-Ab- 1 piece

stuetz
005 1201752 Propeller,left,push 1 piece 1197744
006 1186949 Steering gear compl. 1 piece
007 1187003 Lubrication system cpl. 1 piece
008 1173246 Steam-Section sealing 1 piece
009 1173061 Propeller components 1 piece
010 1132923 Coupling,Airflex 1 piece
011 1174074 Hy-steering connection cpl. 1 piece
012 1187531 Cone support tube 1 piece

49



018 1002224 Sealing Ring A 48,0X 55,0 8 piece 
019 1095792 Level Switch cpl. 1 piece

screw
022 1010473 Round and head grooved pin 4 piece

screw
025 1096188 Double nipple 280-2 1 piece
026 1095911 Ball valve 1 piece
029 1001356 O-ring 65,00x 3,00 1 piece
030 1001433 O-ring 192,00x 4,00 1 piece
031 1001324 O-ring 30,00x 3,00 1 piece

50




050 1026987 Pipe clamp D42 8 piece
051 1017599 Double nipple 280-1 1/2 1 piece
052 1114012 Ball valve, spring return 1 piece
053 1012653 Oil gauge R1 1/2 Z SK 33L 1 piece

16 15 14 13 12 11 10 9 8 7 6 5 4 3 2 1
Achtung:

Flansch nur warm aufziehen.
Nicht mit Öldruck montieren. 40,41 32,29 33MA=68Nm 45,46 36,31 37MA=34Nm B
A-A MA=560Nm Aufschubweg = 9 +1
Schrumpftemperatur 180°C B
M
18 Attention:
M
flange chadt only warm

44
ca.1300
don't use oil pressure
length of mounting = 9 +1
shrink temperature 180°C
315
290
7
1
L L

D
MA=34Nm
480
22
18 2896
-2
-5
1
K 21 F E K
80
185
50
12 F
19 DIN EN ISO 4762 - M20x70
A A
42 MA=560Nm
34,30 D
35
MA=117Nm Einfüllhöhe gekennzeichnet
durch Schild IDNR 1131503.
J J
fill leve marked with
18,44 signeboard IDNO 1131503.
42,43
47,48
18,44 40,41
3200
Einfüllhöhe 775
MA=82Nm 2
50
H
8 H
40,41
2625
2600
3 4
42,43 18,44
6 C
5 18,44 18,44
G G
9
E
Kühlwasseraustritt G1 1/2"
cooling water outlet G1 1/2"
C Kühlwassereintritt G1 1/2"
51 - 53 cooling water intlet G1 1/2"
DIN EN ISO 4029 - M20x25 1415

F F
MA=300Nm
25,26,27,28 10
ca.820
Aufschubweg
4,5mm bei 20°C
280
length of mounting
11 2
4,5mm at 20°C
E
2 E
6
175 h6
280
1633
20 MA=1400Nm
G G
1:5
14 3
D 16 D
4 15
1700 1228
Abstand 3-5mm Leerrohre für Verkabelung, Pos. 49, 50 sind bei der
distance 3-5mm SRP-Montage nach Absprache mit TEL zu befestigen.
C Pipes for cable-protection, Pos. 49, 50 have to C
A:A be installed in acception with TEL.
(Ausführung R/L) MA=2450Nm 23 Montagehinweis:

Alle Flanschflaechen mit Fluessigdichtung Ident-Nr. 1058474 montieren.
Alle Schraubenverbindungen durch Ident-Nr. 1048197 sichern.
F-F Assembly instructions:
Mount all flange surfaces using liquid sealant, ID no. 1058474.
1:5 Secure all screw and bolt connections using ID no. 1048197.
B 41 nach den gueltigen Vorschriften der geforderten

Schiffsklassifikationsgesellschaft B
40 Inspection certificate DIN EN 10204:2005-01 - 3.2

0 175
L
175 h6
I A
-0,025 174,975
EN T
Maß Passung
NFID
CO
Fügetemperatur 115°C Ausfüllen von Nischen nach Ident-Nr. 1079919 Werkstueckkanten Projektionsmethode 1 Allgemeintoleranz DIN ISO 2768-mK Massstab: 1:10 Gewicht: 26.000 kg
shrink temperature 115°C filling of recess see Ident-No. 1079919 DIN ISO 13715
-0.3
+0.8
A A
Gepr. 06.02.2012
AV 07.02.2012
FaerberJ
KensyC
Ruderpropeller SRP1515 R/R
Ident-Nr Ausführung 004 14/2625 22.09.2014 HoerschD Norm 29.09.2014 MalewskiD
DIN EN ISO 4762 - M30x80 Ident-No Version 003 14/2618 19.09.2014 HoerschD Abt. TKG Rudder-Propeller -SRP 1515-R/R
MA=1400Nm 002 12/1198 11.05.2012 RossmannB SCHOTTEL GmbH Zeichnungs-Nr. Index: 004 Format
1187004
1187005
R/R
R/L
001
000
12/0985
0000
07.11.2011 ErbarH
Name
Mainzer Strasse 99
D-56322 Spay/Rhein
Urspr.: 1183277
1187004
Ers. f.: Ers. d.:
Bl.Nr.: 1
von 1 0
16 15 14 13 12 11 10 9 8 7 6 5 4 3 2 1
16. Upper Gear Box I=2,238
52
Part: 1181246

001 1181207 SET OF Bevel Gears cpl.2,238 1 piece
002 1173341 housing, upper gear 1 piece
003 1133055 Housing, power input 1 piece
009 1079355 Tapered roller bearing 1 piece
012 1133106 Disk 1 piece

53

018 1133114 Slotted Nut 1 piece

screw




screw
031 1001458 O-ring 290,00x 3,00 1 piece
032 1159744 O-ring 350,00x 6,00 1 piece
033 1043303 O-ring 485,00x 6,00 1 piece
034 1001316 O-ring 16,00x 3,00 2 piece
035 1001409 O-ring 150,00x 4,00 1 piece
036 1001357 O-ring 65,00x 5,00 1 piece
037 1154952 Internal Rotorseal C2 1 piece
038 1181168 Disk 1 piece

54

040 1181218 hose assembly, in oil 1 piece


041 1058629 Straight Male Stud Fitting 1 piece

046 1001406 O-ring 144,30x 3,00 1 piece
049 1154947 Disk 1 piece

screw
051 1154951 Circlip for Bore SB 290 1 piece

screw
053 1131628 O-ring 810,00x 6,00 1 piece
054 1119548 Screw plug M24X1,5 1 piece

55

061 1108159 Spring pin SM 22,0X 70 M16 1 piece


065 1064377 Plate, Connection 1 piece

16 15 14 13 12 11 10 9 8 7 6 5 4 3 2 1
Ausführung "Tellerrad obenliegend für Anbau KE-Flansch"

version "top crown gear for mounting KE-flange"
M M
L L
2
Ausführung "Tellerrad untenliegend für Anbau Kupplung"
47 version "crown gear for mounting clutch" 24
48 14
K 19 K
5
16
6
35
25
15
J J
1
52
61
56 2
H H
39
53
36 20
24
42
62 50
G 63 49 G
43
58
57
66 44
F
66 F
37 22
40 46
42
60
14
41 6 45
65 23 55
54
E
64 13 33
E
17
27
7
3
32
D D
12
51
M 1 :10 8
29
28
C
4 C
34
21
9
18
30
31
10
26 I A L
B
11 EN T B
N F ID
CO
Getriebe Oberwasser Kegel-Tellerrad-Paar kpl. Ausführung Kegel-Tellerrad-Paar Drehrichtung KE Dieser Entwurf ist geistiges Eigentum Schutzvermerk CAD-ZEICHNUNG Typ: SRP 1515
upper gear box set of bevel gears compl. version set of bevel gears direction of rotation KE der SCHOTTEL GmbH DIN ISO 16016 beachten Manuelle Aenderung verboten !
Tellerrad untenliegend DIN ISO 13715 DIN ISO 128 Schweisskonstr. DIN EN ISO 13920-C
1181209 1181204 1180881 rechts -0.3 Tolerierung DIN ISO 8015 Werkstoff:
für Anbau Kupplung +0.8
1181246 1181207 1180881 rechts Bearb. 22.05.2014 KaulmannB Benennung:
A für Anbau Kupplung A
AV
Getriebe,Oberwasser I=2,238
Tellerrad untenliegend Norm 28.05.2014 LauerI Untenliegendes Tellerrad
1181247 1181204 1180881 rechts Upper gear box I=2,238
für Anbau KE-Flansch Abt. TKG
1181248 1181207
für Anbau KE-Flansch
1180881 rechts 000 0000 22.05.2014 KaulmannB
Mainzer Strasse 99
Ers. f.: Ers. d.:
Bl.Nr.: 1
von 1 0
16 15 14 13 12 11 10 9 8 7 6 5 4 3 2 1
17. Lower gear-box
57
Part: 1170930

001 1150415 Housing,Lower Gear-Box 1 piece
002 1170917 SET OF Bevel Gears 41:14 Q6 1 piece
005 1116470 Cap 1 piece
007 1116460 Bearing hanger 1 piece
012 1125380 Disk 1 piece
014 1117413 bearing spacer 1 piece
017 1117213 Disk 1 piece

58


screw




screw

screw

screw
029 1170923 propeller-shaft-sealing 1 piece
030 1169887 Cover plate assy, cpl. 1 piece
033 1112440 Cylindrical Roller Bearing 1 piece

screw

59



041 1117424 Spacerring 1 piece 
042 1112342 Slotted Nut M190X3,0 1 piece
047 1066042 O-ring 916,50x 8,00 2 piece
048 1148768 O-ring 590,00x 6,00 1 piece
049 1001494 O-ring 100,00x 4,00 2 piece
050 1001331 O-ring 38,00x 4,00 3 piece
056 1001340 O-ring 48,00x 4,00 1 piece
105 1195182 Distance disc 1 piece

16 15 14 13 12 11 10 9 8 7 6 5 4 3 2 1
44 Ausführung "LEACON" und "LEACON+Ölabsaugung"

42 version "LEACON" and "LEACON+Oil scavenging"
M M
43
53 54 111 110
41
39 49
9 56
40
48
L
Ausführung Standard 38 L
version "Standard"
8 51,52
50
45
37 1
K
7 K
33
46
J J
36 51,52
34 55
35
H H
30
29
G 28 31,32 G
22
F 18 F
16
21
19
47
20
E
25 E
24
D 2 D
105
12
13
1 : 10 23
3 T I A L
IDEN
C C
F
47 CON
14 27,26
Ident-Nr.
17 Ident-Nr.
Ident-No.
Kegel-Tellerad-Paar kpl
Ident-No.
Ausführung
Version
Propellerdrehrichtung
direction of rotation
set of bevel gears compl. of the propeller
4 1199532 1170916 Leacon+Ölabsaug. rechts / right

1199533 1170917 Leacon+Ölabsaug. links / left
B 1188815 1188812 Eisklasse rechts / right B
1188816 1188814 Eisklasse links / left

15 1170929
1170930
1170916
1170917
Standard
Standard
rechts / right
links / left
1170931 1170916 Leacon rechts / right
1170932 1170917 Leacon links / left
10
+0.8
Bearb. 25.10.2013 KaulmannB Benennung:
A A
Getriebe,Unterwasser
11
AV
Norm 25.11.2013 MalewskiD Propeller Rechtsdrehend
Abt. TKG Lower gear-box
5
000 0000 25.10.2013

KaulmannB
Name Urspr.:
Mainzer Strasse 99
Ers. f.: Ers. d.:
Bl.Nr.: 1
von 1 0
16 15 14 13 12 11 10 9 8 7 6 5 4 3 2 1
18. propeller-shaft-sealing
61
Part: 1170923

001 1157144 Housing, for Radial Sealing 1 piece
004 1153724 Disk 1 piece
005 1154150 net protection ring 1 piece
006 1153725 Disk 1 piece
007 1150407 Disk 1 piece

screw

screw

screw
015 1148408 Indicator Plug G 1/4 A 2 piece
016 1020517 O-ring 480,00x 4,00 1 piece

62

017 1062416 O-ring 14,00x 3,00 2 piece
018 1020514 O-ring 350,00x 4,00 1 piece


019 1001460 O-ring 297,00x 4,00 1 piece

020 1001447 O-ring 240,00x 4,00 1 piece
8 7 6 5 4 3 2 1
B-B A-A A
1 3
6 5 4 3 1 7
MA=68Nm
9 B
19 20 8 14 15 17
F F
13
E E
R7
240
207,50
D D
H7
240
C C
18
H6
360
12
557 g6
MA=405Nm
16
10 T I A L
11
N FI DEN
MA=48Nm MA=48Nm
C O
B
C A B 360
557
H6
g6
+0,036
0
-0,022
360,036
360
556,978
B
-0,066 556,934
C-C 2 vorgespannt min 0,3mm

prestressed 240 R7 -0,067
-0,113
+0,046
239,933
239,887
240,046
240 H7
0 240
MAßSTAB 1 : 5 Zwischenraum der Radialwellendichtringe mit
Maß Passung
2vorgespannt min 0,6mm Fett "AMBLYGON TA 15/2" (Ident-Nr. 1096549)

gefüllt
Dieser Entwurf ist geistiges Eigentum
der SCHOTTEL GmbH
Schutzvermerk
CAD-ZEICHNUNG
Typ: SRP 1515
prestressed DIN ISO 13715 DIN ISO 128 Schweisskonstr. DIN EN ISO 13920-C
Werkstoff:
space of the shaft sealing rings filled -0.3
+0.8
with "AMBLYGON TA 15/2" grease Datum Name Modell-Nr.:
A Schraubenverbindungen durch EFK gesichert A
alle Flanschflächen mit Flüssigdichtung screw connection secured with EFK
Gepr. 31.10.2008 KaemmerlingR
AV 30.10.2008 Lang
Propellerwellendichtung kpl.
2 DELO-ML 5198 Ident-Nr. 1058474 montiert Norm 09.09.2010 MalewskiD Leacon
Ident-Nr. Produkt Kenn-Nr. Eigenschaft 003 10/2281 08.09.2010 BartelC Abt. TKG propeller-shaft-sealing
all surfaces of flanges are mounted by using id-no. product no. quality
14 15
002 09/0950 23.04.2009 NoskeJ SCHOTTEL GmbH Zeichnungs-Nr. Index: 003 Format
fluid sealing DELO-ML 5198 Ident-No. 1058474

1048197 LOCTITE 245
normal lösbar
normally detachable
001
000
09/0586
Neuanlage
12.03.2009 ChristD
31.10.2008 ChristD
Name Urspr.:
Mainzer Strasse 99
D-56322 Spay/Rhein 1170923
Ers. f.: Ers. d.:
Bl.Nr.: 1
von 1 2
8 7 6 5 4 3 2 1
19. Cover plate assy, cpl.
64
Part: 1169887

001 1101447 Cover Plate 1 piece

screw
005 1099996 Housing 1 piece
007 1100103 Tension spring 1 piece
008 1002348 Retaining rings for bores 1 piece
009 1099998 Disk 1 piece
010 1001348 O-ring 55,00x 3,00 1 piece
014 1001514 O-ring 285,00x 4,00 1 piece

8 7 6 5 4 3 2 1
F F
358
E 3 E
MA=48Nm
MA=48Nm
13
2 2 11 12 5 4 3
1
D A A D
91
14
Ident-Nr. signiert
ident-no. marked
10 6 7 8 9
C C
TI A L
F ID EN
CO N
B B
2
1184734 GGG NiCr202
1169887 GGG
Ident-Nr. Ausführung
Montagehinweis:
Werkstoff:
Alle Schraubenverbindungen durch -0.3
+0.8
ID-Nr. 1048197 gesichert. Datum Name Modell-Nr.:
Bearb. 14.08.2008 ErdleiA Benennung:
A A
Mounting instruction: Gepr. 04.08.2008 ChristD
AV 04.08.2008 LangF
Abschlussplatte kpl.
All screw connections safeted by 003 13/1000 15.04.2013 KaulmannB Abt. TKG Cover plate assy, cpl.
ID-no. 1048197. 002 11/1101 11.05.2011 RossmannB SCHOTTEL GmbH Zeichnungs-Nr. Index: 003 Format
001
000
08/2525
Neuanlage
28.10.2008 ErdleiA
04.09.2008 ErdleiA
Name
Mainzer Strasse 99
D-56322 Spay/Rhein
Urspr.: 1130612
1169887
Ers. f.: Ers. d.:
Bl.Nr.: 1
von 1 2
8 7 6 5 4 3 2 1
20. Lubrication system cpl.
66
Part: 1187003

001 1122487 Hydro pipe cpl. 1 piece
005 1130158 Electro LUB Oil Pump 1 piece 1130158_KRACHT see

Suppliers
008 1007332 Washer 8 8 piece

screw
011 1073218 Cutting ring DS42-L 2 piece
012 1073217 Cap nut M 42-L 2 piece
014 1185977 Change-Over Inline Filter 1 piece
016 1007336 Washer 12 6 piece

67



019 1135648 Equal cross 1 piece
020 1025879 Reducing connection 1 piece 
026 1194295 Flow switches 15-45 l/min 1 piece
028 1094039 Lengthening 2 piece
030 1097385 Glass Thermometer 0-160 C 1 piece
037 1143017 Heat Exchanger 1 piece 1143017_GEA BLOKS-

MA see chapter: Docu-
ments from Suppliers

68

042 1174043 Oil tank 1 piece



046 1007334 Washer 10 56 piece
053 1064006 Adjustable branch tee coupling 1 piece

69

062 1096117 Male Stud Coupling 1 piece


065 1029244 Reducing adaptor 1 piece 
066 1108051 Air filter G3/4 1 piece
068 1129459 Level Indicator 1 piece
069 1131503 Signboard 1 piece
081 1150218 Pipe 1 piece
082 1150219 Pipe 1 piece

70




087 1007334 Washer 10 4 piece

16 15 14 13 12 11 10 9 8 7 6 5 4 3 2 1
22 55 67 66 B 65 67 55 31 70,84 46 47 MA=68Nm 45 82 81 D
55 A
M M
Anordnung der Füllstandsanzeige
31 35
und Einfüllhöhe
siehe Zeichnung Ruderpropeller.
Position of the level-indicator
42 1
22 and fill level
see drawing Rudder-Propeller. 43
MA=560Nm
44
315
290
L L
285
68,69
85, 4 22
35,36 MA=68Nm 86, 3 18
87
30
34
°
K
9,10,11,12 4
K
MA=117Nm 28,30
1
4 5 55
70,84 56 54 53 55 77,78
35 13
23
MA=117Nm 3 22
6,7,8
J J
MA=34Nm
67 67
8,83 22 19 20,21 18 14 18 25 26 25 27,28,29 22 31

H H
MA=34Nm 2 2 2 2 2
1,2
Ausfuehrung: "Verrohrung KE"
version: " piping for KE"
G 77,78 77,78 50,51,52 G
D
C
73,74
F
22 24 41 40 37 41 40 24 F
22
22 Ausfuehrung: "Verrohrung Schlupfkupplung"

39 MA=68Nm version: " piping for slipping clutch" 5
60
61 22 48
35
E E
64
22
18
56
79,80
63 46,49
MA=68Nm
B C I A L
T
35
EN
22
ID
D D
N F
CO
56 Montagehinweis:
62 48 Alle Flanschflaechen mit Fluessigdichtung

Ident-Nr. 1058474 montiert.
75,76 Alle Schraubenverbindungen durch
Ident-Nr. 1048197 gesichert.
46,49 Mounting instruction:
C
22 79,80 All flange surfaces fitted using liquid sealant
C
MA=68Nm
ID no. 1058474.
All screw connections are to be secured using
59 ID no. 1048197.
1,5kW/480V-
1152678
57,58 60Hz/1710UPM
1,5kW/1,8kW-
B 1187003 1130158 B
50Hz/60Hz
Id.-Nr.
Schmierölssystem Id.-Nr. Pumpe Bezeichnung Pumpe
Id.-Nr. Id.-Nr. pump discription pump
lubrication system
+0.8
A A
Gepr. 05.01.2012 RossmannB
Schmieroelsystem kpl.
15 16,17 71,72 75,76 005 15/0170
004 14/1890
003 14/0564
AV 06.01.2012
Norm 19.01.2015
Abt. TKG
KensyC
DioufM
Lubrication system cpl.
MA=117Nm
A
002 13/0125 15.01.2013 KollmannK SCHOTTEL GmbH Zeichnungs-Nr. Index: 005 Format
001
000
12/2749
0000

07.11.2011 ErbarH
Name Urspr.:
Mainzer Strasse 99
D-56322 Spay/Rhein 1187003
Ers. f.: Ers. d.:
Bl.Nr.: 1
von 1 0
16 15 14 13 12 11 10 9 8 7 6 5 4 3 2 1
21. Change-Over Inline Filter
72
Part: 1185977

1181916 Servicing indicator 1 piece
1182087 Sealing KIT 1 piece

8 7 6 5 4 3 2 1
F F
Bezeichnung Filterfeinheit Abmessung A Teile Nr.

Denomination Filter-fineness Dimension A Part No.
Dichtungssatz 1182087
Sealink kit
E Leitungsfilter, umschaltbar 538 mm 1182463 E
Filterelement
25 µm 1177558
Filter insert
Leitungsfilter, umschaltbar
Change-over, inline filter 538 mm 1186972
Filter insert
D Leitungsfilter, umschaltbar 388 mm 1181388
D
A Filterelement
Filterelement
C C
Filter insert
Filterelement
10 µm 1187232
B Filter insert B
CAD-ZEICHNUNG Typ: SRP 1212 CP
+0.8
I AL
E NT
ID
ONF Leitungsfilter, umschaltbar

C AV
A Norm 10.02.2015 LauerI A
Abt. TTD Change-Over Inline Filter
000 0000 05.02.2015

SchulzF
Name Urspr.:
Mainzer Strasse 99
Ers. f.: Ers. d.:
Bl.Nr.: 1
von 1 3
8 7 6 5 4 3 2 1
22. Heat Exchanger
74
Part: 1143017

1143604 O-ring 82,22x 2,62 1 piece
1203968 Pass partition 1 set

1 2 3 4
Bezeichnung Denomination Teile Nr.

Part No.
Enddeckel Cover 1143536
E NTIAL Zinkschutzstab Zinc protector ROD 1143535
F ID
CON O-Ring 82,22x2,62 O-ring 82,22x2,62 1143604
Trennwand Pass partition 1203968
E
+0.8
Gepr. 09.02.2015 FaerberJ
AV
Waermetauscher, seewasserfest
Norm 10.02.2015 LauerI
F Heat Exchanger
Abt. TTD
000 0000 05.02.2015

SchulzF
Name Urspr.:
Mainzer Strasse 99
Ers. f.: Ers. d.:
Bl.Nr.: 1
von 1 4
23. Steam-Section sealing
76
Part: 1173246

001 1172929 Bushing 1 piece
004 1119319 Disk 2 piece
005 1138419 Ring 1 piece
012 1165864 O-ring 760,00x 5,00 1 piece
013 1122219 O-ring 610,00x 4,00 2 piece
014 1001478 O-ring 12,00x 3,00 1 piece
015 1093016 Gland Packing, Aramid 10X10 1 meter
016 1013858 Washer 10 4 piece

8 7 6 5 4 3 2 1
A
F
A-A F
177 ±0,1 7
E 9,10 25
B-B
96 5 C-C
56
6
15 MA= 82 Nm
11
B Z 13 2 1
E 16 3
E
E 2 2
B
890 E-E
D-D 8
780 f6 E
E
R7
20 MA= 82 Nm
605
D D
D
4
C
3
vorgspannt
14
prestressed
C
min. 0,9 mm Z C
D
Fügetemperatur 115°C
12 shrink temperature 115°C
C
KE signiert 1
A KE marked
T IA L
F ID EN
N
B B
C O
605 R7 -0,155 604,845
Montagehinweis: -0,225 604,775
780 f6 -0,080 779,920
-0,130 779,870
Alle Flanschflaechen mit Fluessigdichtung Ident-Nr. 1058474 montiert. Maß Passung
Alle Schraubenverbindungen durch Ident-Nr. 1048197 gesichert. der SCHOTTEL GmbH DIN ISO 16016 beachten
Zwischenraeume der Wellendichtringe mit Fett Ident-Nr. 1096549 gefuellt. DIN ISO 13715 DIN ISO 128 Schweisskonstr. DIN EN ISO 13920-C
Werkstoff:
-0.3
+0.8
A
Mounting instruction: Bearb. 14.04.2009 MudersS Benennung:
A
AV 22.06.2009 PechD
Trag-Steuerrohr-Abdichtung
All flange surfaces fitted with fluid sealing ID-No. 1058474 Norm 22.01.2015 DioufM Standard
003 15/0183 20.01.2015 KaulmannB Abt. TKG Steam-Section sealing complete
All screwed connections safeted by ID-No. 1048197 002 12/1121 14.05.2012 RossmannB SCHOTTEL GmbH Zeichnungs-Nr. Index: 003 Format
Spaces between rotary shaft seals filled with ID-no. 1096549 grease.
001
000
10/2364
Neuanlage
16.09.2010 ForsterF
20.07.2009 ChristD
Mainzer Strasse 99
D-56322 Spay/Rhein
Urspr.: 1171179
1173246
Ers. f.: Ers. d.:
Bl.Nr.: 1
von 1 2
8 7 6 5 4 3 2 1
24. Propeller components
78
Part: 1173061

001 1156622 Propeller Hub 1 piece
003 1017324 Hexagon socket screw plug 4 piece
005 1001454 O-ring 270,00x 4,00 1 piece
010 1137238 Net-cutter 2 piece
011 1013859 Washer 12 4 piece

8 7 6 5 4 3 2 1
12 A
MA=60Nm
11 2 A-A
660,50 5 4
F F
3 9
10
MA=300Nm 6,7
E E
705
D D
8 1 5
C 2,3 C
A N TIAL
FID E
C O N
IDENT-Nr. / IDENT-No. Bezeichnung / description
1190607 Propeller Anbauteile / Edelstahl
3
B 1173061 Propeller Anbauteile B
der SCHOTTEL GmbH
4 Montagehinweis/Mounting instruction: Manuelle Aenderung verboten !
Alle Flanschflächen mit Flüssigdichtung -0.3
+0.8
ID-Nr 1058474 montiert. Datum Name Modell-Nr.:
All flangs surfaces fitted with fluid sealing Bearb. 25.06.2009 ChristD Benennung:
ID-No 1058474. Gepr. 26.06.2009 BaldusM
Propeller Anbauteile
005 13/1587 12.06.2013 HoerschD AV 29.06.2009 PechD
A Alle Schraubenverbindungen durch 004 12/2880 07.11.2012 HoerschD Norm 14.06.2013 MalewskiD
Propeller components
A
003 12/2277 31.08.2012 BlassD Abt. TKG
ID-Nr 1048197 gesichert. 002 12/1006 17.04.2012 HoerschD Zeichnungs-Nr. Index: 005 Format
All screw connections safeted by SCHOTTEL GmbH
ID-No 1048197.
001
000
12/0388
Neuanlage
06.02.2012 HoerschD
29.06.2009 ChristD
Name
Mainzer Strasse 99
D-56322 Spay/Rhein
Urspr.: 1173060
1173061
Ers. f.: Ers. d.:
Bl.Nr.: 1
von 1 3
8 7 6 5 4 3 2 1
25. Hy-steering connection cpl.
80
Part: 1174074

007 1007505 Plate, Connection, Small -E- 1 piece
008 1007504 Plate, Connection, Small -D- 1 piece
009 1007506 Plate, Connection, Small -F- 1 piece

8 7 6 5 4 3 2 1
F
4 3 7,10 1 F
30
E E
853,50
30
8,10 782
18
18
D D
6 5 9,10 2
C C
B B
+0.8
AV 23.06.2009 PechD
HY-Steuerungsanschluss kpl.
A Norm 26.06.2009 MalewskiD A
Abt. TKG Hydro-Steering Connection
000 Neuanlage
23.06.2009 ChristD
Name Urspr.:
Mainzer Strasse 99
D-56322 Spay/Rhein 1174074
Ers. f.: Ers. d.:
Bl.Nr.: 1
von 1 3
8 7 6 5 4 3 2 1
26. Level Switch cpl.
82
Part: 1095792


8 7 6 5 4 3 2 1
Version A
17
Mit DELO gedichtet
F
Mit EFK-A gedichtet
tightened with DELO
ID-NRS: 1040106
F
switch point
Schaltpunkt
20
G
E E
38 101
4 9 10 1 2 7 5 3 8
17

D 17 D
4 9 11 12 10 1 2 13 7 17
switch point
Schaltpunkt
1209304 200 B 1 1/2" 25
1209243 170 A 1 1/2" 24

C C
1209231 970 B 1" 24 17
G
1204084 530 B 1 1/2" 23
ID-NRS: 1029100 16
1168750 700 B 1" 20 101
1166204 250 B 1 1/2" 19 A
Mit DELO gedichtet
1130898 311 B 1 1/2"
15
ID-NRS: 1040106 5 3 8
B
1115800 280 B 1 1/2" B
1115070 466 B 1 1/2"
1113535 150 A 1 1/2" TIA L
ID E N
1113534 320 B 1 1/2" C ONF
1113533 348 B 1 1/2"
1096421 133 A 1 1/2" +0.8
A A
1095792 231 B 1 1/2" 019 07/3056 11.12.2008 KaemmerlingR
024 15/0449
023 14/1346
13.02.2015 AntonB
Gepr. 24.05.1993 Wahl
AV 24.05.1996 Pech
Niveauschalter kpl.
Versionstabelle
015 06/0181 18.01.2006 ScherrW
013 01/0445KG 19.11.2002 DUE
019
018
07/3056
07/1820
Mainzer Strasse 99
D-56322 Spay/Rhein 1089883
Ers. f.: Ers. d.:
Bl.Nr.: 1
von 1 2
8 7 6 5 4 3 2 1
27. Intermediate shaft cpl.
84
Part: 1188944

001 1188943 Intermediate shaft tube273x11, 1 piece
004 1185993 Adapter Sleeves for Bearings 2 piece
005 1185994 Fixing Ring 2 piece
006 1164817 Synthetic Aviation Grease 2 kilogramm
007 1182099 High-performance grease 1 kilogramm

16 15 14 13 12 11 10 9 8 7 6 5 4 3 2 1
M M
0
3300 -2
367 2566 367 Z 2
8x 45° (=360°)
45°
8x 22,1 22,5°
W^ 2 X +0,10 22,5°
8x 22,1 0
A Y
8x
45

°
(=
L L
36
45
0°
°
48°
0
28
Z
28
W
0
0
27
27
0
48°
K K
70
e e
48°
48°
2 2
Loslager
moveable bearing
Schwerpunkt 1 Festlager
4x 30 H12 1
Center of gravity fixed bearing
510
4x 30 H12
ca.1655
J J
3312
H
X1:2,5 H
367 14
Y 1:2,5 367
14
Fettmenge fuer Erst- Bei der Montage mit Fett gefüllt!
befüllung = 1,1 kg
grease quantity for
6 4 3 2 To be filled with grease during
the mounting!
4 3 2 6 Fettmenge fuer Erst-
befüllung = 1,1 kg
DIN 931 Skt
M24x85 - 10.9 A
the first filling 1,1 kg grease quantity for MA=800Nm Lagereinbauvariante mit Distanzstück
the first filling = 1,1 kg Bearing application variant with distance piece
DIN 931 Skt
M24x85 - 10.9
MA=800Nm mit Fett gefüllt Anschläge und Stellbolzen
G filled with grease 7 7 mit Fett gefüllt
filled with grease werftseitig angebracht
stopper and bolts mounted and
G
gleitmo 585 M gleitmo 585 M 170
1182099 1182099 delivered by yard 75 Spannhülse werftseitig
clamping sleeve yard supply
20
MA=350 Nm
150 h9
150 h9
175 h7
175 h7
315
315
430
590
F F
Distanzstück werftseitig
distance piece to be
filled by the yard 12 Ueberall dort, wo eine Gefaehrdung von Mensch und Material
15
durch rotierende Teile moeglich ist, sind vom Anwender und/oder
0
Betreiber entsprechende Sicherheitsvorkehrungen zu treffen!
Befestigungsschrauben Der Einbau darf nur durch fachkundiges Personal durchgefuehrt werden!
170
170
werftseitig angebracht
Fastening screws to be delivered Where danger to people or material can be caused by
100 and mounted by the yard rotating parts, a safety device has to be installed by
Sprengring als Anschlag für Lagereinbauvariante mit Giessharz the user and/or operator!
Nabenflansch (M24, EN 24014-8.8)
240 Bearing application variant with cast resin MA=665 Nm The installation or parts of it is allowed only by specialists!
snap ring as a stop
for the flange hub Anschläge und Stellbolzen Beim Vergiessen sind die Vorschriften des
E 0 e e
0
werftseitig angebracht Giesharzherstellers zu beachten. 15 Gusssteiger
casting riser E
6 -0,20 22
5
22 6 -0,2 stopper and bolts mounted and
delivered by yard
At casting the instructions of cast resin
manufactorer to be observed.
20 Gissharz Einstellschrauben M24  Mit rotem Lack gekennzeichnet:
With red varnish color to sign: Engine side
cast resin werftseitig angebracht(nach dem
Markierungspfeile Vergiessen entfernen)
marking arrows Adjusting screws M24 to be delivered
Fundament
and mounted by the yard(remove Lagergehaeuse zur Welle r max. 0.5°
8 Markierungspfeile
marking arrows Sprengring als Anschlag für
foundation
after casting) Bearing housing to shaft r max. 0.5°
Anstatt der Silikonschnur einbauen Nabenflansch Spannhülse werftseitig
clamping sleeve yard supply Einbauvorschrift ID-Nr:1167641 beachten.
to be mounting instead of silikom- string snap ring as a stop for the flange hub Installation instruction ID-No:1167641 to be observed.
parting line
20 Trennfuge
0
15
Mit der angegebenen Fettmenge im Laengsschnitt Lager gefuellt.
Rest im Gehaeuse so verteilt, dass keine unbenetzten Oberflaechen
760
D mehr vorhanden sind! D
680
Fettmenge pro Lager = 1,1 kg
570
Bearing filled with grease as shown in view longitudinal section,
rest of specified quantity to be distributed in plumber black housing
so that all surfaces are covered!
Grease quantity per bearing = 1,1 kg
MA=350 Nm
Nach Montage der Zwischenwelle kpl. die Ringschrauben demontieren!
Befestigungsschrauben Ring screws by mounting to dismounted.
Giessrahmen werftseitig angebracht
casting frame Fastening screws to be delivered Lage der Fettaustrittsoeffnungen beachten!
Befestigungsschrauben and mounted by the yard Position of grease openings to be observed!
werftseitig angebracht (M24, EN 24014-8.8)
200 Fastening screws to be delivered min. 40 MA=665 Nm Welle und Flansche blank konserviert nach
C
and mounted by the yard Lagerungsplatte Konservierungsvorschrift ID-Nr.1033901. C
260 (M30, EN 24014-8.8) baseplate-bearing Shaft and flanges not to be varnished, preserved
MA=1350 Nm acc. preservation instruction ID-No.1033901.
380

nach den gueltigen Vorschriften der geforderten
Schiffsklassifikationsgesellschaft
Inspection certificate DIN EN 10204:2005-01 - 3.2
B B
ie ce
ep
anc
T I A L
EN
s t
di
0 150
ID
150 h9
k/
F
-0,1 149,9
ta nzs
tü c
CO N 175
Maß
h7 0
-0,04
Passung
175
174,96
Dis Dieser Entwurf ist geistiges Eigentum Schutzvermerk CAD-ZEICHNUNG

der SCHOTTEL GmbH DIN ISO 16016 beachten Typ: STP 1515
+0.8
n
esi
t r Bearb. 26.01.2012 LehmlerR Benennung:
cas
A A
/
Gepr. 26.01.2012 PickM
Zwischenwelle kpl.
arz
AV 27.012012 KensyC
h D315/2x3134/L3300
s s Norm 19.02.2015 MalewskiD
Gie Abt. AAZ Intermediate shaft cpl.

J=4,36026 kgm² 002 15/0131 14.01.2015 NoetzelK SCHOTTEL GmbH Zeichnungs-Nr. Index: 002 Format
c=2963,626 kNm/rad
001
000
14/3666
0000
17.12.2014

26.01.2012
NoetzelK
LehmlerR
Name
Mainzer Strasse 99
D-56322 Spay/Rhein
Urspr.: 1185986
1188944
Ers. f.: Ers. d.:
Bl.Nr.: 1
von 1 0
16 15 14 13 12 11 10 9 8 7 6 5 4 3 2 1
28. Cardan Shaft, cpl. 41-90
86
Part: 1189030

001 1129696 cardan shaft 41-90 1 piece 1129696_GEWES see

Suppliers
002 1100059 Flange, bulkhead seal 1 piece
003 1100080 V-Ring V- 220A 4 piece
004 1186333 Clamping band 4 meter
005 1162281 Buckles 16 piece
006 1186839 Angle 2 piece
007 1021548 Gewindebolzen M12 X 1000 2 meter
012 1007363 Lubricating Nippels Cone Type 1 piece
013 1162280 Screw joint 4 piece

16 15 14 13 12 11 10 9 8 7 6 5 4 3 2 1
M M
1050
653,50
A
E
L L
150
8x
45
150
45
°(=
°
3
60
°)
E
K K
16x22
40
0
,5°(=
22,5°
22,50°
360°
28
0
)
H7
315
315
175
13,5
J J
7
+0,50
0 W
22
H H
22,10
A SCHNITT A-A
Pos. 5 - 4x90°(=360°)
2 9 4,5,13
1
G G
12
Einbauzustand 3
Pos. 5 - 4x90°(=360°)
4,5,13 8
Installation condition
7 3 1
6 Ueberall dort, wo eine Gefaehrdung von Mensch und Material
10 11 durch rotierende Teile moeglich ist, sind vom Anwender und/oder
Betreiber entsprechende Sicherheitsvorkehrungen zu treffen!
Der Einbau darf nur durch fachkundiges Personal durchgefuehrt werden!
Where danger to people or material can be caused by
F rotating parts, a safety device has to be installed by F
the user and/or operator!
The installation or parts of it is allowed only by specialists!
Transporthalterung Pos10, 11, 12, 13 und 15 bei Endmontage entfernen!

Removal transportation device Pos.10, 11, 12, 13 and 15 before final
E
installation. E
Dichtungen Pos.10 gemaess Einzelheit Y montiert.

Sealings Pos.10 mounted according detail Y.
Welle und Flansche blank konserviert nach

Konservierungsvorschrift ID-Nr.1033901.
Shaft and flanges not to be varnished, preserved
acc. preservation instruction ID-No.1033901.
SCHNITT E-E
MAßSTAB 1 : 1
D D
Pos. 4 + 5 lose vormontiert.

Endmontage nach Einbau im Schiff gemäß Enbauvorschrift 1103800.
2 Satz Spannband und Spangen lose als Reserveteile.
Item 4 and 5 moveable to preassambled.
Final mounting on ship acc. to installation drawing instruction 1103800.
2 sets clamping bands and buckles loose as spare parts.
C C
T I A L
F I DEN
CON
Sechskantschraube M12 und
Gummidichtung kein SCHOTTEL-
B
Lieferumfang! B
Bolts and sealing yard supply!
175 H7 0,04 175,04

0 175
Maß Passung
DETAIL W
Werkstueckkanten Projektionsmethode 1 Allgemeintoleranz DIN ISO 2768-mK Massstab: 1:2.5 Gewicht: 306.00 kg
MAßSTAB 2 : 2.5
+0.8
Bearb. 01.02.2012 LehmlerR Benennung:
A A
AV 10.02.2012 KensyC
Gelenkwelle kpl.
Norm 27.01.2014 DioufM Flansch D 315-LZ1050
Abt. AAZ Cardan Shaft, Compl.
001
000
14/0284
0000
27.01.2014
01.02.2012
NoetzelK
LehmlerR
Name Urspr.:
Mainzer Strasse 99
D-56322 Spay/Rhein 1189030
Ers. f.: Ers. d.:
Bl.Nr.: 1
von 1 0
16 15 14 13 12 11 10 9 8 7 6 5 4 3 2 1
29. counter shaft
88
Part: 1129697
Änderungsnummer: 3D

005 1006967 Adapter Sleeves for Bearings 2 piece
006 1006968 Fixing Ring 2 piece
008 1164817 Synthetic Aviation Grease 2 kilogramm

12 11 10 9 8 7 6 5 4 3 2 1
A
Lagereinbauvariante mit Distanzstück
850 Bearing application variant with distance piece
584
H 150 c e H
Anschläge und Stellbolzen
e pie
260 werftseitig angebracht 50 nc
A  stopper and bolts mounted and dista
Spannhülse werftseitig /
delivered by yard
clamping sleeve yard supply st ück
nz
sta
12
Di
X MA=350 Nm
V 12
420
500
125 es in
as tr
G
Z Distanzstück werftseitig
distance piece to be rz/
c G
filled by the yard

Befestigungsschrauben
e ssha
werftseitig angebracht Gi
Fastening screw to be delivered
and mounted by the yard
Anschläge und Stellbolzen Lagereinbauvariante mit Giessharz (M30, EN 24014-8.8)
werftseitig angebracht Bearing application variant with cast resin MA=1310 Nm
150
stopper and bolts mounted and Beim Vergiessen sind die Vorschriften des
delivered by yard 205 Giesharzherstellers zu beachten. 15 Gusssteiger Einstellschrauben M24
At casting the instructions of cast resin 20 Giessharz casting riser werftseitig angebracht(nach dem
manufactorer to be observed. Vergiessen entfernen)
cast resin Adjusting screw M24 to be delivered
Fundament and mounted by the yard(remove Ueberall dort, wo eine Gefaehrdung von Menschen und Material
foundation after casting) durch rotierende Teile moeglich ist, sind vom Anwender und/ oder
F
3 2 3 Befestigungsschrauben Betreiber entsprechende Sicherheitsvorkehrungen zu treffen.
F
Der Einbau darf nur durch fachkundiges Personal durchgefuehrt werden!
20 Trennfuge
parting line
Festlager Loslager werftseitig angebracht
moveable bearing Fastening screw to be delivered
fixed bearing and mounted by the yard Where danger to people or material can be caused by
(M30, EN 24014-8.8) rotating parts, a safety device has to be installed by
the user and / or operator.
540
MA=1310 Nm
710
The installation or parts of it is only allowed by specialists!
125
MA=350 Nm  Mit rotem Lack gekennzeichnet:

With red varnish color to sign: Engine side
Spannhülse werftseitig
clamping sleeve yard supply Lagergehaeuse zur Welle ┴ max. 0,5°!
E Bearing housing to shaft ┴ max. 0,5°! E
Lagerungsplatte
Befestigungsschrauben baseplate-bearing Einbauvorschrift ID-NR:1167641 beachten!
Giessrahmen min. 40 Installation instruction ID-No:1167641 to be observed!
250 casting frame werftseitig angebracht
Fastening screw to be delivered
350 and mounted by the yard Mit der angegebenen Fettmenge Lager gefuellt, Rest im Gehaeuse
(M30, EN 24014-8.8) so verteilt, dass keine unbenetzten Oberflaechen vorhanden sind!
V 1 : 2.5 Bei der Montage mit Fett befüllen! X 1 : 2.5 MA=1350 Nm Fettmenge pro Lager = 1,4 kg
To be filled with grease, during

mounting! Z 1 : 2.5 Bearings are filled up with the specified quantity of grease, the rest
of grease to be distributed in plumber block housing so that all
surfaces are covered!
205 205 grease quantity per bearing = 1,4kg
D D
= = = = 8
Aufschubweg 9,5 0,5 x
22 45 Lage der Fettaustrittsoeffnungen beachten!
push up distance 146 ,5° °( Position of grease openings to be observed!
(25) =3
60
0 °)
8 -0,5 Nach Montage der Vorgelegewelle kpl.
+0,5 Ringschrauben demontieren!
138 0
Eye bolt dismounted after mounting
1:50 counter shaft complete!
A
Welle und Flansche blank, konserviert nach
Rz=6,3 M16 Konservierungsvorschrift ID-NR:1033901
C Shaft and flanges not to varnished to preserved C
acc. preservation instruction ID-No:1033901
Bezugsdurchmesser
reference diameter
125 h9
120
280
( 175 e7)
( 315)

nach den gueltigen Vorschriften der geforderten
Schiffsklassifikationsgesellschaft
123
Inspection certificate DIN EN 10204:2005-01 - 3.2

15° acc. to the rules of the demanded ship' classification society
°
0,57
2
4,27 22,10
B B
0,06 A
0,06 A 6
8 2
1 7 3 4 6 Fettaustrittsbohrung Dieser Entwurf ist geistiges Eigentum Schutzvermerk CAD-ZEICHNUNG
5 grease opening 5 4 3 8 der SCHOTTEL GmbH
Werkstueckkanten Projektionsmethode 1
Allgemeintoleranz DIN ISO 2768-mK
Massstab: 1:5
Typ: SRP 1010
Gewicht: 237.70 kg
Loslager ohne Festringe (POS. 6) +0.8
Moveable bearings without distance rings (POS. 6) Datum Name Modell-Nr.:
A Bearb. 27.11.2000 HoerschD Benennung: A
Bei der Montage auf 220 °C erwärmt!
Demontage mittels Oeldruck!
AV 01.12.2000 VolkJ
Vorgelege
Norm 12.04.2010 MalewskiD FL315/ D125/123 850Lang
For mounting flange heated up to 220 °C! J = 0,51563 kgm² Abt. TKN Counter shaft
Removel of flange by means oil pressure tools! 002 3D 06.04.2010 BoerschS SCHOTTEL GmbH Zeichnungs-Nr. Index: 002 Format
Nm
c = 2.806.126,9 rad 001
000
08/2700
Neuanlage
21.11.2008 BoerschS
19.11.2002 DUE
Mainzer Strasse 99
D-56322 Spay/Rhein
Urspr.: 1126681
1129697
Ers. f.: Ers. d.:
Bl.Nr.: 1
von 1 1
12 11 10 9 8 7 6 5 4 3 2 1
30. Hydro Measuring KIT
90
Part: 1073430
Drawing number:
Änderungsnummer:

001 1091090 Plastic Container, Empty 1 piece
002 1091091 Plastic Container, Insert 1 piece
003 1038016 Gauge adapter 2 piece
004 1046672 Gauge coupling 2 piece
006 1050384 Pressure gauge, w liquid filli 1 piece
007 1038012 Pressure gauge, w liquid filli 1 piece

31. Hydro-Aggregate
91
Part: 1183366

002 1111219 Oil tank NG 44 1 piece
003 1025658 Straight bulkhead connection 1 piece
005 1007521 Plate, Connection, Small -U 1 piece
006 1007523 Plate, Connection, Small -W- 1 piece
009 1033337 Sealing Cord 1 piece
010 1008073 Foot 4 piece
012 1085873 Filler filter 1 piece
013 1181217 Heat exchanger 1 piece 1181217_UNIVERSAL

HYDRAULIK GMBH see
Suppliers
014 1089883 Level switch cpl. 1 piece

92

018 1026903 Gasket DN 15 PN 6 1 piece
019 1068218 Round Washer for Wood 20 2 piece


020 1007016 Straight bulkhead connection 1 piece

022 1018273 Eye nut M 8 2 piece
023 1088603 Sealing Ring 1 piece
029 1001559 Spring Lock Washer B 10 4 piece
034 1043354 Stud M 8X 20 2 piece
037 1091267 Pipe Socket 1 piece
041 1007332 Washer 8 4 piece
043 1128440 Washer 42 2 piece

93

046 1011653 Sealing Rings 1 piece


048 1134547 Blanking plug 1 piece 

16 15 14 13 12 11 10 9 8 7 6 5 4 3 2 1
-2S1
Niveauschalter
level switch
M
36 35 14 25 36 35 47 M
46
-X4 1 2
22,34
L L
9
2
8
ca. 380
1
K 1 20 K
-2S1 3
17
30°
19
639
3
Hydraulik
616
18 23
Schaltpunkt
level switch niveau
min
J J
19 43
125 16,5l
29 44
min
499,65
4,11
43 hydr. oil
26
7 level
35-21,5 tief
deep
H 42 H
10
115
4
50
G G
45 21 5,16 15 11
Biegeradius min. R=420 120 140 281

Bending radius min. R=420
380
536
F F
E E
156
24
37
4,11
38
D
40,41 125
28-24,5 tief
6,16 D
deep Bemerkung / remark
Kühlwasser "Ein" G3/4"

48 Hy-Antriebsstation gut zugänglich und belüftet installiert.
130
Cooling water inlet G3/4"

Blau gekennzeichnet Max. Umgebungstemperatur 45°C.
Blue marked Hy-power pack has to be installed accessible and ventilated.
Max ambient temperature 45°C.
40,41
424
Schlauchleitungen vor dem Grundieren zwischen

den Einbindungen abgeklebt.
C C
Hose lines between the binds before
Kühlwasser "Aus" G3/4" priming masked with tape.
Cooling water outlet G3/4"
Rot gekennzeichnet
red marked Anstrich gemaess Anstrich-Spezifikation ID-Nr. 1099071-
27 2
RAL Farbton siehe Auftrag
painting acc. to painting specification id-no. 1099071-2
13 RAL color see order
Gesichert mit Loctite 245, ID-Nr: 1048197.
1 to fasten with Loctite 245, ID-Nr: 1048197.
B Aufkleben mit "DELO-GUM 3697" ID-Nr. 1040106, B

vorbehandelt mit Reiniger "LOCTITE 7063" ID-Nr. 1034072.
12 To stick on with "DELO-GUM 3697" ID-Nr. 1040106
I A L
after cleaned with "LOCTITE 7063" ID-Nr. 1034072.
DEN T
O N FI
525
C
Dieser Entwurf ist geistiges Eigentum Schutzvermerk CAD-ZEICHNUNG Typ: H 0
799 ohne Flüssigkeits-
DIN ISO 13715
-0.3
+0.8
standanzeige Oberflaechenangaben DIN EN ISO 1302 Rohteil-Nr.:
1183366 Datum Name Modell-Nr.:
without fluid level and Bearb. 08.03.2011 FahrC Benennung:
A temp. gauge A
mit Flüssigkeits-
Gepr. 10.03.2011 LembkeJ
AV 11.03.2011 KensyC
HY-Aggregat
standanzeige Norm 24.02.2012 MalewskiD 44L-EKM 514-D35/D28 M.Schaugl.
1183367 Hydro-Aggregate
with fluid level and Abt. TKS
Zeichnungs-Nr. Index: 001
temp. gauge SCHOTTEL GmbH Format
Pos 8
001
Teile Nr. 000 0000
12/0547
part no. Zust. Aenderung

23.02.2012
08.03.2011
Datum
KollmannK
FahrC
Name
Mainzer Strasse 99
D-56322 Spay/Rhein
Urspr.: 1097669
1183367
Ers. f.: Ers. d.:
Bl.Nr.: 1
von 1 0
16 15 14 13 12 11 10 9 8 7 6 5 4 3 2 1
32. Level switch cpl.
95
Part: 1089883


8 7 6 5 4 3 2 1
Version A
17
Mit DELO gedichtet
F
Mit EFK-A gedichtet
tightened with DELO
ID-NRS: 1040106
F
switch point
Schaltpunkt
20
G
E E
38 101
4 9 10 1 2 7 5 3 8
17

D 17 D
4 9 11 12 10 1 2 13 7 17
switch point
Schaltpunkt
1209304 200 B 1 1/2" 25
1209243 170 A 1 1/2" 24

C C
1209231 970 B 1" 24 17
G
1204084 530 B 1 1/2" 23
ID-NRS: 1029100 16
1168750 700 B 1" 20 101
1166204 250 B 1 1/2" 19 A
Mit DELO gedichtet
1130898 311 B 1 1/2"
15
ID-NRS: 1040106 5 3 8
B
1115800 280 B 1 1/2" B
1115070 466 B 1 1/2"
1113535 150 A 1 1/2" TIA L
ID E N
1113534 320 B 1 1/2" C ONF
1113533 348 B 1 1/2"
1096421 133 A 1 1/2" +0.8
A A
1095792 231 B 1 1/2" 019 07/3056 11.12.2008 KaemmerlingR
024 15/0449
023 14/1346
13.02.2015 AntonB
Gepr. 24.05.1993 Wahl
AV 24.05.1996 Pech
Niveauschalter kpl.
Versionstabelle
015 06/0181 18.01.2006 ScherrW
013 01/0445KG 19.11.2002 DUE
019
018
07/3056
07/1820
Mainzer Strasse 99
D-56322 Spay/Rhein 1089883
Ers. f.: Ers. d.:
Bl.Nr.: 1
von 1 2
8 7 6 5 4 3 2 1
33. Hy-Pump HPV135 cpl. -cw
97
Part: 1160796

001 1156876 Hy-pump HPV135-02 250BAR 1 piece
003 1098300 Flange, SAE 1 1/4-6000PSI 2 piece
005 1007340 Washer 20 2 piece
011 1143212 Straight reduction 1 piece
012 1106219 Temperature Switch cpl. 1 piece

98




028 1152674 Pressure switch 1,0-30,0 bar 1 piece
035 1007501 Plate, Connection, Small -A- 1 piece
036 1007502 Plate, Connection, Small -B- 1 piece
037 1007503 Plate, Connection, Small -C- 1 piece
038 1007508 Plate, Connection, Small -H- 1 piece
039 1065849 Signboard M1 1 piece

99



043 1065953 Signboard "M5" 1 piece
046 1156847 Base Plate 1 piece
047 1156849 Support, Pivotable 1 piece
050 1148953 Pressure switch 40,0-400,0 bar 1 piece
052 1039278 Change Valve 1 piece
057 1007329 Washer 5 2 piece
058 1089111 Stud bolt M 5 X 1000 2 meter
059 1147361 Plate 1 piece
060 1133195 Countersunk head screw M10X 2 piece

25

screw
100

063 1001478 O-ring 12,00x 3,00 2 piece
065 1122443 V-Belt Pulley HPV 135 1 piece



067 1002333 Lock Washer VS 10 8 piece
069 1007550 closure plug 2 piece
075 1026159 Washers for Clamping Devices 3 piece
077 1144537 Hexagon head screw M16X120 2 piece

16 15 14 13 12 11 10 9 8 7 6 5 4 3 2 1
Biegeradius min. R=240mm

Bending radius min. R=240mm
2 2 2 I
M
30 29 56-57-58 33 37-34 33 18 20 25 14 19 48 15 16 17 23 53 24 25 54 55 21 22 71 M
Ø28-16,5 tief
deep
SPB DIN 2211 724

vor dem Grundieren abgeklebt
before to primer to adhesived 53
L L
101
cw
K K
Biegeradius min. R=420mm

I
13 44 70
575
247
254
498
30
J J
Ø35-19,0 tief
225
95,10
deep
305
181
Ø30-26.5 tief
H deep H
114
60
1118
20
51 51
175
350
100 160
G G
400
300
1152
18 36-34 76-75 38-34 35-34 78 77 46 47 65 66-67
4-5 1 3 6 72 39-34 31-30-63 43-34 25 10 45 11 12 25 7 8 69
I
2 Biegeradius min. R=350mm
F F
1
3 4 5 6 7 8 9 10 14 15 16 17
41-34 42-30 31-32 30-63 40-34

1 1 2 1 2 1
1260 min.
1
1
-2S2 -2S3 2 -2S4 3
-2S5 2
L
3
160
T I A
DEN
-4Y1 -4Y2
FI
Hydraulik Hydraulik Hydraulik 30
N
Hydraulik
E druck
min
temperatur
max
Filter
verschmutzt
Druck
max Steuerventil Steuerventil C O E
max hydr. oil

min
hydr. oil filter
max
hydr. oil 59 60-61-62
17
hydr. oil steering valve steering valve
pressure temperature clogged pressure Bermerkung / Remark :
Hy-Antriebsstation gut zugänglich und belüftet installiert.
Max. Umgebungstemperatur 45°C.
Hy-power pack has to be installed accessible and ventilated.
1 -4Y1 -4Y2 1 Max ambient temperature 45°C.
D
Drehrichtungspfeil mit Befüllhinweis. D
rotem Lack angebracht. Vor Erstinbetriebnahme Pumpe mit Hy-Öl befüllen.
Direction of rotation Filling reference.
marked with red arrow. Fill pump with Hy-oil before first start.
-2S2 1
Schlauchleitungen vor dem Grundieren zwischen

500
den Einbindungen abgeklebt.

Hose lines between the binds before
-2S5 1 priming masked with tape.
C Anstrich gemaess Anstrich-Spezifikation ID-Nr. 1099071-2 C

RAL Farbton siehe Auftrag
painting acc. to painting specification id-no. 1099071-2
RAL color see order
Handnotbetätigung
Manual emergency operation
Ersatzfilterelement ID-Nr: 1055379

spare filter element ID-No: 1055379
B Einstellschraube für Förderstrombegrenzung B

Setting screw for oil flow limitation
Ventil- und Schaltereinstellung gemäß Hy-Plan, siehe Auftrag.

valve- and switch adjusting according Hy-diagram, see order.
589 CAD-ZEICHNUNG
-2S4 1 1 -2S3 Dieser Entwurf ist geistiges Eigentum Schutzvermerk
Typ: H 1212
+0.8
A
50 28 27 51 52 26 Datum Name
Bearb. 12.03.2007 LembkeJ
Modell-Nr.:
Benennung:
A
I
max. Druckschalter
I
min. Druckschalter
AV 13.03.2007 PechD
Hy-Pumpe HPV135 kpl.
Norm 02.03.2011 MalewskiD SWK-Kons-KLK+DS+TS-D35/D30/D28
max. Pressure switch min. Pressure switch Abt. THY HU-Pump HPV135 Compl.
002 11/0504 23.02.2011 LembkeJ SCHOTTEL GmbH Zeichnungs-Nr. Index: 002 Format
001
000
11/0226
Neuanlage
25.01.2011
13.03.2007
KollmannK
LembkeJ
Name
Mainzer Strasse 99
D-56322 Spay/Rhein
Urspr.: 1156846
1160796
Ers. f.: Ers. d.:
Bl.Nr.: 1
von 1 0
16 15 14 13 12 11 10 9 8 7 6 5 4 3 2 1
102
34. Temperature Switch cpl.

Part: 1106219

003 1081409 Adapter 1 piece

8 7 6 5 4 3 2 1
78 1 113 1
F F
1
1
178
207
E 35-21,5 tief E
35-21,5 tief
deep
deep
D D
2
112 4
C C
N TI AL
FI D E
CON
B B
+0.8
Bearb. 21.11.1994 Krämer Benennung:
Gepr. 21.11.1994 Nickenig
AV 22.11.1994 Arntzen
Temperaturschalter kpl.
A Norm 09.02.2011 MalewskiD D=35 A
Abt. TKN TEMPERATUR SWITCH
001
000
11/0298
Neuanlage
01.02.2011
19.11.2002
FahrC
DUE
Name Urspr.:
Mainzer Strasse 99
D-56322 Spay/Rhein 1106219
Ers. f.: Ers. d.:
Bl.Nr.: 1
von 1 3
8 7 6 5 4 3 2 1
104
35. Tools for SRP1515 N=1600

Part: 1154883
Drawing number:
Änderungsnummer:

000 1014649 High Pressure Pipe 3 piece

screw
000 1101395 Traverse 2 piece
000 1101426 Oil drain pipe 1 piece
000 1111962 Hydraulic Nut TR 300X 4 1 piece
000 1113864 Oil pump cpl. 3 piece
000 1124494 Pipe 1 piece
000 1127209 Toolbox 1 piece
000 1127235 Turn Handle 1 piece

105
36. Oil pump cpl.

Part: 1113864

001 1014976 Pump clamp 1 piece
002 1014648 Oil pump, hand 1 piece
003 1028030 Pressure gauge 1 piece

107
37. Inductive proximity switch cpl

Part: 1201109

002 1103745 Housing K 11 1 piece
003 1128350 Cable Gland 1 piece

screw
008 1070772 Washer 18 2 piece

8 7 6 5 4 3 2 1
Montageausführung:
Einbauvariante mit Zylinderchrauben
Einbauvariante mit Sechskantschrauben Mounted version:
F Installation Option with hexagon head bolt Installation Option with cap screw F
kein SCHOTTEL Lieferumfang Schaltabstand

no SCHOTTEL supply switching distance
kein SCHOTTEL Lieferumfang Schaltabstand Verstellweg

no SCHOTTEL supply 5 switching distance Adjustment 1
5
1 81 81
1
E E
25
25
1 4 1 4
20
6,7 52 6,7 25 Verstellweg
Adjustment
1 Ma= 2Nm
Ma= 2Nm
2 2
63
63
D D
3 3
PG 13,5 52
1:1
5 5
C C
9
5
brown brown
T I A L
B
I DE N B
blue blue
CO NF
black black

+0.8
Bearb. 29.11.2013 BaumannM Benennung:
A A
AV 02.12.2013 KensyCh
Naeherungsschalteranbau kpl.
Abt. AAZ Inductive proximity switch cpl.
001
000
14/0968
0000
31.03.2014
29.11.2013
NoetzelK
BaumannM
Name Urspr.:
Mainzer Strasse 99
D-56322 Spay/Rhein 1201109
Ers. f.: Ers. d.:
Bl.Nr.: 1
von 1 2
8 7 6 5 4 3 2 1
109
38. Spare Parts SRP+HY

Part: 1189406
Drawing number:
Änderungsnummer:

1001324 O-ring 30,00x 3,00 1 piece
1001351 O-ring 60,00x 3,00 1 piece
1001356 O-ring 65,00x 3,00 1 piece
1001406 O-ring 144,30x 3,00 1 piece
1001409 O-ring 150,00x 4,00 1 piece
1001433 O-ring 192,00x 4,00 1 piece
1001454 O-ring 270,00x 4,00 1 piece
1001478 O-ring 12,00x 3,00 1 piece
1001514 O-ring 285,00x 4,00 1 piece
1002213 Sealing ring A 21,0X 26,0 7 piece
1002218 Sealing Ring A 27,0X 32,0 1 piece
1002221 Sealing Rings A 36,0X 42,0 3 piece
1005989 Usit-Ring U34,3X43,0X2,0 1 piece
1007007 Equal tee 1 piece

110

1007106 Straight coupling 2 piece
1008062 Hose assembly 2 piece


1008065 Straight coupling 2 piece

1010956 Gasket 1 piece
1017324 Hexagon socket screw plug 4 piece
1026903 Gasket DN 15 PN 6 1 piece
1032497 Square Seal 14,70 x 2,62 1 piece
1033337 Sealing Cord 1 piece
1034175 O-ring 100,00x 5,00 1 piece
1055379 Filter 1 piece
1088603 Sealing Ring 1 piece
1117213 Disk 1 piece

111

1140579 Endless Narrow V-Belts 5 piece


1143604 O-ring 82,22x 2,62 4 piece
1146341 Rotary Shaft Seal 1 piece 
1181218 hose assembly, in oil 1 piece

112
39. Switch box cpl.

Part: 1201904
Drawing number:
Änderungsnummer:

1043807 Supporting BAR 1 piece
1053244 Switch box 800x1000x300 1 piece
1069768 Name Plate for Terminal ROW 16 piece
1085605 Busbar 1 piece
1098223 Fuse Holder 1 piece
1103169 Plug Socket 2Polig+PE 1 piece
1109851 Automatic Fuse B 6A 1P 10 piece
1115903 Amplifier 1 piece 1128284
1121638 Main Switch 2 piece
1121639 Cover Plate 2 piece
1121644 Auxiliary Switch 1 piece
1121646 Contactor relay 1 piece
1121648 Power switch 1 piece
1121651 Power switch 1 piece
1121721 Terminal ROW ZDU 6 10 piece

113

1121723 Terminal ROW ZDU 2,5 9 piece


1126105 AC DC Converter 1 piece
1126292 Diode Terminal 1 piece 
1126365 Terminal ROW PE 2 piece
1126367 Terminal ROW PE 1 piece
1126578 Cable Channel 37,5X75 1 piece
1126579 Cable Channel 50X 75,0 1 piece
1126580 Cable Channel 1 piece
1126581 Cable Channel 100X 75,0 1 piece
1126844 Holder for Terminal 31 piece
1128985 Comperator 1 piece
1130039 Terminal ROW 9 piece
1130219 Front bezel set 2 piece
1130223 Lens platic yellow 1 piece
1130224 Lens plastic red 1 piece
1130225 Lens plastic green 1 piece
1130230 Pushbutton actuator illuminate 3 piece
1130416 Protective cover 1 piece
1131114 Switching element 2S 3 piece

114

1133067 Diode Terminal 3 piece
1135768 Door Catch 1 piece


1139809 Fuse Wire Insert 4 piece

1141698 out lett for fan 2 piece
1148645 Isolation Amplifier Progr. 1 piece
1150424 Relay 5 piece
1150425 Throw-Over Relay 2 piece
1150430 Plug Socket 7 piece
1150432 Retaining clip for 1150430 7 piece
1151111 Undervoltage relais 1 piece
1151648 Bracket f. 1151646 8 piece
1153340 24V DC / DC Wandler 10A 1 piece
1154726 out lett for fan 2 piece
1155225 bus terminal 2 piece
1155226 digital input module 8xDI 3ms 0 piece
1155228 digital output module 8xDO 0,5 0 piece
1158756 Single-LED T 1 3/4 28V/14mA 3 piece

115

1159930 Resistor 1 piece
1161797 multiple terminal block 41 piece


1161920 Cable entry 1 piece 
1166167 Impulse storing relais 1 piece
1167520 Logik Modul control bus 2 piece
1167522 DCM RPM control 1 piece 1162900
1167524 DCM steering 1 piece 1162900
1167526 DCM for extern systems 1 piece 1162900
1167823 Feed line module 0 piece
1168411 DPV steering 1 piece 1162901
1170070 handle 1 piece
1170790 Relay Connection single-pole 15 piece
1172147 Ramp generator 1 piece
1174848 Converter bipolar 1 piece
1178231 Cable Channel 80X 100 1 piece
1178897 Support 3 piece
1179008 DPV NFU steering 1 piece 1162901
1179940 DCM indication 1 piece
1184645 Name Plate, -Schottel- 1 piece

100X100
1186019 cable set LCD display 2 piece

116

1187066 AC DC Converter 24V DC / DC 1 piece
1189826 CAN Gateway 1 piece


1192755 parameter list 1 piece

1193931 WAGO Warning unit 1 piece
1194625 LED Diode terminal green 1 piece
1202364 Indication display cpl. 1 piece 1187801

117
40. panel,main cab

Part: 1187218
Drawing number:
Änderungsnummer:

1025675 Hexagon nut M 4 8 piece
1066247 Spring Lock Washer 8 piece
1101794 Protecting hose 1 meter
1121726 Coverplate for 1121725 1 piece
1130139 Washer 4 8 piece
1154316 speed- Indicator 1 piece
1155994 Thrust Direction Indicator 1 piece
1168785 Control panel fix pitch PS 1 piece
1169693 interface module X1 1 piece
1169698 cable set X1 1 piece

118

1169701 cable set X3.1 1 piece



1170035 Copilot Unit 3 1 piece
1170073 mounting plate 1 piece
1170467 Panel fixed pitch 1 piece
1171571 Cable mounting bracket 1 piece

119
41. panel,main cab

Part: 1187219
Drawing number:
Änderungsnummer:

1101794 Protecting hose 1 meter
1154316 speed- Indicator 1 piece
1155994 Thrust Direction Indicator 1 piece
1168786 Control panel fix pitch, STB 1 piece

120

1169701 cable set X3.1 1 piece



1170035 Copilot Unit 3 1 piece
1170073 mounting plate 1 piece
1170467 Panel fixed pitch 1 piece
1171571 Cable mounting bracket 1 piece

121
42. Panel

Part: 1182230
Drawing number:
Änderungsnummer:

1043807 Supporting BAR 1 meter
1101795 Protecting Hose 1 meter
1163274 Panel warning unit 1 piece 1176151
1182229 labelling strips 1 piece

122
43. Spare parts, electric system

Part: 1190438
Drawing number:
Änderungsnummer:

1047533 Diode 3 piece
1130232 Mounting SET 1 piece
1133067 Diode Terminal 3 piece
1139809 Fuse Wire Insert 10 piece
1148645 Isolation Amplifier Progr. 1 piece
1150425 Throw-Over Relay 1 piece
1158756 Single-LED T 1 3/4 28V/14mA 5 piece
1167522 DCM RPM control 1 piece 1162900
1167524 DCM steering 1 piece 1162900
1168411 DPV steering 1 piece 1162901
1170790 Relay Connection single-pole 2 piece
1199323 Fuse Wire Insert 5X25/3,15F 10 piece

5. Documents from Suppliers
BLANK PAGE
Technical Description Edition 2007
Mounting, maintenance and repair of propshafts

with flanged universal joints
1. Recommendations
Assembly, disassembly, maintenance and repair of propshafts should be performed only by
qualified personnel. In addition, for repair work we recommend the use of original spare parts.
Our propshafts are supplied ready for installation and operation. All are lubricated, base
painted and the matching surfaces of the flanges are protected by an anticorrosion-oil-film,
which must be removed before assembling the propshaft into the powertrain.
The propshafts have been dynamically balanced to ensure perfect smooth running. The balance
plates attached to the drive shaft tubes or the joint drivers must not be removed as they are
essential for the vibration-free running of the propshaft. For the same reason, the joints must
not be exchanged with one another. When a propshaft is being installed care must be taken to
ensure that the engraved indicating arrows coincide so that the two joints are located within
one plane, as required for perfect motion.
Fig. 1 yoke
Marking arrows
If the rotating propshaft might be dangerous for its environment, safety-means should
be provided. This applies especially to propshafts rotating at high speed.
The propshaft should be set-up according to the installation instructions issued by the
final manufacturer. For safety reasons, propshafts used in hazardous environments
should be suitably guarded. High-speed propshafts should be guarded by safety
bands to avoid damage in the event of shaft release or fracture. The relevant national
regulations concerning industrial safety and protective efficiency are to be observed.
Dust and dirt adhering to the propshaft may deteriorate the balancing quality. Additionally, oily
dirt may ignite on hot surfaces of the propshaft and this dirt should be removed on a regular
basis. Under normal conditions the surface-temperature of propshafts should not exceed 70
centigrade (158°F). However, under unfavourable conditions the temperature may raise above
70 centigrade (158°F). In such cases please contact our application-engineers for discussing
means to lower the temperature.
During transport and storage, the propshafts should be handled carefully and be protected
against impacts and shocks in order to guarantee the balance quality. Propshafts should
preferably be transported and stored horizontally. Any neglect of these instructions may lead to
impairment of operation or a reduction in functional reliability.
CAUTION – Propshafts with length compensation may become separated at the slip
section causing damage to propshaft components and possible injury. Also universal
joints may tilt in handling possibly causing injury.
Propshafts should be stored in a dry atmosphere preferably in horizontal position and secured
from falling over or rolling.
Gelenkwellenwerk Stadtilm GmbH • Weimarische Str. 62 • D-99326 Stadtilm • Phone +49 3629 6400 • Fax +49 3629 800002 • [email protected] • www.gewes.de Page 1 of 5
Einbau und Wartung englisch – Edition 2007
2. Assembly
Before the propshaft is installed, the faces of the two flanges (shaft flange and connecting
flange) are to be cleaned, i.e. the faces and centring surface must be free of burrs, dirt, paint
and grease. The axial and radial run out tolerances admissible for the companion flange are to
be maintained, otherwise the correct running of the propshaft may be affected (Fig. 2 and
Table 1).
Fig. 2
Recommended radial run out K R Table 1
Radial axial
Speed tolerance
Run out Run out
rpm for d
KR KS
Up to
h8 0,15 0,18/100
500
500 to
h7 0,08 0,10/100
3000
More
than h6 0,05 0,07/100
3000
(KS is in relation to Ø100 mm)
Recommended axial run out K S
Both flanges are connected by means of hexagon bolts according or similar to ISO 4014 of
property class 10.9 and hexagon nuts according to ISO 7042-V of property class 10.
Not all types of our propshafts allow inserting the hexagon bolts from the joint end.
Particular attention should be given to tighten the flange connecting bolts in order to achieve
the necessary frictional torque transfer. Suitable wrenches are to be used. The specified
tightening torques are provided in our latest catalogue.
3. Maintenance
Propshafts without grease nipples are greased for life and therefore require no further
lubrication. If high pressure equipment is used for cleaning, it is important not to direct the jet
directly onto the seal.
For propshafts fitted with a tape red grease nipple (acc. to DIN 71412) or flat grease nipple
(acc. to DIN 3404) it is possible to lubricate the joints with a grease gun (see Fig. 3).
Fig. 3
Joint relubrication spline relubrication
The grease nipples must be cleaned before a grease gun is applied. The 4 bearings of each joint
are lubricated by one central grease nipple.
Complete lubrication is achieved when grease can be observed coming from the bearing seals.
For shafts with regreaseable shaft length compensation, 10 - 40 g of grease should be sufficient
depending on shaft size.
Grease guns must be operated smoothly, at pressures not exceeding 2 MPa to prevent any
damage to the seals.
Regreasing is necessary after cleaning with high pressure equipment. It is important not to
direct the jet directly onto the seal.
Suitable lubricants recommended:
Lithium complex greases of specification KP 1-2 N-30 or KP 2 N-20 DIN 51502
with EP additives.
No greases containing MoS2 or other solid lubricant additives to be used for the joint
bearings as well as sliding part.
When the application temperature limits exceed the normal range of +80°C to -25°C (+176oF
to -13oF), special-purpose greases of the above- mentioned specification should be used.
For general applications, the following directions are recommended:

Propshafts employed in: Maintenance interval
Road motor vehicles 50,000 km (31,000 miles) or 1 year
Off-road motor vehicles 30,000 km (18,500 miles) or 1 year
Off-road motor vehicles in building sites 10,000 km (6,200 miles) or 250 hours
Rail vehicles 3,000 hours or ½ year
Stationary plant 500 hours
Marine drive lines 1,500 hours or ½ year.
Shorter maintenance intervals will be required where the propshafts are operated in extremely
adverse conditions. The maintenance intervals of the propshafts in special applications are to
be agreed with the final customer (OEM).
Propshafts taken out of pro-longed storage (6 months and more) should be lubricated before
being installed.
4. Repair
Only qualified and experienced technicians should repair or assemble propshafts as poor
workmanship and improper procedures may cause malfunction due to excessive wear, heat, or
vibration.
The propshafts can be reconditioned with the aid of simple auxiliary tools, as the joints can be
completely disassembled and the length-compensating attachment can be exchanged.
The principal points of wear are:

Joint bearing:
¾ Visual inspection: Perceptible play in the bearings, damaged sealings
¾ After disassembling: Wear marks and indications of pitting on the bearing surfaces;
damaged rollers; worn sealing,
Sliding part:
¾ Visual inspection: Perceptible play permitting twisting and/or tilting; damaged sealing;
damaged sealing area of the hub (if coated then coated with RILSAN®)
¾ After disassembling: Indications of pitting at profile flanks and at the head periphery;
damaged sealings, damaged coating of the hub/ splined shaft, corrosion.
4.1. Replacing the journal crosses
Pay attention to clean surroundings to avoid any dirt or dust intruding in the bearings to be
assembled, and to a smooth surface of the bore for the bearing.
4.1.1. Closed bearing eye

Because the bearing bushes cannot be removed completely out of the bearing eye (because of
interference with the cross and claw), in a first step the two opposite bearing bushes of the fork
of the weld yoke will be removed half way. Thereafter by applying the ring as shown in fig. 4
or by inserting of discs the complete removal of the bearing bushes can be done. At this
disassembly some damage at the bushing or the plastic disc at the bottom of the bushing may
occur. In this case these parts have to be replaced anyway.
If you still cannot take off the bearing bush by hand after pressing it out half way, you may tap
the yoke ear lightly for loosening the bearing bushing.
The disassembly of the two bearing bushes of the flange yoke follows the same procedure as
described above. (Fig. 5)
Fig. 4 Fig. 5
Press Press
flange sleeve adaptor ring
flange sleeve
journal cross
protection
cover
Auxiliary tool Auxiliary tool
The bearing bush must not be canted while it is being pressed in, it should be seated firmly in
the bore of the flange yoke. The locking rings must fit snugly into the ring grooves provided.
To avoid any deformation, the flange yoke should be supported during the push-in operation, if
possible. Any adjustment necessary to take-up any play in the joints or lack of concentricity
should be carried out at the same time (permissible tolerance +/- 0.05 mm). Play and press fit,
are compensated for by using locking rings of different thickness. The joint must be smooth
moveable to avoid too much friction and heat during operation, by which the joint may fail
prematurely.
4.1.2. Split bearing eye ( bolted yoke)

On joints with split bearing eye bores the bearing caps should be slackened to allow removal of
the cap. After the 2 bearing caps have been removed, the spider, including the bearing sleeves,
can be separated from the yokes.
Note! Bearing caps and yokes are in pairs and therefore must not be interchanged or mounted
in a different position during reassembly (you may mark them differently before disassembly
for this purpose!).
The complete cross will be assembled by inserting it in the yokes and putting the caps on the
yokes. The caps have to be tightened to the yokes with new proper screws applying the
prescribed torque.
To achieve the right backlash you may either use discs of different thickness at the bottom of
the bearing bush ring segments of different thickness, which keep the cross concentric to the 2
claws. The joint must be smooth moveable to avoid too much friction and heat during
operation, by which the joint may fail prematurely.
4.2. Slip assembly

Disassembling and remounting entails experience and craftsmanship besides appropriate
equipment, especially in welding and balancing.
In a first step the tube and the profiled part have to be separated by removing the weld seam on
a lathe (Fig. 6). The profiled hub and shaft always have to be replaced together, because these
parts are matched individually as a unit.
Before welding the tube and profiled part make sure a perfect alignment of both parts, e.g. by
providing an interference fit.
Fig. 6 tool
Splined part centering
tube
The radial tolerance of the alignment should be within 0.5 mm.

After the welding operation this components (tube and profiled part) are put together with the
other profiled part. At this step it has to be observed, that the inner yokes have to be in the
same plane at a radial tolerance of max. 3°.
Thereafter the complete propshaft has to be straightened at a max. radial run out of 0.5 mm.
4.3. Balancing
Balancing too entails craftsmanship, experience and suitable equipment.
If not available, you may use our workshop or ask us for an authorized workshop near your
site.
After a repair (replacement of crosses or slip assembly) generally propshaft running at more
than 500 rpm should be balanced. Unbalanced propshafts may cause vibrations, which
jeopardize operators and can damage or destroy the propshaft itself and adjacent components
of the whole powertrain.
The balancing quality has been regulated by DIN ISO 1940 standard:
Balancing quality G 40 for propshafts for general applications
Balancing quality G 16 for propshafts for special applications
Gelenkwellenwerk Stadtilm GmbH

Weimarische Str. 62
D-99326 Stadtilm
Germany / Deutschland
Telefon: +49 3629 640 0
Telefax: +49 3629 80 00 02
Internet: www.gewes.de
E-Mail: [email protected]
Documentation 24 VC 1000 ! Warning!
as per drawing no. 91 03124 A00
Forward this manual to the person responsible
for Installation, Operation and Maintenance of
the product described herein. Without access to
this information, faulty Installation, Operation or
Maintenance may result in personal injury or
equipment damage.
Installation, Operation
and Maintenance of
Airflex® VC Marine
clutches
! Warning!
Use only genuine Airflex® replacement

parts. The Airflex Division of Kendrion
recommends the use of genuine Airflex
replacement parts. The use of non-genuine
Airflex replacement parts could result in
substandard product performance, and may
void your Kendrion warranty. For spare
parts orders, please contact Kendrion at:
Kendrion GmbH
INDUSTRIAL DRIVE SYSTEMS
Wilhelm Binder Straße 4-6
78048 Villingen Schwenningen
Telephone (0 77 21) 8 77 - 0
Telefax (0 77 21) 8 77 - 4 88
Seite 1 von 11 Betriebs- +Mon. 24VC1000, A00 englisch.doc

General
The Airflex clutch is a pneumatically operated and torsion-resistant clutch with cylindrical friction
surfaces. The clutch is intended for driving rudder propeller with fixed propeller in Z-arrangement.
The clutch has the job of transmitting the output of the diesel engine to the propellers in a power shift.
When the clutch is engaged, it takes up the acceleration of the transmission shaft and of the
propeller.
The slip time during the engagement operation can take several second because of the compressed
air control.
This matches the torque of the clutch to the rated torque of the driving engine, and the starting and
gear changing operations are performed without shock loads.
If there is no compressed air available for operation or if the clutch fails, or no torque is transmitted
and the remedial measures take to long, the emergency bolts (31) can be screwed in temporarily.
The parts are supplied loose and must be kept on board near the clutch. These bolts are rated for
transmission of half the rated torque when four of them are used.
Design and mode of operation
The clutch as per Fig. 1 has a bearing support and is designed to connect a u-joint with the input
gearbox shaft. It has a V-belt pulley to drive auxiliary equipment.
The hub is mounted on the input gearbox shaft by means of the oil injection method.

The basic part of each Airflex clutch is the clutch element (1) as shown in Fig. 2
Figure 2
As its operating element, it has an annular, elastic tube tire 2, which has a cross-section specially
designed such that no joints, levers or adjusting members are necessary for operation. In addition,
there are no parts running on gears, which are subject to wear in view of the changing torques.
There is no cylinder or piston provided with seals; operation is direct by pneumatic means, via the
tube tire 2 and the friction shoes 8 onto the friction drum (2).
The tube tire 2 placed in the rim 10 is made of high-grade Neoprene and reinforced by cord and
fabric. The tube tire 2 is used mainly for the generation of the contact pressure onto the friction shoes
8 and onto the friction drum (2) acting as the primary element. The tire is only slightly involved in the
transmission of the torque. The torque is largely transmitted by the torque rods 6.
The friction drum (2) is connected to the joint shaft, and the torque is introduced through it.
If the tube tire 2 is supplied with compressed air, the friction shoes 8 guided in the torque rods are
moved inwards in the radial direction, against the force of the spring 7, and pressed against the
friction drum (2). This produces the friction engagement.
The friction shoes 8 now transmit the torque via the torque rods 6 to the rim 10 bolted to the side
plate 11+12 and further via the flange plate (3), which in its turn is connected in rotation-proof manner
to the hub (10) and transmission shaft.
The compressed air is supplied through the hollow-bore transmission shaft to the clutch element (1)
by means of a rotor seal arranged to the end of the shaft.
From the transmission shaft, radial holes in the shaft, the hub (15) and the flange plate (3) assure the
air supply to the clutch element (1).

In view of the cylindrical friction surface, there is only one common friction radius in these clutches,
which affords major advantages when it comes to engagement operation compared with other
clutches in which the friction surfaces are arranged in different planes. In an engagement operation,
the inertia moments must be accelerated with a simultaneous increase in the propeller torque, which
can lead to heavy strain on the engine.
With Airflex clutches, it is possible to extend the slip times during engagement to several seconds
using the compressed air control system. This enables the clutch torque to be matched to the
operation torque of the engine. In addition, all clutch operations are performed without heavy shocks.
An acceleration time / slip time of 4 to 7 seconds can be regarded as normal. The maximum
permissible slip time is 10 seconds.
It must be noted that every engagement generates energy which must be absorbed by the clutch as
heat, which also affects the service life of the friction linings. Operations must therefore be with as
short time as possible. This slip time depends on the load to which the engine is subjected.
If the pneumatic control unit for clutch engagement are also supplied, the pressure build-up and the
pressure for gear shifting is already set, based on the clutch size and drive data, and recorded on a
data sheet. These values are based on experience from facilities already manufactured. The various
designs of drive system and the varying inertia moments may necessitate a correction of the set
values during commissioning or during a trial run. In this respect, please refer to the description of the
control unit.
The operating sequence in an engagement operation is generally as follows:

• Starting of the engine at idling speed with the clutch disengaged. A slight increase in the idling
speed that may necessary for operational reasons is possible. The maximum engagement speed
or idling speed is nL =500 rpm. The engine or drive control system must be designed such that an
engine speed increase is not possible during the starting or slip process
• Engagement of the clutch
• After completion of the engagement operation and attainment of the operating air pressure,
further operation is at the engine speed suitable for the slip control system provided and the
intended operation
Working with come home bolts

If there is no compressed air available for operation as if the clutch fails, or no torque is transmitted and the
remedial measures take to long, the emergency bolts (31) can be screwed in temporarily.
By using 4 come home bolts half of the nominal torque can be transferred.
Half of the nominal torque is reached by a reduction in revolutions according to the table below
Rated engine input speed Max. rpm for clutch with working on come home bolts
rpm rpm
750 530
900 630
1000 700
1200 840
1500 1060
1600 1120
1800 1260

Assembly
The clutch is designed such that the internal bearings are a single unit, which is slid into the output
end hub mounted on the transmission shaft and then fastened there. The hub (10) is mounted on the
transmission shaft using pressurised oil.
For this reason, the clutch is supplied in the following parts:
hub (10) with bolted flange plate (3) as a single unit.
bearings as a unit with bolts (27), nuts (28) and spring washers (29)
friction drum (2) with bolts (25) and spring washers (26)
clutch element (1) with bolts (14), nuts (15) and spring washers (16)
Assembly sequence
- Mount the hub (10) with the bolted-on flange plate (3) onto the tapered transmission shaft stub
using pressurised oil.
Please pay attention to the fitting length as shown in drawing.

- Slide the bearing unit into the hub (10) and fasten it with the parts (27/28/29). Please comply with
the bolt tightening torque’s given in the drawing.
- Slide the clutch element (1) into the centring device of the holes for air supply are above one
another and that the seals ⑤ in the clutch element are in the right position.
Fasten the clutch element (1) to the flange plate (3) using the parts (14/15/16).
Please comply with the bolt tightening torque’s given in the drawing.
Pressing together the seals ⑤ produces a pressure – tight connection between the flange plate
and the clutch element.

Slide the friction drum (2) onto the centering device of the shaft (7) of the bearing unit, and fasten it
with the parts (25/26).

Commissioning
Before starting with the clutch, it must first be operated with compressed air while stationary and
all screw and pipe connections must be checked for tightness.
Check also whether the pressures build up and the pressure for gear shifting matches the values
stated in the data sheet.
The set values of the first pressure stage are values calculated on the basis of the clutch size and
the drive data and derived from previous operations.
If the engine is subjected to excessive load during engagement, this can be rectified by
prolonging the pressure increase time.
The data sheet has an attached graph in which the gearshift air pressure can be read off as a
function of the clutch torque for various engagement speeds, in order to obtain a better
adjustment to the engine torque in the first pressure stage.
The stated torque rating of the clutch will be after a certain “wear in” period.
The friction material will after little wear, have to get the same shape as the drum
surface to achieve full contact.
In order to avoid overheating and damage to the clutch parts it will be necessary to follow the
wear in procedure before running at stated torque ratings.
This wear in procedure could be followed during the sea trials.
The air pressure will have to be reduced to 4 bar. The clutch will now have to be engaged while
the diesel engine is accelerated to approx. 80 % of it’s rated speed. The clutch will have to be
disengaged immediately to keep the slip period as short as possible (max. 6 seconds).
The procedure has to be repeated 8 – 10 times.
For safety reasons the temperature rise will have to be checked.
We recommend measuring the temperature in the middle and edge of the drum surface.
The temperature should not exceed 120 degree C.
When this temperature has been reached, a cool–down period must follow. The wear–in
procedure can be continued once the clutch parts have cooled down to approx. 40 degrees C.
After completion of the above described wear-in procedure the air pressure will have to be
adjusted to 10 or 10,5 bar. The exact pressure can be found on the diagram in the control cabinet
or in the operating manual, paragraph 4 “Control unit”.
We recommend to continue the check on the temperature during the continued sea-trial at full
power.
Possible slip should be detected, preferably by means of a Stroboscope otherwise visually.
If during the full power test an undesired temperature increase or slipping of the clutch occurs,
then the test will have to be interrupted with another 3-5 wear-in engagement as described above.
This should only happen when the initial wear-in procedure was insufficient.

Maintenance
No direct maintenance or readjustment work is required on the clutch, but only checks are made,
which relate mainly on the condition of the friction linings and the tightness of the pneumatic units.
Thanks to the design of the clutch element with the tube tyre as an actuating element, abrasion
on the friction linings is automatically compensated
The checks therefore relate mainly to the abrasion on the friction linings, to the condition of the
friction drum surface and to the external effects of foreign matter, such as oil, grease, paint, water
and solid objects that can become embedded in the friction linings.
Since wear on the friction linings occurs only during starting operations, it is not possible to state
any number of operating hours after which new friction linings must be fitted.
The continual checks on the clutch and pneumatic unit for tightness must take into account for the
time intervals of the drive system.
The bearing unit of the clutch is filled with grease.
Relubrication is not necessary. The service life of the bearing unit can be calculated on the basis
of the assumed operating conditions, so that the bearing unit must be checked after 15 000 hours
of operation or after 4 years.
Please refer to the information on the drawing.
The condition of the clutch element and of the friction drum must also include in this time-based
check.

Changing the Friction shoes, Fitting New Friction Linings,
Dismantling the Bearing unit
The friction shoes must be changed or new friction linings must be fitted when the linings have
been worn down to their minimum thickness.
The minimum friction lining thickness depends on the clutch size, and is stated in the following
operating and maintenance instructions for EATON Airflex marine clutches and brakes. These
instructions also describe in detail how to change the friction shoes and to fit new friction linings
and a new tube tyre.
The minimum diameter of the friction drum is also described. To fit new friction linings, friction
shoes or tube tyre, the joint shaft, the friction drum (2) and the clutch element (1) removed.
The further procedure for removal is as follows:
Remove the friction drum (2) from the shaft (7)
Place a loop around the clutch element (1) and pull it slightly taut using the lifting device.
Remove the screw connection parts (14/15/16) at the connection between the clutch
element (1) and the flange plate (3).
Force the clutch element (1) out of the centering device of the flange plate (3).
Move the clutch element (1) axially until it is free and then set it down.
Remove one side plate 11 from the clutch element (1).
Please ensure that the two seals 6 in the front plate are not lost. The insertion of new sealing
rings is recommended when doing this kind of maintenance work.
The friction shoes 8 with the torque rod 6 and spring 7 can now be removed as one unit.
For rapid replacement of worn parts, it is also possible to change the complete friction shoes and
then replace the friction linings at leisure.
It is however also feasible to provide the removed friction shoes with new linings and then put
them back into place.
The first option is however the on taking the least time.
Clean all parts, if necessary by blowing them out, and check the condition of the tube
tyre 2
Insert the torque rod 6 and the spring 7 back into the friction shoe 8 and then insert the
complete unit the side plate 11.
Place the side plate 11 onto the rim 10 and insert the pins of the torque rods into the holes of
the side plate.
Fasten the side plates 11 to the rim 10 again. Ensure that the holes to hold the seals 5 are in
the right position, and force the seals over the pipe.
The clutch element (1) is then assembled in the reverse sequence to that used for dismantling.

Changing the ball bearings:
Remove the friction drum (2) from the shaft (7)

Remove the joint shaft from the friction drum (2).
Remove the clutch element (1) from the flange plate as described above.
The clutch element (1) and the friction drum (2) must be checked as to whether maintenance work is
needed.
Undo the screw connection (27/28/29).

Pull the complete bearing unit out of the hub (10)
Remove the endplates (9) and (11)
Press the shaft (7) downwards out of the bearing casing.
Remove the deep – groove ball bearing (22), which is designed as a movable bearing and axially
prestressed by the compression springs (12) and bolts (13).
Remove the bearing cover (5).
Press the deep – groove ball bearing (23) out of the bearing casing (4).
Clean all parts
Assembly of the bearing unit
Fill the cavities of the deep – groove ball bearings (22/23) with grease.
Please refer to the instruction on the drawing.
Press the deep – groove ball bearing (23) over the outer ring into the casing (4).
To lay the Ring (6) of the bearing (23)
Attach the cover (5) and secure the bolts (21) with a securing with adhesive.
Fit the casing over the shaft (7) and press the deep – groove ball bearing (23) onto the shaft (7).
Ensure that the ring (6) on the shaft (7) is in the right position.
Slide the bush (8) over the shaft (7).
Fill the cavity with grease.
Insert the springs (12) and bolts (13) into the holes.
Press the deep – groove ball bearing (22) over the inner and outer rings onto the shaft (7) and
into the casing (4)
Fasten the endplates (9/11) and secure the bolts (21/30) with adhesive.
Now assemble the bearing unit, the clutch element (1) and the friction drum (2) in reverse order to
that used for dismantling.

Seite 1 von 4 Betriebs- +Mon.allgem.Marine clutch, englisch.doc
Operating and Maintenance Instructions

for Airflex Marine clutch and brake
Important
In any correspondence regarding Fawick Equipment, always refer to the clutch or brake size
(diameter and with at friction surface) and the serial number stamped in the rim near the air –
connection.
Caution
Do not inflate the clutch or brake without having the friction drum aligned on the marching machined
drums, as otherwise this might result in severe damages of the Element assembly.
Air supply
To assure proper operating of the clutch and brake there has to be used clean and dry air.
The air may slightly contain oil as it may occur by the compressed air generator.
Contaminates of any type can quite seriously the life of the clutch and brake and also cause rotorseal
malfunction.
For most efficient operation all joints must be tight and free of leaks.
Working air pressure to actuate clutch or brake you can learn from the data sheets and (or ) drawings.
At compressed air checking you have to care, that a pressure of 10,5 bar does not be passed over.
Air lines
Air lines leading to the clutch / brake should be clean and free of foreign materials such as metal
chips, dirt, lubricants, paint ant joint compound. All pipe ends should be reamed after cutting so as to
assure the realpipe section not be reduced.
Maintenance and inspection
Fawick type “VC” Clutches and Brakes are completely self – adjusting and require very little
maintenance. Wear of the friction lining and friction drum is automatically adjusted.
This type clutches and brakes are so designed that there are no joints or levers required for the
control of the element assembly. The actuation is made direct pneumatically through the pipe and
friction shoes to the clutch- or brake drums. There are no metal or metal moving parts which have to
be lubricated.
Proper operating of the clutch or brake depends upon the gripping of high grade friction blocks
against a finely finished drum. Foreign materials, such as oil, grease, paint, water etc. or solids which
might embed into the friction blocks will greatly reduce the clutch / brake gripping capacity, and cause
abnormal drum wear. This might result in clutch / brake slip and unnecessary heat build – up.
With regard to the clutches this could mean a loss of power to the ship’s propeller and the connection
with the brake a prolongation of the braking time.
The clutch / brake must there fore be kept clean of any foreign material and should be inspected at
regular intervals for such foreign material.
If contaminates do get into the clutch / brake, they must be removed even though a major
disassembly might be required. Routine inspection of the clutch / brake is recommended, whereby
Inspectors should look for:
1. Contaminates by foreign material

Kendrion Binder Magnete GmbH • Postfach 12 20 • D-78002 Villingen Schwenningen • Telefon (0 77 21) 8 77 - 0 • Fax 8 77- 4 88
2. Conditions of friction linings and friction surface of drum

3. Leaks in air lines
4. Broken parts
5. Loose bolts and cap screws
6. Looseness between hub and shaft
Should the clutch / brake prove faulty during operation or during switching on, the following schedule
might be applied to find out the causes and correct the damage:
Type of malfunction Possible cause Correction

Slip of clutch /brake A. Low air pressure A. Increase to max. air
low torque pressure
High clutch / brake B. Foreign material in B. Clean completely
temperature or clutch / brake smoke friction surface C. Replace friction lining
C. Worn friction blocks
Slow engagement or disengagement A. Blocked air lines A. Clean or replace
B. Sticking quick release B. Replace
valves or 4-way valves C. Clean or replace
C. Embedment of foreign
material in friction
shoe
Should the clutch have a break – down i.e. fail to transmit power for one reason or another and the
correction require long dismantling, the emergency “come – home” bolts can be used until corrections
are made.
Friction Lining Replacement, Change of friction shoes and tube, Element Disassembly
Friction shoes with replaceable lining should be replaced when the friction material has worn down to
the minimum thickness allowable. Excessive lining wear can cause release spring breakage and
scoring of the friction surface of the drum.
Please refer to the following table with regard to the minimum thickness allowable of the friction
linings which need replacement. The minimum diameters allowable of the friction drum are also listed
therein.
Element New friction Minimum Type of fastener Min. diameter

size lining thickness thickness allowable of
(mm) allowable friction drum
11,5 VC 500 8 4 Rivets 290
14 VC 500 8 4 Rivets 353
16 VC 500 8 4 Rivets 404
20 VC 600 8 4 Rivets 505
24 VC 650 11 4 Rivets 607
28 VC 650 11 4 Rivets 706
33 VC 650 14 7 Rivets 833
37 VC 650 14 7 Rivets 935
42 VC 650 14 7 Rivets 1062
14 VC 1000 8 4 Rivets 353
16 VC 1000 8 4 Rivets 404
20 VC 1000 8 4 Rivets 505
24 VC 1000 11 4 Rivets 606
28 VC 1000 11 4 Rivets 706
32 VC 1000 14 10 Screws and nuts 808
Element New friction Minimum Type of fastener Min. diameter
size lining thickness thickness allowable of
(mm) allowable friction drum

In most installations the friction shoe assemblies can be removed and reassembled without removing the
element or drum.
In addition to this most clutches are so designed that the clutch element and friction drum can be moved in
radial direction without changing the basic design of the driving or driven parts.
1. Replacement of friction shoes or friction linings
1.1 Match mark the exposed side plate (11) and rim (10). Take out the bolts holding the side plate to the rim
(10) The side plate can then be moved away from the rim (10) and the friction shoes (8) be slipped out
from the element in axial direction, where as the torque bar (6) and the spring (7) remain in the friction
shoe (8).
1.2 The torque bar (6) and springs (7) can be knocked out of the shoes with a block of wood or soft metal
and can be re – installed in the friction shoe assembly after new linings have been added. Should the
friction shoe assembly be completely replaced, see points 3.2 and 3.3 of these instructions. With regard
to lining replacement of the friction shoe assembly proceed as follows:
1.3 Remove rivets or screw holding worn friction block (9) to the shoe assembly (8). New rivets, screw and
nuts are furnished with replacement friction blocks.
1.4 Clean the backing shoes.
1.5 Place the replacement friction block (9) on the backing shoe, set in the new rivet and drive the pin flush
with the head using a punch. Work from the centre of the lining out to the ends.
1.6 Friction blocks must be replaced in complete sets, never a few at a time.
1.7 With regard to mounting of the friction blocks and reassembling see paragraphs 3.2 and 3.3 of the
present Instructions.
2. Replacement of Actuating tube (2)
It is necessary to remove the element and to mark the rim, side plate and adapter plate.
Important:
When removing the element from the adapter plate (element with side air connection only) the air
connection gasket (5) might slip out of this position and has to be retained for re – assembly.
2.1 Loosen the sleeve and nut (3) and remove the elbow.
The element can then be dismantled per Paragraph 1.1
This exposes the actuating tube (2)
As in most cases brake – element assembly (3), air connection tube (4) and gasket (5) are not
incorporated from the adapter plate is not absolutely required.
3. Assembly
3.1 Fit tube (2) into position with valves inserted in the holes provided of the rim (10).
3.2 If relined friction shoes are used, torque bar (6) and spring (7) must be re inserted in the shoe
assembly.
The complete friction shoe assembly can now be re inserted in the element in axial direction, whereby
the bar is installed in the proper hole of the side plate.
3.3 Re – installing the combination is merely the reverse of the disassembly procedures.
Be sure when fastening the clutch element to the adapter plate the air connection gasket (5) be
returned to the proper position.
List of spare parts Airflex clutch- and brake-element type 24 VC 1000
item Drawing no. Part no. Pc. Description

1 142675 .. Element assembly with 2 side connection
2 404675 1 Tube
3 92 x 7 2 Elbow
4 308538 2 Air tube
5 72x12 2 Rubber washer
6 301831 10 Torque bar
7 301832 10 Spring
8 414598 10 Friction shoe assembly
9 414597 10 Friction linings + 110 pc.rivets, part no.130x72
10 404668-01 1 Rim
11 417234 1 Side plate
12 412158 1 Side plate
13 308539 2 Plate
Part no. 142675 TO ABS

Part no. 142675 TI GL
Part no. 142675 TN CCS
Part no. 142675 TH BV
Part no. 142675 DU DNV
Teil Nr. 142675 TR LRoS
Kendrion Binder Magnete GmbH Postfach 1220 78002 Villingen Schwenningen Telefon (07721)877 0 Fax 877 488
Airflex Part list Page 1/1
Partlist no. Index: DIN-A Description Drawing no.

91 03124A00 1 Clutch 24 VC 1000 91 03124A00
Item Pc. Part no./Drawing no. DIN-A Description Material/Supplier

1 1 142675.. 4) 1 Airflex element 24VC1000 1) Airflex
2 1 91 03124A00902 1 Friction drum 3) GGG40
3 1 91 03124A00003 1 Adapterplate 3) GGG40
4 1 91 03120A01004 1 Bearing housing 3) GGG40
5 1 91 03120A01005 3 Bearing retainer 9SMn28G
6 1 91 03120A01006 4 Ring C15 Mat.Nr.125038
7 1 91 03120A01007 2 Shaft 2) 42CrMo4V
8 1 91 03120A01008 4 Bearing spacer St35
9 1 91 03120A01009 3 Endplate 9SMn28G
10 1 91 03120A01010 1 Hub 3) 42CrMo4V
11 1 91 03120A01012 3 Endplate 9SMn28 Mat.Nr.102212
12 12 76 10116A00008 4 Spring
13 12 76 10116A00007 4 Pin 9SMn28K
14 16 M16x65 EN 24014 Hexagon screw 2) 10.9
15 16 A16 DIN 128 Spring washer
16 16 M16 EN 24032 Hexagon nut 2) 10
17 2 91 32116A01026 Washer
18 12 M24x110 DIN 912 Hexagon socket head cap screw 2) 10.9
19 12 M24 EN 24032 Hexahon nut 2) 10
20 12 A24 DIN 128 Spring washer
21 24 M8x30 EN 24017 Hexagon screw 8.8
22 1 6228/C3 Bearing
23 1 6230/C3 Bearing
24 4 M12x1,5 DIN 906 Pipe plug 5.8
25 10 M12x35 DIN 912 Hexagon socket head cap screw 8.8
26 10 12 DIN 7980 Washer
27 12 M16x80 EN 24014 Hexagon screw 2) 10.9
28 12 M16 EN 24032 Hexagon nut 2) 10
29 12 B16 DIN 128 Washer
30 8 M10x35 EN 24014 Hexagon screw
31 4 91 03120A01031 4 Drive screw 2)
32 1 90 70016A15 4 Rotorseal C2 Airflex
36 2 R1/4" Pipe plug
37 2 14x18x1,5 DIN7603 Copper washer
1) Inspection certificate USA

2) Inspections certificate 3.1 EN 10204
3) Inspections certificate 3.2 EN 10204
4) Complete part no. according to survey society
20.02.2001 Faller
Seite 1 von 3 Druckluftsystem.A14 engl..doc
Compressed air system

If a control unit is supplied with the clutch, this is described separately.
The data for air pressure and the pressure increase in the first stage are recorded on a data sheet.
The most common cause of damage to the clutch is excessive heat build up resulting from over –
long slip periods or too low an air pressure.
In addition, constructions in the pipe system, or compressed air containing impurities, can hamper
the free passage of air to the clutch.
It cannot be emphasised enough that a supply of clean air at a sufficient pressure is essential to
achieve good clutch control and actuation for satisfactory operation.
In addition, the pipe size of the supply lines is very important for fault–free operation of the clutch.
If this size is not specified, the nominal width of the rotorseal must take as the basis for the pipe
size.
It is important to use an elastic hose as a connector between the rotorseal and the stationary
piping. This prevents loads and tension from acting on the rotorseal.
The control unit must be arranged as close as possible to the rotorseal.
Fault-free operation of the control unit and the clutch can only be guaranteed when suitable
pneumatic equipment for air supply is provided in front of the control unit.
Fig. 1 illustrates this.

This illustration is only a general guide, further equipment for compressed air monitoring as
specified in operating and monitoring regulations may be necessary.
Attention: No further user are allowed to be connected between the connection: Reservoir 7 -
connection "A" Control unit and connection "B" control unit-connection rotorseal.
The equipment for air supply has the task of reducing the compressed air pressure to the clutch
pressure level and treating the air for the following pneumatic system.
Pipes, Lines, Screw connection
1. To obtain optimum operating conditions, the data in the drawing and figures with regard to
pipe dimensions must be complied with.
2. Pipe quality
The use is recommended of seamless-drawn medium-soft copper pipes that can be bent
without any further pre-treatment (e.g. copper pipe C-Fu F20 as per DIN 17671).
We would advise against the use of hard copper pipes, since these have to be filled with
sand or bent when hot in order to process them. the resultant contamination (scale) cannot
be completely removed from inside the pipes in all cases, leading in later use to incorrect
operation (e.g. due to leaking valve seats, increased friction and grooving).
Acid contact of the pipes must be prevented in any event, since the slightest acidic residues
can cause corrosion in the valves.
Pipes out of stainless steel may also be used.
3. Cutting the pipes to length
Cutting the pipes to the required length should be done with a pipe cutter. The resultant
burr must be removed using a suitable tool. The pipes must then be blown out using
compressed air to remove any chips that might have got inside.
4. Screw connection
The dimensions and types of screw connections needed must be selected to suit the
equipment and thread connections and the pipe dimensions.
In any event, only screw connections can be selected that on the one hand ensure a
detachable yet pressure – tight connection, and on the other hand keep the pipe absolutely
firm even under vibration stresses.
The use of soldered connections is not advisable for the reasons cited under 2. above.
Connecting threads must not be sealed with hemp or liquid dealing agents. Sealing should
be either with Cu or with screw connections having a sealing edge.
The compressed air is set at the pressure reducing valve 3 on the basis of the information on the
data sheet. The shutoff valve 1 is provided to switch off the compressed air supply.
In the “closed” setting, bleeding of the lines as far as the control unit should be possible.
A pressure gauge 8 with cut off cock 9 is to be planed for the air pressure display.
A suitable air reservoir 7 must be provided to ensure sufficient compressed air for gearshift
operations.
The non-return valve 4 prevents compressed air flowing back when the pressure drops in the feed
line.
A safety valve 5 as the pressure relief valve must be provided in order to protect the following
equipment from stresses due to excess pressure. A drainage valve 6 must be provided on the
reservoir to drain off any water precipitated from the air.
The filter 2 prevents impurities getting into the following pneumatic system.
Most filters also have a drainage feature. Assembly of the equipment for air supply must be carried
out at an accessible spot in the vicinity of the control unit.
Air treatment
1. Filtering
In most applications, filters have to fulfil two functions:
 retention of impurities
 drainage
The compressed air is filtered using sintered inserts.
2. Drainage
The water vapour present in the air means that compressed air is practically 100%
saturated when it leaves the compressor.
Any further cooling of this compressed air in the following piping system leads to water
precipitation.
Most of the water vapour condenses in the reservoir of the pressure generating unit.
Careful processing of the compressed air starts with regular drainage of this reservoir.
To drain off water precipitated as a result of further cooling, a filter 2 with drainage feature
must be provided.
After reduction to the clutch pressure level, the percentage of water vapour falls so steeply
in view of the volume increase that the compressed air now available for the pneumatic
system is practically dry. Experience has show that when drainage at the compressed air
generator and at the filter is poor, or the piping is unfavourably laid, water droplets are
drawn out of the generator.
Further water precipitation then takes place in the reservoir 7 and can be drained off
through the valve 6. Drainage at the valve 6 and at the filter 2 must take place at regular
intervals – if necessary daily.
3. Oiling
Installation of an oilier behind the pressure reducing valve 3 is generally not necessary,
since the compressed air is oiled in most compressed air generator. In addition, the number
of operations in marine drive units is low.
4. Temperature
The permissible application of the pneumatic equipment is generally between – 15°C and
+70°C, and is usually sufficient in most applications.
In the case of solenoid valves, a solenoid must be selected that is suitable for this
temperature range.
For all valves, the operating data of the manufacturer must be complied with.
5. Air reservoir
Clutch size Air reservoir size min.

14 VC 1000 30 dm 3
16 VC 600 Dual 40 dm 3
16 VC 1000 40 dm 3
20 VC 600 Dual 50 dm 3
20 VC 1000 50 dm 3
16 VC 1000/600 60 dm 3
20 VC 1000/600 80 dm 3
24 VC 1000 80 dm3
24 VC 1000/650 120 dm³
28 VC 1000 120 dm³
28 VC 1000 Dual 200 dm³
Page 1 of 4 Schalteinheit A14 englisch.doc
Control unit no. 90 78015A14 for Airflex clutches
The control unit is accommodated in a switch cabinet and must be located in the immediate
vicinity of the clutches or rotor seal.
The supply lines from connection "A" to the reservoir and from connection "B" to the rotor seal
must be installed on board.
The control unit has two functions to fulfil for the clutch:
1. Clutch operation with controlled pressure increase in two stages

2. Air pressure control
The clutch is actuated by a signal from the ship / drive control system via a 3/2-port solenoid
valve.
The valve is operated by two independent solenoids to ensure that the clutch remains in the
ENGAGED or DISENGAGED position (depending on the switching status) even in case of power
failure. The valve is arranged in such a way that signal application to connection 14.1 means
"Clutch ENGAGED" and signal application to connection 14.2 means "Clutch DISENGAGED". The
respective signal must be applied for  3 seconds to ensure that the clutch is "ENGAGED" or
"DISENGAGED".
The solenoids are designed for a rated voltage of 24 VDC  20% and for a 100% duty cycle.
The connector boxes feature LEDs which light up as long as voltage is applied to the respective
coil.
Clutch engagement is accomplished in two stages.

During the first stage, the pressure is increased gradually. This allows the clutch torque to be
adjusted to the rated engine torque for the acceleration process at the drive end. Generally
speaking, the acceleration time can be assumed to be 4 to 6 seconds.
The maximum permitted slip time is 10 seconds. This is crucial to ensure that all clutch operations
take place without shocks.
The time-dependent air pressure increase can be adjusted by means of an integral throttle check
valve.
The clutch change-over pressure is set on the integral 3/2-port directional control valve.
During the second stage, the pressure is increased rapidly until the operating pressure is reached.
The time required to accomplish this pressure increase depends entirely on the clutch volume, the
supply lines and the line cross-sections.
The time for the air pressure increase in the first stage up to the change-over can be assumed to
be 3 to 7 seconds.
The change-over to rapid pressure increase can be timed in such a way that the acceleration
process is completed before the rapid pressure increase takes place. This is crucial to avoid major
engine speed reductions.
The control unit also includes two pressure switches featuring an upper and lower switching point
with adjustable switching pressure difference.
Pressure switch 12 is used to control the supply air pressure.
As the air pressure increases (upper switching point), the contact closes to trip the warning
system.
If the air pressure drops (lower switching point), the contact opens. This function must be
integrated into the ship / drive control system or into the safety system so that a visual or acoustic
signal is tripped.
Kendrion Binder Magnete GmbH • Postfach 12 20 • D-78002 Villingen Schwenningen • Tel. +49 (0)7721 877-0 • Fax 877-488
Slip-free torque transmission is no longer ensured when the air pressure drops. This requires an
immediate reduction of the engine speed to  60%. In this case, the clutch must be disengaged if
this is possible without any safety risks.
Pressure switch 13 is used for the "Clutch ENGAGED" status display. When the air pressure
increases (upper switching point), the visual display contact closes.
When the air pressure drops (lower switching point), the contact opens and the display goes off.
Attention!
The clutch is still engaged. Risk of clutch slip in case of further pressure reduction.
Reduce the engine speed to idle speed. The clutch must be disengaged automatically if this is
possible without any safety risks.
The lower switching points of the pressure switches are adjusted in such a way that the supply air
pressure signal is applied before the clutch status display signal.
Check that the engine speed is not increased until there is no more clutch slip.
The upper switching point of pressure switch 13 can be used as signal.
The time setting of the pressure increase on the throttle check valve and the change-over
pressure setting on the 3/2-port directional control valve ensure a wide pressure range for the
clutch engagement setting. The pressure increase and change-over pressure are factory-set for
the specific clutch size and drive specifications. The pressure settings are specified in the data
sheet and are based on previous experience gathered with facilities implemented in the past.
Owing to the diverse designs of the drive systems employed and the varying inertia moments,
correction of the factory-set values may prove necessary during commissioning or test runs.
Change-over limit values: Pmin = 2.5 bar

Pmax = 4.2 bar
tmax = 7 sec.
In the case of the throttle check valve, clockwise rotation of the adjusting screw reduces the flow
cross-section to ensure slow pressure increase.
Counter-clockwise rotation of the adjusting screw enlarges the flow cross-section and provides
faster pressure build-up. The adjusting screw is secured by means of a lock nut and protection
cap to avoid accidental or unintentional adjustments.
In the case of the 3/2-port directional control valve, clockwise rotation of the adjusting knob
increases the change-over pressure, whereas counter-clockwise rotation reduces the change-over
pressure.
The adjusting knob can be turned and locked to avoid accidental or unintentional adjustments.
In order to make the desired adjustments, lift the adjusting knob, turn it and let it snap back into
place.
The fastest engagement time is achieved when the throttle check valve is completely open and
the 3/2-port directional control valve is set to the lowest response pressure for change-over.
Functional description
The pressure of the compressed air delivered by the air supply system is reduced to suit the clutch
pressure. Compressed air is supplied to connection A.
The compressed air is supplied as control air through the filter and enters the control block as
main air.
If an electrical signal is applied to connection 14.1 (connection 14.2 must be de-energised

electrically) of the 3/2-port solenoid valve, the valve is switched over, and compressed air is
delivered to output B on a time-dependent basis according to the set valves.
At the same time, this air pressure is delivered to the pressure gauge and the pressure switch 13.
The pressure gauge indicates the time-dependent pressure increase and the change-over point to
operating pressure.
The pressure gauge can be inspected after having closed the shut-off valve to interrupt the
compressed air supply.
The clutch is disengaged when an electrical signal is applied to connection 14.2 of the 3/2-port
solenoid valve 3 (connection 14.1 must be de-energised electrically).
The signal must be applied for  3 seconds to disengage the clutch. This ensures reliable bleeding
of the control lines. Clutch bleeding is accomplished directly on the control block by means of the
sound absorber 11.
The filter is used for the filtration of the compressed air and for the separation of condensate.
During filtration, solid particles and moisture are removed from the compressed air. The
condensate accumulating in the tank is discharged automatically.
The 3/2-port solenoid valve and the pressure switches 12 and 13 are wired to the terminal strip 14.
The electrical connections are shown in the circuit diagram and drawing.
Clutch operation in case of failure of the ship or drive control system
The 3/2-port solenoid valve is provided with a manual auxiliary actuator for the "DISENGAGED" or
"ENGAGED" positions in order to allow clutch operation even in case of power failure or failure of
the ship / drive control system.
In order to simulate a condition corresponding to that of the excited solenoid, push in the screw
head and turn it clockwise by a quarter rotation (time  3 seconds).
Attention! Manual actuation is permitted only when the system is stationary or when the
same engagement/disengagement conditions as for operation by the ship / drive control
system are given.
Pneumatikschema, Pneumaticschema,
Plan de montage pneumatique
Possible change-over settings, switching points of pressure switches

See drawing no. 90 78015A14 909, 90 78015A14 910 or 90 78015A14 911
Elektrikschema / Circuit diagram / Schema electrique
Airflex Part list page 1/1
Partlist no. DIN-A Description Drawing no.
90 78015A14 1 Control unit 90 78015A14

Item Pc. Part no. DIN-A Description Material/supplier
G1 1 SKS-1/2-02 Control module ATMOS
11 1 145406 DQ Muffler Airflex
12 1 940.2379-905 PVF 16 Pressure switch 1) Trafag
13 1 940.2379-905 PVF 16 Pressure switch 1) Trafag
14 1 90 78015A11100 4 Terminal block Weidmüller
15 1 B18-ML Male stud elbow St
16 1 RLDKO 18/15 Reducing connection St
17 1 SB15-RL Choke free Banjo Coupling St
18 2 K15-L Straight bulkhead connection St
19 15 x 1,5 Cu-tube SF-Cu DIN 1786
20 2 A6-RL wd Male stud coupling St
21 2 SBD 6-RS Swiveling screw fitting St
22 1 SBD 6-RL Swiveling screw fitting St
23 6x1 Stainless-steel-tube 1.4571
24 1 AE 1045.600 Terminal box Rittal
25 2 90 78015A14036 Cable assy.
26 1 SVRE-M Connection U.I.Lapp 52105010
27 1 M20x1,5 Hexagon nut U.I.Lapp 52103020
28 2 23 DIN 125 Washer St
29 1 VBDKO 6-L Adjustable male stud elbow St
30 1 90 78015A14035 Cable assy.
31 4 M5 x 1,8 Setnut St
32 4 M5 x 16 DIN 912 Hex.socket head cap screw 8.8
33 2 M5x12 DIN 933 Hexagonscrew 8.8
34 2 5,3 DIN 125 Washer Mat.no. 318011
35 2 M8 x 120 DIN 933 Hex.socket head cap screw 8.8
36 2 M8 Setnut St
37 2 8 DIN 7980 Spring washer
38 4 Ty 5K 3/5 HS Natur Base Hell
39 2 90 78015A14001 4 Bushing Al
40 1 VE RIT KL 1590.000 1 Fastener kit Rittal
41 1 90 78015A14034 Cable assy.
1) The forward brake over point of position 12 and 13 is adjusted according the technical specifications of each order
Airflex Partlist page 1/1
Partlist no. DIN-A Description Drawing no
90 78015A14100 Control module SKS-1/2-02 90 78015A14100

Item Pc. Part no. DIN-A Description Material/supplier
1 2 1834484050 Socket connector Form C - 9,4mm KA
2 2 SKS-1/2-02-06 3/2-Way-solenoid-valve 24VDC 1,2W
3 2 A820223011 5/2-Way valve M5
4 1 1827231039 Pressure gauge 0-16 bar
5 1 SKS-1/2-02-08 cutt of cock Ms G1/4
6 1 1829207070 Filter-application NL 4-5 μm
7 1 1827009613 Filer-fixation-application NL 4
8 1 1827000000 Muffler G1/8
9 1 1827009344 Box with condensate-drain fully automated
10 1 1823317003 Protective cap
1
2 8
4
5
3
10
6/7/9
Operating instructions
BKF0004EN
Gear pump KF 2,5...200
BKF0004EN_D0024710002-09
Englisch
2012-09-25
Table of Content
1 General points 5
1.1 About the documentation 5

1.2 Manufacturer´s address 5
1.3 Intended use 5
2 Safety 7
2.1 Safety instructions and symbols 7

2.2 Personnel qualification and training 7
2.3 General safety instructions 7
2.4 Hazard statements 8
3 Device description 13
3.1 General points 13

3.2 Basic construction 14
3.2.1 KF 2,5...200 R/L/B (with cover) 14
3.2.2 KF 2,5...200 R/L - D (with pressure relief valve) 16
3.2.3 KF 4...25 U (with universal valve) 18
3.3 Types of seals 22
3.4 Type key 23
3.5 Important special numbers 24
4 Technical data 25
4.1 General characteristics 25

4.2 Overview nominal sizes 26
4.3 Permissible speed 27
4.4 Overview materials 28
4.5 Operating pressure and fluid temperature 29
4.6 Dimensions 31
5 Transport and storage 32
5.1 Transport damage 32

5.2 Transport 32
5.3 Corrosion protection 34
6 Installation 35
6.2 Noise reduction 35
6.3 Definition of the direction of rotation and pumping 36
flow
6.3.1 KF 2,5...200 (with cover or pressure relief valve) 37
6.3.2 KF 2,5...25 U (with universal valve) 38
6.4 Change of the direction of rotation 39
6.5 Design of suction and pressure line 41
6.5.1 Suction line 41
6.5.2 Pressure line 44
6.6 Mounting the clutch 46
6.7 Mechnical installation 49
6.8 Assembly with further components and devices 52
6.9 Electrical connection 52
7 Operation start-up 53
7.1 Preparation 53
7.2 Pumps with liquid seal (quenching connection) 55
7.2.1 General points 55
7.2.2 Seal variants with liquid seal 56
7.3 Setting the pressure relief valve 57
7.4 Further operation start-up 59
8 Removal 60

8.2 Removing the pump 60
9 Maintenance 62

9.2 Unusual noise 64
9.3 Cleaning 65
9.4 Static seals 65
9.5 Confining fluid level 65
9.6 Rotary shaft lip seal 65
9.7 Mechanical seal 66
9.8 Clutch 66
9.9 Screw joints 66
9.10 Damage 66
9.11 Surface temperature 66
9.12 Bearing, gear, wheel chamber housing 67
10 Repairs 68

10.2 Troubleshooting 68
10.3 Elimination of damage 68
10.4 Return 68
10.5 Disposal 69
10.6 Detecting and eliminating problems 69
1 General points
1.1 About the documentation
These operating instructions describe the installation, operation and mainte-

nance of the gear pumps KF 2,5...200, also referred to below as the device.
The device is manufactured in different versions. Information about the ver-
sion concerned in the individual case can be found on the device's type plate.
The structure of the type designation and a more detailed description of the
individual series and nominal sizes can be found in the chapter 3 “Device
description” and in the chapter 4 “Technical data”.
If you have any questions about this operating manual, please contact the
manufacturer.
1.2 Manufacturer´s address
Kracht GmbH
Gewerbestraße 20
DE 58791 Werdohl
phone: +49 (0) 23 92 / 935-0
fax: +49 (0) 23 92 / 935-209
email: [email protected]
web: www.kracht.eu
1.3 Intended use
The device is a pump for continuous delivery of liquids. The various seal var-
iants and materials enable use with different media.
The device has been designed for operation with fluids. Dry operation is not
permitted. The medium must guarantee a minimum lubrication.
The medium must not contain any abrasive constituents.
Petrols, solvents, etc. are not permissible.
Use in explosive areas is not permissible.
The operator must guarantee that the medium to be conveyed is compatible
with the materials used in the device (see "Overview materials" in the chapter
4 “Technical data”). Chemical expertise is required for that.
The maximum permissible operating data listed in the chapter 4 “Technical
data” must always be observed.
BKF0004EN_D0024710002-09 2012-09-25 5
Deviations from the above-mentioned data and operating conditions require

express approval by the manufacturer and/or are specified on the type plate.
Type plates or other references on the device must not be removed nor made
unlegible or unrecognisable.
In cases of noncompliance, all warranty and manufacturer responsibility shall
be void.
6 2012-09-25 BKF0004EN_D0024710002-09
2 Safety
2.1 Safety instructions and symbols
The safety notices in these operating instructions are marked with caution
symbols.
Non-compliance can lead to hazards for people and the device.
In addition, the safety instructions are marked with signal words. They have
the meanings as explained below:
Caution: Identification of a low risk hazard, which could lead to minor or
medium bodily injury if not avoided.
Warning: Identification of a potential medium risk hazard, which would lead
to death or severe bodily injury if not avoided.
Danger: Identification of an immediate hazard, which would result in death
or severe bodily injury if not avoided.
Notice: Flagging of notices to prevent property damage.
Flagging of special user tips and other especially useful or important infor-
mation.
2.2 Personnel qualification and training
The personnel designated to install, operate and maintenance the device

must be properly qualified. This can be through training or specific instruction.
Personnel must be familiar with the contents of this operating manual.
2.3 General safety instructions
The operational safety of the device delivered is only guaranteed when it is

used for the intended purpose (see chapter 1 “General points”).
The limit values given must never be exceeded (see chapter 4 “Technical
data”).
National regulations concerning accident preventation and health and safe-
ty at work must be observed, as well as internal regulations laid down by
the operator, even of these are not specifically mentioned in this manual.
The operator must ensure that this operating manual is accessible to the
personnel responsible at all times.
BKF0004EN_D0024710002-09 2012-09-25 7
2.4 Hazard statements
DANGER
Danger due to breakage or squirting fluids!
Operating the device with impermissibly high pressure can lead to damage
to the device and to the up or downstream plant elements. Breakage can
lead to parts flying around uncontrolled or to fluids squirting out which can
lead to accidents and severe injuries or even result in death.
1. Never allow positive displacement pumps to pump against "closed
gates".
2. A pressure relief valve or other kind of over-pressure safeguard must
be installed as close as possible to the pump pressure connection. The
pressure relief device must be dimensioned so that entire delivery vol-
ume can be conducted through with the lowest possible pressure or
pressureless.
3. Do not put the device into operation without a pressure relief device.
DANGER
Using unsuitable connections and lines can lead to breakage. Parts flying
around uncontrolled or squirting fluids can lead to accidents with severe
injuries or even lead to death.
1. Use only connections and lines approved for the expected pressure
range.
2. The respective manufacturer's regulations must be heeded.
DANGER
Using damaged connections and lines can cause parts to fly around un-
controlled or fluids to squirt out, wich can lead to accidents and severe
injuries or even result in death.
1. Immediately replace damaged connections, pipes and hose lines.
8 2012-09-25 BKF0004EN_D0024710002-09
DANGER
Hazard caused by incorrect direction of rotation!
Operating the device with the incorrect direction of rotation can lead to
damage to the device and to the up or downstream plant elements. Break-
age can lead to parts flying around uncontrolled or to fluids squirting out
which can lead to accidents and severe injuries or even result in death.
1. Always pay attention to the correct direction of rotation when installing
the pump.
2. Always pay attention to the correct direction of rotation when connecting
the motors.
3. Secure the fitting keys against flying off when monitoring the direction
of rotation.
DANGER
Danger due to electric voltage!
Danger of death due to electric shock.
1. Follow the special safety regulations during all work on electrical instal-
lations.
2. Only allow electricians to work on electrical systems.
BKF0004EN_D0024710002-09 2012-09-25 9
WARNING
Hazard caused by rotating parts and fluid squirting out!
During all work on the device, rotating parts and squirting fluids can lead to
accidents and severe injuries or even result in death.
1. Depressurize all connection lines during all work on the device.
2. Depressurize or disconnect the driving motor during all work on the de-
vice.
3. Securely prevent the motor and device from restarting during work.
4. Wear suitable protective clothing.
WARNING
Danger due to hazardous fluid!
Danger of death upon contact with hazardous fluids and when inhaling va-
pours from these liquids.
1. Comply with the safety data sheets and regulations on handling the
hazardous liquids!
2. Collect and dispose leaks of hazardous materials so that no hazards
arise for people or the environment.
3. Comply with national and international rules at the place of installation.
WARNING
Hazard caused by rotating parts!
Rotating parts can cause accidents with severe injuries or result in death
due to body parts, hair or clothing getting caught or wrapped up.
1. Protect rotating parts (e.g., coupling and shaft ends) against uninten-
tional contact.
2. Close any maintenance openings when using bell housings.
3. Do not operate the device without safeguards.
WARNING
Danger due to exposed gears!
Gears can pull in and crush or cut off fingers and hands.
1. Do not reach into the gears.
2. Put the device into operation with connected lines only.
10 2012-09-25 BKF0004EN_D0024710002-09
WARNING
Danger due to falling and or loads falling over!
Due to the size and weight of the device, accidents can occur resulting in
severe injuries or death during transport and shipping.
1. Compliance with applicable industrial safety requirements is mandatory.
2. Use only suitable means of conveyance and lifting tackle with sufficient
load-bearing capacity.
3. Attach lifting tackle only to suitable points (see table 5.1 and table 5.2).
4. Attach the lifting tackle in such a manner that it cannot slip.
5. The device's centre of gravity must lie between the lifting tackle mount-
ing points on the device.
6. Secure the device so that toppling over and falling down is impossible.
7. Always avoid jerks, impacts and strong vibrations during transportation.
8. Never walk under suspended loads, never work under suspended
loads.
9. To prevent damage to the device, be extremely cautious when shipping
or transporting.
BKF0004EN_D0024710002-09 2012-09-25 11
CAUTION
Danger due to hot surfaces!
When operating the device with hot media, there is a danger of being
burned and scaled when touching the hot surfaces.
1. At medium temperatures above 60 °C, take measures against uninten-
ded contact.
2. Wear safety gloves.
CAUTION
1. At medium temperatures above 48 °C, let the device cool off.
12 2012-09-25 BKF0004EN_D0024710002-09
3 Device description
3.1 General points
KF series pumps are external gear pump types that work according to the
positive displacement principle.
When rotated, two gears being engaged with each other cause volume ex-
pansion by opening the tooth gaps in the pump inlet (suction side) so that the
medium can enter while a corresponding volume is being displaced in the
pump outlet (pressure side) through engagement of the teeth into the filled
tooth gap. Fluid transport takes place through entrainment in the tooth gaps
along the wall of the wheel chamber. The so-called geometric flow rate Vg is
being displaced per wheel rotation. A value that is stated in technical docu-
ments as rated volume Vgn to specify the pump size.
The actually delivered amount of liquid does not correspond with the theo-
retical value, it is being reduced through losses due to the necessary toler-
ances. The losses are less the lower the operating pressure and the higher
the viscosity.
Gear pumps are self-priming within wide limits. The displacement cycle de-
scribe initially takes place without exhibiting appreciable pressure build-up.
Only after setting external loads, for example, through delivery head, outlet
resistance, line elements, etc. the required working pressure will arise to
overcome these resistances.
As usual with so-called rigid pumps, i.e. non-axial play compensated pumps,
the lateral clearance between gear and front face has been set in such a way
that the maximum allowable operating pressure is managed in an adequate
and secure way.
The medium lubricates the pump's friction bearings and shaft seal. The
pump's operating life will be reduced if the medium contains abrasive ingre-
dients.
The shaft sealing pocket is connected to the pump's suction side. Therefore,
the max. permissible suction-side pressure is dependent on the type of seal.
Functional principle external gear pumps
pe = suction connection
pb = pressure connection
BKF0004EN_D0024710002-09 2012-09-25 13
3.2 Basic construction
3.2.1 KF 2,5...200 R/L/B (with cover)
* Direction of rotation "B" (clockwise and counterclockwise)
14 2012-09-25 BKF0004EN_D0024710002-09
Description
1. Cover 8. Retaining ring
2. O-Ring 9. Parallel key
3. Housing 10. Hexagonal screw
4. Driven shaft 11. Adapter sleeve
5. Driving shaft 12. Valve
6. Plain bearing bush 13. Adjusting washer
7. Rotary shaft lip seal 14. Retaining ring
See section section 3.3 “Types of seals” for further seal types.
BKF0004EN_D0024710002-09 2012-09-25 15
3.2.2 KF 2,5...200 R/L - D (with pressure relief valve)
16 2012-09-25 BKF0004EN_D0024710002-09
Description
1. Valve cover 10. Set screw
2. O-Ring 11. Hexagonal nut
3. Housing 12. Retaining screw
4. Driven shaft 13. O-Ring
5. Driving shaft 14. Compression spring
6. Plain bearing bush 15. Valve cone
7. Retaining ring 16. Adapter sleeve
8. Rotary shaft lip seal 17. Hexagonal screw
9. Parallel key
BKF0004EN_D0024710002-09 2012-09-25 17
3.2.3 KF 4...25 U (with universal valve)
18 2012-09-25 BKF0004EN_D0024710002-09
Description
1. Valve housing 14. Valve washer
2. Gasket 15. Valve cone
3. Adapter piece 16. Socket head cap screw
4. Plain bearing bush 17. Socket head cap screw
5. O-Ring 18. Rotary shaft lip seal
6. Driven shaft 19. Retaining ring
7. Driving shaft 20. Parallel key
8. Plain bearing bush 21. Cover
9. Housing 22. O-Ring
10. Roller bearing 23. Rod
11. Retaining ring 24. Compression spring
12. Hexagonal screw 25. Centering star
13. Retaining ring 26. Piston
BKF0004EN_D0024710002-09 2012-09-25 19
* View without connection elbow

** View without universal device
20 2012-09-25 BKF0004EN_D0024710002-09
Description
1. Hexagonal screw 15. Parallel key
2. Screw plug 16. Retaining ring
3. Gasket 17. Roller bearing
4. Socket head cap screw 18. Retaining ring
5. Connection elbow 19. Rotary shaft lip seal
6. Gasket 20. Housing
7. Socket head cap screw 21. Plain bearing bush
8. Rod 22. Driving shaft
9. Piston 23. Driven shaft
10. Valve cone 24. O-Ring
11. Compression spring 25. Cover
12. Valve housing 26. Valve
13. O-Ring 27. Adjusting washer
14. Cover 28. Retaining ring
BKF0004EN_D0024710002-09 2012-09-25 21
3.3 Types of seals
Types of seals KF 2,5...200
Pump with single rotary Pump with single rotary Pump with double rota- Pump with double rota-
shaft lip seal shaft lip seal and out- ry shaft lip seal with ry shaft lip seal for vac-
Fixing type: F / W board bearing connection borehole G uum operation with
Seal type: Fixing type: G / X 1/8 for liquid seal connection borehole G
1: NBR Seal type: (quench) 1/8 for liquid seal
2: FKM 1: NBR Fixing type: F / W (quench)
3: PTFE 2: FKM Seal type: Special number 74
9: EPDM 3: PTFE 4: PTFE Fixing type: F / W
23, 31: FKM (low tem- 7: FKM Seal type:
perature) 19: NBR 4: PTFE
32: EPDM 7: FKM
19: NBR
32: EPDM
Pump with triple rotary Pump with mechanical Pump with mechanical Pump without shaft
shaft lip seal for vac- seal seal and connection seal
uum and normal oper- Fixing type: F / W borehole G 1/8 (KF Fixing type: F / W
ation with connection Seal type: 2,5-25) or G 1/4 (KF Seal type:
borehole G 1/8 for liq- 5: FKM 32-80) for liquid seal 30: FKM (O-Ring)
uid seal (quench) 6: PTFE (quench) 36: NBR (O-Ring)
Fixing type: F / W 20: EPDM Special number 198
(on request) Fixing type: F / W
Seal type:
5: FKM
22 2012-09-25 BKF0004EN_D0024710002-09
3.4 Type key
Ordering example KF 2,5...200

KF 40 R F 1 /... - D 15 - ...
1. 2. 3. 4. 5. 6. 7. 8.
Explanation of type key KF 2,5...200

1. Product name
2. Nominal size
Vg Size 1: 2,5; 4; 5; 6; 8; 10; 12; 16; 20; 25 cm3
Size 2: 32; 40; 50; 63; 80 cm3
Size 3: 100; 112; 125; 150; 180; 200 cm3
3. Direction of rotation
R Clockwise B Clockwise and counterclockwise
L Counterclockwise U Universal (Direction of rotation clockwise
and counterclockwise, direction of discharge
consistent)
4. Fixing type
F DIN flange without outboard bear- W Mounting angle without outboard bearing
ing
G DIN flange with outboard bearing X Mounting angle with outboard bearing
5. Seal type
1 Rotary shaft lip seal BABSL NBR 18 Rotary shaft lip seal BAUMX7 FKM
2 Rotary shaft lip seal BABSL FKM 19 Double rotary shaft lip seal BABSL NBR
3 Rotary shaft lip seal PTFE 20 Mechanical seal with EPDM secondary seal
(not resistant to mineral oil)
4 Double rotary shaft lip seal PTFE 23 Rotary shaft lip seal MSS-1 FKM
(low temperature)
5 Mechanical seal with FKM secon- 30 Without shaft seal, O-Ring FKM
dary seal (external leak oil discharge)
6 Mechanical seal with PTFE sec- 31 Rotary shaft lip seal BABSL FKM
ondary seal (low temperature)
7 Double rotary shaft lip seal BABSL 32 Double rotary shaft lip seal EPDM
FKM (not resistant to mineral oil)
9 Rotary shaft lip seal EPDM 36 Without shaft seal, O-Ring NBR
(not resistant to mineral oil) (external leak oil discharge)
6. Special number for special versions
See section 3.5 “Important special numbers”
7. Pressure relief valve (only for direction of rotation R or L)
D 15 Adjustable from 0 - 15 bar D 25 Adjustable from 15 - 25 bar
BKF0004EN_D0024710002-09 2012-09-25 23
Explanation of type key KF 2,5...200

8. Housing and cover material
No specification: EN-GJL-250 (GG-25)
GJS EN-GJS-400-15 (GGG-40)
3.5 Important special numbers
Special Description
number
74 Pump with double rotary shaft lip seal for vacuum operation and connection for liquid
seal (quench), inner rotary shaft lip seal mounted with sealing lip towards shaft end
158 SAE ¾ connections for KF 2,5...12, SAE 1 connections for KF 16...25
197 Noise-optimized version for aerated oils and vacuum
198 Mechanical seal with connection for liquid seal (quench)
232 SAE 2 connection for KF 50...80, SAE 2 1/2 connections for KF 100...112, SAE 3 con-
nections for KF 125...150, SAE 3 1/2 connections for KF 180...200
304 Bearing bushings Iglidur® X, Δpmax = 10 bar
317 Noise-optimized version for aerated oils and vacuum, bearing bushings Iglidur® X,
Δpmax = 10 bar
332 Version for low-viscous media (only in connection with material GJS), bearing bushings
Iglidur® X, νmin = 4 mm²/s at Δpmax = 10 bar
353 Noise-optimized version for aerated oils and vacuum, bearing bushings DP4 (leadfree)
355 Bearing bushing Iglidur® X, SAE ¾ connections for KF 2,5...12, SAE 1 connections for
KF 16...25, Δpmax = 10 bar
363 Version for low-viscous media (only in connection with material GJS), bearing bushings
Iglidur® X, νmin = 4 mm²/s at max. Δpmax = 10 bar, SAE ¾ connections for KF 2,5...12,
SAE 1 connections for KF 16...25
391 Noise optimized version for aerated oils and vacuum, SAE 2 connections for KF 50...80,
SAE 2 1/2 connections for KF 100...112; SAE 3 connections for KF 125...150, SAE 3
1/2 connections for KF 180...200
Particularities in noise-optimized pumps

1. Air trapped in the medium or too high negative pressure can result in
delivery rate reduction for pumps in noise-optimized version.
2. Measures for noise optimisation are only feasible for one rotational di-
rection and only effective for aerated oils or vacuum.
24 2012-09-25 BKF0004EN_D0024710002-09
4 Technical data
4.1 General characteristics
General characteristics KF 2,5...200

Construction External gear pump
Material See section 4.4 “Overview materials”
Fixing type Flange DIN ISO 3019
End of drive shaft ISO R 775 short-cylindrical
Connection type KF 2,5...12 Whitworth thread G 3/4
KF 4...12/158 Flange connection SAE 3/4
KF 16...25 Whitworth thread G 1
KF 16...25/158 Flange connection SAE 1
KF 32...80 Flange connection SAE 1 1/2
KF 50...80/232
Flange connection SAE 2
KF 100...112
KF 100...112/232
Flange connection SAE 2 1/2
KF 125...150
KF 125...150 /232
Flange connection SAE 3
KF 180...200
KF 180...200 /232 Flange connection SAE 3 1/2
Installation position KF ...R/L/B... without quench Arbitrary*
KF ...R/L/B... with quench Horizontal, quenching connec-
tion on top
KF ...U... Horizontal, pressure connection
on top
Viscosity νmin 12 mm2/s**
νmax 20000 mm2/s
Ambient tempera- ϑu min -20 °C
ture ϑu max 60 °C
Speed n See section 4.2 “Overview nominal sizes”
Fluid temperature ϑ
Operating pressure pe and See section 4.5 “Operating pressure and fluid temperature”
pb
Filtering Filter porosity ≤ 60 µm
Permissible media Fluids without abrasive components which are compatible with the
pump materials used. The fluids must guarantee minimum lubrica-
tion. Media-specific characteristics must be taken into account.
Petrols, solvents, etc. are not permissible.
BKF0004EN_D0024710002-09 2012-09-25 25
General characteristics KF 2,5...200

* A reduced service life must be expected for the shaft seal when vertically installed.
** Lower viscosities only on connection with GJS housings and reduced pressures (consult man-
ufacturer).
4.2 Overview nominal sizes
Nominal Geom. Speed Perm. radi- Sound Weight

size* displace- al force** pressure kg
ment nmin nmax Fradial level***** with cover with D- with uni-
Vg N LpA valve versal
rpm rpm
cm3 (n=1500 db(A) valve
rpm)
2,5 2,55
4 4,03
5 5,05
2,9*** 3,7***
6 6,38 6,9
4,2**** 5,0****
8 8,05
200 3000 700 ≤ 67
10 10,11
12 12,58
16 16,09
3,5*** 4,3***
20 20,10 7,5
4,8**** 5,6****
25 25,10
32 32,12
40 40,21 7,7 9,5 27,5
50 50,20 200 3000 1500 ≤ 68
63 63,18
9,4 11,2 29,5
80 80,50
100 101,5
200 3000 1500 ≤ 69 16,0 18,7 -
112 113,5
125 129,4
22,2 26,5
150 155,6
200 3000 1500 ≤ 70 -
180 186,6
24,8 29,1
200 206,2
* See type key and type designation at device
** Radial forces only at version with outboard bearing (Fradial on central shaft end)
*** Valid for nominal size 2,5...25 with Whitworth pipe thread
**** Valid for nominal size 2,5...25 with flange connection SAE
***** n=1500 rpm ; v=34 mm2/s ; p=5...25 bar
26 2012-09-25 BKF0004EN_D0024710002-09
4.3 Permissible speed
Kinematic viscosity ν in mm2/s

< 300 300 500 1000 2000 3000 6000 10000 20000
≥ 1450 1250 1000 750 600 500 400 300 200
Maximal permissible speed nmax in rpm
BKF0004EN_D0024710002-09 2012-09-25 27
4.4 Overview materials
Seal Housing / cover Gear Bearing Shaft seal O-rings

type*
1 NBR NBR
2 FKM FKM
3 PTFE FEP
4 PTFE FEP
5 CrMo-cast- FKM
ing/Carbon
in synthetic
resin, FKM,
1.4571,
1.4401
6 SiC-Si/SiC- FEP
Si (KF
4...25), SiC-
Si/Carbon in
synthetic
resin (KF
DU, P10 32...80),
(Steel, sintered bronze, FFKM,
EN-GJL-250 1.4571
case-hard- PTFE, Pb)
(GG-25)
7 ened steel Iglidur® FKM FKM
EN-GJS-400-15**
9 (1.7139) DP4 EPDM EPDM
(GGG-40)
(Steel, sintered bronze,
18 FKM FKM
PTFE)
19 NBR NBR
20 SiC-Si/Car- EPDM
bon, CrNi-
Steel, CrNi-
Mo-Steel
23 FKM (low FKM
temperature) (low tem-
perature)
30 Without shaft FKM
seal
31 FKM (low FKM
temperature) (low tem-
perature)
32 EPDM EPDM
36 Without shaft NBR
seal
** For version in EN-GJS-400-15 type designation: KF ... - GJS
28 2012-09-25 BKF0004EN_D0024710002-09
4.5 Operating pressure and fluid temperature
Seal type* Operating pressure Fluid temperature

Suction side Pressure side
pe min bar abs.** pe max bar pb bar pb max bar ϑmin °C ϑmax °C
(perm. conti- (Pressure
nous pressure) peaks)
1 90
...6****
2 150
3
2 200
4
5 150
10
6 - 10 200
7 ...6**** 150
9 0,6 *** 120
0,5
18 150
19 ...6**** 25***** 40 90
20 10 120
23 0,5 -30
30 25 -10 150
31 1 -30
32 0,5 120
4/74 200
7/74 -10 150
0,1 0,2
19/74 90
32/74 120
** Heed restictions of pe min = 0,65 bar absolute for universal design (KF .. U.).
*** Temporary during starting state: 0,4 bar absolute.
**** Permissible pressure see table 4.1
***** For size 3 (KF 100...200) type of seal 31: pb = 20 bar
BKF0004EN_D0024710002-09 2012-09-25 29
Tab. 4.1: Permissible operating pressure pe max for seal type 1, 2, 7 and 19
Max. speed nmax in rpm KF 2,5...80 KF 100...200

Permissible pressure pe max in Permissible pressure pe max in bar
bar
750 6 6
1000 5 5
1500 4 3,5
2000 3 2,5
3000 2 1,5
Permissible differential pressure

Δpmax
Bearing
bar
Standard: DU, P10 25
Iglidur® 10
White metal 10
NOTICE
Danger of device damage due to overload
The device bearings can prematurely wear out under overload.
1. Never exceed the maximum permissible differential pressure.
NOTICE
Danger of property damage when simultaneously utilizing multiple
operating limits
When simultaneously utilizing multiple operating limits (see chapter 4
“Technical data”), the pump could become damged or prematurely wear.
1. Do not use minimum and maximum parameters at the same time.
For example, maximum operating pressure is not permissible in con-
nection with low speed and/or low viscosity.
30 2012-09-25 BKF0004EN_D0024710002-09
NOTICE
Danger of property damage when pumping aqueous fluids
When pumping aqueous dispersions or solvents, low pressure on the inlet
port can lead to cavitation damage on the pump.
1. Comply with the media-specific attributes.
2. When designing the inlet line, make sure the inlet port pressure on the
pump inlet during operation is always higher than the steam pressure
of the pumping fluid. While doing so, also take the altitude of the site of
the device over mean sea level into consideration.
3. For aqueous dispersions and solvents, limit the operating temperature
to max. 50 °C, install the pump underneath the liquid level and limit the
rotational speed to maximal 1500 rpm.
4.6 Dimensions
Dimensions of the device can be found in the relevant technical data sheets.
BKF0004EN_D0024710002-09 2012-09-25 31
5.1 Transport damage
Inspect the device for shipping damage as soon as the delivery has been
received.
If shipping damage is discovered, inform the shipping company.
If proper operation of the device is impaired by the damage, the device must
be replaced or repaired. In that case, contact the manufacturer.
5.2 Transport
WARNING
1. Compliance with applicable industrial safety requirements is mandatory.
2. Use only suitable means of conveyance and lifting tackle with sufficient
load-bearing capacity.
3. Attach lifting tackle only to suitable points (see table 5.1 and table 5.2).
4. Attach the lifting tackle in such a manner that it cannot slip.
5. The device's centre of gravity must lie between the lifting tackle mount-
ing points on the device.
6. Secure the device so that toppling over and falling down is impossible.
7. Always avoid jerks, impacts and strong vibrations during transportation.
8. Never walk under suspended loads, never work under suspended
loads.
9. To prevent damage to the device, be extremely cautious when shipping
or transporting.
32 2012-09-25 BKF0004EN_D0024710002-09
Handling aid
1. When transporting individuals devices, the eyebolts can be screwed into
the connecting flanges as a handling aid.
Tab. 5.1: Example for safe transport of pumps
WARNING
1. For pump aggregates: do not use eyebolts on the motor to transport the
pump aggregates. They can only support the weight of the motor.
Tab. 5.2: Examples for safe transport of pump units
BKF0004EN_D0024710002-09 2012-09-25 33
5.3 Corrosion protection
The device's function is tested in the plant with mineral hydraulic oil. Then all
connections are closed. The remaining residual oil protects the interior parts
for about 6 months.
Clean bare outer metal parts have also been protected by anti-corrosive oil
or protective metal paint for a period of 6 months against corrosion.
The device must not be exposed in the influence of the weather and major
fluctuations in temperature during transport and storage and must be stored
in a dry place.
If the device is stored over a longer period, it must be treated on the inside
and outside with a suitable corrosion protecting oil. In addition, it must be
protected from humidity by a humidity-absorbing agent.
If high air humidity or aggressive atmosphere is to be expected during trans-
port, suitable corrosion prevention measures must be carried out.
NOTICE
Corrosion damage on devices with EPDM seals
The functionality of devices with EPDM seals is not tested. There is no
preservation of the interior parts. If the device is not put into operation im-
mediately, corrosion damage can occure.
1. Protect the device by using suitable corrosion-preventing measures.
NOTICE
Chemical impact on the device and the sealing materials
Incompatibility between the preservation agents and the materials and
elastomeres used in the device can lead to damage of the device and the
seals being used.
1. Check to make sure the preservation agent is compatible with the ma-
terials and elastomers used in the device.
2. Check to make sure the preservation agent is compatible with the media
to be pumped.
34 2012-09-25 BKF0004EN_D0024710002-09
6 Installation
6.1 General points
WARNING
vice.
NOTICE
Danger of property damage due to insufficiently qualified personnel
Improper work can lead to damages and malfunctions in the device and in
the plant.
1. Permit only expert and technically qualified personnel to work on the
device.
NOTICE
Danger of property damage due to a lack of cleanliness
During installation, foreign bodies can get into the interior of the device or
the plant due to a lack of cleanliness and cause malfunctions there.
1. Pay attention to cleanliness during all work.
6.2 Noise reduction
Measures for sound optimizing

1. In view of optimising noise protection, it is advisable to mount a vibration
damper between pump and motor as well as vibration damper between
motor and mounting surface. Suction and pressure piping must be able
to move freely or it needs to be elastically suspended.
2. Installation of suction and pressure hoses diminishes the noise level of
hydraulic systems. Some hoses manufacturers offer special, highly flex-
ible suction hoses for this purpose.
3. Installation of the pump above the liquid level diminished the noise level
of hydraulic systems. The pressure pe on the pump's intake should be
approx. 0.8...0.9 bar absolute.
BKF0004EN_D0024710002-09 2012-09-25 35
6.3 Definition of the direction of rotation and pumping flow
DANGER
the pump.
the motors.
of rotation.
36 2012-09-25 BKF0004EN_D0024710002-09
6.3.1 KF 2,5...200 (with cover or pressure relief valve)
The following definition shall apply with respect to the rotation and delivery
direction of external gear pumps in case of pump connections being posi-
tioned below the drive shaft:
Looking at the pump shaft end, the Looking at the pump shaft end, the
pumping flow is from left to right pumping flow is from right to left
when the shaft is moving clock- when the shaft is moving counter-
wise. clockwise.
Without pressure relief valve
pe = suction connec- pb = pressure con-

tion nection
With pressure relief valve
pe = suction connec- pb = pressure con-

tion nection
BKF0004EN_D0024710002-09 2012-09-25 37
6.3.2 KF 2,5...25 U (with universal valve)
With regard to the direction of rotation and pumping flow of pumps with
universal valve the following definition shall apply when looking at the pump
shaft end:
Direction of rotation clock- Direction of discharge consistent
wise and counterclockwise
pe = suction connection pb = pressure connection
With regard to the direction of rotation and pumping flow of pumps with
universal valve the following definition shall apply when looking at the
pump shaft end:
Direction of rotation clockwise and Direction of discharge consistent
counterclockwise
pe = suction connection pb = pressure connection
38 2012-09-25 BKF0004EN_D0024710002-09
6.4 Change of the direction of rotation
Change of the direction of rotation in the case of KF...R... and KF...L... pump
types, i.e. pure clockwise or counterclockwise rotating pumps, is only possible
by converting the pump.
The manufacturer normally carries out the conversion work and the customer
should do this only in case of an emergency.
Pumps in noise-optimized version cannot be converted.
Guarantee and manufacturer responsibility

1. All warranty claims and manufacturer responsibility shall be void when
improper conversation work takes place.
NOTICE
Danger of property damage due to incorrect installation
Improper retrofitting can lead to damage and malfunctions in the device and
in the plant.
device.
NOTICE
Danger of leaks on the device
When altering the device, seals that are removed, damaged or jammed can
lead to leaks during operation.
1. Do not remove, damage or jam seals.
NOTICE
Danger of damage on the device
The cover or pressure relif valve and housing are fixed to each other with
adapter sleeves or dowel pins. If the bearings are damaged when assem-
bling or dismantling the cover or pressure relief valve, e.g. by bending out
of line, there could be malfunctions and a decrease of the service life. Fur-
thermore, the seal faces on the cover or pressure relief valve could be
damaged. That can lead to leaks during operation.
1. When mounting and dismantling the cover or pressure relief valve, do
not damage the bearings, e.g. by bending out of line.
2. When dismantling the cover or pressure relief valve, do not lever in the
joint with a screwdriver or similar tools.
BKF0004EN_D0024710002-09 2012-09-25 39
pe = suction connection * Attachment screws

pb = pressure connection ** Leak oil hole
In case of a pump's change of the direction of rotation the cover and/or pres-
sure relief valve must be rotated through 180°.
● Loose fastening screws.
● Remove the cover or the pressure relief valve respectively from the pump
housing and put it back on rotated by 180°.
● Tighten all fastening screws applying the below mentioned tightening
torques (see table 6.1)
When checking, pay attention to the following points:
● Pumps without pressure relief valve must have their leak oil hole on the
interior cover side at the pump's suction side.
● Pumps with pressure relief valve must have their pressure relief valve
adjusting screw point toward the pump's pressure side.
Tab. 6.1: Tightening torques for fastening screws
Nominal size * 2,5 ... 25 32 ... 80 100 ... 200

Tightening torque 25 Nm 49 Nm 79 Nm
In the case of pumps having seal type 6, the mechanical seal must be re-
placed in addition. During this process, the spring coiling direction must be
observed. Heed the assembly instructions of the respective manufacturer
when replacing the mechanical seal.
40 2012-09-25 BKF0004EN_D0024710002-09
6.5 Design of suction and pressure line
DANGER
range.
NOTICE
Danger of property damage due to distortion
The load on the device due to impermissible external loads can lead to
malfunctions or to breakage of the flange or housing.
1. Pipelines must be fitted absolutely tension-free to the device connec-
tions.
2. Pipelines must be designed in such a way that no tension e.g. caused
by changes in lenght due to fluctuations in temperature can be trans-
ferred to the device.
NOTICE
Danger of property damage caused by foreign bodies in the device
During installation, when using unsuitable sealing materials foreign bodies
can get into the interior of the device or the plant due to a lack of cleanliness
and cause malfunction there.
1. During installation, do not use any hemp or filler as sealing material.
Suction and pressure hoses

1. Installation of suction and pressure hoses diminishes the noise level of
hydraulic systems. Some hoses manufacturers offer special, highly flex-
ible suction hoses for this purpose.
2. Lay pressure hoses in sufficiently lage radii.
6.5.1 Suction line
NOTICE
Malfunction due to incorrectly designed inlet line
Due to excessive underpressure, an incorrectly designed inlet line can lead
to a reduction of the delivery rate, increased noise emissions and cavitation.
1. Design the inlet line with extreme care since it will strongly influence the
pump's performance.
BKF0004EN_D0024710002-09 2012-09-25 41
The suction line must be piped as short as possible and in a straight line.
Avoid large suction heights.
Additional line resistance such as formed parts, fittings and closed meshed
suction filters increase the pipe resistance of the suction line and must be
avoided.
The negative pressure in the suction line is calculated from the sum of all
suction-side resistances and the suction height considering the media-spe-
cific data.
Check the underpressure

1. The negative pressure can be controlled by fitting a vacuum gauge to
the pump suction line connector.
Ensure proper suction when piping the suction line and the distances to the
floor and to the bulkhead partitions must be sufficiently large.
The inlet port must have a sufficient distance to the lowest fluid level.
Nominal width of the suction line

1. The nominal width of the suction line may actually be selected to be
lager than the pump connection.
Expansion of the suction cross section

1. Funnel-shaped formation of the suction port at the pump suction side or
obliquely cutting the suction pipe end is recommended of enlargement
of the suction cross section.
When hose lines are used on the pump suction side, care must be taken to
ensure that the hoses are sufficient stability so that they will not be constricted
through the sucking action.
The media-specific data need to be observed, for example, the device must
be arranged below the fluid level in case of aqueous dispersions and solu-
tions.
NOTICE
Danger of property damage when pumping aqueous fluids
When pumping aqueous dispersions or solvents, low pressure on the inlet
port can lead to cavitation damage on the pump.
1. Comply with the media-specific attributes.
2. When designing the inlet line, make sure the inlet port pressure on the
pump inlet during operation is always higher than the steam pressure
of the pumping fluid. While doing so, also take the altitude of the site of
the device over mean sea level into consideration.
3. For aqueous dispersions and solvents, limit the operating temperature
to max. 50 °C, install the pump underneath the liquid level and limit the
rotational speed to maximal 1500 rpm.
42 2012-09-25 BKF0004EN_D0024710002-09
The recommended flow velocity in the suction line is max. 1,5 m/s.
Piping the suction line as siphon

If there is a possibility that the suction line
can run dry of the pump stops, piping the
suction line as siphon is an option to avoid
suction problems. This way, the pump will
remain permanently filled after initial com-
missioning.
The air in the pressure line can be conduc-
ted directly into the tank via a nozzle (see
section 6.5.2 “Pressure line”).
It is appropriate to employ a foot valve or a
non-return valve in case of longer suction
lines that can run dry while the pump is at
rest. These must have been designed for
use in suction lines and should offer as low
a flow resistance as possible.
Suction line at vacuum operation

If the pump is to intake from a tank under
vacuum, the pump must be arranged ap-
prox. 0.8 m below the tank. The suction line
must run in a straight line and without any
resistances.
The tank may be subjected to vacuum only
then when the pipework and the pump have
been filled with liquid.
For this application, only pumps designed
as a vacuum system may be employed.
* = Vacuum
NOTICE
Malfunction due to exessive underpressure
Undercutting the permissible underpressure can led to a decrease in the
delivery rate (due to short filling of the pump), high noise emission and cav-
itation. Furthermore, in shaft seals the sealing lip can lift up allowing air to
be sucked in.
1. The permissible pressure at the pump inlet shall not be lower than value
pe min as stated in the chapter 4 “Technical data”.
An exception to this is the pump's starting state during which a pressure of

0.4 bar absolute is tolerable for max. 30 minutes.
BKF0004EN_D0024710002-09 2012-09-25 43
NOTICE
Damage or failure of the shaft seal due to high supply pressure
Exceeding the permissible supply pressure can lead to a failure of the shaft
seal or to impermissible heating and incresed wear.
1. The permissible pressuer at the pump inlet must not exceed the value
pe max as stated in the chapter 4 “Technical data”.
6.5.2 Pressure line
DANGER
gates".
pressureless.
The nominal width of the pressure line must be selected such that the maxi-
mum permissible pressure are not exceeded.
The pressure must be checked by a manometer installed as closely as pos-
sible to the pressure connection.
To avoid pump overload caused by an impermissibly high pressure, a pres-
sure relief valve or rupture disc with return to the supply tank must be installed
as closely as possible to the pump´s pressure connection.
Another option of pressure limiting is to mount a pressure relief valve directly
to the pump.
During operation of a pump that has to pump media via a non-return valve in
a pressurized circuit (e.g. reserve pump in a lubricant circuit), intake problems
can occur if the inlet pipe is filled with air. In this case the pressure pipe must
be bled directly upstream of the non-return valve.
This can be carried out by a bleeding valve with return or a throttled bypass,
for example.
44 2012-09-25 BKF0004EN_D0024710002-09
Bleeding valve and throttled bypass
Bleeding valve with return Throttled bypass
If none of the measures described is carried out, the volume of the pressure
pipe between the pump and the non-return valve must be at least 75 % of the
inlet pipe volume.
BKF0004EN_D0024710002-09 2012-09-25 45
6.6 Mounting the clutch
NOTICE
Danger of property damage due to falsely dimensioned coupling
An incorrect design can lead to premature failure on the coupling due to
breakage or wear.
1. When dimensioning the coupling, pay attention to safe dimensioning to
be able to transfer the expected maximum torque reliably and perma-
nently.
2. Take the vibrations, peak torques and temperatures into consideration.
The permissible values from the coupling manufacturer must not be
exceeded.
3. Comply with the coupling manufacturer's installation rules.
When mounting the clutch, keeping the "E" measure exactly is of the essence
so that the clutch will remain axially movable when used. In order to avoid
any frontal pressure against the elastic gear rim, measure "E" should each
be considered as minimum in the case of an axial displacement.
If the shaft clearance is less than clutch clearance "E", one of the shaft ends
can easily extend into the gear rim. Size "dW" corresponds to the max. shaft
diameter that may extend with the parallel key into the gear rim, size "dH". If
there is the chance to offset the parallel key, i.e. only the shaft extends into
the gear rim, the size of the shaft may be increased up to 2 mm below the
specified "dH" size in order not to obstruct the gear rim in its axial movability.
The permissible displacement values of the elastic clutches stated represent
general guide values taking a clutch loading up the the clutch nominal torque
and an operating speed n = 1500 rpm as well as an occurring ambient tem-
perature of +30 °C into account. Consultation with the manufacturer is
necessary for deviating operating conditions.
The displacement data may only be used individually in each case and in case
of simultaneous appearance in proportion only.
Increasing the service life of the coupling

1. Careful and exact shaft alignment inreases clutch life!
46 2012-09-25 BKF0004EN_D0024710002-09
Fig. 6.1: Displacements - aligning the clutch
* Clutch clearance "E"

** Shaft with parallel key extends into the gear rim (dw)
Tab. 6.2: Types of coupling
19 24 28 38 42 48 55 65 75
Type of coupling*
19/24 24/28 28/38 38/45 42/55 48/60 55/70 65/75 75/90
Clutch clearance** E 16 18 20 24 26 28 30 35 40
Dimension** s 2 2 2,5 3 3 3,5 4 4,5 5
Dimension** dH 18 27 30 38 46 51 60 68 80
Dimension** dW 12 20 22 28 36 40 48 55 65
Max. axial displace- ΔKa 1,2 1,4 1,5 1,8 2,0 2,1 2,2 2,6 3,0
ment**
Max. radial displace- ΔKr 0,20 0,22 0,25 0,28 0,32 0,36 0,38 0,42 0,48
ment**
n=1500 1/min
Max. angular dis- ΔKw 1,2° 0,9° 0,9° 1,0° 1,0° 1,1° 1,1° 1,2° 1,2°
placement
n=1500 rpm
* Example: RA19-Z25/14-Z25/19 or RA19/24-Z25/14-Z25/24
** Dimensions in mm
NOTICE
Danger of property damage when mounting other types of couplings
If other coupling types are used, when mounting the coupling the instruc-
tions from the respective manufacturer is binding.
1. The respective manufacturer's installation instructions must be com-
plied with when using other coupling types.
BKF0004EN_D0024710002-09 2012-09-25 47
NOTICE
Danger of property damage if installation is not correct
When installing the respective coupling halves, there is a hazard of dam-
aging the inegrated bearing or the components.
1. Do not knock onto the shafts during installation of the clutch halves!
Easing coupling installation

1. The hubs should be heated for mounting the clutch and slide onto the
shaft while hot.
Using a pinion gear drive, it must also be heated and slide onto the shaft
end while hot.
NOTICE
Danger of property damge due to displacement of the coupling halves
When the coupling hub is not secured against axial displacement on each
shaft, there is a danger that the coupling hub will shift during operation. That
can lead to a failure of the coupling.
1. Prevent axial displacement on every coupling hub on cylindrical shafts
with a threaded pin that presses against the fitting key or the shaft.
48 2012-09-25 BKF0004EN_D0024710002-09
6.7 Mechnical installation
WARNING
vice.
NOTICE
Malfunction due to leaking lines and connections
Leaks can occure and air can be sucked if lines or connections are not tight.
Suctioned air leads to a decrease of the delivery rate and foams up the
medium.
1. Make sure all lines and connections are tight.
● Before installation, the device must be checked for transport damage and
soiling.
● Any preserving agents must be removed before installation using ben-
zine or solvent.
● Clean the pipework of dirt, scale, sand, swarf, etc. prior to installation.
Welded pipes in particularly must be pickled or flushed. Cotton waste
must not be used for cleaning.
● Mount clutch and clutch halves respectively to pump and drive (see sec-
tion 6.6 “Mounting the clutch”").
WARNING
tional contact.
● Mount pump to bellhousing, foot or housing and pay attention to careful

alignment and correct fitting position (see chapter 4 “Technical data”).
● Tighten all fastening screws applying the torque as prescribed by the
manufacturer of the bellhousing avoiding any twisting of the pump in the
process without fail.
BKF0004EN_D0024710002-09 2012-09-25 49
● Remove the protective plugs in the pump's suction and pressure con-
nections.
WARNING
WARNING
hazardous liquids!
● Wet devices interiors with fluid being pumped.
DANGER
range.
NOTICE
Danger of property damage due to distortion
The load on the device due to impermissible external loads can lead to
malfunctions or to breakage of the flange or housing.
1. Pipelines must be fitted absolutely tension-free to the device connec-
tions.
2. Pipelines must be designed in such a way that no tension e.g. caused
by changes in lenght due to fluctuations in temperature can be trans-
ferred to the device.
50 2012-09-25 BKF0004EN_D0024710002-09
● Connect suction and pressure side according to the marking on the pump
or the information on the type plate (see section 6.3 “Definition of the
direction of rotation and pumping flow”).
● Connect the pipework to the suction and pressure piping. Always heed
the respective manufacturer's instructions.
● When operating the pump with liquid seal (quench) mount a suitable tank
for the liquid seal (see chapter 7 “Operation start-up”).
DANGER
gates".
pressureless.
CAUTION
ded contact.
NOTICE
Danger of malfunctions through polluted medium
When filling the storage tank with the medium, impurities or small parts can
get into the tank and cause damage or malfunctions on the device or in the
system.
1. When filling the storage tank pay attention to the greatest possible
cleanliness.
● Before opening, clean filler screw and shutoff on fluid transport and stor-
age tank.
● Check media tank for contamination and clean if necessary. On no ac-
count remove the filter screen on the filler neck or the filter insert during
the filling process.
BKF0004EN_D0024710002-09 2012-09-25 51
● Filling the media tank with the prescribed fluid.

● Ensure sufficient filling of the media tank!
6.8 Assembly with further components and devices
NOTICE
Danger of property damage if installation is not correct
Incorrect assembly with components or devices from other manufacturers
can lead to breakdowns.
1. Comply with each manufacturer's operating instructions when assem-
bling with additional components or devices..
6.9 Electrical connection
DANGER
lations.
DANGER
the pump.
the motors.
of rotation.
● All data stated on the motor type plate must be checked for conformity
to the required operating data.
● Adjust the overload protection to the correct value.
● Check the rotational drive direction of the pump before switching on.
52 2012-09-25 BKF0004EN_D0024710002-09
7 Operation start-up
7.1 Preparation
WARNING
tional contact.
WARNING
WARNING
hazardous liquids!
CAUTION
ded contact.
BKF0004EN_D0024710002-09 2012-09-25 53
NOTICE
Danger of property damage due to incorrect commissioning
Improper commissioning can lead to damages and malfunctions in the de-
vice and in the plant.
device.
2. Comply with the permissible operating data such as rotational speed,
pressure temperature, permissible media, etc. (see chapter 4 “Techni-
cal data”).
4. Before starting the system make sure that a sufficient quantity of the
operating fluid is extant to avoid dry running.
5. Before starting the plant, pumps and inlet line must be filled with oper-
ating fluid to prevent damage to the pump and the shaft seal during dry
runs. That also guarantees pump suction.
6. For pumps with liquid seal (quench), fill the sealing cavity with a suitable
confining fluid before it is used for the first time.
7. Make sure that all lines and connections are tight and that no leakages
can occur or air can be sucked.
● Check the permissible operating data against the operating states to be

expected.
● Check all fastening screws on the device.
● Fill the pump and suction line with the operating fluid.
● In the case of pumps with liquid seal (quench), fill the sealing cavity using
an appropriate confining fluid (see section 7.2 “Pumps with liquid seal
(quenching connection)”).
● Checking the direction of rotation. See section "Change of the direction
of rotation" in chapter 6 “Installation” for any change in rotational direc-
tion.
54 2012-09-25 BKF0004EN_D0024710002-09
7.2 Pumps with liquid seal (quenching connection)
7.2.1 General points
NOTICE
Danger of failure of the seal due to a lack of sealing fluid
A lack of sealing fluid can lead to a failure of the shaft seal and to increased
temperatures and increased wear.
1. Fill the pump's sealing cavity with a suitable sealing medium. The seal-
ing fluid must be compatible with the seals and materials used as well
as with the pumping medium.
2. The confining fluid's minimum and maximum filling level must be en-
sured using appropriate technical and/or organisational measures.
3. The liquid seal in the quenching connection must not be subjected to
pressure or vacuum.
If fluids are delivered,

● that cure in air,
● crystallise in contact with air humidity,
● the leakage of which must not be released into the environment,
● are under vacuum and their seal shall be gastight,
than the employment of a double seal with liquid seal is necessary.
● A tank for the liquid seal is to be connected to the quenching connection.
Suitable tanks are available from the manufacturer.
● The tank for the liquid seal must be placed above the pump.
● The installation position is restricted and the quenching connection shall
be directed upward.
● Check of the fluid level in the tank must be possible at any time.
Flushing connection sealing cavity

1. A second port on the device enables purging of the sealing cavity and
draining of the seal liquid.
BKF0004EN_D0024710002-09 2012-09-25 55
7.2.2 Seal variants with liquid seal
Types of seals: Types of seals: Triple rotary shaft lip Seal type: 5
4, 7, 19, 32 4, 7, 19, 32 seal Special number 198
Special number 74 (on request)
56 2012-09-25 BKF0004EN_D0024710002-09
7.3 Setting the pressure relief valve
Applies for pumps with built-on pressure relief valve

(Type designation: KF ... - D15 or KF ... - D25)
Fig. 7.1: Pressure setting KF 2,5...200 - D..
- response pressure lower

+ response pressure higher
NOTICE
Danger of the pump overheating
The series D.. pressure relief valve are exclusively used to protect the
pump. The valves must only respond for short durations. Permanent drain-
ing of the volumetric flow through the valve will destroy the pump through
overheating.
● Make sure the valve responds only briefly.
For pressure setting on the pressure relief valve see figure 7.1:
● loosen the hexagon nut (1)
● adjust set screw (2)
clockwise = response pressure higher
counterclockwise = response pressure lower
● secure the set screw (2) using hexagon nut (1) once the desired pressure
has been adjusted.
BKF0004EN_D0024710002-09 2012-09-25 57
DANGER
When securing screw (3) is loose, set screw (2) can be screwed into the
valve device until the valve device is completely shut. That can result in
inadmissibly high pressures in the system if there is no other pressure re-
liefe device. Breakage can lead to parts flying around uncontrolled or to
fluids squirting out which can lead to accidents and severe injuries or even
result in death.
Fluid can spurt out from the valve if set screw (2) is completely screwed
out. Than can lead to accidents with severe injuries or result in death.
1. Never operate the device with securing screw (3) or set scerw (1) loos-
ened.
2. Never completely screw set screw (2) into the valve.
3. Never completely unscrew set screw (2) out of the valve.
58 2012-09-25 BKF0004EN_D0024710002-09
7.4 Further operation start-up
● The pumps may only start without or with low pressure load. For this
purpose, open the existing shut-off elements and adjust the pressure
relief valve incorporated in the pressure pipe to the lowest opening pres-
sure.
● Start-up takes place by repeated quick on-off switching of the driving
motor (jog mode) without reaching full speed until proper operation of the
device is evident. This applies particularly when a cold pump is to start
with already heated medium. The reason for this is to achieve slow heat-
ing of the pump and prevent the pump seizing through thermal shock.
● Proper function indicated by noise generation or on the pressure gage
should be reached after max. 30 seconds.
● First of all, run the pump at zero pressure or low pressure for a couple
of minutes after switching on the motor.
● Bleed the plant on the distribution pipes, preferably at the highest point.
● Pressure loading can be gradually increased up to the desired operating
pressure (max. permissible pressures, see chapter 4 “Technical data”)
● Check the temperature of the medium and that of the pump after the
intended operating characteristics have been reached. Checkpoints on
the pump are the bearing locations, the housing and the shaft seal. The
temperatures observed on the pump surface may be approx. 10 °C
above medium temperature.
● Check the fluid level of the plant once more and top up if necessary.
● Check the final operating temperature after several hours running time
(see chapter 4 “Technical data” for max. permissible temperatures).
● Check the static seals on the suction and pressure connections and the
pump's joints for leakages.
● Check the threaded connections for leakages. Such leakages can be
easily eliminated by simply retightening the threaded connections.
● Also check all motor and pump fastening screws after a few hours of
operation.
BKF0004EN_D0024710002-09 2012-09-25 59
8 Removal
8.1 General points
NOTICE
the plant.
device.
NOTICE
A lack of cleanliness can lead to damages and malfunctions in the device
and in the plant.
2. Close all openings with protective caps to prevent dirt from penetrating
into the system.
8.2 Removing the pump
WARNING
vice.
60 2012-09-25 BKF0004EN_D0024710002-09
WARNING
hazardous liquids!
CAUTION
● Remove the depressurised pipelines from the pump.

● Seal the pump connections and pipelines to prevent dirt penetration.
● Disassemble the pump
● Pull off clutch hub resp. the driving pinion from shaft end using an ex-
tractor.
NOTICE
Danger of malfunction due to curing medium
Curing medium can engage the device mechanically and make it unusable.
1. Immediately clean the pump or store it in such a way that curing is def-
initely prevented in cases where the pump was operated with curing
medium.
BKF0004EN_D0024710002-09 2012-09-25 61
9 Maintenance
9.1 General points
NOTICE
the plant.
device.
NOTICE
Danger of damages and malfunctions due to a lack of maintenance
If the device is not regularly maintained, damage that is not discovered or
not repaired can lead to malfunctions and to the failure of the device.
1. Maintain the device regularly.
2. Check the device initially right after commissioning.
3. Adapt the extent and time between maintenance intervals to the de-
mands posed by the location.
4. During visual inspections, look purposefully for possible damages.
5. The device must not be used if visible damages are found.
6. Document the type and extent of the maintenance work. That allows the
fastest possible detection of a change in operating performance.
When designed to the conditions of use and fitted correctly, the devices are
able to be used for long and problem-free operation. They only require a little
maintenance. This is absolutely essential for problem-free operation, howev-
er. Experience shows that a high percentage of the problems and damage
that occur can be traced back to dirt and lack of maintenance.
The extent and time intervals for inspections and maintenance are generally
specified by the operator in a respective plan.
Barriers and instructions

1. All removed barrieres and warning signs must be put back to their orig-
inal position on completing maintenance and/or repair.
Checking the operating data

1. Regular checking of all operating data such as pressure, temperature,
current consumption, degree of filter soiling etc. contributes to early
problem detection.
62 2012-09-25 BKF0004EN_D0024710002-09
NOTICE
A lack of cleanliness can lead to damages and malfunctions in the device
and in the plant.
2. Close all openings with protective caps to prevent dirt from penetrating
into the system.
NOTICE
Malfunction due to leaking lines and connections
Leaks can occure and air can be sucked if lines or connections are not tight.
Suctioned air leads to a decrease of the delivery rate and foams up the
medium.
1. Make sure all lines and connections are tight.
DANGER
Using damaged connections and lines can cause parts to fly around un-
controlled or fluids to squirt out, wich can lead to accidents and severe
injuries or even result in death.
1. Immediately replace damaged connections, pipes and hose lines.
DANGER
lations.
WARNING
vice.
BKF0004EN_D0024710002-09 2012-09-25 63
DANGER
gates".
pressureless.
WARNING
hazardous liquids!
CAUTION
9.2 Unusual noise
Some damage is indicated by unusual noises. If there is a change in the de-

vice's operating noise, a thorough examination of the cause must always take
place.
64 2012-09-25 BKF0004EN_D0024710002-09
9.3 Cleaning
The pump shaft as well as the associated hardware must not run in dust ac-
cumulations.
Regular cleaning of the device and its environment is therefore necessary.
Cleaning the device using a steam jet cleaner is not permissible.
9.4 Static seals
The static seals on the device's separation joints and the connection lines
must be periodically checked for leakproofness.
If there are any visible leaks, immediately stop plant operation.
If the leaks cannot be stopped by simply retightening the connection, replace
all affected seals.
9.5 Confining fluid level
Checking the confining fluid filling level is mandatory for safe pump operation.
Top up the confining fluid as required.
If there is no automatic monitoring, the filling level must be checked at least
befor each shift begins.
The outer but also the inner shaft seal could be leaking if the filling level should
drop unusually fast within a short period of time. The confining fluid will then
leak into the coupling space or it will be sucked into the pump thereby mixing
with the medium.
If the filling level should rise, the inner shaft seal may probably be leaking and
the confining fluid is begin mixed with the pressurised medium.
Stop plant operation immediately in both cases.
9.6 Rotary shaft lip seal
Rotary shaft lip seals are particulary prone to wear for functional reasons and
must accordingly be carfully checked. Excessively high supply pressure or
negative suction pressure, wrong rotational direction or pollution leads to in-
creased wear, increased and impermissible temperature rises.
Small amounts of leakage, however, are indispensable for function. The per-
missible amount of leakage, though, is highly dependet on the operational
conditions and cannot be quantified.
If there are excessive amounts of leakage, stop pump operation immediately.
Replace the rotary shaft lip seal.
BKF0004EN_D0024710002-09 2012-09-25 65
Increased wear on the rotary shaft lip seal should be taken into account in the
case of vertical pump installation.
9.7 Mechanical seal
Mechanical seals are particularly prone to wear for functional reasons and
must accordingly be carfully checked. Too high admission pressure, wrong
rotational direction, frequent star-ups, gas or air portions in the oil or contam-
ination lead to increased wear, increased leckage and impermissible tem-
perature rises.
Small amounts of leckages, however, are indispensable for mechanical seal
function. The permissible amount of leackage, though, is highly dependent
on the operational conditions and cannot be quantified.
If there are excessive amounts of leakage, stop pump operation immediately.
Replace the mechanical seal. In so doing, heed the assembly instructions of
the mechanical seal manufacturer.
Increased wear on the mechanical seal should be taken into account in the
case of vertical pump installation.
9.8 Clutch
Clutches must be maintained according to the specifications of the respective

manufacturer.
9.9 Screw joints
All the screw joints must be checked at regular intervals to make sure they
are tight fit. Loose screw joints must be tightened and, if necessary, secured
against loosening by e.g. Loctite (medium stregth).
9.10 Damage
Check the pump as well as its environment regularly for damage such as
dents in the clutch guard.
9.11 Surface temperature
For identifying premature wear or pump overload, it is useful to check the

temperatures on the pump surface at regular intervals.
66 2012-09-25 BKF0004EN_D0024710002-09
This temperatures should never be much higher (max. 10 °C) than the media
temperature at the pump inlet. Checkpoints on the pump are the bearing lo-
cations, the housing and the shaft seal.
If the measured temperatures are higher than the permissible values, this is
an indication of wear or bearing damages. The pump must be replaced in this
case.
9.12 Bearing, gear, wheel chamber housing
Like shaft seals, bearings, gear and wheel chamber housings are wear items.
Wear largely depends on the occurring loads, life cycle as well as type and
proportion of solids in the medium. Wear cannot be identified from the outside.
The condition of a pump, however, can be analysed by the volumetric effi-
ciency factor. Decrease of the efficiency factor would normally indicate wear.
Therefore, a check on all operating data such as delivery, pressure, temper-
ature, drive data, degree of filter contamination should also be carried out
during maintenance work.
Further investigations into the cause are necessary in the event of major de-
viations (> 10 %) to the reference values. This helps detecting premature
pump failure in time. The pump must immediately be taken out of service at
a drop of delivery or pressure to 80 % of the original values. The achieved
values at initial commissioning serve as reference in this case.
BKF0004EN_D0024710002-09 2012-09-25 67
10 Repairs
10.1 General points
The term repairs covers:

● Troubleshooting, in other words establishing damage, determining and
localising the reason of the damage.
● Elimination of damage, in other words eliminating the primary causes
and replacing or repairing faulty components.
10.2 Troubleshooting
Leaks are the most frequent problem. If these occure on the pipelines, they
can be eliminated by straightforward tightening of the screw joints.
If the device itself is leaking, the respective seals have to be replaced.
10.3 Elimination of damage
Repair damage onsite, predominantly by replacing the defective device. The

device itself is generally repaired by the manufacturer.
If corresponding expertise and sufficient equipment is available, the consum-
er or OEM can also make the repairs. For support, spare part lists and
sectional drawings are available. They can be requested from the manu-
facturer.
NOTICE
Danger of property damage due to incorrect work and use of non-
original spare parts
the plant. That also applies to the use of non-original spare parts.
device.
2. Use only genuine original spare parts.
10.4 Return
If the device has to be repaired or checked over the manufacturer's permises,

ist must be packed suitably for transport. In addition, a safety data sheet for
the medium used must be enclosed with the device. In case of well-known
mineral oils, at least the exact type description is required.
68 2012-09-25 BKF0004EN_D0024710002-09
If harding or agglutinative media are involved, the device must be cleaned

befor it is returned.
Cleaning is also necessary of the device has been operated with hazardous
fluids.
Any openings must be closed.
10.5 Disposal
Disposal of the packaging and used parts must be garried out according to
the regulations valid in the country where the device is installed.
10.6 Detecting and eliminating problems
The following table lists the possible causes of the most frequently occuring
malfunctions and notes on possible remedies.
If the problems cannot be identified, please request help from the manufac-
turer.
Fault Potential causes

Increased Pump ● Negative pressure too high causing pump short filling
noise cavitation ● Suction height too high
● Suction filter plugged or too small
● Inner diameter of suction line too small
● Suction line too long
● Too many bends in the suction line
● Too many local constrictions in the suction line
● Suction line plugged or leaking
● Too high viscosity
● Temperature too low
● Wrong direction of rotation
● Place of installation too high
Foaming ● Suction line leaking
or trap- ● Fluid level in supply tank too low
ped air in
● Too little oil supply
medium
● Return line to tank leaking
● Wrong tank dimensioning
● Shaft seal or seal on suction line leaking
● Return line end above the fluid level in the supply tank
● Insufficient venting
● Too strong foaming in the gear
BKF0004EN_D0024710002-09 2012-09-25 69

Mechani- ● Incorrectly aligned or loose clutch
cal vibra- ● Magnetic coupling defective
tions
● Faulty or insufficient line fastening
● Wobbling pressure relief valve
● No noise-optimized design (missing dampers)
● Unfavourable place of pump installation
● Pump worn out, tooth flanks worn out
● Disturbances in pump operation
Pump does ● Too high negative pressure
not suck ● Fluid level in supply tank too low
● Magnetic coupling torn off
● Wrong direction of rotation
● Throttled shut-off element in the suction line
● Suction line too long
● Suction line leaking
● Suction resistance too high
● Foreign objects in suction line
● Volume of pressure pipe between pump and non-return valve too
little, pump cannot compress the air contained in the suction line
● Non-return valve not bled
● Too high start-up pressure if suction line is filled with air
● Speed too low
Insufficient ● Too high negative pressure
delivery ● Throttled shut-off element in the suction line
● Fluid level in supply tank too low
● Suction filter plugged or too small
● Too high viscosity
● Too low viscosity
● Too high speed
● Too high pressure
● Pressure relief valve set too low
● Pump sucks air
● Pump worn out
● Too high proportion of air in the oil
● Universal valve defective
70 2012-09-25 BKF0004EN_D0024710002-09

Insufficient Delivery ● Too low viscosity
pressure too low, ● Pressure relief valve set too low or does not shut
work
● Too low speed
drags in
pressure ● Driving power too low
pipe too ● Pump worn out
low
Excessive ● Too high pressure
power con- ● Too high viscosity
sumption
● Driving power too low
● Motor winding defective
Excessive ● Pressure relief valve set too high
operating ● Speed too high
temperature
● Cooling and heat dissipation insufficient
● Supply of fluid too low
● Fluid is being delivered into the supply tank via pressure relief valve
under load
Impermissi- ● Delivery-side valve cone not completely shut
ble pump ● Directly mounted pressure relief valve set too low
heating
(does not apply for the "universal valve" and "T-valve" versions)
● Too high pressure
● Gland lid overtightened
● Separating can insufficiently bled
● Admission pressure impermissibly high
● Pump worn out
Leakages ● Admission pressure impermissibly high
on shaft seal ● Wrong direction of rotation
● Too high radial shaft loading
● Temperature at sealing point too high
● Wrong seal material
● Missing confining fluid
● Separating can defective
● Sealing wear due to poorly lubricating medium
● Sealing wear through abrasive components in medium
● Sealing wear through curing medium
● Gland lid not sufficiently tightened
Clutch wear ● Incorrectly aligned or loose clutch
● Axial clutch clearance insufficient
● Clutch overloaded
● Temperature too high
BKF0004EN_D0024710002-09 2012-09-25 71

Magnetic ● Magnetic coupling under-dimensioned
coupling ● Pressure too high
torn off
● Driving motor oversized
● Too high starting torque
● Too high operating temperature
● Pump is blocking due to foreign objects
Short opera- Wear on ● Wear through abrasive components
tional lives bearing, ● Wear due to poorly lubricating medium
gear and
housing
parts ● Check corrosion, material compatibility
● Too high operating pressure for the media properties
72 2012-09-25 BKF0004EN_D0024710002-09
GEA Bloksma Compact Cooler
Instruction Manual
Shell & Tube
engineering for a better world GEA Heat Exchangers

Instruction manual P type Heat exchanger
Contact information
 GEA Bloksma BV
PO Box 1003
1300 BA Almere
The Netherlands
 Industrieterrein De Vaart
Draaibrugweg 15
1332 AB Almere
 Phone: +31 36 5492300

Fax: +31 36 5492390
 [email protected]
www.gea-bloksma.com
 Service Department
[email protected]
2
TABLE OF CONTENTS
1 Introduction ....................................................................................................................... 5
1.1 Notes for the customer ......................................................................................................... 5
1.2 Responsibilities of the owner/operator ............................................................................... 5
1.3 Guarantee and liability ........................................................................................................ 5
1.4 Environment ......................................................................................................................... 6
1.5 Safety ..................................................................................................................................... 6
1.6 Materials ............................................................................................................................... 7
1.7 Inhibitors .............................................................................................................................. 8
2 Installation and start-up.................................................................................................... 9
2.1 Receipt................................................................................................................................... 9
2.2 Installation ............................................................................................................................ 9
2.3 Start-up ............................................................................................................................... 10
3 Maintenance .................................................................................................................... 11
3.1 Cleaning and inspection intervals..................................................................................... 11
3.2 Cleaning of the heat exchanger ......................................................................................... 12
3.2.1 Mechanical cleaning of the tubeside ............................................................................................. 12
3.2.2 Chemical cleaning of the shell-/tubeside ....................................................................................... 12
3.3 Shut down periods.............................................................................................................. 12
3.4 Assembly and disassembly of the bundle ......................................................................... 13
Step 3: Removing the tube bundle ............................................................................................................... 14
3.5 Instructions for gaskets and bolting ................................................................................. 16
3.5.1 Gaskets .......................................................................................................................................... 16
3.5.2 Bolting ........................................................................................................................................... 16
4 Troubleshooting & repairs .............................................................................................. 17
4.1 Insufficient thermal performance..................................................................................... 17
4.2 Leaking tubes / tube-to-tubesheet connection ................................................................. 17
5 Spare parts & tools .......................................................................................................... 18
6 Instructions for storage ................................................................................................... 19
6.1 Standard storage (controlled conditions) ......................................................................... 19
6.2 Advice for conservation (uncontrolled conditions) ......................................................... 19
7 Cleaning of the heat exchanger ...................................................................................... 20
7.1 Chemical cleaning .............................................................................................................. 20
7.2 Post cleaning ....................................................................................................................... 20
8 Validation......................................................................................................................... 21
9 Glossary ........................................................................................................................... 22
3
The P-type heat exchanger can be divided into four sizes: P10, P13, P20 and P28.
The number indicates the shell size in centimetres. The construction of the P10 is slightly
different from the others. When necessary this manual has special texts (“For P10 only:”)
which apply to the P10 only.
There are two executions: the IV (Industrial Version) and the MV (Marine Version). The main
difference is the fact that the MV comes equipped with anodes in the tubeside circuit of the
heat exchanger. When there are differences between the models, this is pointed out in the
text. Please note that the P10-type is only available in MV version.
In addition, this manual applies to P-type heat exchangers with plain tubes (PT-type) as well.
4
1 Introduction
1.1 Notes for the customer

 Read this instruction manual before proceeding.
 Being familiar with the basic safety rules given in the ‘Safety’ chapter of this manual
is a prerequisite for safe and trouble free installation and operation.
The instructions given in this manual must be observed. Disregard may

endanger persons, cause damage to the heat exchanger and lead to
warranty and liability claims becoming forfeited.
1.2 Responsibilities of the owner/operator

 If you are in doubt how to proceed, contact GEA Bloksma.
 The owner/operator is responsible for proper installation of the product.
 The design pressures and design temperatures as stated in the specification sheet and
on the nameplate may never be exceeded.
 Maintenance of the product is the responsibility of the product owner/operator.
 The product should be maintained according the maintenance instructions in this
manual.
 This Instruction Manual is part of the consignment. To guarantee professional
handling of the product, it should be preserved in a way, that installation-,
maintenance- and operating personnel have access to it.
 The owner is held to supplement this manual by including any provisions required by
applicable accident prevention and environmental protection rules and regulations.
 The owner is held to observe the generally accepted rules governing safe and skilled
working practices.
 The owner is to observe the skill level and authorizations of the persons installing and
operating this product.
1.3 Guarantee and liability

The “General sales conditions of GEA Bloksma B.V.” are applicable. Also refer to the order
confirmation for possible additions.
Liability and warranty claims are excluded:
 If the instructions in this manual are not observed.
 If the heat exchanger is incorrectly operated or handled incorrectly.
 If the heat exchanger is used for a different than the intended application.
 If operating conditions deviate from those, used for the thermal calculation.
 If the heat exchanger is being used outside the design limits, including deviation from
used media as defined in the specification.
 If the heat exchanger is modified.
 If protective guards are left unused or taken out of service as a whole or partly.
 If equipment functions are changed without GEA Bloksma’s prior written consent.
5
 If applicable safety provisions are not observed.

 If the heat exchanger including pertinent accessories are maintained inexpertly
(timewise/expertise).
 In case of use of non-original parts.
 In case of any kind of corrosion.
1.4 Environment
Always respect the environmental laws and rules of the area where the heat exchanger is
installed.
If applicable the rules of the classification societies have to be respected.
Always be alert to the possibility of leakage!
1.5 Safety
Some symbols are used in the text to underline safety aspects:
Danger: risk of injury or danger to life.
Danger: risk of damage to the heat exchanger.
Warning for explosion risk due to explosive atmosphere. Ignition

sources may not be used. No welding, cutting, grinding allowed.
Warning that injuries may occur due to suspended loads. Only

employ suitable and approved lifting equipment. Secure loads to
prevent slipping and overturning during lifting.
Warning against burning hazards caused by hot surfaces.
Fire and smoking are not allowed.
You are entering a dangerous area. Authorized personnel permitted

only.
6
Warning that personal protective means must be worn when

carrying out work on the heat exchanger. Protective clothing, safety
goggles, safety shoes, safety gloves, ear protection and/or hard hat
should be used depending on the situation, otherwise there will be a
risk of injuries.
Warning that safety goggles must be worn when carrying out work
on the heat exchanger, otherwise there will be a risk of eye
damage/loss of vision.
Warning that hearing protection must be worn when carrying out

work on the heat exchanger, otherwise there will be a risk of hearing
damage or disorder.
Warning that compliance with (local) waste disposal regulations is

required.
Important information.
Maintenance and repair: cool down to ambient temperature and

depressurize the heat exchanger before any work is done on the
cooler.
General Note:
Most heat exchangers contain media, which can be irritating or dangerous

to humans. These media may cause problems in case of leakage. Since the
medium in the heat exchanger is at a raised temperature level, any leaks
may cause burns of the skin.
A heat exchanger is a pressure vessel designed for operation at certain

specific limits of pressure and temperature. All operating personnel should
be made aware of this specific design pressure and temperature, which is
stated on the name plate.
1.6 Materials
Always check if the media that flowing through the heat exchanger is consistent with the
materials used. GEA Bloksma makes its material choices on the basis of the media types
7
specified by the client, but is often not informed of possible contamination, higher/lower acid
levels than normal, additives and other aspects relevant to the choice of materials.
1.7 Inhibitors
Inhibitors may be added to the cooling medium in the heat exchanger. Contact the supplier of
the inhibitor to check for compliance of the inhibitor with the materials of the heat exchanger
(see specification sheet). Without proper prevention, micro organisms may grow excessively
in the cooling medium and can cause corrosion of metals. Bacteria also give an accumulation
of slurry / mud, forming a viscous film on the tube wall and blocking the flow and heat flux,
causing insufficient cooling.
Follow the instructions of the supplier for use of the inhibitor and
maintenance procedures.
8
2 Installation and start-up
2.1 Receipt
Upon reception of the heat exchanger check the packaging and the product:
 Report any damage to GEA Bloksma.
 Compare the data on the nameplate, the drawing and the GEA Bloksma order
confirmation/packing list.
 Check whether or not the correct instruction manual is present by comparing the
article number on the cover sheet with the article number of the instruction manual on
the order confirmation/packing list.
 Always store the heat exchanger in its original packing in a dry room at constant
temperature. When the heat exchanger is not being put into operation immediately
after receipt, follow the “Instructions for storage” (Chapter 6, Instructions for storage).
GEA Bloksma reserves the right to plug off a maximum 1% of the tubes (as per TEMA RGP-
RCB-2) (not applicable for parts used in nuclear installations).
2.2 Installation
Corrosion preventive fluid is present inside the heat exchanger. Before

installation drain the heat exchanger to remove this fluid. When complete
removal of the conservation fluid is necessary, it may be removed by
flushing with a mineral solvent like petroleum.
Only use tools and lifting equipment suitable for the task to be performed.
Load carrying equipment should be approved, of adequate size and
undamaged. Make sure no person pass or stay under the goods lifted during
handling.
9
2.3 Start-up
Do not exceed the design temperature and pressure as specified on the
nameplate, specification sheet and/or drawing. Avoid abrupt temperature
fluctuations; these may cause leaking of the tube-to-tubesheet connections
or other connections.
 Make sure that the cold medium circulation is established first, followed by the gradual
introduction of the hot medium.
 Vent both circuits.
 Vent both circuits again when the operating temperatures and pressures are reached.
 Check for leakage.
Respect the flow as specified on the specification sheet. Lower/higher speeds

may cause corrosion/erosion.
Avoid standstill: in non-conditioned circuits this may cause corrosion. In case of

standstill follow the instructions for shut down periods.
10
3 Maintenance
If necessary refer to “Assembly and disassembly of the bundle” for
(dis-)assembly instructions.
3.1 Cleaning and inspection intervals

The end user is responsible for (preventive) maintenance.
Because the degree of fouling strongly depends on the operating conditions we recommend
the following:
 Inspect the tubeside at least quarterly.
 Inspect the shellside at least twice a year.
With the results of these inspections you will be able to determine the required cleaning
intervals. Always keep performing regular inspections.
3.2 Galvanic protection

Not applicable for IV models (without anodic protection).
The MV models of P-type heat exchangers are fitted soft iron anodes on the tubeside. When
inspecting the tubeside of the heat exchanger, also inspect the condition of the anodes (always
drain the tubeside circuit before removing the anodes).
The consumption of the anodes strongly depends on the operating conditions. If most of the
anode material is dissolved, they need to be replaced. For spare parts, contact our Service
Department at [email protected].
For example only:
The anode 1 is a new one (for comparison), anode 2 should be replaced if a high consumption
of the anodes has been determined. Anode 3 and anode 4 should be replaced immediately.
Please note that the above example is indicative only, the user should estimate when the
anodes need replacement.
11
3.3 Cleaning of the heat exchanger
3.3.1 Mechanical cleaning of the tubeside

The tubes can be cleaned with a tube brush. Use original GEA Bloksma brushes only; these
have the correct dimensions and are of a suitable material. Other brushes may damage the
protective layer that is in the normal course of events present on the tube walls.
3.3.2 Chemical cleaning of the shell-/tubeside

Cleaning of the shellside is normally seldom necessary.
The shell- as well as the tubeside can be cleaned by circulating a chemical solution through
the heat exchanger. Another possibility is disassembling of the bundle and submerging the
tubebundle in a tank filled with a chemical solution.
There are various international companies (please refer to Appendix B) which can deliver
products for the chemical cleaning. They have world-wide offices in many countries and can
give you cleaning advice or can clean the heat exchanger for you.
Chemical cleaning can damage the heat exchanger. Let the supplier of the
chemical cleaning agent determine whether the agent is suitable in combination
with the materials of the heat exchanger (see specification sheet).
3.4 Shut down periods
Avoid the heat exchanger standing still in freezing conditions: this may
cause damage to the tubes. Check for the proper glycol content to prevent
freezing.
During shut down periods longer than a week the heat exchanger has to be
drained completely and dried by means of preheated compressed air.
When a corrosive medium is used in the heat exchanger: during shut down
periods longer than 24 hours. After draining a corrosive medium, the heat
exchanger has to be rinsed with fresh water.
When not used continuously, the heat exchanger should be drained, rinsed
with fresh water and dried for periods longer than 24 hours.
Stopping of the flows, cooling down and draining of the heat exchanger
has to be done in a manner to minimize thermal stresses on the heat
exchanger.
Never stop one of the flows of the heat exchanger while the other one stays
in operation, because of the risk of boiling.
12
3.5 Assembly and disassembly of the bundle
The circumference of one of the tubesheets is fitted with three grooves (fixed tubesheet). The
two outer grooves carry O-rings (sealing between shell- and tubeside). The middle groove of
the fixed tubesheet is for the fixation of the position of the tubebundle by means of ‘fixation
plates’.
1 Tubesheet 4 Shell
2 O-ring 5 Tubes
3 Fixation plate
Figure 1: Schematic drawing of tubesheet construction
The other tubesheet (floating tubesheet) will be not fixed and is supposed to slide according to
thermal extension.
13
For P10 only: Instead of fixation plates the P10 has a metal spring ring in the middle groove of
the tubesheet. As soon as the bolts are loosened the position of the tube bundle is no longer
fixated. Tubeside inspection or cleaning remains possible, but extra attention is required
because the tube bundle is not fixed anymore. Except when performing a pressure test, we
recommend to drain both circuits.
Step 1: Disassembly
Cool down to ambient temperature and depressurize the heat exchanger

before any work is done on the cooler.
 Depressurize both circuits.

 Drain the tubeside circuit, by opening the drain in the lowest point and the vent in the
highest point.
 Mark the position of all parts that will be disassembled, so they can be re-assembled in the
correct position later on.
In case the heat exchanger is placed vertically, take care the bundle
is supported before proceeding with untightening the nuts (fixation
plates come loose as well).
 Remove the waterboxes by untightening the nuts (the fixation plates come loose as well)
 Assemble the fixation plates again with the nuts (not necessary when the tubebundle is
going to be removed (see step 3))
 2- or 3-pass heat exchangers have composite (or optional Brass) partitions on the
tubesheet(s) for dividing the tubeside circuit; mark their position and remove them
 Remove the outer O-ring from both tubesheets
 Only for a pressure test: pressurize the shellside again. Depressurize the shellside again
after the pressure test.
For P10 only: Remember that the tube bundle is not fixed!
Step 2: Removing the tube bundle

 Drain the shellside circuit, by opening the drain in the lowest point and the vent in the
highest point.
 Mark the position of the tube bundle.
 Move the tube bundle to one side until the inner O-ring shows (do not move the tube
bundle further than necessary) and remove the O-ring.
14
 Move the tube bundle to the other side and remove the outer O-ring on this side as well.
 Carefully pull the tube bundle from the shell.
 Support the tube bundle under the baffle(s) or support sheet(s) when lifting it, be careful
not to bend the baffles (this would affect the thermal performance of the heat exchanger).
The fins are very fragile parts of the heat exchanger and should be handled
with care.
For casting design with a blind side, bundle is designed with a small and a
big tubesheet. The small tubesheet is inserted at first in the casting with the
4 o-rings already mounted. The fixed tubesheet has to be placed always at
the channel side (for 2 pass execution).
Step 3: Assembly
 Push the tube bundle in the shell. Do not push it completely into the shell. For big
bundle sizes, it is preferable (when possible) to insert the bundle vertically in the shell.
The tube bundle can be lifted vertically with the help of threaded holes in the
tubesheets (1). For horizontal assembly the bundle should be supported under the
baffle or support sheet.
 Check the position of the (optional) baffle(s). The position of the first baffle should
always be at the same side as oil inlet.
 Assemble the inner O-ring on the first tubesheet.
 Move the tube bundle gently inwards until both O-ring grooves in the other tubesheet
are accessible.
 Assemble the inner O-ring on the second tubesheet.
Hint: when it is difficult to move the tube bundle through the shell, you
can use a strip between tubesheet and channel and then tighten bolts and
nuts.
 Move the tube bundle in its final position.
Tubeside assembly:
 Assemble the outer O-rings on both sides
 Assemble the composite (or optional Brass) partition(s) on the tubesheets of 2- or 3-pass
models.
 Position the fixation plates (3) to secure the bundle in the shell. Note that the fixation
plates of the cooler with an even number of tube passes should always be mounted on
the same side as the channel.
 Assemble the waterboxes and all connections
 Start-up the heat exchanger again:
15
 Make sure that the cold medium circulation is established first, followed by the
gradual introduction of the hot medium
 Vent both circuits
 Vent both circuits again when the operating temperatures and pressures are reached
 Check for leakage.
3.6 Instructions for gaskets and bolting
3.6.1 Gaskets
One type of gasket is being used in this heat exchanger:
O-rings: After disassembly of the heat exchanger never use the old O-rings again. Replace
them with new and original O-rings.
Warning: The O-rings have to be lubricated with a special O-ring

lubricant (O-ring silicone paste or Parker O-lube) for easy assembly and
a good sealing capacity. Lubricants not suited for O-rings can affect the
sealing capacity of the O-ring (for instance never use Vaseline).
3.6.2 Bolting
Check bolts and nuts for damages. Tighten the bolts crosswise (see figure 2).
Figure 2: (Un-)bolting sequence
16
4 Troubleshooting & repairs
4.1 Insufficient thermal performance

In case of insufficient thermal performance check the following items:
 Whether all connections have been made according to the drawing.

 Whether the heat exchanger and the system have been properly vented.
 Whether the flows are according to the specification (check all valves, pipelines and
pumps, as well as the flow directions) .
 Whether the shell- as well as the tubeside have been cleaned recently (fouling can cause a
drop in performance and an increased pressure loss; an increased pressure drop is a good
indication that cleaning is necessary).
 Whether the heat exchanger has been re-assembled properly after disassembly. The
position of the tube bundle may accidentally be mounted rotated 180° around its axis.
4.2 Leaking tubes / tube-to-tubesheet connection

It is often very hard to determine whether leakage occurs because of a leaking tube or because
of a leaking tube-to-tubesheet connection. The shellside of the heat exchanger can be
hydrotested, after disassembly of the tubeside. Follow the instructions in “Assembly and
disassembly of the bundle”. Subsequently pressurize the shellside. After hydrotesting
depressurize and drain the shellside again. Assemble the heat exchanger again.
The tubes are expanded into the tubesheet. It is either not possible (finned tubebundles) or
relatively complicated (plain tube bundles) to replace a leaking tube, but it can be plugged
with soft copper GEA Bloksma plugs (other materials are too hard and may cause leakage of
the adjacent tube-to-tubesheet connections) in both tube ends. Contact GEA Bloksma for
support when plugging off tubes is necessary.
17
5 Spare parts & tools
Available spare parts and tools for this type of heat exchangers:
 Set of gaskets (four O-rings)

 Set of soft metal rings for drains/vents
 Soft copper plugs
 Nylon tube brush
 Bolts / nuts
 Complete tube bundle
 For P10 only: Metal spring ring
 Fixation plates (for types > P10)
 Composite (or optional Brass) partitions (not for 1-pass heat exchangers)
 Waterbox
 Cover
 Anode
When placing orders please specify all data as stated on the nameplate.
Gaskets are subject to ageing. Expected lifetime of spare gaskets is

approx. 5 years when stored according to the rules below.
Rules for storage:

Dry, non-freezing environment at a constant temperature of about
20°C
Constant humidity level
Keep away from direct sunlight
Horizontally stored (not hanging on hooks)
Gasket material should be correctly disposed, observing the

environmental needs and regulations. Any national rules and directives
should be adhered to.
For updated spare parts lists of each GEA-Bloksma heat exchanger type, please visit www.gea-
bloksma.com in order to download an original parts list or contact your local GEA-Bloksma
supplier.
18
6 Instructions for storage
6.1 Standard storage (controlled conditions)

Every GEA Bloksma quality product is pressure tested before leaving the factory. The test is
performed using a conservation fluid, thus ensuring adequate protection against corrosion
during a maximum of six months after delivery. This fluid will protect the heat exchanger
when it is stored at controlled conditions, i.e. inside, in a dry room at constant
temperature. The conservation fluid is a petroleum based fluid.
6.2 Advice for conservation (uncontrolled conditions)

When the above mentioned storage conditions are not met, all openings have to be closed
airtight and you will have to fill the heat exchanger with an inert gas at a slight overpressure
(additionally silica gel can be added to absorb liquids). Attach a pressure gauge and check the
pressure at regular intervals. Alternatively, the heat exchanger can be treated with a rust
preventive liquid of a type suited for long term conservation.
When necessary contact a specialised company. Take the materials of the heat exchanger (see
specification sheet) into consideration. Be aware that in uncontrolled storage conditions large
amounts of water can accumulate in the heat exchanger as a result of condensation.
19
7 Cleaning of the heat exchanger
7.1 Chemical cleaning

For chemical cleaning several companies offer a comprehensive solution. The table below
lists a number of applicable cleaning agents that may be used for chemical cleaning.
manufacturer product
Drew HDE-777
Nalfleet MaxiClean 2
Unitor Aquabreak
Vecom Ultrasonic Multi Cleaner
Please refer to the manufacturer’s datasheet for specific properties,

concentration, duration of cleaning, temperature, etc.
7.2 Post cleaning

After cleaning work on the product has been done:
 Check the condition of the tube surfaces and coating.
 Check and clean all gasket surfaces.
 Replace damaged parts.
 Install new gaskets.
20
8 Validation
This is to certify the this manual has been validated internally by the GEA Bloksma
Engineering department.
The validation comprised of checks by a group of engineers, service personnel and users
whether the instructions in this manual comply with the tasks to be done by the owner and
relevant personnel.
The manual is validated against NEN 5509.
Almere, The Netherlands
P. van Leeuwen
Manager Engineering/R&D
21
9 Glossary
Refer to the figure(s) in the paragraph “Assembly and disassembly of the bundle” for an
explanation of the designation of parts of the heat exchanger in the text.
Conditioned circuit Closed circuit with a non-corrosive medium.
Unconditioned circuit Open circuit (for instance seawater) or a closed circuit

with a corrosive medium.
Coating Composite polymer layer that protects the material on
which it is applied against corrosion.
Inhibitor Additive to a medium flowing through the heat

exchanger which –expressly tailored to that medium-
reduces the speed of chemical reactions like corrosion.
Anodes / galvanic protection Introducing a soft iron anode in the tubeside circuit that is
more reactive to the corrosive medium flowing through
the heat exchanger. The anode slowly dissolves and is
leaving a corrosion protective layer on the inside of the
tubes.
22
10 Appendix B: Constructional directions for mounting a P-type

heat exchanger in a piping design.
Pay attention to the following points:

 Level (horizontal) and square mounting possibility.
 Bends in the piping must be located at a distance of at least three times the nominal
diameter of the pipe from the inlet of the heat exchanger.
 When a vaporizing cryogenic medium is used, the heat exchanger has to be placed under an
angle of 3° - 10°, in order for the vapour to be able to exit the heat exchanger, aided by
natural circulation. For a proper thermosyphon functioning, the height between the oil
cooler and the condenser should be at least 3 meters.
 Check if vent and drain connections are present in both circuits of the heat exchanger (when
not present on the heat exchanger, then construct them in the piping).
 Put a filter (with a permeability of 3 mm) before the inlet of both circuits of the heat
exchanger.
 Stress- and vibration free mounting possibility of the connections and the supports (fit
expansion bellows and/or silencer blocks when necessary).
 Disassembling possibility of the tube bundle (and other parts like drain and vent plugs).
 Expansion possibility of lockable liquid circuits.
 Danger of freezing of liquid circuits.
 The design data of the heat exchanger on the specification sheet1 and the drawing. E.g. the
flows: deviating from these can cause unacceptable high or low velocities.
A (temporary) lower flow in a conditioned circuit is acceptable when caused by a
temperature control valve in the conditioned circuit. Avoid standstill (unless the heat
exchanger is drained and flushed according to GEA Bloksma instructions at 3.4).
 When adding an inhibitor to one of the fluids in the heat exchanger, always check whether
this inhibitor can be harmful for the materials of the heat exchanger (see specification
sheet).
 Make sure that in case of flow control (with conditioned circuits only) this is done gradually
(no ‘on-off-control’).
 To prevent leakages at cold start-ups (especially PF-type oil coolers) the shellside of the heat
exchanger must always be completely filled with the operating fluid before start up.
 GEA Bloksma reserves the right (according to TEMA RGP-RCB-2) to plug a maximum of 1%
of the tubes.
 When selecting a heat exchanger, GEA Bloksma’s choice for use of materials is based and
judged on the fluids specified by the customer at the time of selection.
However, if possible contaminations, higher or lower than normal pH-values and other
important properties are exceeding levels as specified at the time of the selection of the heat
exchanger, GEA Bloksma cannot be held responsible. Therefore, please always check
whether both fluids are compatible with the materials of the heat exchanger.
 Check whether the materials of the connecting piping are compatible with the materials of
the heat exchanger to prevent galvanic corrosion. E.g. the combination of stainless steel
piping running to and from the heat exchanger when CuNi 90/10 tubes are used, might lead
to a faster corrosion process than normal.
1
In connection with the applied materials the instruction manuals refer to the specification sheet of the heat
exchanger. Therefore always keep the specification sheet at your documentation.
23
Excellence Passion Integrity Responsibility GEA-versity
GEA Group is a global mechanical engineering company w ith multi - billion euro s ales and operations
in more than 50 countries. Founded in 1881, the company is one of the largest providers of
innovative equipm ent and process technology. GEA group is listed in the STOXX Europe 600 Index.
© GEA Group AG · All rights reserved · IM-P-EN Rev.C·200022301
GEA Heat Exchangers

GEA Bloksma B.V.
Draaibrugweg15, 1332 AB Almere, Netherlands
Phone +31 3654 92 3 00, Fax +31 3654 923 90
[email protected], www.gea-bloksma.com
Operating Instructions
Shell-and-Tube Heat Exchanger

Series EKM, ECM, SKM
Universal Hydraulik GmbH
Siemensstraße 33
D-61267 Neu-Anspach
Phone: +49 (0) 60 81 94 18-0

Fax: +49 (0) 60 81 96 02 20
E-Mail: [email protected]
Internet: www.universalhydraulik.de
Status: Edition 07/2011 (Copy Deadline 09.02.12)
© 2010 Universal Hydraulik GmbH

These operating instructions are not subject of the updating service. Passing on as well as reproduction
of these operating instructions and all associated documents, use and disclosure of their content is pro-
hibited, unless expressly permitted by Universalhydraulik GmbH in writing. Violations obligate to compen-
sation.
In case of registered patents, utility models or designs all rights remain reserved.
Table of contents
Table of contents
1 Introduction ...................................................................................... 3
1.1 About these operating instructions .......................................................... 3
1.2 Notes on use ........................................................................................... 3
1.3 Intended use ........................................................................................... 4
1.4 Warranty and liability............................................................................... 5
2 Notes on safety ................................................................................ 6

2.1 Standards and regulations ...................................................................... 6
2.2 General safety measures ........................................................................ 6
2.3 Technical condition ................................................................................. 7
2.4 Safety requirements concerning assembly and installation .................... 7
2.5 Notes on safety for operation .................................................................. 8
2.6 Requirements concerning personnel ...................................................... 8
2.7 Handling ancillary materials and service fluids ....................................... 9
2.8 Warning decals and type plate .............................................................. 10
3 Technical data ................................................................................ 11

3.1 Oil/water heat exchangers series EKM ................................................. 11
3.2 Oil/water heat exchangers series ECM ................................................. 11
3.3 Requirements concerning the water quality .......................................... 11
3.3.1 Water hardness..................................................................................... 12
3.3.2 pH-value ............................................................................................... 12
3.3.3 Assessment of cooling water based on constituents............................. 13
3.3.4 Types of cooling waters/peculiarities .................................................... 14
Industrial water...................................................................................... 14
Fresh water ........................................................................................... 14
Sea water .............................................................................................. 14
Brackish water ...................................................................................... 14
3.3.5 Flow velocity of cooling water ............................................................... 15
3.3.6 Applicability for seawater ...................................................................... 15
3.3.7 Filtration of cooling water ...................................................................... 17
4 Technical description .................................................................... 17

4.1 Design ................................................................................................... 18
4.2 Description of function .......................................................................... 19
4.3 Connections .......................................................................................... 20
Dokument 2010/08/00004;2;1 BA Edition 07/2011 1

EKM, SKM, SKM - englisch
Table of contents
5 Transport and storage ................................................................... 21

6 Assembly/disassembly ................................................................. 22
6.1 Assembly conditions ............................................................................. 22
6.2 Installing and connecting the heat exchanger ...................................... 23
6.3 Disassembling the heat exchanger....................................................... 25
7 Operation ....................................................................................... 26
8 Maintenance, repair and cleaning ................................................ 27
8.1 Maintenance ......................................................................................... 27
8.1.1 Maintenance intervals ........................................................................... 27
8.1.2 Replacing the zinc anode ..................................................................... 28
8.2 Cleaning ............................................................................................... 28
8.2.1 Notes on safety for cleaning ................................................................. 28
8.2.2 Internal cleaning of the tube bundles .................................................... 29
8.2.3 Reinstallation after cleaning ................................................................. 30
9 Waste disposal .............................................................................. 31
2 Edition 07/2011 Dokument 2010/08/00004;2;1 BA

Introduction
1 Introduction
1.1 About these operating instructions
These operating instructions will help you to become familiar with the use of
shell-and-tube heat exchangers of series EKM, SKM and ECM from Univer-
sal Hydraulik GmbH. These instructions enable a quick lead-in and contain
all information required for safe and professional use of the heat exchang-
ers.
This manual describes the functionality and handling or heat exchangers of
series EKM, SKM and ECM. Further information can be found in the associ-
ated data sheets. Information on other models is available on request from
Universal Hydraulik GmbH or under www.universalhydraulik.com.
Knowing these instructions is mandatory for using shell-and-tube heat ex-
changers of series EKM, SKM and ECM from Universal Hydraulik GmbH.
You should therefore make yourself familiar with the contents and follow the
notes on safety for handling heat exchangers in particular. You will thereby
ensure full utilization of the product's capacity. The right for product modifica-
tions within the scope of further technical development remains reserved.
1.2 Notes on use

These operating instructions are divided into 9 chapters. The chapter title
appears on each page at the right or left in the header. The footer contains
information about the status of the operating instructions in form of a release
date and the page number. For easier navigation these operating instruc-
tions contain cross-references, which help you to find your way through the
document.
If you work with the electronic document a click with the left mouse button
will bring you directly to the referenced point in the document. In the same
way you can jump to the desired point from the table of contents and from
the list of illustrations.

Introduction
These operating instructions use the following symbols for warnings

and notes as well as signal words:
DANGER
Warning of possible dangers for health and life
DANGER
Warning of possible dangers for health and life caused by poison
ATTENTION
Warning of possible damage to property and equipment
NOTE
Hints for use and useful information
NOTE
Note on environmental protection
1.3 Intended use

Shell-and-tube heat exchangers from Universal Hydraulik GmbH have been
designed for use with certain fluids, pressures, temperatures, operating
characteristics, etc. The exact specification must be determined on basis of
the prevailing operational requirements and conditions at the operating com-
pany before putting the heat exchanger into use. The technical conditions for
use of each heat exchanger can be taken from the type plate.
The shell-and-tube heat exchanger must only be operated by instructed ex-
pert personnel in compliance with the notes on safety specified in these op-
erating instructions. Safe and trouble free operation is only assured if the
unit is used for the purpose it is intended for and in accordance with these
instructions.
Any use beyond these limits is considered unintended. The manufacturer will
not assume liability for any damage to persons or property resulting from un-
intended use, as this is the sole responsibility of the operating company.

Introduction
1.4 Warranty and liability

The general terms of sales and delivery which were handed over to the user
of the shell-and-tube heat exchanger by Universal Hydraulik GmbH are gen-
erally valid. If these are not available, they must be requested from the man-
ufacturer.
Warranty and liability claims for damage to persons and property are ex-
cluded, if they result from one or several of the following causes:
 Unintended use of the heat exchanger
 Inappropriate commissioning, installation, operation and maintenance or
repair of the heat exchanger
 Structural changes to the heat exchanger
 Operation of the heat exchanger with incorrectly installed connections to
the plant systems and defective or incorrectly assembled safety features
 Negligence of the safety regulations and notes in these operating instruc-
tions
 Use of spare parts and wear items as well as operating materials and
cleansing agents other than those recommended by the manufacturer
Universal Hydraulik GmbH solely assumes warranty and liability for material
and manufacturing faults.

Notes on safety
2 Notes on safety
2.1 Standards and regulations
The shell-and-tube heat exchanger has been built in accordance with the
currently valid technical rules and regulations and is safe to operate. The
design of the heat exchanger is based on the general health and safety re-
quirements of the applicable laws, standards and directives. The safety of
the heat exchanger will be confirmed by the CE-sign and the declaration of
conformity, if this should be necessary.
All notes on safety in these operating instructions refer to the currently valid
national laws and the directives of the European Union. In other countries
the applicable laws and country specific regulations must be adhered to.
Beside the safety regulations in these operating instructions you must also
observe and follow the generally valid regulations for prevention of accidents
and protection of the environment. All information in these operating instruc-
tions must be fully complied with at all times. Apart from this you must also
follow the notes on safety in the "data sheet for warnings and notes on safe-
ty for hydraulic systems".
2.2 General safety measures

The following general safety measures must be adhered to at all times:
 The shell-and-tube heat exchanger must only be used for the purpose it
is intended for.
 The heat exchanger must only be installed, operated and serviced by
trained and specially instructed skilled personnel. These persons must
have read and understood the operating instructions. This includes spe-
cific knowledge of how to avoid risks of injury for the operator and third
parties.
 All safety regulations in these operating instructions and in the applicable
documents must be observed and complied with.
 Unauthorized persons should not be able to access the heat exchanger.
 Loss of use and environmental impacts caused by incorrect handling
must be ruled out.
 Transport, assembly and disassembly, operation as well as care and
maintenance must be performed in strict compliance with the applicable
regulations concerning industrial safety and protection of the environ-
ment.
 All work on the heat exchanger must be carried out with care and under
due consideration of the "Safety" aspect.

Notes on safety
 When installing the heat exchanger into a system, the manufacturer of

this system is obliged to include the regulations, notes and descriptions
contained in this manual into the operating instructions issued by him.
 Spare parts must generally be purchased from Universal Hydraulik
GmbH. Universal Hydraulik GmbH will not assume liability for damage
resulting from the use of spare parts from other manufacturers.
2.3 Technical condition

The following must be observed:
 In order to rule out potential dangers and assure an optimal perfor-
mance, no changes or modifications should be made to the heat ex-
changer.
 The operator is obliged to operate the heat exchanger only in proper and
safe condition. The technical state must always comply with the legal re-
quirements and regulations.
 Before every start-up of the system in which the heat exchanger is inte-
grated, the heat exchanger must be inspected for damage and proper
condition.
 Any changes to the heat exchanger, which may affect the safety, must
be immediately reported to the user by the personnel.
 The heat exchanger must only be connected to supply lines provided
and designed for this purpose.
2.4 Safety requirements concerning assembly and

installation
The following safety requirements must be strictly fulfilled when as-
sembling and installing the shell-and-tube heat exchanger:
 The heat exchanger must solely be assembled by trained and instructed
personnel.
 Unauthorized assembly and installation work is not permitted.
 All heat exchanger components must be secured according to the in-
structions for the transport aid used during transportation.
 Only sufficiently dimensioned lifting gear and tackle may be used for
transportation.

Notes on safety
2.5 Notes on safety for operation

The following notes on safety must be followed in operation of the
shell-and-tube heat exchanger:
 Depending on the application related requirements the user must provide
safety facilities like safety valves, heat insulation covers, temperature
sensors, etc. The heat exchanger must only be operated if all safety fea-
tures are in place and functional. The proper state of the safety features
must be checked regularly, possibly occurring faults must be rectified
immediately.
 The heat exchanger must be provided with a mechanical protection
against unauthorized access and contact.
 The heat exchanger must not be exposed to excessive temperature and
overpressure.
 Safe operation of the heat exchanger must be assured at all times.
 Throughout the entire operation the prevailing conditions must suit the
operation of the heat exchanger.
 The system must be immediately shut down if changes on the heat ex-
changer, such as e.g. an increased operating temperature, are detected
during operation.
 Work on the heat exchanger must only be carried out with the system
shut down.
 A label stating that work on the heat exchanger is in progress should be
attached near the on/off switch of the system.
 Welding work on the heat exchanger is not allowed.
2.6 Requirements concerning personnel

All personnel must be made familiar with dangers that may arise when han-
dling shell-and-tube heat exchangers before starting any work. Dangers of
injury may arise from the heat exchanger if it is used by untrained personnel.
Any person entrusted with starting, operating or servicing the heat exchang-
er must have read and understood the complete operating instructions. This
is also valid if the corresponding personnel has already worked with the heat
exchanger or has been trained accordingly.
The operating instructions must always be within the reach of the personnel.
It is recommended to obtain a written confirmation from the personnel for re-
ceiving the instructions and understanding their contents. Knowing the con-
tents of the operating instructions is a major prerequisite for protecting
people against dangers, avoiding mistakes and the safe and trouble free op-
eration of the heat exchanger.

Notes on safety
In the end the responsibility for accident-free operation lies with the operator
or the authorized persons who have to deal with heat exchangers as part of
their duties.
In order to ensure safe handling of the shell-and-tube heat exchanger
the personnel is obliged to the following:
 Smoking, eating and drinking is not permitted in the vicinity of the heat
exchanger.
 Work on the heat exchanger is not permitted if you are overtired, under
the influence of alcohol and/or medication.
 The personnel must not be physically handicapped to such an extent that
the attentiveness and the judgement is temporarily or permanently re-
stricted.
 The personnel must wear protective clothing, gloves and, if necessary,
goggles and breather mask, according to the occurring work.
 All notes on safety in these operating instructions and in the accompany-
ing documents must be taken notice of and adhered to.
 When noticing dangers that could cause personal injuries the system
with integrated heat exchanger must be shut down immediately.
 The personnel must have profound knowledge of the following operation
sequences, instructions, modes of conduct and components:
– Operation sequences in the interplay between heat exchanger and
system
– Safety features of the heat exchanger and their correct function
– Borders, safety devices and identification of the danger zone around
the heat exchanger
– Behaviour and action in case of danger
 Maintenance and repair work on the heat exchanger must only be carried
out by trained skilled personnel.
2.7 Handling ancillary materials and service fluids

For all lubricants and service fluids as well as cleansing agents used in con-
nection with operation and maintenance of the heat exchanger the regula-
tions and EC safety data sheets concerning storage, handling, use and
waste disposal, issued by the corresponding manufacturer, must be ob-
served.
The following must be observed when handling ancillary materials and
service fluids:
 Do not use substances with unknown properties. If necessary, consult
the manufacturer.
 Fuels and lubricants, cleansing agents and the respective containers
must not be disposed of together with normal domestic refuse or seep in-
to the sewer or the ground. For waste disposal you should strictly follow
the corresponding regulations.

Notes on safety
 Please observe the instructions on the safety data sheets for handling
the permitted cleansing agents. The following measures must be applied,
among others:
– After contact with the skin clean off with water and soap
– After eye contact rinse the eyes for at least 10 minutes under flowing
water, if necessary consult a medical specialist
– After inhaling ensure an adequate supply of fresh air or oxygen, if
necessary consult a medical specialist
2.8 Warning decals and type plate

The following decals can be found on the shell-and-tube heat exchang-
er (see Fig. 1):
 Type plate
 Warning decal "Warning: hot surface"
Fig. 1: Decals on heat exchanger

Technical data
3 Technical data
3.1 Oil/water heat exchangers series EKM/SKM
Designation Value
Operating pressure shell max 35 bar
Operating pressure tubes max 16 bar
Operating temperature min/max 5 °C/95 °C
Tab. 1: Technical data series EKM/SKM
3.2 Oil/water heat exchangers series ECM

Designation Value
Operating pressure shell max 20 bar
Operating pressure tubes max 10 bar
Operating temperature min/max 5 °C/95 °C
Tab. 2: Technical data series ECM
NOTE
Specifications on technical data, such as e.g. dimensions, performance data
and calculation examples for all heat exchangers of series EKM and ECM
can be found in the associated data sheets.
3.3 Requirements concerning the water quality
NOTE
Any specifications concerning the water quality are recommendations. In ex-
ceptional cases unexpected reactions may occur due to certain concentra-
tions of constituents.
For the assessment of the available cooling water for use in shell-and-tube
heat exchangers both the water quality and the constituents are of signifi-
cance.
The water quality is determined by:
 Water hardness
 ph-value of the water

Technical data
3.3.1 Water hardness

The water hardness specifies the content of hardness constituents (car-
bonates and bicarbonates).
Especially with higher temperatures these hardness constituents deposit on
the tube surfaces and cause a reduction of heat exchanger performance.
The critical water-temperature is 63 °C. With extremely hard water these de-
posits must be taken into consideration when designing the heat exchanger.
Degree of hardness Water quality

0 – 5 °dH very soft water
5 – 10 °dH soft water
10 – 20 °dH medium hard water
20 – 30 °dH hard water
> 30 °dH very hard water
Tab. 3: Classification of the water quality acc. to German hardness °dH
The following applies as a rule of thumb for converting to German

hardness:
 10 mg/l hardness constituent correspond with 1 °dH
3.3.2 pH-value
The following applies for shell-and-tube heat exchangers with copper
and copper-nickel tubes:
 pH-value not < 6. Lower values may cause corrosion problems.
The following applies with alkaline water:

 Water hardness not < 6°dH. With lower values corrosion caused by free
carbonic acid may occur.
pH-value Water quality

4,5 highly acidic
4,5 – 6,0 acidic
6,0 – 6,8 weak acidic
7,0 neutral
7,2 – 7,7 weak alkaline
7,7 – 8,2 alkaline
8,2 highly alkaline
Tab. 4: Classification of water quality acc. to pH-value

Technical data
3.3.3 Assessment of cooling water based on constituents

The following table gives an overview over the compatibility of copper tubes
against water constituents in non-drinking waters.
Assessment criterion Approx. concentration range in Assessment Assessment

mg/l Cu-DHP CuNi10Fe1Mn
pH-value <6 0 0
6 to 9 + +
>9 0 0
Chloride to 1000 + +
> 1000 0 +(<25000mg/l)
Sulphate to 70 + +
70 to 300 0 +
> 300 – +(<25000mg/l)
Nitrate to 100 + +
> 100 0 0
free (aggressive) to 20 + +
carbonic acid
20 to 50 0 0
> 50 – –
Oxygen to 2*) + +
>2 0 +
Ammonium to 2 + +
2 to 20 0 +
> 20 – –
Iron (dissolved) to 10 + 0
> 10 0 -
Manganese (dissolved) to 1 + 0
>1 0 -
free chlorine to 5 + steady <0,5mg/l
>5 0 Push <3,0mg/l
Sulphide – 0
Ammonia – + (<15mg/l)
Tab. 5: Assessment of cooling water quality by constituents

Technical data
Explanation on table column "Assessment":

+: normally good compatibility
0: Corrosion problems can arise, especially if several factors are evaluated 0
–: use is not recommended
*): SF-copper has proven best in total absence of oxygen and sulphides dissolved in the water
3.3.4 Types of cooling waters/peculiarities

Industrial water
The following peculiarities must be taken into account:
 Normally untreated water (no drinking water)
 Very often extremely contaminated
 For the assessment a water analysis is required
 Copper, brass and steel show good resistance against industrial water
Water from rivers and water ditches

 It is recommended to use copper-nickel tubes
 Cast iron parts must be protected against corrosion by a suitable coating
 Normally untreated water (no drinking water)
 Very often extremely contaminated
 For the assessment a water analysis is required
Sea water
 Higher NaCl-content, therefore good electrolyte
 Pairing different materials causes the risk of electrolytic corrosion
 Materials required, which are not too far apart in the electrochemical se-
ries, or use a zinc anode
 Brass and copper-nickel alloys show good resistance against seawater
Brackish water
 Mixture of sea and fresh water
 Mostly high content of ammonia and chloride, therefore do not use brass
 Higher NaCl-content, therefore good electrolyte
 Pairing different materials causes the risk of electrolytic corrosion
 Materials required, which are not too far apart in the electrochemical se-
ries, or use a zinc anode

Technical data
3.3.5 Flow velocity of cooling water

The minimum cooling water velocity should be 1 meter/sec.
Seawater:
The maximum cooling water velocity should not exceed 1,5 meter/sec.
Freshwater:
The maximum cooling water velocity for Cu - tubes should not exceed 2 me-
ter/sec.
The maximum cooling water velocity for CuNi - tubes should not exceed 3
meter/sec.
Please see recommendations of the German Copper Institute for seawater
with includes sand and suspended matter.
3.3.6 Applicability for seawater

The Heat-exchangers were designed for the use with sea-water as cooling
medium. There are still some things to note.
Pitting corrosion on/in water tubes can be caused by many reasons.
- Sucked in sand will damage the inner surface of the tubes, these new
craters are good places for corrosion attack (Filtration required!)
- Especially ferritic / metallic particles can cause pitting corrosion on in-
ner surface of tubes
- Sources of these particles are often the harbour basin and internal
water pipes (made from iron) of the ship
- Acidly products of metabolism from biofouling supports the corrosion
process as well
Variant A: The water bonnet of the cooler is made from casted iron and is
coated with a layer of nickel. Electrochemical potential of the nickel-layer
isn’t far from this of the water-tubes and tube-sheet. A zinc-anode is not
necessary, but provides a greater security and may give a longer lifetime
under heavy conditions.
Also here ferritic particles (rust) are critical when transported in this area.
Then an attack on the nickel-layer is possible and pitting corrosion can oc-
cur.
Variant B: The water bonnet is made complete from gunmetal incl. zinc-
anode. The anode is either consumed (fully or partly) or not at all after a
certain amount of time.

Technical data
- Not consumed  you do have a problem with the material combina-

tion (the electrochemical series of the different materials involved).
Now other materials, which are lower within the electrochemical se-
ries, can corrode.
- Consumed (fully or partly)  it shows that it works and you have to
control it regularly. A mostly consumed anode loose its function and
other materials could corrode.
You will get a positive effect if heat-exchanger is installed vertical. So parti-
cles will sink down while water is not flowing.
Starting up procedure
Excellent using attributes of Copper-Nickel-materials are primary caused by
a protective layer of Cu(I)-oxide. Rising of this layer needs a certain time
(min. 24 hours) so the operating conditions while implementing the hydraulic
system are essential for the lifetime. Fill the system with clean seawater prior
to entering, while within and when leaving the harbour. However, establish-
ment of a fully mature film takes from 2 to 3 months at temperatures of 15-
17°C. On the other hand at 27°C common inlet temperature for the Middle
East, the establishment of the protective film occur within a few hours. The
first starting up should ideally be performed with clean seawater, to build up
of this protective layer.
Shutdown periods
If polluted water has been used, it should be disposed of and the pipe work
should be rinsed properly with clean seawater or fresh water. Replace the
water in systems with stagnation conditions every 4 – 5 days with oxygenat-
ed clean seawater. For prevention of Biofouling, if subsequent long stagnant
conditions are expected, blow-drying of the system is advisable. However,
this can lead to dehydration and spalling of the protective film.
NOTE
Avoid stagnation of water flow. If water not circulates, corrosion can occur.

Technical data
3.3.7 Filtration of cooling water

A possibilty to keep away ferritic particles, sand and biologic matter is water
filtration before water inlet/cooler.
We strongly recommend to use a water filtration before the seawater enter
the Heat Exchanger with a max. of 50 to 100 µm.

Technical description
4 Technical description
The shell-and-tube heat exchangers mainly consist of the following
components:
 Housing with one inlet and one outlet port for the medium to be cooled
 Tube bundle with aluminium fins
 Removable lids with cooling water inlet and outlet ports
 Angle bracket for installation
NOTE
Specifications on technical data, such as e.g. dimensions, performance data
and calculation examples for all heat exchangers of series EKM and ECM
can be found in the associated data sheets.
4.1 Design
NOTE
All heat exchangers of series EKM, SKM and ECM consist of the same
basic components. They are only different in design and pairing of material
(see corresponding data sheets).
Fig. 2: Components of shell-and-tube heat exchanger (series EKM and ECM)

1 Shell with inlet and outlet socket
2 Tube bundle with aluminium fins
3 Lid with inlet and outlet socket
4 Angle bracket for installation

The tubes of the tube bundles are tightly rolled into the shell. The two lids on
cooling water inlet and outlet side are tightly bolted to the shell with their
flanges. Sealing is achieved via gaskets between shell and lids. The alumin-
ium fins provide additional cooling area. These are pushed over the tube
bundles and metallically connected with the copper or copper-nickel tubes.
Through one drain port each the fluids can be drained from the pressure re-
lieved heat exchanger (e.g. for the purpose of maintenance or disassembly).
NOTE
Heat exchangers of series EKM are not equipped with a drain port for the
medium to be cooled.
Series EKM 500 is not equipped with a cooling water drain port. For correct
draining of all fluids, e.g. in case of a repair, on heat exchangers of this se-
ries a drain plug must be installed into the corresponding outlet pipe.
4.2 Description of function

The medium to be cooled (e.g. hydraulic oil) enters the heat exchanger
through an inlet port on the shell, runs through reversing segments and final-
ly leaves the heat exchanger through an outlet port. The cooling water flows
through the inlet and outlet ports and circulates once or several times
through the tube bundle. The heat from the medium to be cooled is trans-
ferred via the surface of the aluminium fins to the cooling water and dissipat-
ed to the outside by the cooling water flow.

4.3 Connections
Fig. 3: Connections on heat exchanger 1-way type "O"

1 Cooling water inlet
2 Cooling water outlet
3 Outlet for cooled medium
4 Inlet for medium to be cooled
Fig. 4: Connections on heat exchanger 2-way type "T"

3 Inlet/outlet for medium to be cooled
Fig. 5: Connections on heat exchanger 4-way type "F"


Transport and storage

DANGER
Danger of injury by improper transport.
The total mass of heat exchangers of series EKM, SKM and ECM can be up
to 150 kg. For this reason only sufficiently dimensioned lifting gear and lifting
tackle acc. to DIN 15003 "Lifting gear; load suspension devices, loads, forc-
es, terminology" and BGV D8 must be used for transport purposes.
ATTENTION
Warning of possible damage to sealing surfaces.
During transportation take care not to scratch the sealing surfaces on the
connecting flanges.
NOTE
Danger of contamination caused by conserving agents.
When using conserving agents make sure that these do not seep into the
ground or the sewer system. These must be disposed of in compliance with
the applicable regulations for protection of the environment. This applies al-
so for de-conservation.
Depending on their weight, heat exchangers are either transported in card-

board boxes or on wooden pallets. All openings on the heat exchanger are
closed with plugs.
Before storage of the heat exchanger you must make sure that all fluid ports
are closed with plugs. The heat exchanger must be treated with a conserv-
ing agent (e.g. anti-corrosion oil) as protection against corrosion. The stor-
age period for the heat exchanger must not exceed 2 years. All conserving
agents must be completely removed before reinstallation.
In order to avoid frost damage when storing at temperatures below zero the
heat exchanger must be emptied from all cooling water. Most of the standard
models are provided with drainage ports to serve this purpose. For models
without drainage port such a port must be installed in the outlet pipe for me-
dium 1.

Assembly/disassembly
6 Assembly/disassembly
DANGER
Danger of injury.
Before assembling or disassembling the heat exchanger the system must be
shut down and secured against switching back on.
DANGER
Danger of escaping fluids with the risk of contamination.
If the heat exchanger is installed in a system with tank, you should check
whether the tank filling level is above the installation position before assem-
bling or disassembling the heat exchanger. In this case the tank must be
emptied beforehand.
DANGER
Danger of injury by improper transport.
The total mass of heat exchangers of series EKM and ECM can be up to
150 kg. For assembly and disassembly work be sure to use sufficiently di-
mensioned lifting gear and lifting tackle acc. to DIN 15003 "Lifting gear; load
suspension devices, loads, forces, terminology" and BGV D8.
6.1 Assembly conditions

The full utilization of the heat exchanger performance depends on certain
measures, which must be observed during assembly and installation.
 Use only pipes and fittings of identical or matching material (type specifi-
cation) when connecting the heat exchanger.
 Check the heat exchanger for contamination and foreign bodies in the
connecting ports, to ensure free flow of the fluids.
 Connect the heat exchanger so that the fluid drain ports for cooling water
and fluid to be cooled are on the underside of the heat exchanger.
 Keep the connecting ports free of strain when connecting the pipeline
system. If necessary support the pipelines properly.
 When using an automatic water throttle valve it should be installed at the
inlet of the heat exchanger.
 Route the cooling water outlet pipe in such a way, that the heat ex-
changer remains filled with water at any time.

6.2 Installing and connecting the heat exchanger

The heat exchanger must be tightly installed in its intended place and all
pipe connections are to be correctly assembled.
ATTENTION
Danger of damage to the system.
Do not mix up inlet and outlet pipes by mistake. Follow the piping diagrams.
ATTENTION
Danger of cracking.
Using sealing tape on the pipe threads increases the resistance between the
connecting components and thus the risk of cracks appearing in the castings
of the heat exchanger. The threads should not be overtightened.
ATTENTION
Danger of damage to heat exchanger components.
Heat exchangers with sea and brackish water coolant circuit must be fitted
with a zinc anode in order to prevent electrolytic corrosion.
ATTENTION
The water-drain port must in any case be arranged at the bottom as other-
wise the heat exchanger cannot be drained.
Proceed as follows to assemble the heat exchanger:
ATTENTION
Danger of cracking caused by inappropriate tightening of the fastening
screws on the connecting flanges. The screws must be evenly tightened
crosswise.
ATTENTION
Heat exchangers of series EKM 500 are not equipped with a water drain
port. To assure correct drainage of cooling water in case of repairs a water
drain port must be installed at the cooling water outlet.

 Empty the tank if necessary

 If necessary, fasten the heat exchanger on a solid foundation or another
fixed base, using the angle brackets provided for this purpose.
 Connect cooling water inlet and outlet pipes with the appropriate seals to
the corresponding connecting ports on the lids (see chapter 4.3)
 Connect inlet and outlet pipes for the medium to be cooled with the cor-
responding seals to the connecting ports on the shell side (see Fig. 4.3),
tighten the fastening screws on lids and flanges of the supply pipes
evenly crosswise.
The following measures can be applied to ensure correct functioning of

the heat exchanger in different systems:
 Install the safety valve into the supply pipe for the medium to be cooled
or into the cooling water supply pipe, as a protection against excessive
flow and pressure fluctuations.
 Install a filter into the supply pipe for the medium to be cooled or into the
cooling water supply to protect the heat exchanger against contamination
or soiling, especially if the water is not taken from the municipal water
supply.
 Install a zinc anode (only possible with bonnets made from gunmetal) in-
to the lid or the inlet pipe (see chapter 8.1.2), to prevent electrolytic cor-
rosion on components of the heat exchanger
 Install the automatic throttle valve into the corresponding inlet pipe, in or-
der to compensate overpressure
NOTE
For information on the selection and installation of safety and throttle valves
as well as filters, please contact Universal Hydraulik GmbH.

6.3 Disassembling the heat exchanger
DANGER
Danger of injury caused by fluids under pressure.
Always relieve all systems from pressure and secure the systems according
to the valid accident prevention instructions before starting disassembly
work on the heat exchanger.
DANGER
Danger of burning on hot parts.
Touching heated up components (e.g. supply pipes) on the heat exchanger
can cause burns. Allow all components to cool down before disassembling
heat exchanger and supply pipes.
DANGER
Risk of contamination caused by drained off fluids.
When draining off fluids do not let these seep into the ground or the sewer
system. Such fluids must be collected in safe containers and disposed of in
compliance with the valid regulations for the protection of the environment.
ATTENTION
Danger of injury by the heat exchanger dropping down.
Use sufficiently dimensioned lifting gear and lifting tackle to secure the heat
exchanger against falling down, before starting to disassemble.
Proceed as follows to disassemble the heat exchanger:

1. Shut down the system and secure it reliably against being switched on
again
2. Relieve the heat exchanger and the connected system pipes from
pressure and shut these off by the corresponding valves
3. Drain off all fluids through the drain plugs provided for this purpose, if
necessary empty the tank
4. Disconnect the inlet and outlet pipes for the medium to be cooled from
the connections on the shell side
5. Disconnect the cooling water inlet and outlet pipes from the ports on
the lids
6. Unscrew the fastening screws on the heat exchanger, lift the heat ex-
changer out with a sufficiently dimensioned lifting gear and place it
safely

Operation
7 Operation
After installation in the system the heat exchanger can be started up. In case
of using seawater Universal Hydraulik recommends a flushig of the whole
cooling-water-system with an inhibitior to prevent corrosion. Duration of this
flushing should be approximateley 48hrs. Operator is responsible for inhibi-
tor-liquid. Type of liquid depends on used materials and type of cooling me-
dium.
After start-up you should check the correct function of the heat exchanger.
The following inspections are required:
 Check connections for leaks
 If necessary, check valves, fittings and filters for unrestricted flow and
proper function
 Check the correct function of the heat exchanger
ATTENTION
Danger of system damage caused by drops in performance.
Drops in performance can be caused by deposits of oil slurry on the shell
side or by lime deposits on the tube side. In this context read chapter 8.2.
NOTE
For a better determination of service intervals for newly installed heat ex-
changers it is recommended to record all parameters which permit conclu-
sions on the performance of the heat exchanger.
NOTE
If faults occur during operation of the heat exchanger which cannot be recti-
fied immediately, you should contact Universal Hydraulik GmbH.
Peculiarities of heat exchangers with sea or brackish water cooling cir-

cuit:
ATTENTION
Danger of material damage to components caused by aggressive cooling
fluids, like sea or brackish water.
Sea or brackish water and other caustic fluids must not be used as cooling
fluids in the standard models. The use of these aggressive cooling fluids re-
quires special materials.
The use of heat exchangers with cooling fluids such as sea or brackish wa-
ter requires special materials. Applications of this nature should strictly be
discussed with Universal Hydraulik GmbH.

Maintenance, repair and cleaning
8 Maintenance, repair and cleaning

DANGER
Danger of fluids escaping.
If the heat exchanger is installed in a system with tank, you should check
whether the tank filling level is above the installation position before starting
repair or cleaning work on the heat exchanger. In this case the tank must be
emptied beforehand.
NOTE
Repairs on the tube bundles of the heat exchanger are only permitted in
emergency situations. In this case Universal Hydraulik GmbH must generally
be contacted. Disturbed functions must be analyzed and reported to the
manufacturer.
NOTE
Contact the manufacturer to order spare parts and wear items.
Universal Hydraulik GmbH
Siemensstr. 33
D-61267 Neu-Anspach
8.1 Maintenance
8.1.1 Maintenance intervals
DANGER
Danger of drop in performance.
The maintenance intervals for the heat exchanger must be determined in a
way, that operation of the heat exchanger is not endangered by a drop in
performance.
The service life of a heat exchanger depends to a high degree on the quality
of the fluids and their constituents. The operator is solely responsible for the
determination of maintenance intervals. The performance parameters and
performance specifications detected during operation must be used for this
purpose.
The following information must be observed:
 When using a zinc anode this should be checked for wear two weeks af-
ter initial start-up, afterwards every 2 months.
 With the visual inspection of the anode determine the inspection inter-
vals, the corrosion thickness detected on the zinc metal can be used as
basis for this determination
 Replace the zinc anode after 70 % of the zinc quantity have been lost
8.1.2 Replacing the zinc anode

The zinc anode is replaced as follows:
1. Shut down the system and secure it against being switched on again
2. Shut off cooling water inlet and outlet pipes on the heat exchanger
3. Relieve the heat exchanger from any pressure and drain off all cooling
water
4. Unscrew the zinc anode, estimate the wear and replace it if necessary
5. Vent the pipes before switching the system back on
8.2 Cleaning
NOTE
Regular cleaning of heat exchangers of series EKM and ECM on the shell
side is not recommended by the manufacturer, because proper cleaning is
not possible on the shell side.
On the tube side the tube bundles can be cleaned internally. The perfor-
mance parameters and performance specifications detected during opera-
tion must be used to establish the cleaning intervals. The intervals must be
determined in such a way, that operation of the system is not endangered by
a drop in heat exchanger performance.
8.2.1 Notes on safety for cleaning
DANGER
Danger of injury by caustic burns or poisoning.
When cleaning the tube bundles with cleansing agents such as hydrochloric
acid or comparable products caustic burns to parts of the body or eye inju-
ries may occur, when failing to comply with the applicable industrial safety
regulations.
You should therefore always strictly comply with the applicable industrial
safety regulations when handling cleansing agents.
Always wear protective clothing, gloves and, if necessary, goggles and a
breather mask when working with aggressive cleansing agents.
ATTENTION
Properly vent the heat exchanger and the connected system before taking it
back into service.

ATTENTION
Danger of contaminating the medium.
By experience, the cleansing agent cannot be completely removed. For this
reason it is important to make sure that the cleansing agent is compatible
with the medium.
ATTENTION
Before using other comparable aggressive cleansing agents you should
generally contact Universal Hydraulik GmbH, in order to prevent important
components from being damages by incorrect treatment. Universal Hy-
draulik can arrange a cleandown of the heat exchanger.
NOTE
Danger of contamination by cleansing agents.
When using cleansing agents, such as e.g. hydrochloric acid, make sure
that it is properly disposed of.
For waste disposal you must strictly follow the national regulations for pro-
tection of the environment.
8.2.2 Internal cleaning of the tube bundles
DANGER
Danger of injury.
For internal cleaning of the tube bundles you must strictly comply with the
notes on safety listed in chapter 8.2.1.
ATTENTION
Danger of corrosion caused by scratches.
Scratches on the inside surfaces of the tube bundles can lead to severe cor-
rosion. For this reason use a brush with soft bristles for internal cleaning.
NOTE
For the use of cleansing agents you should contact Universal Hydraulik
GmbH.

The following cleaning measures are recommended:

 Inside the tube you may use a mixture of 50 % hydrochloric acid with in-
hibitors and 50 % water to remove lime deposits.
 With tube Ø >5 mm the tube bundle can be internally cleaned with a
brush. Make sure that a brush with soft bristles is used, to avoid scratch-
ing of the tube walls.
 Before using other cleansing agents to remove lime deposits you should
contact Universal Hydraulik GmbH accordingly.
 After completion of cleaning work and before taking the heat exchanger
back into service make sure that all cleansing agent residues are re-
moved from the tubes, as far as this is possible.
The following steps are required for cleaning:

1. Shut down the system and secure it against being switched on again
2. Shut off cooling water inlet and outlet pipes on the heat exchanger
3. Relieve the heat exchanger from any pressure and drain off all cooling
water
4. Remove the lids
5. Perform cleaning and reassemble the lids with new gaskets (replacing
the seals see chapter 8.2.3)
6. Vent the pipes before switching the system back on
8.2.3 Reinstallation after cleaning
DANGER
Danger of fluids escaping under pressure.
Before fitting new gaskets the sealing surfaces must be thoroughly cleaned
of any gasket residuals. Dirty sealing surfaces can lead to injury, e.g. to the
eyes, if fluids escape under pressure upon restarting.
ATTENTION
Danger of damage to sealing surfaces.
Do not clean sealing surfaces with sharp objects. Scores in sealing surfaces
may cause leaks.
Before reassembly after cleaning work the following activities are nec-
essary:
 Remove old gaskets
 Clean the sealing surfaces from gasket residuals, take care not to dam-
age the sealing surfaces.
 Install new gaskets, ensure correct fit
 Replace O-rings, if present
Waste disposal
9 Waste disposal
NOTE
Fuels and lubricants, cleansing agents and the respective containers must
not be disposed of together with normal domestic refuse or seep into the
sewer or the ground. Dispose of these materials and the heat exchanger in
strict compliance with the applicable national regulations for the protection of
the environment.
The heat exchanger must be disposed of as special refuse.

6. Diagrams
BLANK PAGE
BLANK PAGE
BLANK PAGE
BLANK PAGE
BLANK PAGE
SERVICE MANUAL
VOLUME 2
Rudderpropeller SRP 1515 FP
Key Word: BONNY 39

Order Number: 14338705-1
Serial Numbers: SRP-119555/ SRP-119556
Input Power (kW): 2000
Input Speed (rpm): 1600
Minimum Operating Speed (rpm): 600
Classification Society: ABS
Distribution and Duplication Disclaimer

The distribution or duplication of this Service Manual and the utilisation We have checked the content of this Service Manual regarding
and communication of its content is not permitted, unless this has been compliance with the described hardware and software. Nevertheless,
expressly granted. variances cannot be ruled out, which means that we will not guarantee
Any violations will necessitate compensation. full compliance.
All rights reserved, particularly in the case of granting a patent or The information provided in this Service Manual is reviewed regularly,
registering a utility model. however, and any necessary amendments will be included in the
following issues. We will be grateful for any suggestions for
improvement.
TTD-db 14338705-1 19 May 2015 1/2

Revision History
Rev. Revision Chapter Description Document Document Document Document

No. Date No. No. Revision replaced added
DD.MM.YYYY Code
0 19/05/2015
SCHOTTEL GmbH
Mainzer Str. 99
56322 Spay/Rhein
GERMANY
Phone: +49 2628 61‐0
Fax: +49 2628 61‐300 and 61‐345
E‐mail: [email protected]
Internet: www.schottel.de
TTD-db 14338705-1 19 May 2015 2/2

Table of Contents
VOLUME 1
Rev. No. Part. No.
1 Technical Specification
Technical Specification ................................................................................ Rev. 0, 2014-09-02 ......... TS-52290
2 Installation Instructions
Installation Drawing ....................................................................................................... 15/0535 ........... 1188330
Pointer ........................................................................................................................... 09/0098 ........... 1108411
Alignment Data Sheet............................................................................................................. for ........... 1191153
Center of Gravity ........................................................................................................................ ........... 1201784
Schedule of Measuring Points .................................................................................. 07.12.2011 ........... 1188111
3 Operating, Mounting and Maintenance Instructions
Safety and Environmental Protection Regulation "SV 1" ...................................... 348/98 ........... 1099236
3.1 Mechanics
Operating Instructions SCHOTTEL RUDDER PROPELLER 1515 FP ............... 12/May. ........... 1191501
Lubrication Oil Specifications for SCHOTTEL Propulsion Units
with FP Propellers ............................................................................................... 15/0360 ........... 1145139
Shafting Installation Instruction ........................................................................... 14/1382 ........... 1191153
Installation Instructions for Propellers ................................................................. 13/June ........... 1197744
Propeller Installation Record Sheet SRP-SCD 1515 FP (Pusher Propeller) ........ 13/Nov ........... 1199454
Mounting and Maintenance of the Self-Aligning Roller Bearings
in Shaft Lines (two−lip seal) with Synthetic Lubricating Grease ......................... 11/1140 ........... 1167641
Installation Instructions for Bolted Connections and Sealants ............................ 14/0208 ........... 1180737
Preservation Instructions ....................................................................................... 641/02 ........... 1104097
3.2 Hydraulics
Operating Instructions Hydraulic System SST 612 ........................................... 12/March ........... 1189950
Hydraulic Oil Specifications for SCHOTTEL Propulsion Units ............................ 14/0100 ........... 1196665
Flushing Specification for Hydraulic Systems
with Variable Displacement Pump ...................................................................... 07/3151 ........... 1100933
Installation Specifications for Hydraulic Systems and their Components ........... 12/1810 ........... 1099237
3.3 Electrics
Control and Electrical System ............................................................................ 2014/10. ........... 1207405
Examples of Steering Manoeuvres ..................................................................... 13/April. ........... 1196570
User Documentation for System Display S-ODS V2.00.10 ................................. 13/Feb. ........... 1187801
Warning System ................................................................................................... 10/Feb. ........... 1176151
Speedronic Motor Control Unit MSV Id. No. 1115903 .......................................... July/00 ........... 1128284
Operating Instructions DCM Module ................................................................... 10/1597 ........... 1162900
Operating Instructions DPV Module ................................................................... 10/1598 ........... 1162901
4 Spare Parts Catalogue
en TTD-db Table of Contents 14338705-1 19 May 2015 1/2

Rev. No. Part. No.
5 Documents from Suppliers

Technical Description Mounting, Maintenance
and Repair of Propshafts with Flanged Universal Joints
for SCHOTTEL Part No. 1129696 .......................................................................... Edition 2007 ........... GEWES
Installation, Operation and Maintenance of Airflex VC Marine Clutches

for SCHOTTEL Part No. 1146427 .............................................................................................. ...... KENDRION
Operating Instructions Gear pump KF 2,5...200 ......................................................2012-09-25 .......... KRACHT
Compact Cooler Instruction Manual P Type Heat Exchanger

for SCHOTTEL Part No. 1143017 ............................................................................... Rev.C .... GEA BLOKSMA
Operating Instructions Shell - and - Tube Heat Exchanger

for SCHOTTEL Part No. 1181217 ................................................ Edition 07/2011 ...UNIVERSAL HYDRAULIK
6 Diagrams

Pneumatic Diagram Binder .............................................................................................. ........... 1149617

Hydraulic Circuit Diagram ................................................................................... 11/0454 ........... 1151373
VOLUME 2
6.3 Wiring Diagrams

Wiring Diagram SRP 1515 FP ............................................................................ 15/0578 ........... 1201903
Key for individual terms and letters in the Spare Parts Catalogue:
SSS XXXX YY Z/Z
Bsp. R/R Right/Right

Bsp. L/L Left/Left
FP Fixed Pitch Propeller

CP Controlable Pitch Propeller
Bsp. 1515 Size

Bsp. 2020
SCHOTTEL propulsion unit
HY Hydraulic
OI Operating Instructions SCHOTTEL
K Sub-assemblies (further partlist available)
L Operating Instruction Supplier
2/2 TTD-db Table of Contents 14338705-1 19 May 2015 en

6.3 Wiring Diagrams
BLANK PAGE
0 1 2 3 4 5 6 7 8 9
SCHOTTEL GmbH
Mainzerstrasse 99
D-56322 Spay
+49 2628 / 61 - 0
2x SCHOTTEL RUDDERPROPELLER
TYPE SRP 1515 FP
Number of pages: 260
004 15/0578 26.02.2015 BJU Date 26.02.2015 = INFO 1/ 12

003 14/2239 15.08.2014 MSC Ed. BJU CONFIDENTIAL Order Datas 1201903 +
Appr © SCHOTTEL GmbH Page 1
Modification Date Name Standard Page 260
0 1 2 3 4 5 6 7 8 9
main desk main desk

=AZ1+MDP =AZ2+MDP
ID.NR.:1187218 ID.NR.:1187219
main desk
warning unit
+MDWP
AZX
ID.NR.:1182230
FWD
SCHOTTEL SCHOTTEL
control control
switch box switch box
=AZX+SCS- =AZX+SCS-
ID.NR.:1201904 ID.NR.:1201904
switch box switch box

clutch clutch
control control
SRP SRP
AZ1 = AZ2 =
Ps unit Stb unit
004 15/0578 26.02.2015 BJU Date 26.02.2015 = INFO 2/ 12

Ed. BJU CONFIDENTIAL Unit Arrangement 1201903 +
0 1 2 3 4 5 6 7 8 9
Structure Indicators
Unit identifier Unit description Mounting location Mounting location description
identifier
INFO Project overview SCS Switch Cabinet Control Sytem
MSB Main Switch Board MDP Main Desk Panel
ESB Emergency Switch Board MDWP Warning panel
NOTES Cable Informations ENR Components Engine Room
AZ1 Azimuth Unit 1 CLU Clutch control
AZ2 Azimuth Unit 2 SRP SCHOTTEL Rudder Propeller
YARD Yard Components PM Propulsion Motor
PARTS Parts List SWU Ships Warning Unit
CABLE Cable List YARD Yard Components
WH Wheelhouse PARTS Parts List
CABLE Cable List
AP Autopilot
HYP Hydraulic Pump
HYT Hydraulic Tank
FIFI FIFI Pump System
Date 15.08.2014 = INFO 3/ 12

Ed. MSC CONFIDENTIAL Structure Indicators 1201903 +
0 1 2 3 4 5 6 7 8 9
Contents
Page Page description Unit Place Page Changes Date Edited by
1 Order Datas INFO 1 003 14/2239 15.08.2014 MSC 002 14/1725 23.06.2014 MSC 15.08.2014 MSC
2 Unit Arrangement INFO 2 06.02.2014 ROM
3 Structure Indicators INFO 3 15.08.2014 MSC
4 Contents INFO 4 15.08.2014 MSC
13 Cable Informations NOTES CABLE 1 18.06.2014 MSC
14 Notes NOTES CABLE 2 24.06.2014 MMU
15 Cable Diagramm NOTES CABLE 3 18.06.2014 MSC
16 Cable List NOTES CABLE 6 15.08.2014 MSC
19 Terminal Groups AZ1 SCS 1 18.06.2014 MSC
20 DIP Switches Digital Modules AZ1 SCS 2 15.08.2014 MSC
22 Power Distribution AZ1 SCS 4 002 14/1725 23.06.2014 MSC 001 14/0773 12.03.2014 ROM 15.08.2014 MSC
23 Power Distribution AZ1 SCS 5 15.08.2014 MSC
26 Power Distribution AZ1 SCS 8 001 14/0773 12.03.2014 ROM 18.06.2014 MSC
27 NFU Control ON AZ1 SCS 9 18.06.2014 MSC
28 NFU Systems AZ1 SCS 10 001 14/0773 12.03.2014 ROM 15.08.2014 MSC
29 Data Bus AZ1 SCS 11 18.06.2014 MSC
32 Desk Control AZ1 SCS 14 18.06.2014 MSC
Date 15.08.2014 = INFO 4/ 12

Ed. MSC CONFIDENTIAL Contents 1201903 +
0 1 2 3 4 5 6 7 8 9
Contents

37 FFU Speed Control AZ1 SCS 19 18.06.2014 MSC
41 FFU Speed Control AZ1 SCS 23 003 14/2239 15.08.2014 MSC 001 14/0773 12.03.2014 ROM 15.08.2014 MSC
42 Thrust Direction Indicator AZ1 SCS 24 18.06.2014 MSC
45 FFU Thrust Direction Steering AZ1 SCS 27 15.08.2014 MSC
46 FFU Thrust Direction Steering Control Signals AZ1 SCS 28 18.06.2014 MSC
50 NFU Steering AZ1 SCS 32 15.08.2014 MSC
51 Clutch Control AZ1 SCS 33 15.08.2014 MSC
52 Interface External Systems AZ1 SCS 34 18.06.2014 MSC
56 Warning Unit AZ1 SCS 38 002 14/1725 23.06.2014 MSC 15.08.2014 MSC
57 Warning Unit AZ1 SCS 39 15.08.2014 MSC
62 Warning Unit AZ1 SCS 44 003 14/2239 15.08.2014 MSC 001 14/0773 12.03.2014 ROM 15.08.2014 MSC
Date 15.08.2014 = INFO 5/ 12

0 1 2 3 4 5 6 7 8 9
Contents
65 Interface To Drive Motor AZ1 SCS 47 15.08.2014 MSC

66 Interface To Ship Warning unit AZ1 SCS 48 18.06.2014 MSC
67 Interface To Autopilot AZ1 SCS 49 18.06.2014 MSC
68 OPTION Interface To FIFI pump AZ1 SCS 50 18.06.2014 MSC
69 Switch Cabinet AZ1 SCS 51 18.06.2014 MSC
71 Switch Cabinet Mounting Plate AZ1 SCS 53 15.08.2014 MSC
73 Terminal Groups AZ1 MDP 1 18.06.2014 MSC
74 Power Supply AZ1 MDP 2 18.06.2014 MSC
76 NFU Signals AZ1 MDP 4 15.08.2014 MSC
77 Control Bus AZ1 MDP 5 18.06.2014 MSC
78 Connection Control Handle AZ1 MDP 6 18.06.2014 MSC
79 Indicators AZ1 MDP 7 18.06.2014 MSC
80 Panel main desk AZ1 MDP 8 18.06.2014 MSC
83 Terminal Groups AZ1 MDWP 1 18.06.2014 MSC
84 warning panel AZ1 MDWP 2 15.08.2014 MSC
87 Connection Engine Room AZ1 ENR 1 18.06.2014 MSC
91 Connection Clutch AZ1 CLU 1 18.06.2014 MSC
92 Clutch Control AZ1 CLU 2 18.06.2014 MSC
93 Connection Propulsor AZ1 SRP 1 18.06.2014 MSC
96 Terminal Groups AZ2 SCS 1 23.06.2014 MSC
Date 15.08.2014 = INFO 6/ 12

0 1 2 3 4 5 6 7 8 9
Contents

99 Power Distribution AZ2 SCS 4 002 14/1725 23.06.2014 MSC 001 14/0773 12.03.2014 ROM 15.08.2014 MSC
103 Power Distribution AZ2 SCS 8 001 14/0773 12.03.2014 ROM 23.06.2014 MSC
104 NFU Control ON AZ2 SCS 9 23.06.2014 MSC
105 NFU Systems AZ2 SCS 10 001 14/0773 12.03.2014 ROM 15.08.2014 MSC
118 FFU Speed Control AZ2 SCS 23 003 14/2239 15.08.2014 MSC 001 14/0773 12.03.2014 ROM 15.08.2014 MSC
122 FFU Thrust Direction Steering AZ2 SCS 27 15.08.2014 MSC
127 NFU Steering AZ2 SCS 32 15.08.2014 MSC
128 Clutch Control AZ2 SCS 33 15.08.2014 MSC
Date 15.08.2014 = INFO 7/ 12

0 1 2 3 4 5 6 7 8 9
Contents

133 Warning Unit AZ2 SCS 38 002 14/1725 23.06.2014 MSC 15.08.2014 MSC
139 Warning Unit AZ2 SCS 44 003 14/2239 15.08.2014 MSC 001 14/0773 12.03.2014 ROM 15.08.2014 MSC
142 Interface To Drive Motor AZ2 SCS 47 15.08.2014 MSC
143 Interface To Ship Warning unit AZ2 SCS 48 23.06.2014 MSC
144 Interface To Autopilot AZ2 SCS 49 23.06.2014 MSC
145 Interface To FIFI pump AZ2 SCS 50 23.06.2014 MSC
148 Switch Cabinet Mounting Plate AZ2 SCS 53 15.08.2014 MSC
150 Terminal Groups AZ2 MDP 1 18.06.2014 MSC
153 NFU Signals AZ2 MDP 4 15.08.2014 MSC
154 Control Bus AZ2 MDP 5 18.06.2014 MSC
155 Connection Control Handle AZ2 MDP 6 18.06.2014 MSC
156 Indicators AZ2 MDP 7 18.06.2014 MSC
160 Terminal Groups AZ2 MDWP 1 18.06.2014 MSC
Date 15.08.2014 = INFO 8/ 12

0 1 2 3 4 5 6 7 8 9
Contents

168 Connection Clutch AZ2 CLU 1 18.06.2014 MSC
169 Clutch Control AZ2 CLU 2 18.06.2014 MSC
173 Drive Motor Unit AZ YARD PM 1 18.06.2014 MSC
174 Connections To Drive Motor AZ1 YARD PM 2 18.06.2014 MSC
175 Connections To Drive Motor AZ2 YARD PM 3 18.06.2014 MSC
176 Connection To Warning Unit YARD SWU 1 18.06.2014 MSC
177 Connection To Warning Unit YARD SWU 2 18.06.2014 MSC
178 Warning Interface Protocol YARD SWU 3 18.06.2014 MSC
179 Warning Interface Protocol YARD SWU 4 18.06.2014 MSC
180 Terminal diagram =YARD+SWU-X1 YARD SWU 5 18.06.2014 MSC
181 Connection To Autopilot YARD AP 1 18.06.2014 MSC
182 Connection To Autopilot YARD AP 2 18.06.2014 MSC
183 Connection To FIFI Pumpe YARD FIFI 1 18.06.2014 MSC
184 Connection To FIFI Pumpe YARD FIFI 2 18.06.2014 MSC
185 Parts List PARTS PARTS 1 06.02.2014 ROM
186 Parts List PARTS PARTS 2 15.08.2014 MSC
Date 15.08.2014 = INFO 9/ 12

0 1 2 3 4 5 6 7 8 9
Contents

202 Cable Drawings CABLE YARD 1 06.02.2014 ROM
203 =AZ1-W200 Cable Drawings CABLE YARD 2 15.08.2014 MSC
Date 15.08.2014 = INFO 10 / 12

0 1 2 3 4 5 6 7 8 9
Contents

Date 15.08.2014 = INFO 11 / 12

0 1 2 3 4 5 6 7 8 9
Contents

260 =WH-W10 Cable Drawings CABLE YARD 59 15.08.2014 MSC
Date 15.08.2014 = INFO 12 / 12

0 1 2 3 4 5 6 7 8 9
cable informations
Date 18.06.2014 = NOTES 1/ 6

Ed. MSC CONFIDENTIAL Cable Informations 1201903 + CABLE
0 1 2 3 4 5 6 7 8 9
* = no supply from SCHOTTEL

Type of cables: MPRXCX or TCX(C) ( IEC 92-3 ) according to the rules
length of cable between the control panels
The cable typ TCX(C) must be installed with twisted pair wires
Cable installation according to EMC requirements IEC 61000-5-2
Minimum distance between signal cables of SCHOTTEL controls and cables with power current is 50cm ( 20 inch )
Allowable voltage drop in the cables <5%
Cable connection Shield connected to the ground.
terminal
Cable
max 15cm
-CB
shield connected inside cable gland to ground
main desk
-SB
shield connected to ships body
Electromagnetic cable categories

W-300
categorie sensitivity radiation type
K1* insensitive high AC feed line
K2* insensitive small AC feed line
K3* sensitive without control signals
K4* high sensitive without control bus cable No. cross length cross length
section section
K5* insensitive high frequency drives
W-300 2,5mm² 150m 4mm² 240m
Attention:
For installation and power supply at SCHOTTEL electric systems the requirements of the classification society for
"steering gear circuits" must be observed !
There must be separate power supplies for the units.
Wiring Colours
BK
Main Circuit: Black
LiBU
Neutral conductor: Light Blue
GNYE
Protective conductor (PE): Green/Yellow
RD
Control Circuit AC: Red
BU
Control Circuit 24VDC: Dark Blue
OG
External Voltage: Orange
VT
Wires Current Transducer: Violet
WH
Analog Values: White
Date 24.06.2014 = NOTES 2/ 6

Ed. MMU CONFIDENTIAL Notes 1201903 + CABLE
0 1 2 3 4 5 6 7 8 9
marking of cable=AZX+W-100 main desk

X = 1 is Ps unit control panel
=AZX+MDP
X = 2 is Stbd unit
main desk main desk main desk
cables are desgin control panel control panel control panel
for a max length =AZX+MDWP =AZ1+MDP =AZ2+MDP
of 70m
to the switch box
=AZX+W-381*
=AZX+W-380*
=AZX+W-305*
=AZX+W-304* =AZX+W-10*
=AZX+W-303*
=AZX+W-302*
*
=AZX+W-301*
=MSB =AZX+W-300*
switchboard
AC power
SCHOTTEL
control
=AZX+W-200* switch box
=AZX+W-201*
=AZX+SCS =AZX+W-202*
=AZX+W-210* =AZX+W-220* =AZX+W-240* =AZX+W-241* =AZX+W-242* =AZX+W-203* =AZX+W-820* =AZX+W-720* =AZX+W-780* =AZX+W-710*
=AZX+W-211* =AZX+W-204* =AZX+W-711*
=AZX+W-213*
=AZX+W-214*
=AZX+W-216* * ICS *
switch box terminal box speed pick up thrust ESB Integrated * * PM
clutch control hydraulic pump hydraulic direction emergency control and switchbox switch box switch box
+CLU +HYP pump indicator switchboard monitoring autopilot FIFI pump propulsion
-ENR+4B1 24V DC system +AP +FIFI motor
SRP
=AZX+W-248*
terminal box
hydraulic tank
+HYT
Date 18.06.2014 = NOTES 3/ 6

Ed. MSC CONFIDENTIAL Cable Diagramm 1201903 + CABLE
0 1 2 3 4 5 6 7 8 9
Cable Overview
Cable Source Target (to) cable type all Conductors used cross section cable categories
designation (from) conductors [mm²]
=AZ1-W200 =MSB+SCS-400VX1 =AZ1+SCS-X1 MPRXCX 3 3 1,5 K2*
=AZ1+SCS-SH
=AZ1+SCS-SH
=AZ1-W202 =AZ1+SCS-X1 =AZ1+SCS-SH MPRXCX 1 1 16 K1*
=AZ1-W203 =ESB+SCS-24-X1 =AZ1+SCS-X2 MPRXCX 2 2 6 K3*
=AZ1+SCS-SH
=AZ1-W204 =ESB+SCS-24-X1 =AZ1+SCS-X2 MPRXCX 2 2 2,5
=AZ1+SCS-SH
=AZ1-W210 =AZ1+SCS-X41 =AZ1+SRP-4A4 TCX(C) 2x2 4 0,75 K3*
=AZ1+SCS-SH
=AZ1+SCS-SH
=AZ1-W212 =AZ1+SCS-X51 =AZ1+SRP-X5 TCX(C) 2x2 4 0,75 K3*
=AZ1+SCS-X51.V1 =AZ1+SCS-SH
=AZ1+SCS-SH
=AZ1-W214 =AZ1+SCS-X21 =AZ1+SRP-X2 TCX(C) 4x2 5 0,75 *K3
=AZ1-W216 =AZ1+SCS-X10 =AZ1+SRP-M1 MPRXCX 3 3 1,5 *K3
=AZ1-W220 =AZ1+SCS-X52 =AZ1+CLU-X5 MPRXCX 10 8 1,5 K2*
=AZ1+SCS-SH
=AZ1-W240 =AZ1+SCS-X21 =AZ1+HYP-X2 MPRXCX 10 10 1,5 K3*
=AZ1+SCS-X42 =AZ1+HYP-X4
=AZ1+SCS-SH
=AZ1-W241 =AZ1+SCS-X42 =AZ1+ENR-4B1.1 TCX(C) 2x2 3 0,75 K3*
=AZ1+SCS-SH
=AZ1-W242 =AZ1+SCS-X44 =AZ1+ENR-4A3 TCX(C) 4x2 6 0,75 K4*
=AZ1+SCS-SH
=AZ1-W248 =AZ1+HYP-X2 =AZ1+HYT-2S1 TCX(C) 2x2x 2 0,75 *K3
=AZ1-W300 =AZ1+SCS-X12 =AZ1+MDP-AX1 MPRXCX 4 4 2,5 K3*
=AZ1+SCS-SH
=AZ1-W301 =AZ1+SCS-X12 =AZ1+MDP-AX9 MPRXCX 3 2 2,5
=AZ1+SCS-SH
=AZ1+MDP-AX2
=AZ1+SCS-SH
=AZ1-W303 =AZ1+SCS-X12 =AZ1+MDP-AX3 TCX(C) 2x2 4 0,75 K4*
=AZ1+SCS-SH
=AZ1+SCS-SH
=AZ1+SCS-SH
=AZ1-W380 =AZ1+SCS-X22 =AZ1+MDWP-X21 MPRXCX 5 3 1,5 K3*
=AZ1+SCS-SH
=AZ1-W381 =AZ1+SCS-X22 =AZ1+MDWP-X21 TCX(C) 2x2 4 0,75 K4*
Date 15.08.2014 = NOTES 6/ 6

Ed. MSC CONFIDENTIAL Cable List 1201903 + CABLE
0 1 2 3 4 5 6 7 8 9
Cable Overview
=AZ1+SCS-SH
=AZ1-W710 =AZ1+SCS-X3 =YARD+PM-AZ1-X1 TCX(C) 7x2 9 0,75 K3*
=AZ1+SCS-X3.K3 =AZ1+SCS-SH
=AZ1+SCS-X3.K12
=AZ1+SCS-SH
=AZ1-W720 =AZ1+SCS-X5 =YARD+AP-X1 TCX(C) 4x2 6 0,75 K3*
=AZ1-W820 =YARD+SWU-X1 =AZ1+SCS-X4.K1 TCX(C) 2x2 4 0,75 K3*
=AZ1+SCS-X4.K2
=AZ1+SCS-SH
=AZ2+SCS-SH
=AZ2+SCS-SH
=AZ2-W202 =AZ2+SCS-X1 =AZ2+SCS-SH MPRXCX 1 1 16 K1*
=AZ2-W203 =ESB+SCS-24-X1 =AZ2+SCS-X2 MPRXCX 2 2 6 K3*
=AZ2+SCS-SH
=AZ2-W204 =ESB+SCS-24-X1 =AZ2+SCS-X2 MPRXCX 2 2 2,5
=AZ2+SCS-SH
=AZ2+SCS-SH
=AZ2+SCS-SH
=AZ2+SCS-X51.V1 =AZ2+SCS-SH
=AZ2+SCS-SH
=AZ2-W214 =AZ2+SCS-X21 =AZ2+SRP-X2 TCX(C) 4x2 5 0,75 *K3
=AZ2-W216 =AZ2+SCS-X10 =AZ2+SRP-M1 MPRXCX 3 3 1,5 *K3
=AZ2-W220 =AZ2+SCS-X52 =AZ2+CLU-X5 MPRXCX 10 8 1,5 K2*
=AZ2+SCS-SH
=AZ2-W240 =AZ2+SCS-X21 =AZ2+HYP-X2 MPRXCX 10 10 1,5 K3*
=AZ2+SCS-X42 =AZ2+HYP-X4
=AZ2+SCS-SH
=AZ2-W241 =AZ2+SCS-X42 =AZ2+ENR-4B1.1 TCX(C) 2x2 3 0,75 K3*
=AZ2+SCS-SH
=AZ2-W242 =AZ2+SCS-X44 =AZ2+ENR-4A3 TCX(C) 4x2 6 0,75 K4*
=AZ2+SCS-SH
=AZ2-W248 =AZ2+HYP-X2 =AZ2+HYT-2S1 TCX(C) 2x2x 2 0,75 *K3
=AZ2+SCS-SH
=AZ2-W301 =AZ2+SCS-X12 =AZ2+MDP-AX9 MPRXCX 3 2 2,5
=AZ2+SCS-SH
Date 15.08.2014 = NOTES 7/ 6

0 1 2 3 4 5 6 7 8 9
Cable Overview
=AZ2+MDP-AX2
=AZ2+SCS-SH
=AZ2+SCS-SH
=AZ2+SCS-SH
=AZ2+SCS-SH
=AZ2-W380 =AZ2+SCS-X22 =AZ2+MDWP-X21 MPRXCX 5 3 1,5 K3*
=AZ2+SCS-SH
=AZ2-W381 =AZ2+SCS-X22 =AZ2+MDWP-X21 TCX(C) 2x2 4 0,75 K4*
=AZ2+SCS-SH
=AZ2+SCS-X3.K12
=AZ2+SCS-SH
=AZ2-W720 =AZ2+SCS-X5 =YARD+AP-X2 TCX(C) 4x2 6 0,75 K3*
=AZ2-W780 =YARD+FIFI-AZ2-X1 =AZ2+SCS-X8.K41 TCX(C) 4x2 5 0,75 *K3
=AZ2+SCS-X8
=AZ2+SCS-SH
=AZ2-W820 =YARD+SWU-X1 =AZ2+SCS-X4.K1 TCX(C) 2x2 4 0,75 K3*
=AZ2+SCS-X4.K2
=AZ2+SCS-SH
=WH-W10 =AZ1+MDP-X30 =AZ2+MDP-X30 TCX(C) 2x2 4 0,75 K4*
=AZ2+MDP-SH
Date 15.08.2014 = NOTES 8/ 6

0 1 2 3 4 5 6 7 8 9
Overview Terminal Blocks
Unit =AZ1 Location +SCS
terminal strip terminal description
-X1 connection AC feed line earth

-X2 connection DC feed line
-X3 connection to Propulsion motor
-X4 connection to Shipwarning unit
-X5 connection to Autopilot System
-X8 connection to FIFI pump (OPTION)
-X10 connection to lube oil pump

-X12 connection to steering desks
-X41 connection CAN bus steering system to thruster
-X42 connection to hydraulic aggregate
-X44 connection to azimuth indicator near hydraulic aggregate

-X51 connection speed pick up thruster
-X52 connection clutch
-X54 connection shaft speed indicator
-X21 connection warning transmitter
-X22 connection warning unit
-GND ground
-L+ 24VDC
Date 18.06.2014 = AZ1 1/ 54

Ed. MSC CONFIDENTIAL Terminal Groups 1201903 + SCS
Appr © SCHOTTEL GmbH switch cabinet SCS Page 19
0 1 2 3 4 5 6 7 8 9
Settings DIP-Switches Digital Modules

-3A1 -4A3 -2A1.0
/19.1 DCM SPEED 1167522 modul /24.6 DPV Steering NFU 1179008 Modul /39.0 WAGO MASTER CONTROLLER 1193931 modul
DCM 1167523 programm DPV 1179009 programm WAGO 1193932 programm
S3 ON NFU S3 ON
J7
1 2 3 4 5 6 7 8 1 2 3 4 5 6 7 8 120 Ohm ON
S4 ON S4 ON ON
1 2 3 OFF 1 2 3 4 5 6 7 8
1 2 3 4 5 6 7 8 1 2 3 4 5 6 7 8
Extern
Intern
-3A4 -A81 -2A10 1163275 panel
/23.2 RAMP GENERATOR /34.0 DCM EXTERNAL SYSTEM 1 1167526 modul /38.2 WARNING PANEL
RG1
J7 DCM 1167527 programm WAP
S3 ON S3 ON
S1
Jumper
ON 1 2 3 4 5 6 7 8 120 Ohm
1 2 3 4 5 6 7 8
1 2 3 J7 ON
S4 ON
1 2 3 4 S4 ON J8 OFF
0..10V
0..20mA
f
ramp gen
1 2 3 4 5 6 7 8 1 2 3 1 2 3 4 5 6 7 8
-4A1 -A40
/27.1 DCM AZIMUTH 1167524 modul
/24.1 DCM INDICATION 1179940 Modul
Jumper
DCM 1167525 programm DCM 1179941 programm J1
S3 ON S3 ON J2 AO0
1 2 3 4 5 6 7 8 J3
1 2 3 4 5 6 7 8
S4 ON S4 ON J4
1 2 3 4 5 6 7 8 J5 AO1
1 2 3 4 5 6 7 8
J6
1 2 3
U I
-4A2 -1A1.0
/27.4 DPV Steering 1168411 modul /11.0 WAGO MASTER CONTROLLER 1167520 modul
DPV 1168412 programm WAGO 1167521 programm
S3 ON
1 2 3 4 5 6 7 8
ON
S4 ON
1 2 3 4 5 6 7 8
1 2 3 4 5 6 7 8
15/0578
004 15/0578 26.02.2015 BJU Date 26.02.2015 = AZ1 2/ 54

Ed. BJU CONFIDENTIAL DIP Switches Digital Modules 1201903 + SCS
0 1 2 3 4 5 6 7 8 9

Weidmüller MAZ DC/DC WAGO 857-409
SCHOTTEL IDNr: 1148645 SCHOTTEL IDNr: 1174848
-AXX -AXX -AXY
MAZ DC/DC DC/DC ISOLATION CONVERTER MAZ DC/DC DC/DC ISOLATION CONVERTER WAGO DC/DC ISOLATION CONVERTER
0-10V/0-20mA 0-10V/4..20mA ±10V/2-10V
.. ...... .. ...... .... ......

S1 S2 S1 S2 S1 S2
1 2 1 2 3 4 5 6 1 2 1 2 3 4 5 6 1 2 3 4 1 2 3 4 5 6
on on on on on on
off off off off off off
-AXX -AXY
MAZ DC/DC DC/DC ISOLATION CONVERTER WAGO DC/DC ISOLATION CONVERTER
0-20mA/0-10V 0-10V/2-10V
.. ...... ......
S1 S2 S1 S2
....
1 2 1 2 3 4 5 6 1 2 3 4 1 2 3 4 5 6
on on on on
off off off off
-AXX -AXY
4-20mA/0-10V 0-20mA/4-20mA
.. ...... ......
S1 S2 S1 S2
....
1 2 1 2 3 4 5 6 1 2 3 4 1 2 3 4 5 6
on on on on
off off off off
-AXX -AXY
0-20mA/0-20mA 4-20mA/2-10V
.. ...... .... ......

S1 S2 S1 S2
1 2 1 2 3 4 5 6 1 2 3 4 1 2 3 4 5 6
on on on on
off off off off
These are the DIP switch settings for default values of analog converters.
They have to be independently assigned to the appropriate converters.
Date 18.06.2014 = AZ1 3/ 54

Ed. MSC CONFIDENTIAL DIP Switches Digital Modules 1201903 + SCS
0 1 2 3 4 5 6 7 8 9
not especially signed areas 1,5mm²

400V / 50Hz
BK BK BK BK BK BK
2,5 2,5 2,5 2,5 2,5 2,5
1 3 5 13 21 1 3 5
-F1 -F2
3,5-5A 14 22 1,8-2,5A
4A 1,9A
/44.4
L1 L2 L3 I> I> I> I> I> I>
2 4 6 2 4 6
-S1
T1 T2 T3
BK BK BK
1,5 1,5 1,5
BK BK BK BK BK BK
1,5 1,5 1,5 1,5 1,5 1,5
-F3
OR OR OR GNYE OR OR GNYE 1 3 5 400V L1 L2 L3
2,5 2,5 2,5 2,5 PE 1,5 1,5 1,5
-5K3 2s
/33.3 2 4 6 -A1
BK BK BK /5.2 PE L3 L2 L1
1,5 1,5 1,5
/8.1
-X1 1 2 3 PE 4 5 6 PE
-W200 -SH -W202 -W201 -SH N PE L
MPRXCX MPRXCX MPRXCX -X10 1 2 3
3x1,5 mm² 1x16 mm² 2x2,5 mm² -SP -SH
375V - 575V AC
K2* BK BU BN K1* BK K2* BK BU
-W216
MPRXCX 25VDC / 20A
PE 3x1,5 mm²
-SH *K3
/4.1
=MSB -400VX1 1 2 3 -220VX1 1 2
+SRP/2.6 / M1:U
+SRP/2.7 / M1:V
+SRP/2.7 / M1:W
20A 6A
L1 L1 L L
L2 L2 N N
L3 L3
AC feedline switch box earth connection service plug AC / DC converter
14
12 11 /44.4
24
22 21
14/00773 14/1725
002 14/1725 23.06.2014 MSC Date 15.08.2014 = AZ1 4/ 54
001 14/0773 12.03.2014 ROM Ed. MSC CONFIDENTIAL Power Distribution 1201903 + SCS
0 1 2 3 4 5 6 7 8 9
24V DC not especially signed areas 0,75mm²

BK
2,5
BK L+ / 6.0
2,5
L- / 6.0
-P5 / +MDP/7.0
-P6 / +MDP/7.0
BK BK
2,5 2,5
-A2 - +
-A1
/8.3 /4.7 - +
-W301
MPRXCX
3x2,5 mm² BK BU
24VDC / 10A
25VDC / 20A -SH
24VDC
-X12 5 6
375V - 575V AC OR OR
1,5 1,5
+ Input -
OR
-A+ / 24.0
OR
-A- / 24.0
AC / DC converter
BK BK
2,5 2,5
-A3 + -
24VDC / 5A
L1 L2
-S2 24VDC
T1 T2
+ Input -
OR OR
2,5 2,5 OR OR
2,5 2,5
-X2 1 2
-SH
3 4
-SH
-W203
MPRXCX -W204
2x6 mm² MPRXCX
K3* BK BU 2x2,5 mm² BK BU
=ESB -24-X1 1 2 24-X1 3 4
16A 4A
L+ L+
L- L-
24V DC +30% -25% AC ripple <1V
emergency switchboard 24V DC
feedline switch cabinet feedline indicators

24V DC
Date 15.08.2014 = AZ1 5/ 54

Ed. MSC CONFIDENTIAL Power Distribution 1201903 + SCS
0 1 2 3 4 5 6 7 8 9
5.6 / -L+ -L+ / 7.0

5.6 / L-
2 2 2 2 2
-1F0 -1F1 -1F2 -1F3 -1F4
B6A 1 B6A 1 B6A 1 B6A 1 B6A 1
BU BU BU BU BU
1,5 1,5 1,5 1,5 1,5
1L- / 7.0
-GND 0 1 2 3 4
-L+ 0
-L+ 1 -L+ 2 -L+ 3 -L+ 4
BU BU BU BU BU BU BU BU BU BU BU BU BU BU BU BU BU BU BU
14.0 / -1F1.1+
14.0 / -1F1.2+
11.0 / -1F1.3+
13.0 / -1F1.4+
17.0 / 1F1.2-
11.0 / 1F1.3-
13.0 / 1F1.4-
9.0 / -1F2.2+
9.0 / 1F2.1-
9.0 / -1F3.1+
9.0 / -1F3.2+
23.0 / -1F3.3+
9.0 / 1F3.1-
9.0 / 1F3.2-
23.0 / 1F3.3-
8.0 / -1F4.2+
20.0 / -1F4.4+
8.0 / 1F4.2-
20.0 / 1F4.4-
BU BU BU BU BU BU
1,5 1,5 1,5 1,5 1,5 1,5
-X12 1 2 3 4 -X12 7 8
-SH
-W300 -W302
MPRXCX MPRXCX
4x2,5 mm² 19x1,5 mm²
K3* BK BU BN WH K3* 1 2
+MDP/2.1 / -P3
+MDP/2.1 / -P4
+MDP/2.7 / -P7
+MDP/2.7 / -P8
+MDP/2.0 / -P1
+MDP/2.0 / -P2
feedline control panels control system instrument light NFU systems SCHOTTEL
control signals
Date 15.08.2014 = AZ1 6/ 54

0 1 2 3 4 5 6 7 8 9
6.9 / -L+
2 2 2 2
1
-1F5 -2F1 -4F1 -5F1
B6A 1
-1F6 B6A 1 B6A 1 B6A 1
B6A 2
BU BU BU BU BU
1,5 1,5 1,5 1,5 1,5
6.9 / 1L-
-GND 5 6 7 8 9 10
-L+ 5 -L+ 6 -L+ 7 -L+ 8 -L+ 9
BU BU
1,5 1,5
BU BU BU -1M0 BU BU BU BU BU BU BU BU BU BU BU BU BU BU BU
M
20.0 / -1F5.4+
20.0 / 1F5.2-
47.0 / 1F5.4-
38.0 / -2F1.1+
42.0 / -2F1.2+
39.0 / -2F1.3+
40.0 / -2F1.4+
38.0 / 2F1.1-
39.0 / 2F1.3-
40.0 / 2F1.4-
27.0 / -4F1.3+
27.0 / 4F1.3-
33.0 / -5F1.2+
33.0 / -5F1.3+
33.7 / -5F1.4+
33.0 / 5F1.2-
33.0 / 5F1.3-
33.0 / 5F1.4-
interface fan warning FFU steering clutch control
external systems switch box unit power part
Date 26.02.2015 = AZ1 7/ 54

Ed. BJU CONFIDENTIAL Power Distribution 1201903 + SCS
0 1 2 3 4 5 6 7 8 9

BU
6.7 / -1F4.2+
-A1 -A2
/4.7 13 /5.0 13
14 14
BU BU
BU BU
-FL.AC / 42.1 FL.DC / 42.2
A1 A1
-K1 -K2
A2 A2
BU BU
6.8 / -1F4.2- -1F4.2- / 28.0
failure failure
AC / DC converter emergency feed line
24V DC
14 14
12 11 /15.3 12 11 /15.3
14/0773
Date 26.02.2015 = AZ1 8/ 54

001 14/0773 12.03.2014 ROM Ed. BJU CONFIDENTIAL Power Distribution 1201903 + SCS
0 1 2 3 4 5 6 7 8 9

BU BU BU
6.6 / -1F3.2+ -1F3.2+ / 32.0
BU BU
6.4 / 1F2.2+
BU
6.5 / -1F3.1+
41 11 21 1
13 23 -1K6 -K3 -1K2 -1K5
-1S1 -1S2 /18.8 42 44 /18.2 12 14 /9.0 12 14 /9.8 2
-P10 / +MDP/3.0
/9.4 14 /14.3 24
-P9 / +MDP/4.0
green
BU
BU
BU
REM / 17.5
SC / 18.1
-W302
MPRXCX -1K5
10.0 / REM1
19x1,5 mm²
K3* 3 4 /9.8 4
BU
-X12 9 10
12 14 12 14
-1K6 -1K2.1 BU BU
BU
/18.8 11 /9.4 11 BU BU
BU
x2 x2 x2
-1S2 -S3 -1S1
/14.3 x1 /16.7 x1 /9.1 x1
-1V2
BU BU BU
BU
A1 11 A1 A1 A1
-1K2 -1K2.1 -1K4 -1K5
A2 41 A2 A2 48VAC A2
BU
6.4 / -1F2.1-
6.6 / -1F3.1-
BU BU BU BU
6.6 / -1F3.2- -1F3.2- / 10.0
local control send command to remote fault local control NFU control ON NFU control ON / OFF
remote in service unit in service
14 14 14 1 2 /9.5
12 21 /9.4 12 11 /9.2 12 11 /15.1 3 4 /9.8
44 44 24
42 31 /14.1 42 41 /31.4 22 21 /19.6
34
32 31 /27.7
44
42 41
Date 26.02.2015 = AZ1 9/ 54

Ed. BJU CONFIDENTIAL NFU Control ON 1201903 + SCS
0 1 2 3 4 5 6 7 8 9
BU BU BU
9.4 / REM1
12 14 12 14
-4K4 -3K1
/32.5 11 /19.6 11
BU BU
12 14 12 14
-4K5 -3K5
/28.8 11 /20.7 11
BU BU
-X12 11 12 13 14 15 16
-W302 -W302
MPRXCX MPRXCX
19x1,5 mm² 19x1,5 mm²
K3* 5 6 K3* 7 8 9
K3* K3*
+MDP/4.4 / -P11
+MDP/3.1 / -P12
+MDP/4.2 / -P13
+MDP/4.2 / -P14
+MDP/3.1 / -P16
BU
BU
A1 A1
-4K11 -4K10
A2 A2
BU BU
9.9 / -1F3.2- -1F3.2- / 23.0
indication NFU steering ON thruster thruster thruster thruster NFU RPM control
turning turning turning turning in service
ccw cw ccw cw
14 14
12 11 /31.6 12 11 /31.5
14/0773
Date 15.08.2014 = AZ1 10 / 54

001 14/0773 12.03.2014 ROM Ed. MSC CONFIDENTIAL NFU Systems 1201903 + SCS
0 1 2 3 4 5 6 7 8 9
24V DC not designated cross sections: 0,75mm²

BU BU
6.2 / -1F1.3+ -1F1.3+ / 15.0
-P22 / +MDP/5.0
-P23 / +MDP/5.0
-P24 / +MDP/5.1
-P25 / +MDP/5.1
-W303
TCX(C)
2x2x0,75 mm²
K4* 1.1 1.2 2.1 2.2
-SH
-X12 22 23 24 25
-XC
CAN
7 3 2
GN YE
-CANG / 12.0
-CANH / 12.0
-CANL / 12.0
BU
BU
-1A1.0 1 5 2 6 3 7 4 8 -1A1.1 5 1 4 2 6
5 4 3 2 1
/2.3 -FB
24VBUS 0VBUS 24V 24V 0V 0V PE PE V+ CAN_H CAN_SH CAN_L GND 0VOUT 24VOUT 24VIN 24V 24V
0VIN 0V 0V
WAGO Controller CAN open 750-837 1167520 modul 1167521 software WAGO filter modul 750-626 8 3 7
BU BU
6.3 / -1F1.3- -1F1.3- / 19.0
power supply control bus CAN service plug
Date 26.02.2015 = AZ1 11 / 54

Ed. MSC CONFIDENTIAL Data Bus 1201903 + SCS
0 1 2 3 4 5 6 7 8 9
-3A1 -P1 -4A1 -4A2

/19.1 120 Ohm /24.4 /27.1 120 Ohm /27.4 120 Ohm
DCM Display DCM DPV
ON ON ON
OFF OFF OFF
4 CAN-GND
CAN-GND
4 CAN-GND
4 CAN-GND
2 CAN-H
CAN-H
2 CAN-H
2 CAN-H
3 CAN-L
CAN-L
3 CAN-L
3 CAN-L
-SB
7 2 3
-CAN1
GN YE GN YE GN YE
SUB-D cable
1186019 GN GY YE PK BN WH
11.9 / -CANH -CANH / 13.0

11.9 / -CANL -CANL / 13.0
BU BU
11.9 / -CANG -CANG / 13.0
DCM speed control Display DCM azimuth steering DPV azimuth steering
Date 18.06.2014 = AZ1 12 / 54

0 1 2 3 4 5 6 7 8 9
-A81
/34.0 120 Ohm
DCM
ON
OFF
4 CAN-GND
2 CAN-H
3 CAN-L
GN YE
12.9 / -CANH
12.9 / -CANL
12.9 / -CANG
6.2 / -1F1.4+
6.3 / -1F1.4-
GN
YE
-W210 -X41 5 6 7 8
TCX(C) -SH
2x2x0,75 mm²
K3* 1.1 1.2 2.1 2.2
+SRP/3.3 / -4A4.6
-4A4.7
+SRP/3.3 / -4A4.8
+SRP/3.3 / -4A4.9
+SRP/3.3 /
DCM external systems 1 feedback unit steering
Date 18.06.2014 = AZ1 13 / 54

0 1 2 3 4 5 6 7 8 9

24V DC
BU
6.2 / -1F1.1+ -1F1.1+ / 16.0
BU
6.2 / -1F1.2+ -1F1.2+ / 15.0
42 44 13
-1K2 -1S2
/9.0 31 /9.1 14
/9.2
yellow
CL.AU / 33.0
CL.EN / 33.5
BU BU
-1A1.2 1 5 2 6 3 7 4 8
DI0 DI1 DI2 DI3 DI4 DI5 DI6 DI7
WAGO 750-430 8DI; 24VDC; 3,0 ms
local desk ON ECR desk ON send command reserve thruster retracted thruster lowered clutch in auto mode clutch engaged remote control
in service
Date 26.02.2015 = AZ1 14 / 54

Ed. MSC CONFIDENTIAL Desk Control 1201903 + SCS
0 1 2 3 4 5 6 7 8 9

BU
11.9 / -1F1.3+ 1F1.3+ / 19.0
BU BU BU
14.9 / -1F1.2+ 1F1.2+ / 28.0
HOL / 43.0
12 14 12 14 12 14 HOP / 28.0
-1K4 -2K0 -K1
/9.5 11 /45.2 11 /8.1 11
BU
12 14
-K2
/8.3 11 CL.AIR / 33.5
BU BU BU
-1A1.3 1 5 2 6 3 7 4 8
WAGO 750-430 8DI; 24VDC; 3,0 ms
NFU steering fault unit fault power hy oil level oil pressure oil pressure oil pressure reserve
manual supply min steering ok pitch control ok clutch ok
Date 26.02.2015 = AZ1 15 / 54

0 1 2 3 4 5 6 7 8 9
14.9 / -1F1.1+
13
-S3
/9.3 14
red
BU
FIFI.ON / 50.0
-1A1.4 1 5 2 6 3 7 4 8
WAGO 750-430 8DI; 24VDC; 3,0 ms
FiFi Mode ON Generator Mode ON reserve brake closed reserve reserve ACK reserve
control system
Date 26.02.2015 = AZ1 16 / 54

0 1 2 3 4 5 6 7 8 9
-1A1.5 WAGO 750-530 8DO; 24VDC; 0,5A
DO0 DO1 DO2 DO3 DO4 DO5 DO6 DO7
1 5 2 6 3 7 4 8
BU BU BU
9.1 / REM
A1 11
-1K7
A2 41
BU BU
6.3 / -1F1.2- -1F1.2- / 18.0
ECR desk reserve reserve el. shaft el. shaft remote control clutch clutch OFF
in service in line healthy active auto mode
14
12 21 /33.2
44
42 31 /50.3
Date 26.02.2015 = AZ1 17 / 54

0 1 2 3 4 5 6 7 8 9
-1A1.6 WAGO 750-530 8DO; 24VDC; 0,5A -1A1.7 WAGO 750-600
end terminal
1 5 2 6 3 7 4 8
BU BU BU
9.2 / -SC
BU
-FL.CO / 42.8
A1 A1
-K3 -1K6
A2 A2
BU BU
17.9 / -1F1.2- -1F1.2- / 19.0
send command buzzer cleaning mode Hy-pump ON Hy-pump OFF FiFi Mode Generator Mode failure control
to remote in service in service system
14 14
12 11 /9.3 12 11 /9.1
44
42 41 /9.3
Date 26.02.2015 = AZ1 18 / 54

Ed. BJU CONFIDENTIAL Desk Control 1201903 + SCS
0 1 2 3 4 5 6 7 8 9

BU BU
15.9 / -1F1.3+ -1F1.3+ / 27.0
BU BU
-FFU.RPM / 42.3
-3A1
/2.0 26 28 9 10
/12.1
UB 24V
UB 24V
1167522 modul
/20.0
/21.1 1167523 programm
/22.1
DCM
GND 24V
GND 24V
25 27
22 24
-1K4
/9.5 21
BU
BU
A1 A1
-3K1 -3K2
A2 A2
BU
11.9 / -1F1.3- -1F1.3- / 27.0
BU BU
18.9 / -1F1.2- -1F1.2- / 27.0
DCM speed control failure FFU speed control
14 14
12 11 /10.6 12 11 /21.3
24 24
22 21 /23.3 22 21 /47.5
34 34
32 31 /23.2 32 31 /47.5
44 44
42 41 /33.2 42 41 /23.5
Date 26.02.2015 = AZ1 19 / 54

Ed. BJU CONFIDENTIAL FFU Speed Control 1201903 + SCS
0 1 2 3 4 5 6 7 8 9

BU
6.7 / -1F4.4+ -1F4.4+ / 28.0
BU
7.1 / -1F5.4+ -1F5.4+ / 47.0
-PM23 / =YARD+PM/2.1
-5B1.1 / +SRP/3.6
-5B1.3 / +SRP/3.6
-5B1.4 / +SRP/3.6
-5B3.4 / +SRP/3.8
-W710 -W212
TCX(C) TCX(C)
7x2x0,75 mm² 2x2x0,75 mm² +
K3* 1.1 1.2 2.1 2.2 3.1 K3* 1.1 1.2 2.1 2.2
K3*
-X51.V1
-SH
-X3 1 2 3 4 5 -X51 1 2 3 - +
BU
BU BU BU BU
BU
BU
IDLE / 50.0
FIFI.ENG / 50.0
-3A1
/19.1 13 14 15 16 17 18 19 20
DCM
DI 0.0
DI 0.1
DI 0.2
DI 0.3
DI 1.0
DI 1.1
DI 1.2
DI 1.3
Propulsion Propulsion Propulsion overload FiFi Mode Generator Mode speed Generator
motor motor motor in service in service pick up at
OFF ON in idle (clutch engaged) (clutch engaged) bus bar
BU BU
A1 A1
-3K5 -3K6
A2 A2
BU
6.8 / -1F4.4- -1F4.4- / 28.0
BU BU
7.1 / -1F5.2- -1F5.2- / 50.0
Feedline Propulsion Propulsion Propulsion overload shaft speed pick up Propulsion Propulsion
signals motor motor motor control system motor motor
OFF ON in idle ON overload
14 14
12 11 /10.6 12 11 /21.6
24 44
22 21 42 41
34
32 31 /43.1
44
42 41 /28.2
Date 10.09.2014 = AZ1 20 / 54

Ed. RGM CONFIDENTIAL FFU Speed Control 1201903 + SCS
0 1 2 3 4 5 6 7 8 9
WH
3.FB / 23.3
12 14 12 14
-3K2 -3K6
/19.7 11 /20.7 11
3A1.29 / 23.3
WH WH WH WH
-3A1
/19.1 21 22 23 24 30 29
DCM
AI 1
AI 2
AI 3
AI 4
10V REF
GND
setpoint speed ship load
analogue feedback speed signal
setpoint analogue speed feedback ship speed load signal
Date 15.08.2014 = AZ1 21 / 54

Ed. MSC CONFIDENTIAL FFU Speed Control 1201903 + SCS
0 1 2 3 4 5 6 7 8 9
-3A1
/19.1
DCM
lever open bypass decrease increase setpoint

in idle valve RPM RPM speed
DO 0
DO 1
DO 2
DO 3
AO 0
AO 1
5 6 7 8 31 32
WH
BU BU BU
-3A1.32 / 47.4
23.5 / -3A1.5
23.1 / -RPM.DE
23.1 / -RPM.IN
lever in idle open bypass valve decrease increase torque speed value for
RPM RPM feedback propulsion motor
Date 15.08.2014 = AZ1 22 / 54

0 1 2 3 4 5 6 7 8 9

BU BU
6.6 / -1F3.3+ -1F3.3+ / 47.0
BU
6.6 / -1F3.3- -1F3.3- / 47.0
WH
21.9 / 3A1.29 3A4.2 / 47.4
WH
21.9 / 3.FB 3A4.3 / 47.4
-3A4 15 16
/2.0 14 13 4 3 2
/33.2
UB 24V
GND 24V
0...10V
0...15V
AGND
> 4,5mA
DZ / GND
DZ / 24V
DZ / IN
MF2
MF1
1 5 7 6 8
9 10 11 12
BU BU
BU
31 21
-3K1 22.1 / -3A1.5
/19.6 34 32 24 22
44 42
-3K2
22.3 / RPM.DE /19.7 41
22.4 / RPM.IN
BU BU
-X12 17 18
-SH BU
-W302
MPRXCX
19x1,5 mm²
K3* 10 11
+MDP/4.1 / -P20
+MDP/4.1 / -P21
BU
A1 A1
-3K3 -X3.K3
A2 A2
BU BU
10.9 / -1F3.2- -1F3.2- / 32.0
14 14
12 11 /33.3 12 11 /47.1
44
42 41
14/2239 14/0773
003 14/2239 15.08.2014 MSC Date 26.02.2015 = AZ1 23 / 54

001 14/0773 12.03.2014 ROM Ed. BJU CONFIDENTIAL FFU Speed Control 1201903 + SCS
0 1 2 3 4 5 6 7 8 9

OR OR OR OR OR
5.6 / -A+ -A+ / 25.0
OR OR OR OR OR OR
5.6 / -A- -A- / 25.0
-4F3
2A
OR
OR
-A40 -P1 X1 -4A3

/2.3 26 28 25 27 9 10 11 12 /12.2 + - /2.3 26 28 25 27 30 32 29 31 9 10 11 12
/25.1 Display /31.1
GND 24V
GND 24V
GND 24V
GND 24V
GND 24V
GND 24V
UB 24V
UB 24V
UB 24V
UB 24V
UB 24V
UB 24V
/26.0 /32.3
RXD
RXD
TXD
TXD
DCM /32.6
DPV
CAN-GND
NFU
CAN-H
CAN-L
4 CAN-GND
CAN-GND
2 CAN-H
CAN-H
3 CAN-L
CAN-L
2 7 3
4
CAN2
SUB-D cable
YE GN 1186019 YE PK GN GY BN WH
OR
-A- / 26.9
YE GN YE GN
-X41 1 2 3 4
-SH -X44 1 2 3 4 5 6 -X12 26 27 28 29
-SH
-W211 -W242 -SH -W304
TCX(C) TCX(C) TCX(C)
2x2x0,75 mm² 4x2x0,75 mm² 2x2x0,75 mm²
K4* 1.1 1.2 2.1 2.2 K4* 1.1 1.2 2.1 2.2 3.1 3.2 K4* 1.1 1.2 2.1 2.2
SH K4*
+SRP/3.1 / -4A4.1
+SRP/3.1 / -4A4.2
+SRP/3.1 / -4A4.3
+SRP/3.1 / -4A4.4
+ENR/3.1 / -4A3.1
+ENR/3.2 / -4A3.2
+ENR/3.2 / -4A3.3
+ENR/3.2 / -4A3.4
+ENR/3.2 / -4A3.5
+ENR/3.3 / -4A3.6
+MDP/7.1 / -P26
+MDP/7.1 / -P27
+MDP/7.1 / -P28
+MDP/7.3 / -P29
CAN BUS Indicator thrust direction indicator CAN BUS Indicator
hydraulic aggregate
Date 18.06.2014 = AZ1 24 / 54

Ed. MSC CONFIDENTIAL Thrust Direction Indicator 1201903 + SCS
0 1 2 3 4 5 6 7 8 9
-5B2.1 / +SRP/3.7
-5B2.3 / +SRP/3.7
-5B2.4 / +SRP/3.7
-W213
TCX(C)
2x2x0,75 mm²
K3* 1.1 1.2 2.1
-SH
-X51 4 5 6
OR
24.9 / -A+ -A+ / 26.0
OR
24.9 / -A- -A- / 26.0
OR
-A40
/24.1 13 14 15 16 17 18 19 20
DCM
DI 0.0
DI 0.1
DI 0.2
DI 0.3
DI 1.0
DI 1.1
DI 1.2
DI 1.3
shaft speed
pick up
shaft speed pick up

indication
Date 23.06.2014 = AZ1 25 / 54

0 1 2 3 4 5 6 7 8 9
-A40
/24.1 21 22 23 24 30
DCM
AI 1
AI 2
AI 3
AI 4
10V REF
feedback pitch not used not used not used
4..20mA 4..20mA
pitch in zero pitch max stern pitch max ahead speed switch point pitch indicator speed indicator
AGND
DO 0
DO 1
DO 2
DO 3
AO 0
AO 1
5 6 7 8 31 32 29
WH
WH WH
OR
25.9 / -A+ -A+ / 31.0
25.9 / -A- -A- / 24.9
-X12 30 31 32 33 -X54 1 2 3 4
-W305 -SH
TCX(C) WH
2x2x0,75 mm²
K3* 1.1 1.2 2.1 2.2
+MDP/7.3 / -P30
+MDP/7.4 / -P31
+MDP/7.4 / -P32
+MDP/7.4 / -P33
suppressing propeller propeller
lube oil flow RPM indicator RPM indicator
Date 18.06.2014 = AZ1 26 / 54

0 1 2 3 4 5 6 7 8 9

BU BU BU
19.9 / -1F1.3+ -1F1.3+ / 28.0
7.5 / -4F1.3+
BU BU BU
-FFU.STEER / 42.5
-4A1 -4A2
/2.0 26 28 9 10 /2.0 26 28 30 32 9 10
/12.5 /12.7
UB 24V
UB 24V
UB 24V
UB 24V
UB 24V
UB 24V
/28.1 1167524 modul /30.1 1168411 modul
/29.1 1167525 programm /32.0 1168412 programm
DCM DPV
GND 24V
GND 24V
GND 24V
GND 24V
GND 24V
GND 24V
25 27 25 27 29 31
32 34
-1K4
/9.5 31
BU
BU
A1 A1
-4K1 -4K2
7.6 / -4F1.3- A2 A2
BU BU
19.9 / -1F1.3- -1F1.3- / 34.0
BU BU
19.9 / -1F1.2- -1F1.2- / 29.0
DCM azimuth control failure FFU steering
14 14
12 11 /32.5 12 11 /32.1
44 24
42 41 /31.4 22 21 /32.1
34
32 31 /32.2
44
42 41 /32.2
Date 26.02.2015 = AZ1 27 / 54

Ed. BJU CONFIDENTIAL FFU Thrust Direction Steering 1201903 + SCS
0 1 2 3 4 5 6 7 8 9
20.9 / -1F4.4+
BU
27.9 / -1F1.3+ -1F1.3+ / 34.0
15.9 / -1F1.2+
-4B1.3 / +ENR/3.8
-4B1.1 / +ENR/3.7
4B1.4 / +ENR/3.8
42 44
-3K5
/20.7 41
-W241
TCX(C)
2x2x0,75 mm²
K3* 1.1 1.2 2.1
-SH
-X42 8 9 10
BU BU
BU
15.9 / HOP HOP / 43.0
-4A1
/27.1 13 14 15 16 17 18 19 20
DCM
DI 0.0
DI 0.1
DI 0.2
DI 0.3
DI 1.0
DI 1.1
DI 1.2
DI 1.3
main backup overload pick up -4V1
power plant power plant power plant RPM hy-pump
steering ON steering ON steering
BU
A1
-4K5
A2
20.9 / -1F4.4-
8.9 / -1F4.2-
main backup overload speed pickup power unit

power unit power plant power plant hydraulic pump steering in service
14
12 11 /10.1
44
42 41
Date 18.06.2014 = AZ1 28 / 54

Ed. MSC CONFIDENTIAL FFU Thrust Direction Steering 1201903 + SCS
Appr © SCHOTTEL GmbH Control Signals switch cabinet SCS Page 46
0 1 2 3 4 5 6 7 8 9
-4A1
/27.1
DCM
steering steering steering setpoint

cw ccw locked frequency converter
AGND
DO 0
DO 1
DO 2
DO 3
AO 0
AO 1
5 6 7 8 31 32 29
BU
A1
-2K7
A2
BU
27.9 / -1F1.2- -1F1.2- / 37.0
FFU
steering
locked
14
12 11 /42.7
Date 18.06.2014 = AZ1 29 / 54

0 1 2 3 4 5 6 7 8 9
-4A2
/27.4 23 21 22 24 17 18 19 20
DPV
AI 1
AGND
10V REF
AI 2
DI 1.0
DI 1.1
DI 1.2
DI 1.3
steering value overload hy pump additonal additonal
input ±10V in service steering system steering system
±10V = ±45° ±10V = ±180°
ON ON
steering signal overload hy pump additonal additonal

remote control in service steering system steering system
±10V = ±45° ±10V = ±180°
ON ON
Date 18.06.2014 = AZ1 30 / 54

0 1 2 3 4 5 6 7 8 9

OR OR
26.9 / -A+
42 44 12 14 12 14
-4K1 -4K10 -4K11
/27.7 41 /10.3 11 /10.2 11
OR
42 44
-1K2.1
/9.4 41
OR OR OR
-4A3
/24.6 23 21 22 24 17 18 19 20
DPV
10V REF
NFU
DI 1.0
DI 1.1
DI 1.2
DI 1.3
AGND
AI 2
AI 3
converter overload NFU ON = 24V turn cw turn ccw

OFF NFU OFF = 0V
NFU ON turn cw turn ccw
Date 18.06.2014 = AZ1 31 / 54

0 1 2 3 4 5 6 7 8 9

BU
9.9 / -1F3.2+ -1F3.2+ / 42.0
-4A2 -4A3
/27.4 /24.6
DPV DPV
NFU
AO 1 COM
AO 2 COM
AO 1 COM
AO 2 COM
AO 1
AO 2
AO 1
AO 2
6 5 7 8 6 5 7 8
BU
-4A3
WH WH WH WH WH WH WH WH /24.6 10
12 14 22 24 32 34 42 44
-4K2 9
/27.7 11 21 31 41
WH WH WH WH
-W240
-X42 1 2 3 4
-X42 5 6 7
MPRXCX
10x1,5 mm²
K3* 1 2 3 4 12 14
K3*
-4K1
/27.7 11
BU
FL.NFU / 42.6
+ENR/2.6 / -4Y1.1
+ENR/2.6 / -4Y1.2
+ENR/2.8 / -4Y2.1
+ENR/2.8 / -4Y2.2
BU
A1
-4K4
A2
23.9 / -1F3.2-
steering valves NFU steering ON
14
12 11 /10.1
44
42 41
15/0578
004 15/0578 26.02.2015 BJU Date 26.02.2015 = AZ1 32 / 54

Ed. BJU CONFIDENTIAL NFU Steering 1201903 + SCS
0 1 2 3 4 5 6 7 8 9
7.7 / -5F1.2+ 7.7 / -5F1.4+

21
7.7 / -5F1.3+
-1K7
/17.6 14 12
BU BU
14.9 / CL.AU
BU
-5V1
BU
41
-3K1
/19.6 42 44
BU
BU
-3A4
/23.2 15
11
-3K3
/23.5 12 14
10 9
BU
BU BU
BU 15.9 / CL.AIR -CL.AIR / 44.3
BU BU BU BU
14.9 / CL.EN
-5A3
1 4 3 BU
2 5 6 -X52 5 6 7 8 -SH
-W220
K2* 5 6 7 8
BU BU
BU
BU BU
+CLU/2.3 / -5S1.1
+CLU/2.3 / -5S1.2
+CLU/2.4 / -5S2.1
+CLU/2.4 / -5S2.2
-W220 -X52 1 2 3 4
MPRXCX
10x1,5 mm²
K2* 1 2 3 4
+CLU/2.0 / -5Y1.1
+CLU/2.1 / -5Y1.2
+CLU/2.2 / -5Y2.1
+CLU/2.2 / -5Y2.2
A1
A1 A1
7.8 / -5F1.3-
-X3.K12
-5K3 -2K9 A2
7.8 / -5F1.4- A2 A2
BU BU
7.8 / -5F1.2-
clutch clutch lube oil supressing lube clutch clutch

disengaging engaging pump ON flow engaged air pressure min
1 2 /4.6 14 14
3 4 /4.6 12 11 /44.3 12 11 /47.2
5 6 /4.6
13 14
Date 15.08.2014 = AZ1 33 / 54

Ed. MSC CONFIDENTIAL Clutch Control 1201903 + SCS
0 1 2 3 4 5 6 7 8 9
24V DC
BU BU
28.9 / -1F1.3+ -1F1.3+ / 36.0
BU
-FL.EXT / 43.0
-A81
/2.3 26 28 9 10 12 4
/13.1
GND 24
UB 24V
UB 24V
/35.1 1167526 modul
RXD
/36.1 1167527 programm
/37.1
DCM
GND 24V
GND 24V
25 27
BU
27.9 / -1F1.3- -1F1.3- / 36.0
DCM external systems 1
Date 18.06.2014 = AZ1 34 / 54

Ed. MSC CONFIDENTIAL Interface External Systems 1201903 + SCS
0 1 2 3 4 5 6 7 8 9
-APR / 49.0
BU
BU
-A81
/34.0 13 14 15 16 17 18 19 20
DCM
DI 0.0
DI 0.1
DI 0.2
DI 0.3
DI 1.0
DI 1.1
DI 1.2
DI 1.3
autopilot autopilot DP system DP system
not used not used not used not used
take control in service activated ready for service
autopilot not used autopilot not used not used not used not used not used
take control in service
Date 18.06.2014 = AZ1 35 / 54

0 1 2 3 4 5 6 7 8 9

BU
34.9 / -1F1.3+ -1F1.3+ / 47.0
34.9 / -1F1.3-
-A83
/49.4 3 4 7 8
+ -
0-20mA
0-10V
GND
24V
+ -
5 6 7 8
WH WH
-A81
/34.0 21 22 23 24 29
DCM
GND
AI 1
AI 2
AI 3
AI 4
setpoint setpoint setpoint
steering value speed value steering value not used
from AP system from DP system from DP system
setpoint setpoint setpoint not used

steering value speed value steering value
Date 18.06.2014 = AZ1 36 / 54

0 1 2 3 4 5 6 7 8 9
-A81
/34.0
DCM
feedback
autopilot unit ready
not used DP mode
in service for DP system
in service
DO 0
DO 1
DO 2
DO 3
AO 0
AO 1
5 6 7 8 31 32
BU
A1
-X5.K1
A2
29.9 / 1F1.2-
autopilot
in service
14
12 11 /49.2
Date 18.06.2014 = AZ1 37 / 54

0 1 2 3 4 5 6 7 8 9
7.4 / -2F1.1+
-2A10
/2.6
RS232_GND
RS232_RXD
RS232_TXD
CAN_VCC
24V DC
CAN_H
CAN_G
CAN_L
GND
1 2 3 4 5 6 7 8 9 10 11
-X1
YE GN
WARN1 / 45.0
BU
WARN2 / 45.0
CANH / 39.0
CANL / 39.0
BU
CANG / 40.0
BU
7.4 / -2F1.1-
002 14/1725 23.06.2014 MSC Date 15.08.2014 = AZ1 38 / 54

Ed. MSC CONFIDENTIAL Warning Unit 1201903 + SCS
0 1 2 3 4 5 6 7 8 9
7.4 / -2F1.3+
YE
38.9 / CANH -CANH / 40.0
GN
38.9 / CANL -CANL / 40.0
BU
BU
-2A1.0 1 5 2 6 3 7 4 8 -2A1.1 5 1 4 2 6
5 4 3 2 1
/2.6 -FB
0VIN 0V 0V
BU
7.4 / -2F1.3-
Date 26.02.2015 = AZ1 39 / 54

0 1 2 3 4 5 6 7 8 9

BU
7.4 / -2F1.4+ -2F1.4+ / 43.0
-P2.10 / +MDWP/2.4
-P2.11 / +MDWP/2.5
-P2.1 / +MDWP/2.2
-P2.2 / +MDWP/2.2
-P2.3 / +MDWP/2.2
-P2.4 / +MDWP/2.3
-P2.8 / +MDWP/2.4
SH
-W381 SH -W380
TCX(C) MPRXCX
2x2x0,75 mm² 5x1,5 mm²
K4* 1.1 1.2 2.1 2.2 K3* 1 2 3
-SH
-SH
-X22 1 2 3 4 5 6 7
YE GN
38.9 / CANG
39.9 / CANH
39.9 / CANL
A1
-2K20
A2
BU BU
7.4 / -2F1.4- -2F1.4- / 45.0
CAN BUS feed line
warning panel warning panel
14
12 11 /45.3
Date 15.08.2014 = AZ1 40 / 54

0 1 2 3 4 5 6 7 8 9
-2A1.2 1 5 2 6 3 7 4 8
1 2 3 4
WAGO 750-430 8DI; 24VDC; 3,0 ms
config lamp suppressing buzzer

check all alarms off
Date 26.02.2015 = AZ1 41 / 54

0 1 2 3 4 5 6 7 8 9

BU
7.4 / -2F1.2+ -2F1.2+ / 44.0
32.9 / -1F3.2+
12 14
-2K7
/29.4 11
FFU.STEER / 27.9
-FFU.RPM / 19.9
FL.NFU / 32.7
-FL.CO / 18.9
-FL.AC / 8.1
FL.DC / 8.4
BU
-2A1.3 1 5 2 6 3 7 4 8
2s 2s 2s 2s 2s 2s 2s 2s
5 5
6 7 8 9 10 11 12
WAGO 750-430 8DI; 24VDC; 3,0 ms
failure failure failure not used failure failure follow up failure

AC / DC 24V DC FFU speed FFU steering NFU stering steering control
converter feedline control locked system
15/0578
004 15/0578 26.02.2015 BJU Date 26.02.2015 = AZ1 42 / 54

Ed. BJU CONFIDENTIAL Warning Unit 1201903 + SCS
0 1 2 3 4 5 6 7 8 9

BU BU
40.9 / -2F1.4+
-2S12.2 / +SRP/2.2
-2S11.1 / +SRP/2.1
-2S11.2 / +SRP/2.1
-2S1.1 / +ENR/2.2
-2S1.2 / +ENR/2.2
-2S2.2 / +ENR/2.3
-2S3.2 / +ENR/2.3
-2S4.2 / +ENR/2.4
-2S5.2 / +ENR/2.5
-SH
-W214
TCX(C)
4x2x0,75 mm²
*K3 1.1 1.2 2.1
-W240
MPRXCX
10x1,5 mm²
K3* 5 6 7 8 9 10
32 34 K3*
-3K5
/20.7 31 -X21 1 2 3 4 5 6 7 8 9 10
BU
15.9 / HOL
BU BU
28.9 / HOP
34.9 / FL.EXT
BU BU BU BU BU BU BU
-2A1.4 1 5 2 6 3 7 4 8
2s 10s 3s 5s 5s 5s 10s 5s
13 14 15 16 17 18 19 20
WAGO 750-430 8DI; 24VDC; 3,0 ms
failure hydr. oil hydr. oil hydr. oil hydr. oil hydr. oil lube oil lube oil
extern level min pressure temperature filter pressure level min temp. max
system min max clogged max
Date 26.02.2015 = AZ1 43 / 54

0 1 2 3 4 5 6 7 8 9

BU BU
42.9 / -2F1.2+
13
-F1
-2S13.2 / +SRP/2.3
-2S15.2 / +SRP/2.4
/4.6 14
-CL.AIR / 33.9
2
-B1
50° 3
-W214 -F3
TCX(C)
4x2x0,75 mm² /4.6 12 14
*K3 2.2 3.1
-X21 11 12
11
12 14
-2K9
/33.4 11
BU
BU BU BU BU
-2A1.5 1
5 2 6 3 7 4 8
DI1
DI1 DI2 DI3 DI4 DI5 DI6 DI7
5s 5s 5s 5s 5s
21 22 23 24 25 26 27 28
WAGO 750-430 8DI; 24VDC; 3,0 ms
lub oil lub oil clutch failure overtemp not used not used not used
filter flow control lube oil switch cabinet
dirty min air min pump
14/2239 14/0773
003 14/2239 15.08.2014 MSC Date 26.02.2015 = AZ1 44 / 54

001 14/0773 12.03.2014 ROM Ed. BJU CONFIDENTIAL Warning Unit 1201903 + SCS
0 1 2 3 4 5 6 7 8 9
-2A1.6 WAGO 750-530 8DO; 24VDC; 0,5A
1 5 2 6 3 7 4 8
BU
38.9 / WARN1
38.9 / WARN2
12 14
-2K20
/40.3 11
BU
BU
BU
A1 A1 A1
-2K0 -X4.K1 -X4.K2
A2 A2 A2
BU BU
40.9 / -2F1.4-
collective failure
alarm warning
unit
14 14 14
12 11 /15.2 12 11 /48.3 12 11 /48.4
Date 26.02.2015 = AZ1 45 / 54

0 1 2 3 4 5 6 7 8 9
end terminal
1 5 2 6 3 7 4 8
Date 26.02.2015 = AZ1 46 / 54

0 1 2 3 4 5 6 7 8 9

BU
20.9 / -1F5.4+ -1F5.4+ / 49.0
7.2 / -1F5.4-
36.9 / -1F1.3+
23.9 / -1F3.3+
23.9 / -1F3.3-
23.5 / 3A4.2
22.9 / -3A1.32
23.5 / 3A4.3
22 24 32 34
-3K2
/19.7 21 31
WH BU
-3A2
MAZ DC/DC 1 2 4 3
+ -
12 14 12 14
0-10V
-X3.K3 -X3.K12 4-20mA
/23.6 11 /33.6 11
GND
24V
+ -
6 5 4 3
WH WH
-W710
-SH
-W711 -X3 13 14
-SH
15 16
TCX(C) TCX(C)
7x2x0,75 mm² 2x2x0,75 mm²
K3* 4.1 4.2 5.1 5.2 K3* 1.1 1.2
K3*
SH
=YARD+PM/2.6 / -PM31
lever in idle clutch engaged speed value
Date 15.08.2014 = AZ1 47 / 54

Ed. MSC CONFIDENTIAL Interface To Drive Motor 1201903 + SCS
0 1 2 3 4 5 6 7 8 9
12 14 12 14
-X4.K1 -X4.K2
/45.2 11 /45.3 11
-W820
TCX(C)
2x2x0,75 mm² -SH
K3* 1.1 1.2 2.1 2.2
=YARD+SWU/2.0 / -SWU1
failure common
SCHOTTEL SCHOTTEL
warning unit unit
Date 18.06.2014 = AZ1 48 / 54

Ed. MSC CONFIDENTIAL Interface To Ship Warning unit 1201903 + SCS
0 1 2 3 4 5 6 7 8 9

WH
47.9 / -1F5.4+ -1F5.4+ / 50.0
35.3 / APR
-A83
/36.1 5 6 7 8
+ -
0-10V
0-20mA
GND
24V
+ -
3 4 7 8
WH WH
11
-X5.K1
/37.2 12 14
-X5 1 2 -X5 3 4
-SH
-W720
TCX(C)
4x2x0,75 mm²
K3* 1.1 1.2 2.1 2.2 3.1 3.2
-AP1
-AP2
-AP3
-AP4
-AP5
-AP6
=YARD+AP/2.1 /
=YARD+AP/2.1 /
=YARD+AP/2.2 /
=YARD+AP/2.2 /
=YARD+AP/2.3 /
=YARD+AP/2.3 /
Autopilot Autopilot setpoint

system ready mode steering value
for service in service from AP system
Date 10.09.2014 = AZ1 49 / 54

Ed. RGM CONFIDENTIAL Interface To Autopilot 1201903 + SCS
0 1 2 3 4 5 6 7 8 9

WH
49.9 / -1F5.4+
20.9 / FIFI.ENG
16.2 / FIFI.ON
42 44
-1K7
/17.6 31
clutch off
WH
12 14
11 BU BU
-3K7
/50.1 11
-X8.K41
/50.3 12 14
-X8 41 42 43
WH
20.9 / IDLE
A1 A1
-3K7 -X8.K41
A2 A2
WH
20.9 / -1F5.2-
engine FIFI feed FIFI FIFI

at idle Mode line MODE System
possible ON Ready
14 14
12 11 /50.3 12 11 /50.5
44
42 41
Date 10.09.2014 = AZ1 50 / 54

Ed. RGM CONFIDENTIAL Interface To FIFI pump 1201903 + SCS
0 1 2 3 4 5 6 7 8 9
1S1 1S2 S3
-P1 AZ RPM
LD1/19 LD2/20 LD3/ LD4/ LD5/ LD6/
FAILURE FAILURE OVERTEMP

EXTERN LUBE OIL SWITCH
SYSTEM PUMP CABINET
LD7/12 LD8/13 LD9/24 LD10/25 LD11/ LD12/
RPM RPM
LD13/5 LD14/6 LD15/7 LD16/8 LD17/9 LD18/10
LD19/19 LD20/20 LD21/23 LD22/ LD23/22 LD24/
1100 mm
HY HY HY HY HY bar
bar
LD25/14 LD26/15 LD27/17 LD28/16 LD29/18 LD30/11
AIR TEST
PRESS
1000
LD31/23 LD32/ LD33/ S1 H1 S2
M1
800 300 mm 78 mm
d=8
cable input
holes must be drilled by the yard
glands are yard supply
technical datas of switch box
960 mm
mechanic colors
Protection class: IP 54 switch box housing: RAL 7035
weight: approx 160kg panel: black
internal wiring
NAXAF ( GL 47682 HH, no. 07/90 )
temperature: engine room temperature 45°C
screened cable type: LIYCY 95% humidity without condensation
20 mm
vibration 0,7g 760 mm 20 mm
Date 18.06.2014 = AZ1 51 / 54

Ed. MSC CONFIDENTIAL Switch Cabinet 1201903 + SCS
0 1 2 3 4 5 6 7 8 9
200 mm
LD1/19 LD2/20 LD3/ LD4/ LD5/ LD6/

SYSTEM PUMP CABINET
LD7/12 LD8/13 LD9/24 LD10/25 LD11/ LD12/
RPM RPM
180 mm
LD13/5 LD14/6 LD15/7 LD16/8 LD17/9 LD18/10
LD19/19 LD20/20 LD21/23 LD22/ LD23/22 LD24/
HY HY HY HY HY bar
bar
LD25/14 LD26/15 LD27/17 LD28/16 LD29/18 LD30/11
AIR
TEST
PRESS
LD31/23 LD32/ LD33/ S1 H1 S2
Date 18.06.2014 = AZ1 52 / 54

0 1 2 3 4 5 6 7 8 9
-A2
-A1
-A3
switch cabinet articles
-1F0
-1F1
-1F2
-1F3
-1F4
-1F5
-1F6
-2F1
-4F1
-5F1
-4F3
-F1
-F2
-5K3
Order number Quantity designation
-S1
-S2
-5A3
1053244 1 Schaltschrank 800x1000x300
switch box 800x1000x300
-1K2.1
-4K10
-4K11
-1K2
-1K4
-1K5
-1K7
-3K1
-3K2
-3K5
-4K2
-1K6
-3K3
-3K6
-3K7
-4K1
-4K4
-4K5
-GND
-A83
-K1
-K2
-K3
Türfeststeller
-L+
1135768 1
-1V2
-5V1
door stay hinge
1085605 4 Tragschiene 35x15

mounting rail 35x15
1170070 1 Handlauf
-4V1
-5K3
-3A2
handrail
1178897 3 Tragschienenhalter
-2K0
-2K9
mounting rail holder
1184645 1 SCHOTTEL Logo 100x100

SCHOTTEL logo 100x100
1161920 1 Kabeleinführungsflansch
-2A0.0
-2A1.1
-2A1.2
-2A1.3
-2A1.4
-2A1.5
-2A1.6
-2A1.7
1A1.0
1A1.1
1A1.2
1A1.3
1A1.4
1A1.5
1A1.6
1A1.7
-XC
-2K7
-2K20
switch box cable entry
-3A1
-3A4
-4A1
-4A2
-4A3
-A40
-A81
1126844 4 Endwinkel
end bracket
-X8.K41
-X3.K3
-X5.K1
-X4.K1
1126578 2,749 Verdrahtungskanal 37.5x75

-SP
wiring duct 37.5x75
1178231 0,739 Verdrahtungskanal 80x100mm

wiring duct 80x100mm
1126580 0,739 Verdrahtungskanal 75x75

-X3.K12
-X4.K2
wiring duct 75x75

-X12
-X41
-X42
-X44
-X51
-X52
-X54
-X22
-X10
-X1
-X2
-X3
-X5
-X8
1043807 2,028 Tragschiene 35x7,5

mounting rail 35x7,5
1069768 2 Gruppenbezeichnung
group designation
Date 15.08.2014 = AZ1 53 / 54

Ed. MSC CONFIDENTIAL Switch Cabinet Mounting Plate 1201903 + SCS
0 1 2 3 4 5 6 7 8 9
280 260
35 mm 35 mm
27X21
66,5 66,5
180
100
63,5
62,5 62,5
66,5
94 94
63,5
66,5
5
215
167 mm
161 mm
200
150 150 10,5
245
66,5 66,5
62,5 62,5
66,5
66,5
5
Date 15.08.2014 = AZ1 54 / 54

0 1 2 3 4 5 6 7 8 9
Unit =AZ1 Location +MDP
-AX1 connection terminal feed line control panel

-AX2 connection terminal signals backup control system
-AX3 connection terminal control bus panel
-AX9 connection terminal indicator
-X21 connection terminal warning panel
Date 18.06.2014 = AZ1 1/ 10

Ed. MSC CONFIDENTIAL Terminal Groups 1201903 + MDP
Appr © SCHOTTEL GmbH main panel Page 73
0 1 2 3 4 5 6 7 8 9
-A1
/3.0
/4.0 control panel 1168785 FSP-FP PS SRP/STP
/5.0
/6.0
1170467 STANDARD
Montageplatte AFT
1170073 mounting plate aft
-X1 1 2 3 4 5 6 7 8
-AX1 1 2 3 4 5 6 7 8
/3.0
/7.2
-F1 -F2
3,15A 3,15A
F F
1 2 3 4 1 2 3 4 5 6 5 6 7 8 7 8
+SCS/6.1 / +SCS-P1
+SCS/6.1 / +SCS-P2
+SCS/6.4 / +SCS-P3
+SCS/6.4 / +SCS-P4
+SCS/6.6 / +SCS-P7
+SCS/6.6 / +SCS-P8
feedline control panels instrument light indicators feedline input NFU systems
Date 18.06.2014 = AZ1 2/ 10

Ed. MSC CONFIDENTIAL Power Supply 1201903 + MDP
0 1 2 3 4 5 6 7 8 9
-A1
/2.0 NFU
ON
RPM Azimuth control panel
SH
-X1 9 10 11 12 13 14
-AX1 9 10 11 12 13 14
/2.0
SH
9 10 11 12 9 10 11 12 13 14
+SCS/9.8 / +SCS-P10
+SCS/10.6 / +SCS-P16
+SCS/10.1 / +SCS-P12
indication NFU systems
Date 18.06.2014 = AZ1 3/ 10

0 1 2 3 4 5 6 7 8 9
-A1
/2.0
control panel
-X2 2 3 4 5 6 7 8 9 1
-AX2 1 2 3 4 5 6 7 8 9
14 24 34 44 54 64 74 84 13 14 24 34 44 54 64 74 84 13
+SCS/9.8 / +SCS-P9
+SCS/23.2 / +SCS-P20
+SCS/23.3 / +SCS-P21
+SCS/10.4 / +SCS-P13
+SCS/10.4 / +SCS-P14
+SCS/10.1 / +SCS-P11
NFU decrease increase thruster thruster not used not used feedline
ON RPM RPM turning turning decrease increase
ccw cw pitch pitch
Date 15.08.2014 = AZ1 4/ 10

Ed. MSC CONFIDENTIAL NFU Signals 1201903 + MDP
0 1 2 3 4 5 6 7 8 9
-A1
/2.0
control panel
CAN-GND
CAN-GND
CAN-H
CAN-H
CAN-L
CAN-L
PE
-X3 2 3 4 5 6 7 -X6 1 2 3 4 5 6
PE
-AX3 7 2 3 9 4 5
PE
CAN-SERVICE ON
PLUG 120
Ohm
OFF
1 2 3 4 5 6 7 8
-X30 1 2 3 4
+SCS/11.4 / +SCS-P22
+SCS/11.5 / +SCS-P23
+SCS/11.5 / +SCS-P24
+SCS/11.6 / +SCS-P25
=AZ2/5.3 / -P1
=AZ2/5.3 / -P2
=AZ2/5.3 / -P3
=AZ2/5.3 / -P4
control bus spare
Date 18.06.2014 = AZ1 5/ 10

Ed. MSC CONFIDENTIAL Control Bus 1201903 + MDP
0 1 2 3 4 5 6 7 8 9
-A2
Azimuth Speed speed lever in zero
IDNR REMARK
yellow
yellow
brown
brown
violett
violett
green
green
white
white
grey
grey
blue
blue
pink
pink
red
red
1170035 with handwheel
CODE SWITCH CODE SWITCH

+VCC 24V DC
AZIMUTH SPEED
lever in zero
CAN GND
CAN GND
S2 S1
CAN H
CAN H
CAN L
CAN L
GND
2 9
-X1 1 2 3 4 5 6 7 8 9
-A1 -X3.1 1 2 3 4 5 6 7 8 9 -X7 1 2

/2.0
control panel
connection COPILOT
Date 18.06.2014 = AZ1 6/ 10

Ed. MSC CONFIDENTIAL Connection Control Handle 1201903 + MDP
0 1 2 3 4 5 6 7 8 9
azimuth indication speed indication

-P41 -P51
120 Ohm
power supply
ON
OFF
CONTROLLER CONTROLLER
+ - + -
4...20mA
1 2 4 5 8 9 6 7 3 3 1 2 4 5 8 9
H
L
D
D
N
N
V
V
GN
GN
CA
CA
+ - - + + -
PE
PE
24
24
24V GND CAN L CAN H
-AX9 -X91 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 -X92 1 2 3 4 5 6 7
PE PE PE PE
120 Ohm
ON
OFF
PE
1 2 3 4 5 8 9 10 11 13 14 15 16 17 18 1 2 6 7 5 13 14 15 16 17 18
12
PE
5 6
-AX1
/2.0
+SCS/5.4 / +SCS-P5
+SCS/5.4 / +SCS-P6
+SCS/24.8 / +SCS-P26
+SCS/24.8 / +SCS-P27
+SCS/24.8 / +SCS-P28
+SCS/24.8 / +SCS-P29
+SCS/26.6 / +SCS-P30
+SCS/26.6 / +SCS-P31
+SCS/26.7 / +SCS-P32
+SCS/26.7 / +SCS-P33
feedline CAN BUS instrument propeller RPM indication

indicators Indicator light
Date 18.06.2014 = AZ1 7/ 10

Ed. MSC CONFIDENTIAL Indicators 1201903 + MDP
0 1 2 3 4 5 6 7 8 9
290,000
290 4
stay bolt M5x20
RPM BACKUP CONTROL AZIMUTH

440
260 175
panel top view
Date 18.06.2014 = AZ1 8/ 10

Ed. MSC CONFIDENTIAL Panel main desk 1201903 + MDP
0 1 2 3 4 5 6 7 8 9
desk cut out for control panel
10 135 135
panel
140
20
140
250
hole d= 6
400
length of cable 1200mm
140
80 4 350
hole d= 6
10
20
300
270
AX1 AX2 AX3 X30 AX9
wiring duct for ship cables
15 320
15
mounting plate
earth connection M8x20
mounting holes
Technical datas panel
mechanic
Protection class top side: IP 54
Protection class back side: IP 20
colors
control panel : black
Date 18.06.2014 = AZ1 9/ 10

0 1 2 3 4 5 6 7 8 9
control panel
PE LED
RUN
1 6 1 8 1 9 1 8 PWR
X6 X4 X5 X2 RES
1
PE X8 S1
1 14
X1 PROG. RUN 8
1
S2
8
OFF ON
X3.1 X3
1 2
X7 ON OFF OFF ON
ON OFF
Date 18.06.2014 = AZ1 10 / 10

0 1 2 3 4 5 6 7 8 9
Unit =AZ1 Location +MDWP
-X21 panel warning unit
Date 18.06.2014 = AZ1 1/ 4

Ed. MSC CONFIDENTIAL Terminal Groups 1201903 + MDWP
Appr © SCHOTTEL GmbH main desk warning Page 83
Modification Date Name Standard panel Page 260
0 1 2 3 4 5 6 7 8 9
-2A10
RS232_GND
RS232_RXD
RS232_TXD
S3 ON
CAN_VCC
120 Ohm
24V DC
CAN_H
CAN_G
1 2 3 4 5 6 7 8
CAN_L
ON
GND
S4 ON
OFF
1 2 3 4 5 6 7 8
1 2 3 4 5 6 7 8 9 10 11
-X1
YE GN
-X21 1 2 3 4 5 6 7 8
+SCS/40.2 / +SCS-P2.4
+SCS/40.1 / +SCS-P2.1
+SCS/40.2 / +SCS-P2.2
+SCS/40.2 / +SCS-P2.3
+SCS/40.3 / +SCS-P2.8
+SCS/40.4 / +SCS-P2.10
+SCS/40.4 / +SCS-P2.11
CAN BUS feed line
Date 15.08.2014 = AZ1 2/ 4

Ed. MSC CONFIDENTIAL warning panel 1201903 + MDWP
0 1 2 3 4 5 6 7 8 9
200 mm
FAILURE OVERTEMP
LUBE OIL SWITCH
PUMP CABINET
desk cut out
LD1/24 LD2/25 LD3/ LD4/ LD5/ LD6/
92,5 92,5
FAILURE
EXTERN
SYSTEM
LD7/12 LD8/13 LD9/24 LD10/25 LD11/ LD12/

167
84,5
RPM RPM
161
180 mm
LD13/5 LD14/6 LD15/7 LD16/8 LD17/9 LD18/10
84,5
LD19/19 LD20/20 LD21/21 LD22/ LD23/22 LD24/
HY HY HY HY HY bar 4,5
bar
LD25/14 LD26/15 LD27/17 LD28/16 LD29/18 LD30/11
AIR TEST
PRESS
LD31/23 LD32/ LD33/ S1 H1 S2
terminal row
004 15/0578 26.02.2015 BJU Date 26.02.2015 = AZ1 3/ 4

Ed. BJU CONFIDENTIAL warning panel 1201903 + MDWP
0 1 2 3 4 5 6 7 8 9
failure SCHOTTEL main feed line HY min hydraulic oil level

failure desk control
failure SCHOTTEL secound feed line HY min hydraulic oil pressure

FAILURE
EXTERN
SYSTEM bar
RPM failure FFU RPM control HY hydraulic oil filter clogged
RPM failure NFU RPM control HY max hydraulic oil temperature
failure FFU steering HY bar max hydraulic oil pressure
failure NFU steering steering locked
min lub oil level propulsor AIR min air pressure clutch
PRESS
max lub oil temperature propulsor max temperature clutch
1 propulsor lub oil filter 1 clogged EMERG emergency disengaging clutch
2 propulsor lub oil filter 2 clogged TEST lamp check
propulsor min lub oil flow
waterleekage elastic mounting horn OFF
Date 18.06.2014 = AZ1 4/ 4

0 1 2 3 4 5 6 7 8 9
SCHOTTEL Components
Date 18.06.2014 = AZ1 1/ 4

Ed. MSC CONFIDENTIAL Connection Engine Room 1201903 + ENR
Appr © SCHOTTEL GmbH engine room Page 87
0 1 2 3 4 5 6 7 8 9
+SCS-4Y1.1 / +SCS/32.1
+SCS-4Y1.2 / +SCS/32.1
+SCS-4Y2.1 / +SCS/32.2
+SCS-4Y2.2 / +SCS/32.2
+SCS-2S1.1 / +SCS/43.2
+SCS-2S1.2 / +SCS/43.2
+SCS-2S2.2 / +SCS/43.3
+SCS-2S3.2 / +SCS/43.4
+SCS-2S4.2 / +SCS/43.5
+SCS-2S5.2 / +SCS/43.6
+HYP
-X4 14 15 16 17
-X2 1 2 3 4 5 6 7 8 9 10
PE PE
PE PE PE PE
1 2 1 2
-4Y1 -4Y2
-2S2 P -2S3 -2S4 P -2S5 P
+HYT
-W248
TCX(C)
2x2x0,75 mm²
*K3
PE
-2S1
min min max hydr. oil max steering steering

hydr. oil hydr. oil hydr. oil filter hydr. oil valve valve
level pressure temperature clogged pressure
Date 26.02.2015 = AZ1 2/ 4

Ed. BJU CONFIDENTIAL Connection Engine Room 1201903 + ENR
0 1 2 3 4 5 6 7 8 9
-4A3
1 2
120 Ohm
GND
24V
ON
OFF
power supply
CONTROLLER
+SCS-4B1.1 / +SCS/28.6
+SCS-4B1.3 / +SCS/28.6
+SCS-4B1.4 / +SCS/28.6
+ -
1 2 3 4 5 8 9
-4B1.1 1 3 4
+SCS/24.5 / +SCS-4A3.1
+SCS/24.5 / +SCS-4A3.2
+SCS/24.6 / +SCS-4A3.3
+SCS/24.6 / +SCS-4A3.4
+SCS/24.6 / +SCS-4A3.5
+SCS/24.7 / +SCS-4A3.6
1 3
+ -
-4B1
4
thrust direction indicator hydraulic-

near hy pump pump RPM
Date 18.06.2014 = AZ1 3/ 4

0 1 2 3 4 5 6 7 8 9
118
144 14 90
12,5
25
ø 11
mm
17
145
118
Date 18.06.2014 = AZ1 4/ 4

0 1 2 3 4 5 6 7 8 9
clutch control
Date 18.06.2014 = AZ1 1/ 2

Ed. MSC CONFIDENTIAL Connection Clutch 1201903 + CLU
Appr © SCHOTTEL GmbH clutch control Page 91
0 1 2 3 4 5 6 7 8 9
+SCS-5Y1.1 / +SCS/33.1
+SCS-5Y1.2 / +SCS/33.2
+SCS-5Y2.1 / +SCS/33.2
+SCS-5Y2.2 / +SCS/33.2
+SCS-5S2.1 / +SCS/33.8
+SCS-5S2.2 / +SCS/33.8
+SCS-5S1.1 / +SCS/33.7
-X5 1 2 3 4 5 +SCS-5S1.2 / +SCS/33.7

6 7 8
1 2 1 2
-5Y1 -5Y2 -5S1 P -5S2 P
clutch clutch clutch clutch

disengaging engaging engaged air pressure
min
Date 18.06.2014 = AZ1 2/ 2

Ed. MSC CONFIDENTIAL Clutch Control 1201903 + CLU
0 1 2 3 4 5 6 7 8 9
SCHOTTEL Components
Date 18.06.2014 = AZ1 1/ 3

Ed. MSC CONFIDENTIAL Connection Propulsor 1201903 + SRP
Appr © SCHOTTEL GmbH connection SRP Page 93
0 1 2 3 4 5 6 7 8 9
+SCS-2S12.2 / +SCS/43.8
+SCS-2S13.2 / +SCS/44.1
+SCS-2S15.2 / +SCS/44.2
+SCS-2S11.1 / +SCS/43.7
+SCS-2S11.2 / +SCS/43.7
+SCS-M1:W / +SCS/4.6
+SCS-M1:U / +SCS/4.6
+SCS-M1:V / +SCS/4.6
-X2 11 12 15 16 17 18 19 20
PE PE PE PE
13
-2S11 -2S13 -2S4 P -2S15
14
-M1
M
1,5kW 3~
380V
50Hz PE
Lube oil Lube oil Lube oil Lube oil lube oil
level min temp. max filter clogged flow min pump
Date 15.08.2014 = AZ1 2/ 3

0 1 2 3 4 5 6 7 8 9
+SCS-4A4.1 / +SCS/24.1
+SCS-4A4.2 / +SCS/24.1
+SCS-4A4.3 / +SCS/24.1
+SCS-4A4.4 / +SCS/24.2
+SCS-5B1.1 / +SCS/20.5
+SCS-5B1.3 / +SCS/20.5
+SCS-5B1.4 / +SCS/20.5
+SCS-5B2.1 / +SCS/25.6
+SCS-5B3.4 / +SCS/20.6
+SCS-4A4.6 / +SCS/13.7
+SCS-4A4.7 / +SCS/13.7
+SCS-4A4.8 / +SCS/13.7
+SCS-4A4.9 / +SCS/13.7
+SCS-5B2.3 / +SCS/25.7
+SCS-5B2.4 / +SCS/25.7
-X5 1 2 3 4 5 6 7 8 9
-4A4 1 2 3 4 5 6 7 8 9 10
1179731 1179731 1179731
sensor cable BN BU BK sensor cable BN BU BK sensor cable BN BU WH
1 3 1 3 1 3
red
blue
yellow
green
brown
white
grey
pink
violett
red
blue
yellow
green
brown
white
grey
pink
violett
+ - + - + -
-5B1 -5B2 -5B3
4 4 2
feedback thrust direction feedback thrust direction shaft speed pickup shaft speed pickup SRP in
indicating steering control system indicator zero pos.
Date 23.06.2014 = AZ1 3/ 3

0 1 2 3 4 5 6 7 8 9
Unit =AZ2 Location +SCS
-X1 connection AC feed line earth

-X2 connection DC feed line
-X3 connection to Propulsion motor
-X4 connection to Shipwarning unit
-X5 connection to Autopilot System
-X8 connection to FIFI pump (OPTION)
-X10 connection to lube oil pump

-X12 connection to steering desks
-X41 connection CAN bus steering system to thruster
-X42 connection to hydraulic aggregate
-X44 connection to azimuth indicator near hydraulic aggregate

-X51 connection speed pick up thruster
-X52 connection clutch
-X54 connection shaft speed indicator
-X21 connection warning transmitter
-X22 connection warning unit
-GND ground
-L+ 24VDC
Date 23.06.2014 = AZ2 1/ 54

Ed. MSC CONFIDENTIAL Terminal Groups 1201903 + SCS
0 1 2 3 4 5 6 7 8 9

-3A1 -4A3 -2A1.0
/19.1 DCM SPEED 1167522 modul /24.6 DPV Steering NFU 1179008 Modul /39.0 WAGO MASTER CONTROLLER 1193931 modul
DCM 1167523 programm DPV 1179009 programm WAGO 1193932 programm
S3 ON NFU S3 ON
J7
1 2 3 4 5 6 7 8 1 2 3 4 5 6 7 8 120 Ohm ON
S4 ON S4 ON ON
1 2 3 OFF 1 2 3 4 5 6 7 8
1 2 3 4 5 6 7 8 1 2 3 4 5 6 7 8
Extern
Intern
-3A4 -A81 -2A10 1163275 panel
/23.2 RAMP GENERATOR /34.0 DCM EXTERNAL SYSTEM 1 1167526 modul /38.2 WARNING PANEL
RG1
J7 DCM 1167527 programm WAP
S3 ON S3 ON
S1
Jumper
ON 1 2 3 4 5 6 7 8 120 Ohm
1 2 3 4 5 6 7 8
1 2 3 J7 ON
S4 ON
1 2 3 4 S4 ON J8 OFF
0..10V
0..20mA
f
ramp gen
1 2 3 4 5 6 7 8 1 2 3 1 2 3 4 5 6 7 8
-4A1 -A40
/27.1 DCM AZIMUTH 1167524 modul
/24.1 DCM INDICATION 1179940 Modul
Jumper
DCM 1167525 programm DCM 1179941 programm J1
S3 ON S3 ON J2 AO0
1 2 3 4 5 6 7 8 J3
1 2 3 4 5 6 7 8
S4 ON S4 ON J4
1 2 3 4 5 6 7 8 J5 AO1
1 2 3 4 5 6 7 8
J6
1 2 3
U I
-4A2 -1A1.0
/27.4 DPV Steering 1168411 modul /11.0 WAGO MASTER CONTROLLER 1167520 modul
DPV 1168412 programm WAGO 1167521 programm
S3 ON
1 2 3 4 5 6 7 8
ON
S4 ON
1 2 3 4 5 6 7 8
1 2 3 4 5 6 7 8
15/0578
004 15/0578 26.02.2015 BJU Date 26.02.2015 = AZ2 2/ 54
Ed. BJU CONFIDENTIAL DIP Switches Digital Modules 1201903 + SCS
0 1 2 3 4 5 6 7 8 9

Weidmüller MAZ DC/DC WAGO 857-409
SCHOTTEL IDNr: 1148645 SCHOTTEL IDNr: 1174848
-AXX -AXX -AXY
MAZ DC/DC DC/DC ISOLATION CONVERTER MAZ DC/DC DC/DC ISOLATION CONVERTER WAGO DC/DC ISOLATION CONVERTER
0-10V/0-20mA 0-10V/4..20mA ±10V/2-10V
.. ...... .. ...... .... ......

S1 S2 S1 S2 S1 S2
1 2 1 2 3 4 5 6 1 2 1 2 3 4 5 6 1 2 3 4 1 2 3 4 5 6
on on on on on on
off off off off off off
-AXX -AXY
0-20mA/0-10V 0-10V/2-10V
.. ...... ......
S1 S2 S1 S2
....
1 2 1 2 3 4 5 6 1 2 3 4 1 2 3 4 5 6
on on on on
off off off off
-AXX -AXY
4-20mA/0-10V 0-20mA/4-20mA
.. ...... ......
S1 S2 S1 S2
....
1 2 1 2 3 4 5 6 1 2 3 4 1 2 3 4 5 6
on on on on
off off off off
-AXX -AXY
0-20mA/0-20mA 4-20mA/2-10V
.. ...... .... ......

S1 S2 S1 S2
1 2 1 2 3 4 5 6 1 2 3 4 1 2 3 4 5 6
on on on on
off off off off
These are the DIP switch settings for default values of analog converters.
They have to be independently assigned to the appropriate converters.
Date 23.06.2014 = AZ2 3/ 54

Ed. MSC CONFIDENTIAL DIP Switches Digital Modules 1201903 + SCS
0 1 2 3 4 5 6 7 8 9

400V / 50Hz
BK BK BK BK BK BK
2,5 2,5 2,5 2,5 2,5 2,5
1 3 5 13 21 1 3 5
-F1 -F2
3,5-5A 14 22 1,8-2,5A
4A 1,9A
/44.4
L1 L2 L3 I> I> I> I> I> I>
2 4 6 2 4 6
-S1
T1 T2 T3
BK BK BK
1,5 1,5 1,5
BK BK BK BK BK BK
1,5 1,5 1,5 1,5 1,5 1,5
-F3
OR OR OR GNYE OR OR GNYE 1 3 5 400V L1 L2 L3
2,5 2,5 2,5 2,5 PE 1,5 1,5 1,5
-5K3 2s
/33.3 2 4 6 -A1
BK BK BK /5.2 PE L3 L2 L1
1,5 1,5 1,5
/8.1
-X1 1 2 3 PE 4 5 6 PE
-W200 -SH -W202 -W201 -SH N PE L
MPRXCX MPRXCX MPRXCX -X10 1 2 3
3x1,5 mm² 1x16 mm² 2x2,5 mm² -SP -SH
375V - 575V AC
K2* BK BU BN K1* BK K2* BK BU
-W216
MPRXCX 25VDC / 20A
PE 3x1,5 mm²
-SH *K3
/4.1
=MSB -400VX1 4 5 6 -220VX1 3 4
+SRP/2.6 / M1:U
+SRP/2.7 / M1:V
+SRP/2.7 / M1:W
20A 6A
L1 L1 L L
L2 L2 N N
L3 L3
AC feedline switch box earth connection service plug AC / DC converter
14
12 11 /44.4
24
22 21
14/00773 14/1725
002 14/1725 23.06.2014 MSC Date 15.08.2014 = AZ2 4/ 54
001 14/0773 12.03.2014 ROM Ed. MSC CONFIDENTIAL Power Distribution 1201903 + SCS
0 1 2 3 4 5 6 7 8 9

BK
2,5
BK L+ / 6.0
2,5
L- / 6.0
-P5 / +MDP/7.0
-P6 / +MDP/7.0
BK BK
2,5 2,5
-A2 - +
-A1
/8.3 /4.7 - +
-W301
MPRXCX
3x2,5 mm² BK BU
24VDC / 10A
25VDC / 20A -SH
24VDC
-X12 5 6
375V - 575V AC OR OR
1,5 1,5
+ Input -
OR
-A+ / 24.0
OR
-A- / 24.0
AC / DC converter
BK BK
2,5 2,5
-A3 + -
24VDC / 5A
L1 L2
-S2 24VDC
T1 T2
+ Input -
OR OR
2,5 2,5 OR OR
2,5 2,5
-X2 1 2
-SH
3 4
-SH
-W203
MPRXCX -W204
2x6 mm² MPRXCX
K3* BK BU 2x2,5 mm² BK BU
=ESB -24-X1 5 6 24-X1 7 8
16A 4A
L+ L+
L- L-
24V DC +30% -25% AC ripple <1V
emergency switchboard 24V DC
feedline switch cabinet feedline indicators

24V DC
Date 15.08.2014 = AZ2 5/ 54

0 1 2 3 4 5 6 7 8 9
5.6 / -L+ -L+ / 7.0

5.6 / L-
2 2 2 2 2
-1F0 -1F1 -1F2 -1F3 -1F4
B6A 1 B6A 1 B6A 1 B6A 1 B6A 1
BU BU BU BU BU
1,5 1,5 1,5 1,5 1,5
1L- / 7.0
-GND 0 1 2 3 4
-L+ 0
-L+ 1 -L+ 2 -L+ 3 -L+ 4
BU BU BU BU BU BU BU BU BU BU BU BU BU BU BU BU BU BU BU
14.0 / -1F1.1+
14.0 / -1F1.2+
11.0 / -1F1.3+
13.0 / -1F1.4+
17.0 / 1F1.2-
11.0 / 1F1.3-
13.0 / 1F1.4-
9.0 / -1F2.2+
9.0 / 1F2.1-
9.0 / -1F3.1+
9.0 / -1F3.2+
23.0 / -1F3.3+
9.0 / 1F3.1-
9.0 / 1F3.2-
23.0 / 1F3.3-
8.0 / -1F4.2+
20.0 / -1F4.4+
8.0 / 1F4.2-
20.0 / 1F4.4-
BU BU BU BU BU BU
1,5 1,5 1,5 1,5 1,5 1,5
-X12 1 2 3 4 -X12 7 8
-SH
-W300 -W302
MPRXCX MPRXCX
4x2,5 mm² 19x1,5 mm²
K3* BK BU BN WH K3* 1 2
+MDP/2.1 / -P3
+MDP/2.1 / -P4
+MDP/2.7 / -P7
+MDP/2.7 / -P8
+MDP/2.0 / -P1
+MDP/2.0 / -P2
feedline control panels control system instrument light NFU systems SCHOTTEL
control signals
Date 15.08.2014 = AZ2 6/ 54

0 1 2 3 4 5 6 7 8 9
6.9 / -L+
2 2 2 2
1
-1F5 -2F1 -4F1 -5F1
B6A 1
-1F6 B6A 1 B6A 1 B6A 1
B6A 2
BU BU BU BU BU
1,5 1,5 1,5 1,5 1,5
6.9 / 1L-
-GND 5 6 7 8 9 10
-L+ 5 -L+ 6 -L+ 7 -L+ 8 -L+ 9
BU BU
1,5 1,5
BU BU BU -1M0 BU BU BU BU BU BU BU BU BU BU BU BU BU BU BU
M
20.0 / -1F5.4+
20.0 / 1F5.2-
47.0 / 1F5.4-
38.0 / -2F1.1+
42.0 / -2F1.2+
39.0 / -2F1.3+
40.0 / -2F1.4+
38.0 / 2F1.1-
39.0 / 2F1.3-
40.0 / 2F1.4-
27.0 / -4F1.3+
27.0 / 4F1.3-
33.0 / -5F1.2+
33.0 / -5F1.3+
33.7 / -5F1.4+
33.0 / 5F1.2-
33.0 / 5F1.3-
33.0 / 5F1.4-
interface fan warning FFU steering clutch control
external systems switch box unit power part
Date 26.02.2015 = AZ2 7/ 54

Ed. BJU CONFIDENTIAL Power Distribution 1201903 + SCS
0 1 2 3 4 5 6 7 8 9

BU
6.7 / -1F4.2+
-A1 -A2
/4.7 13 /5.0 13
14 14
BU BU
BU BU
-FL.AC / 42.1 FL.DC / 42.2
A1 A1
-K1 -K2
A2 A2
BU BU
6.8 / -1F4.2- -1F4.2- / 28.0
failure failure
AC / DC converter emergency feed line
24V DC
14 14
12 11 /15.3 12 11 /15.3
14/0773
Date 26.02.2015 = AZ2 8/ 54

001 14/0773 12.03.2014 ROM Ed. BJU CONFIDENTIAL Power Distribution 1201903 + SCS
0 1 2 3 4 5 6 7 8 9

BU BU BU
6.6 / -1F3.2+ -1F3.2+ / 32.0
BU BU
6.4 / 1F2.2+
BU
6.5 / -1F3.1+
41 11 21 1
13 23 -1K6 -K3 -1K2 -1K5
-1S1 -1S2 /18.8 42 44 /18.2 12 14 /9.0 12 14 /9.8 2
-P10 / +MDP/3.0
/9.4 14 /14.3 24
-P9 / +MDP/4.0
green
BU
BU
BU
REM / 17.5
SC / 18.1
-W302
MPRXCX -1K5
10.0 / REM1
19x1,5 mm²
K3* 3 4 /9.8 4
BU
-X12 9 10
12 14 12 14
-1K6 -1K2.1 BU BU
BU
/18.8 11 /9.4 11 BU BU
BU
x2 x2 x2
-1S2 -S3 -1S1
/14.3 x1 /16.7 x1 /9.1 x1
-1V2
BU BU BU
BU
A1 11 A1 A1 A1
-1K2 -1K2.1 -1K4 -1K5
A2 41 A2 A2 48VAC A2
BU
6.4 / -1F2.1-
6.6 / -1F3.1-
BU BU BU BU
6.6 / -1F3.2- -1F3.2- / 10.0
local control send command to remote fault local control NFU control ON NFU control ON / OFF
remote in service unit in service
14 14 14 1 2 /9.5
12 21 /9.4 12 11 /9.2 12 11 /15.1 3 4 /9.8
44 44 24
42 31 /14.1 42 41 /31.4 22 21 /19.6
34
32 31 /27.7
44
42 41
Date 26.02.2015 = AZ2 9/ 54

Ed. BJU CONFIDENTIAL NFU Control ON 1201903 + SCS
0 1 2 3 4 5 6 7 8 9
BU BU BU
9.4 / REM1
12 14 12 14
-4K4 -3K1
/32.5 11 /19.6 11
BU BU
12 14 12 14
-4K5 -3K5
/28.8 11 /20.7 11
BU BU
-X12 11 12 13 14 15 16
-W302 -W302
MPRXCX MPRXCX
19x1,5 mm² 19x1,5 mm²
K3* 5 6 K3* 7 8 9
K3* K3*
+MDP/4.4 / -P11
+MDP/3.1 / -P12
+MDP/4.2 / -P13
+MDP/4.2 / -P14
+MDP/3.1 / -P16
BU
BU
A1 A1
-4K11 -4K10
A2 A2
BU BU
9.9 / -1F3.2- -1F3.2- / 23.0
indication NFU steering ON thruster thruster thruster thruster NFU RPM control
turning turning turning turning in service
ccw cw ccw cw
14 14
12 11 /31.6 12 11 /31.5
14/0773
Date 15.08.2014 = AZ2 10 / 54

001 14/0773 12.03.2014 ROM Ed. MSC CONFIDENTIAL NFU Systems 1201903 + SCS
0 1 2 3 4 5 6 7 8 9

BU BU
6.2 / -1F1.3+ -1F1.3+ / 15.0
-P22 / +MDP/5.0
-P23 / +MDP/5.0
-P24 / +MDP/5.1
-P25 / +MDP/5.1
-W303
TCX(C)
2x2x0,75 mm²
K4* 1.1 1.2 2.1 2.2
-SH
-X12 22 23 24 25
-XC
CAN
7 3 2
GN YE
-CANG / 12.0
-CANH / 12.0
-CANL / 12.0
BU
BU
-1A1.0 1 5 2 6 3 7 4 8 -1A1.1 5 1 4 2 6
5 4 3 2 1
/2.3 -FB
0VIN 0V 0V
BU BU
6.3 / -1F1.3- -1F1.3- / 19.0
Date 26.02.2015 = AZ2 11 / 54

0 1 2 3 4 5 6 7 8 9
-3A1 -P1 -4A1 -4A2

/19.1 120 Ohm /24.4 /27.1 120 Ohm /27.4 120 Ohm
DCM Display DCM DPV
ON ON ON
OFF OFF OFF
4 CAN-GND
CAN-GND
4 CAN-GND
4 CAN-GND
2 CAN-H
CAN-H
2 CAN-H
2 CAN-H
3 CAN-L
CAN-L
3 CAN-L
3 CAN-L
-SB
7 2 3
-CAN1
GN YE GN YE GN YE
SUB-D cable
1186019 GN GY YE PK BN WH
11.9 / -CANH -CANH / 13.0

11.9 / -CANL -CANL / 13.0
BU BU
11.9 / -CANG -CANG / 13.0
DCM speed control Display DCM azimuth steering DPV azimuth steering
Date 23.06.2014 = AZ2 12 / 54

0 1 2 3 4 5 6 7 8 9
-A81
/34.0 120 Ohm
DCM
ON
OFF
4 CAN-GND
2 CAN-H
3 CAN-L
GN YE
12.9 / -CANH
12.9 / -CANL
12.9 / -CANG
6.2 / -1F1.4+
6.3 / -1F1.4-
GN
YE
-W210 -X41 5 6 7 8
TCX(C) -SH
2x2x0,75 mm²
K3* 1.1 1.2 2.1 2.2
+SRP/3.3 / -4A4.6
-4A4.7
+SRP/3.3 / -4A4.8
+SRP/3.3 / -4A4.9
+SRP/3.3 /
DCM external systems 1 feedback unit steering
Date 23.06.2014 = AZ2 13 / 54

0 1 2 3 4 5 6 7 8 9

24V DC
BU
6.2 / -1F1.1+ -1F1.1+ / 16.0
BU
6.2 / -1F1.2+ -1F1.2+ / 15.0
42 44 13
-1K2 -1S2
/9.0 31 /9.1 14
/9.2
yellow
CL.AU / 33.0
CL.EN / 33.5
BU BU
-1A1.2 1 5 2 6 3 7 4 8
WAGO 750-430 8DI; 24VDC; 3,0 ms
local desk ON ECR desk ON send command reserve thruster retracted thruster lowered clutch in auto mode clutch engaged remote control
in service
Date 26.02.2015 = AZ2 14 / 54

0 1 2 3 4 5 6 7 8 9

BU
11.9 / -1F1.3+ 1F1.3+ / 19.0
BU BU BU
14.9 / -1F1.2+ 1F1.2+ / 28.0
HOL / 43.0
12 14 12 14 12 14 HOP / 28.0
-1K4 -2K0 -K1
/9.5 11 /45.2 11 /8.1 11
BU
12 14
-K2
/8.3 11 CL.AIR / 33.5
BU BU BU
-1A1.3 1 5 2 6 3 7 4 8
WAGO 750-430 8DI; 24VDC; 3,0 ms
NFU steering fault unit fault power hy oil level oil pressure oil pressure oil pressure reserve
manual supply min steering ok pitch control ok clutch ok
Date 26.02.2015 = AZ2 15 / 54

0 1 2 3 4 5 6 7 8 9
14.9 / -1F1.1+
13
-S3
/9.3 14
red
BU
FIFI.ON / 50.0
-1A1.4 1 5 2 6 3 7 4 8
WAGO 750-430 8DI; 24VDC; 3,0 ms
FiFi Mode ON Generator Mode ON reserve brake closed reserve reserve ACK reserve
control system
Date 26.02.2015 = AZ2 16 / 54

0 1 2 3 4 5 6 7 8 9
-1A1.5 WAGO 750-530 8DO; 24VDC; 0,5A
1 5 2 6 3 7 4 8
BU BU BU
9.1 / REM
A1 11
-1K7
A2 41
BU BU
6.3 / -1F1.2- -1F1.2- / 18.0
ECR desk reserve reserve el. shaft el. shaft remote control clutch clutch OFF
in service in line healthy active auto mode
14
12 21 /33.2
44
42 31 /50.3
Date 26.02.2015 = AZ2 17 / 54

0 1 2 3 4 5 6 7 8 9
end terminal
1 5 2 6 3 7 4 8
BU BU BU
9.2 / -SC
BU
-FL.CO / 42.8
A1 A1
-K3 -1K6
A2 A2
BU BU
17.9 / -1F1.2- -1F1.2- / 19.0
send command buzzer cleaning mode Hy-pump ON Hy-pump OFF FiFi Mode Generator Mode failure control
to remote in service in service system
14 14
12 11 /9.3 12 11 /9.1
44
42 41 /9.3
Date 26.02.2015 = AZ2 18 / 54

Ed. BJU CONFIDENTIAL Desk Control 1201903 + SCS
0 1 2 3 4 5 6 7 8 9

BU BU
15.9 / -1F1.3+ -1F1.3+ / 27.0
BU BU
-FFU.RPM / 42.3
-3A1
/2.0 26 28 9 10
/12.1
UB 24V
UB 24V
1167522 modul
/20.0
/21.1 1167523 programm
/22.1
DCM
GND 24V
GND 24V
25 27
22 24
-1K4
/9.5 21
BU
BU
A1 A1
-3K1 -3K2
A2 A2
BU
11.9 / -1F1.3- -1F1.3- / 27.0
BU BU
18.9 / -1F1.2- -1F1.2- / 27.0
DCM speed control failure FFU speed control
14 14
12 11 /10.6 12 11 /21.3
24 24
22 21 /23.3 22 21 /47.5
34 34
32 31 /23.2 32 31 /47.5
44 44
42 41 /33.2 42 41 /23.5
Date 26.02.2015 = AZ2 19 / 54

Ed. BJU CONFIDENTIAL FFU Speed Control 1201903 + SCS
0 1 2 3 4 5 6 7 8 9

BU
6.7 / -1F4.4+ -1F4.4+ / 28.0
BU
7.1 / -1F5.4+ -1F5.4+ / 47.0
-5B1.1 / +SRP/3.6
-5B1.3 / +SRP/3.6
-5B1.4 / +SRP/3.6
-5B3.4 / +SRP/3.8
-W710 -W212
TCX(C) TCX(C)
7x2x0,75 mm² 2x2x0,75 mm² +
K3* 1.1 1.2 2.1 2.2 3.1 K3* 1.1 1.2 2.1 2.2
K3*
-X51.V1
-SH
-X3 1 2 3 4 5 -X51 1 2 3 - +
BU
BU BU BU BU
BU
BU
IDLE / 50.0
FIFI.ENG / 50.0
-3A1
/19.1 13 14 15 16 17 18 19 20
DCM
DI 0.0
DI 0.1
DI 0.2
DI 0.3
DI 1.0
DI 1.1
DI 1.2
DI 1.3
Propulsion Propulsion Propulsion overload FiFi Mode Generator Mode speed Generator
motor motor motor in service in service pick up at
OFF ON in idle (clutch engaged) (clutch engaged) bus bar
BU BU
A1 A1
-3K5 -3K6
A2 A2
BU
6.8 / -1F4.4- -1F4.4- / 28.0
BU BU
7.1 / -1F5.2- -1F5.2- / 50.0
Feedline Propulsion Propulsion Propulsion overload shaft speed pick up Propulsion Propulsion
signals motor motor motor control system motor motor
OFF ON in idle ON overload
14 14
12 11 /10.6 12 11 /21.6
24 44
22 21 42 41
34
32 31 /43.1
44
42 41 /28.2
Date 15.08.2014 = AZ2 20 / 54

0 1 2 3 4 5 6 7 8 9
WH
3.FB / 23.3
12 14 12 14
-3K2 -3K6
/19.7 11 /20.7 11
3A1.29 / 23.3
WH WH WH WH
-3A1
/19.1 21 22 23 24 30 29
DCM
AI 1
AI 2
AI 3
AI 4
10V REF
GND
setpoint speed ship load
analogue feedback speed signal
setpoint analogue speed feedback ship speed load signal
Date 15.08.2014 = AZ2 21 / 54

0 1 2 3 4 5 6 7 8 9
-3A1
/19.1
DCM
lever open bypass decrease increase setpoint

in idle valve RPM RPM speed
DO 0
DO 1
DO 2
DO 3
AO 0
AO 1
5 6 7 8 31 32
WH
BU BU BU
-3A1.32 / 47.4
23.5 / -3A1.5
23.1 / -RPM.DE
23.1 / -RPM.IN
lever in idle open bypass valve decrease increase torque speed value for
RPM RPM feedback propulsion motor
Date 15.08.2014 = AZ2 22 / 54

0 1 2 3 4 5 6 7 8 9

BU BU
6.6 / -1F3.3+ -1F3.3+ / 47.0
BU
6.6 / -1F3.3- -1F3.3- / 47.0
WH
21.9 / 3A1.29 3A4.2 / 47.4
WH
21.9 / 3.FB 3A4.3 / 47.4
-3A4 15 16
/2.0 14 13 4 3 2
/33.2
UB 24V
GND 24V
0...10V
0...15V
AGND
> 4,5mA
DZ / GND
DZ / 24V
DZ / IN
MF2
MF1
1 5 7 6 8
9 10 11 12
BU BU
BU
31 21
-3K1 22.1 / -3A1.5
/19.6 34 32 24 22
44 42
-3K2
22.3 / RPM.DE /19.7 41
22.4 / RPM.IN
BU BU
-X12 17 18
-SH BU
-W302
MPRXCX
19x1,5 mm²
K3* 10 11
+MDP/4.1 / -P20
+MDP/4.1 / -P21
BU
A1 A1
-3K3 -X3.K3
A2 A2
BU BU
10.9 / -1F3.2- -1F3.2- / 32.0
14 14
12 11 /33.3 12 11 /47.1
44
42 41
14/2239 14/0773
003 14/2239 15.08.2014 MSC Date 26.02.2015 = AZ2 23 / 54

001 14/0773 12.03.2014 ROM Ed. BJU CONFIDENTIAL FFU Speed Control 1201903 + SCS
0 1 2 3 4 5 6 7 8 9

OR OR OR OR OR
5.6 / -A+ -A+ / 25.0
OR OR OR OR OR OR
5.6 / -A- -A- / 25.0
-4F3
2A
OR
OR
-A40 -P1 X1 -4A3

/2.3 26 28 25 27 9 10 11 12 /12.2 + - /2.3 26 28 25 27 30 32 29 31 9 10 11 12
/25.1 Display /31.1
GND 24V
GND 24V
GND 24V
GND 24V
GND 24V
GND 24V
UB 24V
UB 24V
UB 24V
UB 24V
UB 24V
UB 24V
/26.0 /32.3
RXD
RXD
TXD
TXD
DCM /32.6
DPV
CAN-GND
NFU
CAN-H
CAN-L
4 CAN-GND
CAN-GND
2 CAN-H
CAN-H
3 CAN-L
CAN-L
2 7 3
4
CAN2
SUB-D cable
YE GN 1186019 YE PK GN GY BN WH
OR
-A- / 26.9
YE GN YE GN
-X41 1 2 3 4
-SH -X44 1 2 3 4 5 6 -X12 26 27 28 29
-SH
-W211 -W242 -SH -W304
TCX(C) TCX(C) TCX(C)
2x2x0,75 mm² 4x2x0,75 mm² 2x2x0,75 mm²
K4* 1.1 1.2 2.1 2.2 K4* 1.1 1.2 2.1 2.2 3.1 3.2 K4* 1.1 1.2 2.1 2.2
SH K4*
+SRP/3.1 / -4A4.1
+SRP/3.1 / -4A4.2
+SRP/3.1 / -4A4.3
+SRP/3.1 / -4A4.4
+ENR/3.1 / -4A3.1
+ENR/3.2 / -4A3.2
+ENR/3.2 / -4A3.3
+ENR/3.2 / -4A3.4
+ENR/3.2 / -4A3.5
+ENR/3.3 / -4A3.6
+MDP/7.1 / -P26
+MDP/7.1 / -P27
+MDP/7.1 / -P28
+MDP/7.3 / -P29
CAN BUS Indicator thrust direction indicator CAN BUS Indicator
hydraulic aggregate
Date 23.06.2014 = AZ2 24 / 54

0 1 2 3 4 5 6 7 8 9
-5B2.1 / +SRP/3.7
-5B2.3 / +SRP/3.7
-5B2.4 / +SRP/3.7
-W213
TCX(C)
2x2x0,75 mm²
K3* 1.1 1.2 2.1
-SH
-X51 4 5 6
OR
24.9 / -A+ -A+ / 26.0
OR
24.9 / -A- -A- / 26.0
OR
-A40
/24.1 13 14 15 16 17 18 19 20
DCM
DI 0.0
DI 0.1
DI 0.2
DI 0.3
DI 1.0
DI 1.1
DI 1.2
DI 1.3
shaft speed
pick up
shaft speed pick up

indication
Date 23.06.2014 = AZ2 25 / 54

0 1 2 3 4 5 6 7 8 9
-A40
/24.1 21 22 23 24 30
DCM
AI 1
AI 2
AI 3
AI 4
10V REF
feedback pitch not used not used not used
4..20mA 4..20mA
pitch in zero pitch max stern pitch max ahead speed switch point pitch indicator speed indicator
AGND
DO 0
DO 1
DO 2
DO 3
AO 0
AO 1
5 6 7 8 31 32 29
WH
WH WH
OR
25.9 / -A+ -A+ / 31.0
25.9 / -A- -A- / 24.9
-X12 30 31 32 33 -X54 1 2 3 4
-W305 -SH
TCX(C) WH
2x2x0,75 mm²
K3* 1.1 1.2 2.1 2.2
+MDP/7.3 / -P30
+MDP/7.4 / -P31
+MDP/7.4 / -P32
+MDP/7.4 / -P33
suppressing propeller propeller
lube oil flow RPM indicator RPM indicator
Date 23.06.2014 = AZ2 26 / 54

0 1 2 3 4 5 6 7 8 9

BU BU BU
19.9 / -1F1.3+ -1F1.3+ / 28.0
7.5 / -4F1.3+
BU BU BU
-FFU.STEER / 42.5
-4A1 -4A2
/2.0 26 28 9 10 /2.0 26 28 30 32 9 10
/12.5 /12.7
UB 24V
UB 24V
UB 24V
UB 24V
UB 24V
UB 24V
/28.1 1167524 modul /30.1 1168411 modul
/29.1 1167525 programm /32.0 1168412 programm
DCM DPV
GND 24V
GND 24V
GND 24V
GND 24V
GND 24V
GND 24V
25 27 25 27 29 31
32 34
-1K4
/9.5 31
BU
BU
A1 A1
-4K1 -4K2
7.6 / -4F1.3- A2 A2
BU BU
19.9 / -1F1.3- -1F1.3- / 34.0
BU BU
19.9 / -1F1.2- -1F1.2- / 29.0
DCM azimuth control failure FFU steering
14 14
12 11 /32.5 12 11 /32.1
44 24
42 41 /31.4 22 21 /32.1
34
32 31 /32.2
44
42 41 /32.2
Date 26.02.2015 = AZ2 27 / 54

Ed. BJU CONFIDENTIAL FFU Thrust Direction Steering 1201903 + SCS
0 1 2 3 4 5 6 7 8 9
20.9 / -1F4.4+
BU
27.9 / -1F1.3+ -1F1.3+ / 34.0
15.9 / -1F1.2+
-4B1.3 / +ENR/3.8
-4B1.1 / +ENR/3.7
4B1.4 / +ENR/3.8
42 44
-3K5
/20.7 41
-W241
TCX(C)
2x2x0,75 mm²
K3* 1.1 1.2 2.1
-SH
-X42 8 9 10
BU BU
BU
15.9 / HOP HOP / 43.0
-4A1
/27.1 13 14 15 16 17 18 19 20
DCM
DI 0.0
DI 0.1
DI 0.2
DI 0.3
DI 1.0
DI 1.1
DI 1.2
DI 1.3
main backup overload pick up -4V1
power plant power plant power plant RPM hy-pump
BU
A1
-4K5
A2
20.9 / -1F4.4-
8.9 / -1F4.2-
main backup overload speed pickup power unit

power unit power plant power plant hydraulic pump steering in service
14
12 11 /10.1
44
42 41
Date 23.06.2014 = AZ2 28 / 54

0 1 2 3 4 5 6 7 8 9
-4A1
/27.1
DCM
steering steering steering setpoint

cw ccw locked frequency converter
AGND
DO 0
DO 1
DO 2
DO 3
AO 0
AO 1
5 6 7 8 31 32 29
BU
A1
-2K7
A2
BU
27.9 / -1F1.2- -1F1.2- / 37.0
FFU
steering
locked
14
12 11 /42.7
Date 23.06.2014 = AZ2 29 / 54

0 1 2 3 4 5 6 7 8 9
-4A2
/27.4 23 21 22 24 17 18 19 20
DPV
AI 1
AGND
10V REF
AI 2
DI 1.0
DI 1.1
DI 1.2
DI 1.3
steering value overload hy pump additonal additonal
input ±10V in service steering system steering system
±10V = ±45° ±10V = ±180°
ON ON
steering signal overload hy pump additonal additonal

remote control in service steering system steering system
±10V = ±45° ±10V = ±180°
ON ON
Date 23.06.2014 = AZ2 30 / 54

0 1 2 3 4 5 6 7 8 9

OR OR
26.9 / -A+
42 44 12 14 12 14
-4K1 -4K10 -4K11
/27.7 41 /10.3 11 /10.2 11
OR
42 44
-1K2.1
/9.4 41
OR OR OR
-4A3
/24.6 23 21 22 24 17 18 19 20
DPV
10V REF
NFU
DI 1.0
DI 1.1
DI 1.2
DI 1.3
AGND
AI 2
AI 3
converter overload NFU ON = 24V turn cw turn ccw

OFF NFU OFF = 0V
NFU ON turn cw turn ccw
Date 23.06.2014 = AZ2 31 / 54

0 1 2 3 4 5 6 7 8 9

BU
9.9 / -1F3.2+ -1F3.2+ / 42.0
-4A2 -4A3
/27.4 /24.6
DPV DPV
NFU
AO 1 COM
AO 2 COM
AO 1 COM
AO 2 COM
AO 1
AO 2
AO 1
AO 2
6 5 7 8 6 5 7 8
BU
-4A3
WH WH WH WH WH WH WH WH /24.6 10
12 14 22 24 32 34 42 44
-4K2 9
/27.7 11 21 31 41
WH WH WH WH
-W240
-X42 1 2 3 4
-X42 5 6 7
MPRXCX
10x1,5 mm²
K3* 1 2 3 4 12 14
K3*
-4K1
/27.7 11
BU
FL.NFU / 42.6
+ENR/2.6 / -4Y1.1
+ENR/2.6 / -4Y1.2
+ENR/2.8 / -4Y2.1
+ENR/2.8 / -4Y2.2
BU
A1
-4K4
A2
23.9 / -1F3.2-
steering valves NFU steering ON
14
12 11 /10.1
44
42 41
15/0578
004 15/0578 26.02.2015 BJU Date 26.02.2015 = AZ2 32 / 54

Ed. BJU CONFIDENTIAL NFU Steering 1201903 + SCS
0 1 2 3 4 5 6 7 8 9
7.7 / -5F1.2+ 7.7 / -5F1.4+

21
7.7 / -5F1.3+
-1K7
/17.6 14 12
BU BU
14.9 / CL.AU
BU
-5V1
BU
41
-3K1
/19.6 42 44
BU
BU
-3A4
/23.2 15
11
-3K3
/23.5 12 14
10 9
BU
BU BU
BU 15.9 / CL.AIR -CL.AIR / 44.3
BU BU BU BU
14.9 / CL.EN
-5A3
1 4 3 BU
2 5 6 -X52 5 6 7 8 -SH
-W220
K2* 5 6 7 8
BU BU
BU
BU BU
+CLU/2.3 / -5S1.1
+CLU/2.3 / -5S1.2
+CLU/2.4 / -5S2.1
+CLU/2.4 / -5S2.2
-W220 -X52 1 2 3 4
MPRXCX
10x1,5 mm²
K2* 1 2 3 4
+CLU/2.0 / -5Y1.1
+CLU/2.1 / -5Y1.2
+CLU/2.2 / -5Y2.1
+CLU/2.2 / -5Y2.2
A1
A1 A1
7.8 / -5F1.3-
-X3.K12
-5K3 -2K9 A2
7.8 / -5F1.4- A2 A2
BU BU
7.8 / -5F1.2-
clutch clutch lube oil supressing lube clutch clutch

disengaging engaging pump ON flow engaged air pressure min
1 2 /4.6 14 14
3 4 /4.6 12 11 /44.3 12 11 /47.2
5 6 /4.6
13 14
Date 15.08.2014 = AZ2 33 / 54

Ed. MSC CONFIDENTIAL Clutch Control 1201903 + SCS
0 1 2 3 4 5 6 7 8 9
24V DC
BU BU
28.9 / -1F1.3+ -1F1.3+ / 36.0
BU
-FL.EXT / 43.0
-A81
/2.3 26 28 9 10 12 4
/13.1
GND 24
UB 24V
UB 24V
/35.1 1167526 modul
RXD
/36.1 1167527 programm
/37.1
DCM
GND 24V
GND 24V
25 27
BU
27.9 / -1F1.3- -1F1.3- / 36.0
DCM external systems 1
Date 23.06.2014 = AZ2 34 / 54

0 1 2 3 4 5 6 7 8 9
-APR / 49.0
BU
BU
-A81
/34.0 13 14 15 16 17 18 19 20
DCM
DI 0.0
DI 0.1
DI 0.2
DI 0.3
DI 1.0
DI 1.1
DI 1.2
DI 1.3
autopilot autopilot DP system DP system
not used not used not used not used
take control in service activated ready for service
autopilot not used autopilot not used not used not used not used not used
take control in service
Date 23.06.2014 = AZ2 35 / 54

0 1 2 3 4 5 6 7 8 9

BU
34.9 / -1F1.3+ -1F1.3+ / 47.0
34.9 / -1F1.3-
-A83
/49.4 3 4 7 8
+ -
0-20mA
0-10V
GND
24V
+ -
5 6 7 8
WH WH
-A81
/34.0 21 22 23 24 29
DCM
GND
AI 1
AI 2
AI 3
AI 4
setpoint setpoint setpoint
steering value speed value steering value not used
setpoint setpoint setpoint not used

steering value speed value steering value
Date 23.06.2014 = AZ2 36 / 54

0 1 2 3 4 5 6 7 8 9
-A81
/34.0
DCM
feedback
autopilot unit ready
not used DP mode
in service for DP system
in service
DO 0
DO 1
DO 2
DO 3
AO 0
AO 1
5 6 7 8 31 32
BU
A1
-X5.K1
A2
29.9 / 1F1.2-
autopilot
in service
14
12 11 /49.2
Date 23.06.2014 = AZ2 37 / 54

0 1 2 3 4 5 6 7 8 9
7.4 / -2F1.1+
-2A10
/2.6
RS232_GND
RS232_RXD
RS232_TXD
CAN_VCC
24V DC
CAN_H
CAN_G
CAN_L
GND
1 2 3 4 5 6 7 8 9 10 11
-X1
YE GN
WARN1 / 45.0
BU
WARN2 / 45.0
CANH / 39.0
CANL / 39.0
BU
CANG / 40.0
BU
7.4 / -2F1.1-
002 14/1725 23.06.2014 MSC Date 26.02.2015 = AZ2 38 / 54

0 1 2 3 4 5 6 7 8 9
7.4 / -2F1.3+
YE
38.9 / CANH -CANH / 40.0
GN
38.9 / CANL -CANL / 40.0
BU
BU
-2A1.0 1 5 2 6 3 7 4 8 -2A1.1 5 1 4 2 6
5 4 3 2 1
/2.6 -FB
0VIN 0V 0V
BU
7.4 / -2F1.3-
Date 26.02.2015 = AZ2 39 / 54

0 1 2 3 4 5 6 7 8 9

BU
7.4 / -2F1.4+ -2F1.4+ / 43.0
-P2.10 / +MDWP/2.4
-P2.11 / +MDWP/2.5
-P2.1 / +MDWP/2.2
-P2.2 / +MDWP/2.2
-P2.3 / +MDWP/2.2
-P2.4 / +MDWP/2.3
-P2.8 / +MDWP/2.4
SH
-W381 SH -W380
TCX(C) MPRXCX
2x2x0,75 mm² 5x1,5 mm²
K4* 1.1 1.2 2.1 2.2 K3* 1 2 3
-SH
-SH
-X22 1 2 3 4 5 6 7
YE GN
38.9 / CANG
39.9 / CANH
39.9 / CANL
A1
-2K20
A2
BU BU
7.4 / -2F1.4- -2F1.4- / 45.0
CAN BUS feed line
14
12 11 /45.3
Date 26.02.2015 = AZ2 40 / 54

0 1 2 3 4 5 6 7 8 9
-2A1.2 1 5 2 6 3 7 4 8
1 2 3 4
WAGO 750-430 8DI; 24VDC; 3,0 ms
config lamp suppressing buzzer

check all alarms off
Date 26.02.2015 = AZ2 41 / 54

0 1 2 3 4 5 6 7 8 9

BU
7.4 / -2F1.2+ -2F1.2+ / 44.0
32.9 / -1F3.2+
12 14
-2K7
/29.4 11
FFU.STEER / 27.9
-FFU.RPM / 19.9
FL.NFU / 32.7
-FL.CO / 18.9
-FL.AC / 8.1
FL.DC / 8.4
BU
-2A1.3 1 5 2 6 3 7 4 8
2s 2s 2s 2s 2s 2s 2s 2s
5 5
6 7 8 9 10 11 12
WAGO 750-430 8DI; 24VDC; 3,0 ms
failure failure failure not used failure failure follow up failure

AC / DC 24V DC FFU speed FFU steering NFU stering steering control
converter feedline control locked system
15/0578
004 15/0578 26.02.2015 BJU Date 26.02.2015 = AZ2 42 / 54

0 1 2 3 4 5 6 7 8 9

BU BU
40.9 / -2F1.4+
-2S12.2 / +SRP/2.2
-2S11.1 / +SRP/2.1
-2S11.2 / +SRP/2.1
-2S1.1 / +ENR/2.2
-2S1.2 / +ENR/2.2
-2S2.2 / +ENR/2.3
-2S3.2 / +ENR/2.3
-2S4.2 / +ENR/2.4
-2S5.2 / +ENR/2.5
-SH
-W214
TCX(C)
4x2x0,75 mm²
*K3 1.1 1.2 2.1
-W240
MPRXCX
10x1,5 mm²
K3* 5 6 7 8 9 10
32 34 K3*
-3K5
/20.7 31 -X21 1 2 3 4 5 6 7 8 9 10
BU
15.9 / HOL
BU BU
28.9 / HOP
34.9 / FL.EXT
BU BU BU BU BU BU BU
-2A1.4 1 5 2 6 3 7 4 8
2s 10s 3s 5s 5s 5s 10s 5s
13 14 15 16 17 18 19 20
WAGO 750-430 8DI; 24VDC; 3,0 ms
failure hydr. oil hydr. oil hydr. oil hydr. oil hydr. oil lube oil lube oil
extern level min pressure temperature filter pressure level min temp. max
system min max clogged max
Date 26.02.2015 = AZ2 43 / 54

0 1 2 3 4 5 6 7 8 9

BU BU
42.9 / -2F1.2+
13
-2S13.2 / +SRP/2.3
-2S15.2 / +SRP/2.4
-F1
/4.6 14
-CL.AIR / 33.9
2
-B1
50° 3
-W214
TCX(C)
4x2x0,75 mm²
2.2 3.1
-F3
*K3
/4.6 12 14
-X21 11 12
11
12 14
-2K9
/33.4 11
BU
BU BU BU BU
-2A1.5 1
5 2 6 3 7 4 8
DI1
DI1 DI2 DI3 DI4 DI5 DI6 DI7
5s 5s 5s 5s 5s
21 22 23 24 25 26 27 28
WAGO 750-430 8DI; 24VDC; 3,0 ms
lub oil lub oil clutch failure overtemp not used not used not used
filter flow control lube oil switch cabinet
dirty min air min pump
14/2239 14/0773
003 14/2239 15.08.2014 MSC Date 26.02.2015 = AZ2 44 / 54

001 14/0773 12.03.2014 ROM Ed. BJU CONFIDENTIAL Warning Unit 1201903 + SCS
0 1 2 3 4 5 6 7 8 9
-2A1.6 WAGO 750-530 8DO; 24VDC; 0,5A
1 5 2 6 3 7 4 8
BU
38.9 / WARN1
38.9 / WARN2
12 14
-2K20
/40.3 11
BU
BU
BU
A1 A1 A1
-2K0 -X4.K1 -X4.K2
A2 A2 A2
BU BU
40.9 / -2F1.4-
collective failure
alarm warning
unit
14 14 14
12 11 /15.2 12 11 /48.3 12 11 /48.4
Date 26.02.2015 = AZ2 45 / 54

0 1 2 3 4 5 6 7 8 9
end terminal
1 5 2 6 3 7 4 8
Date 26.02.2015 = AZ2 46 / 54

0 1 2 3 4 5 6 7 8 9

BU
20.9 / -1F5.4+ -1F5.4+ / 49.0
7.2 / -1F5.4-
36.9 / -1F1.3+
23.9 / -1F3.3+
23.9 / -1F3.3-
23.5 / 3A4.2
22.9 / -3A1.32
23.5 / 3A4.3
22 24 32 34
-3K2
/19.7 21 31
WH BU
-3A2
MAZ DC/DC 1 2 4 3
+ -
12 14 12 14
0-10V
-X3.K3 -X3.K12 4-20mA
/23.6 11 /33.6 11
GND
24V
+ -
6 5 4 3
WH WH
-W710
-SH
-W711 -X3 13 14
-SH
15 16
TCX(C) TCX(C)
7x2x0,75 mm² 2x2x0,75 mm²
K3* 4.1 4.2 5.1 5.2 K3* 1.1 1.2
K3*
SH
lever in idle clutch engaged speed value
Date 15.08.2014 = AZ2 47 / 54

Ed. MSC CONFIDENTIAL Interface To Drive Motor 1201903 + SCS
0 1 2 3 4 5 6 7 8 9
12 14 12 14
-X4.K1 -X4.K2
/45.2 11 /45.3 11
-W820
TCX(C)
2x2x0,75 mm² -SH
K3* 1.1 1.2 2.1 2.2
failure common
SCHOTTEL SCHOTTEL
warning unit unit
Date 23.06.2014 = AZ2 48 / 54

Ed. MSC CONFIDENTIAL Interface To Ship Warning unit 1201903 + SCS
0 1 2 3 4 5 6 7 8 9

WH
47.9 / -1F5.4+ -1F5.4+ / 50.0
35.3 / APR
-A83
/36.1 5 6 7 8
+ -
0-10V
0-20mA
GND
24V
+ -
3 4 7 8
WH WH
11
-X5.K1
/37.2 12 14
-X5 1 2 -X5 3 4
-SH
-W720
TCX(C)
4x2x0,75 mm²
K3* 1.1 1.2 2.1 2.2 3.1 3.2
-AP1
-AP2
-AP3
-AP4
-AP5
-AP6
=YARD+AP/2.6 /
=YARD+AP/2.6 /
=YARD+AP/2.7 /
=YARD+AP/2.7 /
=YARD+AP/2.8 /
=YARD+AP/2.8 /
Autopilot Autopilot setpoint

system ready mode steering value
for service in service from AP system
Date 23.06.2014 = AZ2 49 / 54

Ed. MSC CONFIDENTIAL Interface To Autopilot 1201903 + SCS
0 1 2 3 4 5 6 7 8 9

WH
49.9 / -1F5.4+
20.9 / FIFI.ENG
16.2 / FIFI.ON
42 44
-1K7
/17.6 31
clutch off
WH
12 14
11 BU BU
-3K7
/50.1 11
-X8.K41
/50.3 12 14
-X8 41 42 43
WH
-SH
-W780
TCX(C)
4x2x0,75 mm²
*K3 1.1 1.2 2.1 2.2 3.1
=YARD+FIFI/2.1 / FIFI14
20.9 / IDLE
A1 A1
-3K7 -X8.K41
A2 A2
WH
20.9 / -1F5.2-
engine FIFI feed FIFI FIFI

at idle Mode line MODE System
possible ON Ready
14 14
12 11 /50.3 12 11 /50.5
44
42 41
Date 23.06.2014 = AZ2 50 / 54

Ed. MSC CONFIDENTIAL Interface To FIFI pump 1201903 + SCS
0 1 2 3 4 5 6 7 8 9
1S1 1S2 S3
-P1 AZ RPM
LD1/19 LD2/20 LD3/ LD4/ LD5/ LD6/

SYSTEM PUMP CABINET
LD7/12 LD8/13 LD9/24 LD10/25 LD11/ LD12/
RPM RPM
LD13/5 LD14/6 LD15/7 LD16/8 LD17/9 LD18/10
LD19/19 LD20/20 LD21/23 LD22/ LD23/22 LD24/
1100 mm
HY HY HY HY HY bar
bar
LD25/14 LD26/15 LD27/17 LD28/16 LD29/18 LD30/11
AIR TEST
PRESS
1000
LD31/23 LD32/ LD33/ S1 H1 S2
M1
800 300 mm 78 mm
d=8
cable input
holes must be drilled by the yard
glands are yard supply
technical datas of switch box
960 mm
mechanic colors
Protection class: IP 54 switch box housing: RAL 7035
weight: approx 160kg panel: black
internal wiring
NAXAF ( GL 47682 HH, no. 07/90 )
temperature: engine room temperature 45°C
screened cable type: LIYCY 95% humidity without condensation
20 mm
vibration 0,7g 760 mm 20 mm
Date 23.06.2014 = AZ2 51 / 54

0 1 2 3 4 5 6 7 8 9
200 mm
LD1/19 LD2/20 LD3/ LD4/ LD5/ LD6/

SYSTEM PUMP CABINET
LD7/12 LD8/13 LD9/24 LD10/25 LD11/ LD12/
RPM RPM
180 mm
LD13/5 LD14/6 LD15/7 LD16/8 LD17/9 LD18/10
LD19/19 LD20/20 LD21/23 LD22/ LD23/22 LD24/
HY HY HY HY HY bar
bar
LD25/14 LD26/15 LD27/17 LD28/16 LD29/18 LD30/11
AIR
TEST
PRESS
LD31/23 LD32/ LD33/ S1 H1 S2
Date 23.06.2014 = AZ2 52 / 54

0 1 2 3 4 5 6 7 8 9
-A2
-A1
-A3
switch cabinet articles
-1F0
-1F1
-1F2
-1F3
-1F4
-1F5
-1F6
-2F1
-4F1
-5F1
-4F3
-F1
-F2
-5K3
Order number Quantity designation
-S1
-S2
-5A3
1053244 1 Schaltschrank 800x1000x300
switch box 800x1000x300
-1K2.1
-4K10
-4K11
-1K2
-1K4
-1K5
-1K7
-3K1
-3K2
-3K5
-4K2
-1K6
-3K3
-3K6
-3K7
-4K1
-4K4
-4K5
-GND
-A83
-K1
-K2
-K3
Türfeststeller
-L+
1135768 1
-1V2
-5V1
door stay hinge
1085605 4 Tragschiene 35x15

mounting rail 35x15
1170070 1 Handlauf
-4V1
-5K3
-3A2
handrail
1178897 3 Tragschienenhalter
-2K0
-2K9
mounting rail holder
1184645 1 SCHOTTEL Logo 100x100

SCHOTTEL logo 100x100
1161920 1 Kabeleinführungsflansch
-2A0.0
-2A1.1
-2A1.2
-2A1.3
-2A1.4
-2A1.5
-2A1.6
-2A1.7
1A1.0
1A1.1
1A1.2
1A1.3
1A1.4
1A1.5
1A1.6
1A1.7
-XC
-2K7
-2K20
switch box cable entry
-3A1
-3A4
-4A1
-4A2
-4A3
-A40
-A81
1126844 4 Endwinkel
end bracket
-X8.K41
-X3.K3
-X5.K1
-X4.K1
1126578 2,749 Verdrahtungskanal 37.5x75

-SP
wiring duct 37.5x75
1178231 0,739 Verdrahtungskanal 80x100mm

wiring duct 80x100mm
1126580 0,739 Verdrahtungskanal 75x75

-X3.K12
-X4.K2
wiring duct 75x75

-X12
-X41
-X42
-X44
-X51
-X52
-X54
-X22
-X10
-X1
-X2
-X3
-X5
-X8
1043807 2,028 Tragschiene 35x7,5

mounting rail 35x7,5
1069768 2 Gruppenbezeichnung
group designation
Date 15.08.2014 = AZ2 53 / 54

Ed. MSC CONFIDENTIAL Switch Cabinet Mounting Plate 1201903 + SCS
0 1 2 3 4 5 6 7 8 9
280 260
35 mm 35 mm
27X21
66,5 66,5
180
100
63,5
62,5 62,5
66,5
94 94
63,5
66,5
5
215
167 mm
161 mm
200
150 150 10,5
245
66,5 66,5
62,5 62,5
66,5
66,5 5
Date 15.08.2014 = AZ2 54 / 54

0 1 2 3 4 5 6 7 8 9
Unit =AZ2 Location +MDP
-AX1 connection terminal feed line control panel

-AX2 connection terminal signals backup control system
-AX3 connection terminal control bus panel
-AX9 connection terminal indicator
-X21 connection terminal warning panel
Date 18.06.2014 = AZ2 1/ 10

Ed. MSC CONFIDENTIAL Terminal Groups 1201903 + MDP
0 1 2 3 4 5 6 7 8 9
-A1
/3.0
/4.0 control panel 1168785 FSP-FP PS SRP/STP
/5.0
/6.0
1170467 STANDARD
Montageplatte AFT
1170073 mounting plate aft
-X1 1 2 3 4 5 6 7 8
-AX1 1 2 3 4 5 6 7 8
/3.0
/7.2
-F1 -F2
3,15A 3,15A
F F
1 2 3 4 1 2 3 4 5 6 5 6 7 8 7 8
+SCS/6.1 / +SCS-P1
+SCS/6.1 / +SCS-P2
+SCS/6.4 / +SCS-P3
+SCS/6.4 / +SCS-P4
+SCS/6.6 / +SCS-P7
+SCS/6.6 / +SCS-P8
feedline control panels instrument light indicators feedline input NFU systems
Date 18.06.2014 = AZ2 2/ 10

0 1 2 3 4 5 6 7 8 9
-A1
/2.0 NFU
ON
RPM Azimuth control panel
SH
-X1 9 10 11 12 13 14
-AX1 9 10 11 12 13 14
/2.0
SH
9 10 11 12 9 10 11 12 13 14
+SCS/9.8 / +SCS-P10
+SCS/10.6 / +SCS-P16
+SCS/10.1 / +SCS-P12
indication NFU systems
Date 18.06.2014 = AZ2 3/ 10

0 1 2 3 4 5 6 7 8 9
-A1
/2.0
control panel
-X2 2 3 4 5 6 7 8 9 1
-AX2 1 2 3 4 5 6 7 8 9
14 24 34 44 54 64 74 84 13 14 24 34 44 54 64 74 84 13
+SCS/9.8 / +SCS-P9
+SCS/23.2 / +SCS-P20
+SCS/23.3 / +SCS-P21
+SCS/10.4 / +SCS-P13
+SCS/10.4 / +SCS-P14
+SCS/10.1 / +SCS-P11
NFU decrease increase thruster thruster not used not used feedline
ON RPM RPM turning turning decrease increase
ccw cw pitch pitch
Date 15.08.2014 = AZ2 4/ 10

Ed. MSC CONFIDENTIAL NFU Signals 1201903 + MDP
0 1 2 3 4 5 6 7 8 9
-A1
/2.0
control panel
CAN-GND
CAN-GND
CAN-H
CAN-H
CAN-L
CAN-L
PE
-X3 2 3 4 5 6 7 -X6 1 2 3 4 5 6
PE
-AX3 7 2 3 9 4 5
PE
CAN-SERVICE ON
PLUG 120
Ohm
OFF
1 2 3 4 5 6 7 8
-X30 1 2 3 4
=WH-W10
TCX(C) -SH
2x2x0,75 mm²
K4* 1.1 1.2 2.1 2.2
+SCS/11.4 / +SCS-P22
+SCS/11.5 / +SCS-P23
+SCS/11.5 / +SCS-P24
+SCS/11.6 / +SCS-P25
=AZ1/5.3 / =AZ1+MDP-P1
=AZ1/5.3 / =AZ1+MDP-P2
=AZ1/5.3 / =AZ1+MDP-P3
=AZ1/5.3 / =AZ1+MDP-P4
control bus spare
Date 18.06.2014 = AZ2 5/ 10

Ed. MSC CONFIDENTIAL Control Bus 1201903 + MDP
0 1 2 3 4 5 6 7 8 9
-A2
Azimuth Speed speed lever in zero
IDNR REMARK
yellow
yellow
brown
brown
violett
violett
green
green
white
white
grey
grey
blue
blue
pink
pink
red
red
1170035 with handwheel
CODE SWITCH CODE SWITCH

+VCC 24V DC
AZIMUTH SPEED
lever in zero
CAN GND
CAN GND
S2 S1
CAN H
CAN H
CAN L
CAN L
GND
2 9
-X1 1 2 3 4 5 6 7 8 9
-A1 -X3.1 1 2 3 4 5 6 7 8 9 -X7 1 2

/2.0
control panel
connection COPILOT
Date 18.06.2014 = AZ2 6/ 10

Ed. MSC CONFIDENTIAL Connection Control Handle 1201903 + MDP
0 1 2 3 4 5 6 7 8 9
azimuth indication speed indication

-P41 -P51
120 Ohm
power supply
ON
OFF
CONTROLLER CONTROLLER
+ - + -
4...20mA
1 2 4 5 8 9 6 7 3 3 1 2 4 5 8 9
H
L
D
D
N
N
V
V
GN
GN
CA
CA
+ - - + + -
PE
PE
24
24
24V GND CAN L CAN H
-AX9 -X91 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 -X92 1 2 3 4 5 6 7
PE PE PE PE
120 Ohm
ON
OFF
PE
1 2 3 4 5 8 9 10 11 13 14 15 16 17 18 1 2 6 7 5 13 14 15 16 17 18
12
PE
5 6
-AX1
/2.0
+SCS/5.4 / +SCS-P5
+SCS/5.4 / +SCS-P6
+SCS/24.8 / +SCS-P26
+SCS/24.8 / +SCS-P27
+SCS/24.8 / +SCS-P28
+SCS/24.8 / +SCS-P29
+SCS/26.6 / +SCS-P30
+SCS/26.6 / +SCS-P31
+SCS/26.7 / +SCS-P32
+SCS/26.7 / +SCS-P33
feedline CAN BUS instrument propeller RPM indication

indicators Indicator light
Date 18.06.2014 = AZ2 7/ 10

Ed. MSC CONFIDENTIAL Indicators 1201903 + MDP
0 1 2 3 4 5 6 7 8 9
290,000
290 4
stay bolt M5x20
RPM BACKUP CONTROL AZIMUTH

440
260 175
panel top view
Date 18.06.2014 = AZ2 8/ 10

0 1 2 3 4 5 6 7 8 9
desk cut out for control panel
10 135 135
panel
140
20
140
250
hole d= 6
400
140
80 4 350
hole d= 6
10
20
300
270
AX1 AX2 AX3 X30 AX9
wiring duct for ship cables
15 320
15
mounting plate
earth connection M8x20
mounting holes
Technical datas panel
mechanic
Protection class top side: IP 54
Protection class back side: IP 20
colors
control panel : black
Date 18.06.2014 = AZ2 9/ 10

0 1 2 3 4 5 6 7 8 9
control panel
PE LED
RUN
1 6 1 8 1 9 1 8 PWR
X6 X4 X5 X2 RES
1
PE X8 S1
1 14
X1 PROG. RUN 8
1
S2
8
OFF ON
X3.1 X3
1 2
X7 ON OFF OFF ON
ON OFF
Date 18.06.2014 = AZ2 10 / 10

0 1 2 3 4 5 6 7 8 9
Unit =AZ2 Location +MDWP
-X21 panel warning unit
Date 18.06.2014 = AZ2 1/ 4

Ed. MSC CONFIDENTIAL Terminal Groups 1201903 + MDWP
0 1 2 3 4 5 6 7 8 9
-2A10
S3 ON
RS232_GND
RS232_RXD
RS232_TXD
1 2 3 4 5 6 7 8 120 Ohm
CAN_VCC
ON
24V DC
CAN_H
CAN_G
S4 ON
CAN_L
OFF
GND
1 2 3 4 5 6 7 8
1 2 3 4 5 6 7 8 9 10 11
-X1
YE GN
-X21 1 2 3 4 5 6 7 8
+SCS/40.2 / +SCS-P2.4
+SCS/40.1 / +SCS-P2.1
+SCS/40.2 / +SCS-P2.2
+SCS/40.2 / +SCS-P2.3
+SCS/40.3 / +SCS-P2.8
+SCS/40.4 / +SCS-P2.10
+SCS/40.4 / +SCS-P2.11
CAN BUS feed line
Date 15.08.2014 = AZ2 2/ 4

0 1 2 3 4 5 6 7 8 9
200 mm
FAILURE OVERTEMP
LUBE OIL SWITCH
PUMP CABINET
desk cut out
LD1/24 LD2/25 LD3/ LD4/ LD5/ LD6/
92,5 92,5
FAILURE
EXTERN
SYSTEM
LD7/12 LD8/13 LD9/24 LD10/25 LD11/ LD12/

167
84,5
RPM RPM
161
180 mm
LD13/5 LD14/6 LD15/7 LD16/8 LD17/9 LD18/10
84,5
LD19/19 LD20/20 LD21/21 LD22/ LD23/22 LD24/
HY HY HY HY HY bar 4,5
bar
LD25/14 LD26/15 LD27/17 LD28/16 LD29/18 LD30/11
AIR TEST
PRESS
LD31/23 LD32/ LD33/ S1 H1 S2
terminal row
004 15/0578 26.02.2015 BJU Date 26.02.2015 = AZ2 3/ 4

Ed. BJU CONFIDENTIAL warning panel 1201903 + MDWP
0 1 2 3 4 5 6 7 8 9
failure SCHOTTEL main feed line HY min hydraulic oil level

failure desk control
failure SCHOTTEL secound feed line HY min hydraulic oil pressure

FAILURE
EXTERN
SYSTEM bar
RPM failure FFU RPM control HY hydraulic oil filter clogged
RPM failure NFU RPM control HY max hydraulic oil temperature
failure FFU steering HY bar max hydraulic oil pressure
failure NFU steering steering locked
min lub oil level propulsor AIR min air pressure clutch
PRESS
max lub oil temperature propulsor max temperature clutch
1 propulsor lub oil filter 1 clogged EMERG emergency disengaging clutch
2 propulsor lub oil filter 2 clogged TEST lamp check
propulsor min lub oil flow
waterleekage elastic mounting horn OFF
Date 18.06.2014 = AZ2 4/ 4

0 1 2 3 4 5 6 7 8 9
SCHOTTEL Components
Date 18.06.2014 = AZ2 1/ 4

0 1 2 3 4 5 6 7 8 9
+SCS-4Y1.1 / +SCS/32.1
+SCS-4Y1.2 / +SCS/32.1
+SCS-4Y2.1 / +SCS/32.2
+SCS-4Y2.2 / +SCS/32.2
+SCS-2S1.1 / +SCS/43.2
+SCS-2S1.2 / +SCS/43.2
+SCS-2S2.2 / +SCS/43.3
+SCS-2S3.2 / +SCS/43.4
+SCS-2S4.2 / +SCS/43.5
+SCS-2S5.2 / +SCS/43.6
+HYP
-X4 14 15 16 17
-X2 1 2 3 4 5 6 7 8 9 10
PE PE
PE PE PE PE
1 2 1 2
-4Y1 -4Y2
-2S2 P -2S3 -2S4 P -2S5 P
+HYT
-W248
TCX(C)
2x2x0,75 mm²
*K3
PE
-2S1
min min max hydr. oil max steering steering

hydr. oil hydr. oil hydr. oil filter hydr. oil valve valve
level pressure temperature clogged pressure
Date 26.02.2015 = AZ2 2/ 4

Ed. BJU CONFIDENTIAL Connection Engine Room 1201903 + ENR
0 1 2 3 4 5 6 7 8 9
-4A3
1 2
120 Ohm
GND
24V
ON
OFF
power supply
CONTROLLER
+SCS-4B1.1 / +SCS/28.6
+SCS-4B1.3 / +SCS/28.6
+SCS-4B1.4 / +SCS/28.6
+ -
1 2 3 4 5 8 9
-4B1.1 1 3 4
+SCS/24.5 / +SCS-4A3.1
+SCS/24.5 / +SCS-4A3.2
+SCS/24.6 / +SCS-4A3.3
+SCS/24.6 / +SCS-4A3.4
+SCS/24.6 / +SCS-4A3.5
+SCS/24.7 / +SCS-4A3.6
1 3
+ -
-4B1
4
thrust direction indicator hydraulic-

near hy pump pump RPM
Date 23.06.2014 = AZ2 3/ 4

0 1 2 3 4 5 6 7 8 9
118
144 14 90
12,5
25
ø 11
mm
17
145
118
Date 18.06.2014 = AZ2 4/ 4

0 1 2 3 4 5 6 7 8 9
clutch control
Date 18.06.2014 = AZ2 1/ 2

Ed. MSC CONFIDENTIAL Connection Clutch 1201903 + CLU
0 1 2 3 4 5 6 7 8 9
+SCS-5Y1.1 / +SCS/33.1
+SCS-5Y1.2 / +SCS/33.2
+SCS-5Y2.1 / +SCS/33.2
+SCS-5Y2.2 / +SCS/33.2
+SCS-5S2.1 / +SCS/33.8
+SCS-5S2.2 / +SCS/33.8
+SCS-5S1.1 / +SCS/33.7
-X5 1 2 3 4 5 +SCS-5S1.2 / +SCS/33.7

6 7 8
1 2 1 2
-5Y1 -5Y2 -5S1 P -5S2 P
clutch clutch clutch clutch

disengaging engaging engaged air pressure
min
Date 18.06.2014 = AZ2 2/ 2

Ed. MSC CONFIDENTIAL Clutch Control 1201903 + CLU
0 1 2 3 4 5 6 7 8 9
SCHOTTEL Components
Date 23.06.2014 = AZ2 1/ 3

0 1 2 3 4 5 6 7 8 9
+SCS-2S12.2 / +SCS/43.8
+SCS-2S13.2 / +SCS/44.1
+SCS-2S15.2 / +SCS/44.2
+SCS-2S11.1 / +SCS/43.7
+SCS-2S11.2 / +SCS/43.7
+SCS-M1:W / +SCS/4.6
+SCS-M1:U / +SCS/4.6
+SCS-M1:V / +SCS/4.6
-X2 11 12 15 16 17 18 19 20
PE PE PE PE
13
-2S11 -2S13 -2S4 P -2S15
14
-M1
M
1,5kW 3~
380V
50Hz PE
Lube oil Lube oil Lube oil Lube oil lube oil
level min temp. max filter clogged flow min pump
Date 15.08.2014 = AZ2 2/ 3

0 1 2 3 4 5 6 7 8 9
+SCS-4A4.1 / +SCS/24.1
+SCS-4A4.2 / +SCS/24.1
+SCS-4A4.3 / +SCS/24.1
+SCS-4A4.4 / +SCS/24.2
+SCS-5B1.1 / +SCS/20.5
+SCS-5B1.3 / +SCS/20.5
+SCS-5B1.4 / +SCS/20.5
+SCS-5B2.1 / +SCS/25.6
+SCS-5B3.4 / +SCS/20.6
+SCS-4A4.6 / +SCS/13.7
+SCS-4A4.7 / +SCS/13.7
+SCS-4A4.8 / +SCS/13.7
+SCS-4A4.9 / +SCS/13.7
+SCS-5B2.3 / +SCS/25.7
+SCS-5B2.4 / +SCS/25.7
-X5 1 2 3 4 5 6 7 8 9
-4A4 1 2 3 4 5 6 7 8 9 10
1179731 1179731 1179731
sensor cable BN BU BK sensor cable BN BU BK sensor cable BN BU WH
1 3 1 3 1 3
red
blue
yellow
green
brown
white
grey
pink
violett
red
blue
yellow
green
brown
white
grey
pink
violett
+ - + - + -
-5B1 -5B2 -5B3
4 4 2
feedback thrust direction feedback thrust direction shaft speed pickup shaft speed pickup SRP in
indicating steering control system indicator zero pos.
Date 23.06.2014 = AZ2 3/ 3

0 1 2 3 4 5 6 7 8 9
switch cabinet
connection propulsion motor
Date 18.06.2014 = YARD 1/ 3

Ed. MSC CONFIDENTIAL Drive Motor Unit AZ 1201903 + PM
Appr © SCHOTTEL GmbH PM Page 173
0 1 2 3 4 5 6 7 8 9
*
switch cabinet propulsion motor control
! ATTENTION !
The correct terminal numbers signed in the drawings of the propulsion motor control
engine stop DI1 DI2

or engine engine engine DI DI + -
emergency stop running at idle overload
feedline
feedline
4-20mA
S S
+ -
-AZ1-X1 1 2 3 4 5 6 7 8 9 10 11
=AZ1+SCS/20.1 / =AZ1+SCS-PM23
feedline motor motor motor motor speed lever clutch speed value
OFF ON at idle overload in zero disengaged
Date 18.06.2014 = YARD 2/ 3

Ed. MSC CONFIDENTIAL Connections To Drive Motor AZ1 1201903 + PM
0 1 2 3 4 5 6 7 8 9
*
switch cabinet propulsion motor control
! ATTENTION !
The correct terminal numbers signed in the drawings of the propulsion motor control
engine stop DI1 DI2

or engine engine engine DI DI + -
emergency stop running at idle overload
feedline
feedline
4-20mA
S S
+ -
-AZ2-X1 1 2 3 4 5 6 7 8 9 10 11
feedline motor motor motor motor speed lever clutch speed value
OFF ON at idle overload in zero disengaged
Date 18.06.2014 = YARD 3/ 3

Ed. MSC CONFIDENTIAL Connections To Drive Motor AZ2 1201903 + PM
0 1 2 3 4 5 6 7 8 9
switch cabinet
connection warning unit
Date 18.06.2014 = YARD 1/ 5

Ed. MSC CONFIDENTIAL Connection To Warning Unit 1201903 + SWU
Appr © SCHOTTEL GmbH SWU Page 176
0 1 2 3 4 5 6 7 8 9
*
ship warning unit
Alarm indicating in the weehlhouse according to the classification rules!
! ATTENTION !
The correct terminal numbers signed in the drawings of the warning unit
delay time
0...2s 0...2s 0...2s 0...2s
-X1 1 2 3 4 5 6 7 8
=AZ1+SCS/48.3 / =AZ1+SCS-SWU1
failure failure failure failure

AC / DC 24V DC AC / DC 24V DC
converter feedline converter feedline
Date 18.06.2014 = YARD 2/ 5

Ed. MSC CONFIDENTIAL Connection To Warning Unit 1201903 + SWU
0 1 2 3 4 5 6 7 8 9
Warnings SCO_WARN_V2
Checklist SCHOTTEL Warnings
Connection
function text Target designation point Page / column tested approved Comment
Lube oil level min =AZ1+SCS -X21 8 /2.1

Lube oil temp. max =AZ1+SCS -X21 10 /2.2
Lube oil temp. max /2.2
Lube oil filter clogged /2.3
Lube oil filter clogged =AZ1+SCS -X21 11 /2.3
Lube oil flow min /2.4
Lube oil flow min =AZ1+SCS -X21 12 /2.4
Date, Location service engineer Date, Location Yard, Owner Class
Date 18.06.2014 = YARD 3/ 5

Ed. MSC CONFIDENTIAL Warning Interface Protocol 1201903 + SWU
0 1 2 3 4 5 6 7 8 9
Connection

Lube oil temp. max =AZ2+SCS -X21 10 /2.2
Lube oil temp. max /2.2
Lube oil filter clogged /2.3
Lube oil filter clogged =AZ2+SCS -X21 11 /2.3
Lube oil flow min /2.4
Lube oil flow min =AZ2+SCS -X21 12 /2.4
Date 18.06.2014 = YARD 4/ 5

Ed. MSC CONFIDENTIAL Warning Interface Protocol 1201903 + SWU
0 1 2 3 4 5 6 7 8 9
Connection
failure AC / DC converter =AZ1+SCS -X4.K1 11 /2.0

failure 24V DC feedline =AZ1+SCS -X4.K2 11 /2.1
Date 18.06.2014 = YARD 5/ 5

Ed. MSC CONFIDENTIAL Terminal diagram =YARD+SWU-X1 1201903 + SWU
0 1 2 3 4 5 6 7 8 9
switch cabinet
connection Autopilot
Date 18.06.2014 = YARD 1/ 2

Ed. MSC CONFIDENTIAL Connection To Autopilot 1201903 + AP
Appr © SCHOTTEL GmbH Autopilot Page 181
0 1 2 3 4 5 6 7 8 9
DI DI
feedline
feedline
+ - + -
! ATTENTION !
S S
4..20mA
The correct terminal numbers signed in the drawings of the Autopilot 4.,.20mA
+ - + -
-X1 1 2 3 4 5 6 -X2 1 2 3 4 5 6
=AZ1+SCS-AP1
=AZ1+SCS-AP2
=AZ1+SCS-AP3
=AZ1+SCS-AP4
=AZ1+SCS-AP5
=AZ1+SCS-AP6
=AZ2+SCS-AP1
=AZ2+SCS-AP2
=AZ2+SCS-AP3
=AZ2+SCS-AP4
=AZ2+SCS-AP5
=AZ2+SCS-AP6
=AZ1+SCS/49.2 /
=AZ1+SCS/49.2 /
=AZ1+SCS/49.2 /
=AZ1+SCS/49.3 /
=AZ1+SCS/49.4 /
=AZ1+SCS/49.4 /
=AZ2+SCS/49.2 /
=AZ2+SCS/49.2 /
=AZ2+SCS/49.2 /
=AZ2+SCS/49.3 /
=AZ2+SCS/49.4 /
=AZ2+SCS/49.4 /
Autopilot Autopilot mode setpoint Autopilot Autopilot mode setpoint
ready for service in service AP control ready for service in service AP control
unit AZ1 unit AZ1 unit AZ1 unit AZ2 unit AZ2 unit AZ2
Date 18.06.2014 = YARD 2/ 2

Ed. MSC CONFIDENTIAL Connection To Autopilot 1201903 + AP
Appr © SCHOTTEL GmbH Autopilot Page 182
0 1 2 3 4 5 6 7 8 9
switch cabinet
connection FIFI Pumpe
System
Date 18.06.2014 = YARD 1/ 2

Ed. MSC CONFIDENTIAL Connection To FIFI Pumpe 1201903 + FIFI
Appr © SCHOTTEL GmbH FIFI Pump Page 183
0 1 2 3 4 5 6 7 8 9
*
13
-S1 switch cabinet FIFI Pump Sytem
14
! ATTENTION !
The correct terminal numbers signed in the drawings of the switch cabinet
-K3 FIFI Mode possible

-K1 -K1
-K1 -K2
-K1 -Y1 -K2
-AZ2-X1 1 2 FIFI FIFI pump FIFI pump 3 4 5

Mode clutch clutch
ON valve engaged
=AZ2+SCS/50.6 / =AZ2+SCS-FIFI1
FIFI feed FIFI FIFI

Mode line MODE System
possible ON Ready
Date 18.06.2014 = YARD 2/ 2

Ed. MSC CONFIDENTIAL Connection To FIFI Pumpe 1201903 + FIFI
Appr © SCHOTTEL GmbH FIFI Pump Page 184
0 1 2 3 4 5 6 7 8 9
parts list
Date 06.02.2014 = PARTS 1/ 17

Ed. ROM CONFIDENTIAL Parts List 1201903 + PARTS
0 1 2 3 4 5 6 7 8 9
Parts List
device tag Quantity SCHOTTEL Bezeichnung Denomination Type number supplier Page
Id.Nr.
=AZ1+SCS-A1 1 1126105 Stromversorgung power supply QUINT-PS/ 3AC/24DC/20 Phönix GmbH =AZ1+SCS/4.7
=AZ1+SCS-A2 1 1153340 Netzgerät 24V DC / 24V DC / 10A DC DC converter 2320092 Phönix GmbH =AZ1+SCS/5.0
=AZ1+SCS-A40 1 1179940 DCM CP-ANZEIGE DCM CP-INDICATOR DCM CP-ANZEIGE SCHOTTEL =AZ1+SCS/24.1
=AZ1+SCS-A81 1 1167526 DCM externe Systeme DCM external systems DCM EXTERNESYSTEME 1BUS SYSTEM GESAS =AZ1+SCS/34.0
=AZ1+SCS-A83 1 1174848 Trennverstärker Bipolar converter bipolar 857-409 Weidmüller =AZ1+SCS/36.1
=AZ1+SCS-1A1.0 1 1167520 WAGO Fahrstandswahl 1BUS system desk control DIO modul 1 Bus SCHOTTEL =AZ1+SCS/11.0
=AZ1+SCS-1A1.0 1 1192755 Parameterliste parameter list SCHOTTEL =AZ1+SCS/11.0
=AZ1+SCS-1A1.1 0 1167823 Netzfilter feed line filter 750-626 WAGO =AZ1+SCS/11.6
=AZ1+SCS-1A1.2 0 1155226 Digitaleingang 8xDI digital input 8xDI 750-430 WAGO =AZ1+SCS/14.0
=AZ1+SCS-1A1.5 0 1155228 Digitalausgang 8xDO 0,5A digital output 8xDO 0,5A 750-530 WAGO =AZ1+SCS/17.1
=AZ1+SCS-1A1.7 1 1155225 Busendklemme bus terminal 750-600 WAGO =AZ1+SCS/18.8
=AZ1+SCS-2A0.0 1 1167520 WAGO Fahrstandswahl 1BUS system desk control DIO modul 1 Bus SCHOTTEL =AZ1+SCS (AZ1 Schaltschrank.S1)
=AZ1+SCS-2A1.0 1 1193931 WAGO Port Erweiterung WAGO Port Extension =AZ1+SCS/39.0
=AZ1+SCS-2A1.5 0 1155228 Digitalausgang 8xDO 0,5A digital output 8xDO 0,5A 750-530 WAGO =AZ1+SCS (AZ1 Schaltschrank.S1)
=AZ1+SCS-2A1.7 0 1155225 Busendklemme bus terminal 750-600 WAGO =AZ1+SCS (AZ1 Schaltschrank.S1)
=AZ1+SCS-2A10 1 1163274 Warnpanel Warning panel WAP GESAS =AZ1+SCS/38.2
=AZ1+SCS-2A10 8 1130139 Scheibe 4,3 disc B 4,3 DIN 125 A2 DIN =AZ1+SCS/38.2
=AZ1+SCS-2A10 8 1066247 Federscheibe M4 4,2 SCHOTTEL =AZ1+SCS/38.2
=AZ1+SCS-2A10 8 1000977 Sechskantmutter M4 nut M4 SCHOTTEL =AZ1+SCS/38.2
=AZ1+SCS-3A1 1 1167522 DCM RPM control DCM RPM control DCM RPM 1BUS SYSTEM GESAS =AZ1+SCS/19.1
=AZ1+SCS-3A2 1 1148645 Trennverstärker Programmierbar galvanic isolated output MAZ DC / DC SELECT Weidmüller =AZ1+SCS/47.5
=AZ1+SCS-3A4 1 1172147 Rampengenerator ramp generator 113640000 GESAS =AZ1+SCS/23.2
=AZ1+SCS-4A1 1 1167524 DCM steering DCM steering DCM STEUERUNG 1BUS SYSTEM GESAS =AZ1+SCS/27.1
=AZ1+SCS-4A2 1 1168411 DPV DPV DPV 1BUS SYSTEM GESAS =AZ1+SCS/27.4
=AZ1+SCS-4A3 1 1179008 DPV Zeitabhängige Steuerung DPV NFU control steering GESAS =AZ1+SCS/24.6
=AZ1+SCS-5A3 1 1115903 Motoransteuerung amplifier MSV 1.0 SPEEDRONIC SCHOTTEL =AZ1+SCS/33.0
=AZ1+SCS-B1 1 1196882 Temperaturregler Öffner thermostat NC TRO 60 RÜBSAMEN & HERR =AZ1+SCS/44.5
=AZ1+SCS-F1 1 1121648 Leistungsschalter 3,5-5A power switch 3,5-5A 3RV10 11-1FA10 Siemens =AZ1+SCS/4.6
=AZ1+SCS-F1 1 1121644 Hilfsschalter Leistungsschalter auxiliary switch circuit breaker 3RV1901-1E Siemens =AZ1+SCS/4.6
=AZ1+SCS-F2 1 1121651 Leistungsschalter 1,8-2,5A power switch 1,8-2,5A 3RV10 11-1CA10 Siemens =AZ1+SCS/4.8
=AZ1+SCS-F3 1 1127605 Phasenüberwachung Phase control 3UG45 13-1BR20 Siemens =AZ1+SCS/4.6
=AZ1+SCS-1F0 1 1109851 Sicherungsautom, 1pol B6A automatic fuse 24049 Merlin Gerin =AZ1+SCS/6.1
Date 15.08.2014 = PARTS 2/ 17

Ed. MSC CONFIDENTIAL Parts List 1201903 + PARTS
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Parts List
Id.Nr.
=AZ1+SCS-4F3 1 1098223 Sicherungsklemme terminal for fuse Weidmüller =AZ1+SCS/24.6
=AZ1+SCS-4F3 4 1139809 Glassicherung fuse 5X20/2,0A(F) Weidmüller =AZ1+SCS/24.6
=AZ1+SCS-4F3 1 1069764 Abschlußplatte safety plate WAP 2,5...10 Weidmüller =AZ1+SCS/24.6
=AZ1+SCS-GND 1 1126844 Endwinkel safety angle WEW 35/2 Weidmüller =AZ1+SCS/1.2
=AZ1+SCS-GND 1 1069768 Gruppenbezeichnung name plate for terminal row WGB 5 Weidmüller =AZ1+SCS/1.2
=AZ1+SCS-GND 1 1130041 Abschlußplatte für 1130039 cover plate for 1130039 ZAP Weidmüller =AZ1+SCS/1.2
=AZ1+SCS-GND 1 1130039 Durchgangsklemme ZDU 2,5/4AN terminal ZDU 2,5/4AN ZDU 2,5 4AN Weidmüller =AZ1+SCS/6.1
=AZ1+SCS-K1 1 1170790 Relais relay G2RV-SL500-24VDC OMRON =AZ1+SCS/8.1
=AZ1+SCS-1K2 1 1150425 Relais, Kipp throwover relay MY2K 24VDC OMRON =AZ1+SCS/9.0
=AZ1+SCS-1K2 1 1150430 Stecksockel plug socket PYF 14S OMRON =AZ1+SCS/9.0
=AZ1+SCS-1K2 1 1150432 Haltebügel zu MY clip PYCM 14S OMRON =AZ1+SCS/9.0
=AZ1+SCS-1K2 1 1150435 Sockelbrücke socket bridge PYDM-14SB OMRON =AZ1+SCS/9.0
=AZ1+SCS-1K2 2 1047533 Diode diode 1 N 4007 Motorola =AZ1+SCS/9.0
=AZ1+SCS-1K2.1 1 1151646 Relais relay MY2 IN1 24VDC OMRON =AZ1+SCS/9.4
=AZ1+SCS-1K2.1 1 1151647 Stecksockel plug socket PYF 08S OMRON =AZ1+SCS/9.4
=AZ1+SCS-1K2.1 1 1151648 Haltebügel zu MY clip PYCM 08S OMRON =AZ1+SCS/9.4
=AZ1+SCS-1K2.1 1 1151649 Sockelbrücke socket bridge PYDM-08SB OMRON =AZ1+SCS/9.4
=AZ1+SCS-1K4 1 1150424 Relais relay MY4 IN1 24V DC OMRON =AZ1+SCS/9.5
=AZ1+SCS-1K5 1 1166167 Stromstoßrelais impulse relay 15522 Merlin Gerin =AZ1+SCS/9.8
=AZ1+SCS-1K5 1 1126292 Diodenklemme diode terminal ZDK 2.5/1.5/D/2 Weidmüller =AZ1+SCS/9.8
=AZ1+SCS-1K6 1 1151646 Relais relay MY2 IN1 24VDC OMRON =AZ1+SCS/18.8
Date 15.08.2014 = PARTS 3/ 17

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Parts List
Id.Nr.

=AZ1+SCS-2K0 1 1170790 Relais relay G2RV-SL500-24VDC OMRON =AZ1+SCS/45.2
Date 15.08.2014 = PARTS 4/ 17

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Parts List
Id.Nr.

=AZ1+SCS-5K3 1 1121646 Schütz, 7A, 24V DC relay, 7A, 24V DC 3RT10 15-1BB41 Siemens =AZ1+SCS/33.3
=AZ1+SCS-L+ 1 1126844 Endwinkel safety angle WEW 35/2 Weidmüller =AZ1+SCS/1.2
=AZ1+SCS-L+ 1 1069768 Gruppenbezeichnung name plate for terminal row WGB 5 Weidmüller =AZ1+SCS/1.2
=AZ1+SCS-L+ 1 1130041 Abschlußplatte für 1130039 cover plate for 1130039 ZAP Weidmüller =AZ1+SCS/1.2
=AZ1+SCS-L+ 1 1130039 Durchgangsklemme ZDU 2,5/4AN terminal ZDU 2,5/4AN ZDU 2,5 4AN Weidmüller =AZ1+SCS/6.1
=AZ1+SCS-L+ 1 1126844 Endwinkel safety angle WEW 35/2 Weidmüller =AZ1+SCS (AZ1 Schaltschrank.S1)
=AZ1+SCS-1M0 1 1196880 Filterlüfter LV250 24V DC filter fan LV 250 24V DC RÜBSAMEN & HERR =AZ1+SCS/7.2
=AZ1+SCS-1M0 1 1196881 Austrittsfilter GV250 exhaust filter GV 250 RÜBSAMEN & HERR =AZ1+SCS/7.2
=AZ1+SCS-1M0 1 1196882 Temperaturregler Öffner thermostat NC TRO 60 RÜBSAMEN & HERR =AZ1+SCS (AZ1 Schaltschrank.S1)
=AZ1+SCS-P1 1 1187576 LCD Systemanzeige LCD display LCD DISPLAY BEIJER =AZ1+SCS/12.2
=AZ1+SCS-P1 2 1186019 Kabel LCD Display cable LCD display Weidmüller =AZ1+SCS/12.2
=AZ1+SCS-S1 1 1121638 Hauptschalter 32A main switch 32A 3LD2230-0TK11 Siemens =AZ1+SCS/4.1
=AZ1+SCS-S1 2 1121639 Klemmenabdeckung für 1121638 cover plate for 1121638 3LD9221-1A Siemens =AZ1+SCS/4.1
=AZ1+SCS-S3 1 1130230 Leucht Drucktaste push button with lamp EAO 61-1100.0 Lumitas =AZ1+SCS/16.7
=AZ1+SCS-S3 1 1130224 Druckhaube / rot front part EAO 61-9681.2 Lumitas =AZ1+SCS/16.7
=AZ1+SCS-S3 1 1131114 Schaltelement SP/2S lower part EAO 61-8420.12 Lumitas =AZ1+SCS/16.7
=AZ1+SCS-S3 1 1130219 Frontrahmenset front set EAO 61-9931.0 Lumitas =AZ1+SCS/16.7
=AZ1+SCS-S3 1 1158756 LED 28V 14mA LED EAO 10-2313.3139 Lumitas =AZ1+SCS/16.7
=AZ1+SCS-1S1 1 1130416 Schutzklappe Flacher Einbau front set EAO 61-9922.0 Lumitas =AZ1+SCS/9.1
=AZ1+SCS-1S1 1 1130230 Leucht Drucktaste push button with lamp EAO 61-1100.0 Lumitas =AZ1+SCS/9.1
=AZ1+SCS-1S1 1 1130225 Druckhaube / grün front part EAO 61-9681.5 Lumitas =AZ1+SCS/9.1
=AZ1+SCS-1S1 1 1131114 Schaltelement SP/2S lower part EAO 61-8420.12 Lumitas =AZ1+SCS/9.1
=AZ1+SCS-1S1 1 1158756 LED 28V 14mA LED EAO 10-2313.3139 Lumitas =AZ1+SCS/9.1
=AZ1+SCS-1S2 1 1130223 Druckhaube / gelb fornt part EAO 61-9681.4 Lumitas =AZ1+SCS/14.3
Date 15.08.2014 = PARTS 5/ 17

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Parts List
Id.Nr.
=AZ1+SCS-1S2 1 1130219 Frontrahmenset front set EAO 61-9931.0 Lumitas =AZ1+SCS/14.3
=AZ1+SCS-SP 1 1103169 Einbausteckdose 220V socket BBC =AZ1+SCS/4.4
=AZ1+SCS-SWBOX 1 1053244 Schaltschrank 800x1000x300 switch box AE1180 Rittal-Werk =AZ1+SCS/53.5
=AZ1+SCS-SWBOX 1 1135768 Türfeststeller switch box door holder 2519.000 Rittal-Werk =AZ1+SCS/53.5
=AZ1+SCS-SWBOX 4 1085605 Tragschiene 35x15 supporting bar TS35X15 Weidmüller =AZ1+SCS/53.5
=AZ1+SCS-SWBOX 1 1170070 Handlauf hand rail GN 667-30-300-SW GANTER =AZ1+SCS/53.5
=AZ1+SCS-SWBOX 3 1178897 Tragschienenhalter holder 1201604 =AZ1+SCS/53.5
=AZ1+SCS-SWBOX 1 1184645 SCHOTTEL Logo 100x100 SCHOTTEL LOGO SCHOTTEL LOGO Halmer =AZ1+SCS/53.5
=AZ1+SCS-SWBOX 1 1161920 Kabeleinführungsflansch switch box cable entry 2563.100 Rittal-Werk =AZ1+SCS/53.5
=AZ1+SCS-SWBOX 1 1069768 Gruppenbezeichnung name plate for terminal row WGB 5 Weidmüller =AZ1+SCS (AZ1 Schaltschrank.S1)
=AZ1+SCS-1V2 1 1133067 Diodenklemme doppelt diode terminal ZDK 2.5/1.5/D6 Weidmüller =AZ1+SCS/9.5
=AZ1+SCS-1V2 1 1133067 Diodenklemme doppelt diode terminal ZDK 2.5/1.5/D/6 Weidmüller =AZ1+SCS (AZ1 Schaltschrank.S1)
=AZ1+SCS-4V1 1 1133067 Diodenklemme doppelt diode terminal ZDK 2.5/1.5/D/6 Weidmüller =AZ1+SCS/28.8
=AZ1+SCS-X1 1 1121723 Durchgangs-Reihenklemme ZDU 2.5 terminal ZDU 2,5 ZDU 2.5 Weidmüller =AZ1+SCS/4.1
=AZ1+SCS-X1 1 1121724 Abschlußplatte für 1121723 cover plate for 1121723 ZAP Weidmüller =AZ1+SCS/4.1
=AZ1+SCS-X1 2 1126844 Endwinkel safety angle WEW 35/2 Weidmüller =AZ1+SCS/4.1
=AZ1+SCS-X1 1 1069768 Gruppenbezeichnung name plate for terminal row WGB 5 Weidmüller =AZ1+SCS/4.1
=AZ1+SCS-X1 1 1126365 Erdungsklemme terminal PE-2.5 ZPE 2.5 Weidmüller =AZ1+SCS/4.1
=AZ1+SCS-X1 1 1126367 Schutzleiterklemme 16mm² earth terminal 16mm² ZPE 16 Weidmüller =AZ1+SCS/4.2
=AZ1+SCS-X2 1 1121721 Durchgangs-Reihenklemme ZDU 6 terminal ZDU 6 ZDU 6 Weidmüller =AZ1+SCS/5.1
=AZ1+SCS-X3 1 1161797 Mehrstock-Reihenklemme ZDLD 2.5-2N terminalZDLD 2.5-2N ZDLD 2.5-2N Weidmüller =AZ1+SCS/20.1
=AZ1+SCS-X3 1 1161797 Mehrstock-Reihenklemme ZDLD 2.5-2N terminalZDLD 2.5-2N ZDLD 2.5-2N Weidmüller =AZ1+SCS (AZ1 Schaltschrank.S1)
Date 15.08.2014 = PARTS 6/ 17

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Parts List
Id.Nr.
=AZ1+SCS-X3.K3 1 1170790 Relais relay G2RV-SL500-24VDC OMRON =AZ1+SCS/23.6
=AZ1+SCS-X10 1 1121723 Durchgangs-Reihenklemme ZDU 2.5 terminal ZDU 2,5 ZDU 2.5 Weidmüller =AZ1+SCS (AZ1 Schaltschrank.S1)
=AZ1+SCS-X12 1 1069768 Gruppenbezeichnung name plate for terminal row WGB 5 Weidmüller =AZ1+SCS (AZ1 Schaltschrank.S1)
=AZ1+SCS-X12 1 1121722 Abschlußplatte für 1121721 cover plate for 1121721 ZAP Weidmüller =AZ1+SCS (AZ1 Schaltschrank.S1)
=AZ1+SCS-X12 1 1126844 Endwinkel safety angle WEW 35/2 Weidmüller =AZ1+SCS (AZ1 Schaltschrank.S1)
Date 15.08.2014 = PARTS 7/ 17

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Parts List
Id.Nr.
=AZ1+SCS-X41 1 1178898 Bezeichnungsschild für Klemmleiste name plate for terminal row WAD 8 Weidmüller =AZ1+SCS/24.1
=AZ1+SCS-X51.V1 1 1194625 LED-Reihenklemme, grün LED terminal WDK 2.5 LD GR 1R 24VDC =AZ1+SCS/20.7
=AZ1+SCS-X51.V1 1 1114133 Abschlußplatte, Doppelklemme safety plate WAP/WDK 2.5 Weidmüller =AZ1+SCS/20.7
Date 15.08.2014 = PARTS 8/ 17

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Parts List
Id.Nr.

=AZ1+SCS-XC 1 1128985 Übergabeelement connector D-SUB 9 Weidmüller =AZ1+SCS/11.6
=AZ1+MDP-A1 1 1168785 Bedienpanel Fix Pitch PS control panel Fix Pitch PS FSP-FP PS SRP/STP GESAS =AZ1+MDP/2.0
=AZ1+MDP-A1 1 1170467 Platine gebohrt panel drilled STANDARD Halmer =AZ1+MDP/2.0
=AZ1+MDP-A1 1 1170073 Montageplatte AFT mounted plate aft Montageplatten =AZ1+MDP/2.0
=AZ1+MDP-A1 8 1025675 Sechskantmutter M4 nut DIN 934 M4 A4-80 DIN =AZ1+MDP/2.0
=AZ1+MDP-A1 8 1066247 Federscheibe M4 4,2 SCHOTTEL =AZ1+MDP/2.0
=AZ1+MDP-A1 8 1130139 Scheibe 4,3 disc B 4,3 DIN 125 A2 DIN =AZ1+MDP/2.0
=AZ1+MDP-A1 1,5 1101794 Geflechtschlauch 30mm fine braided tubing 30mm PP-FG B-30 Hellermann =AZ1+MDP/2.0
=AZ1+MDP-A1 1 1171571 Winkel Kabelbefestigung groß angle cable fixing Halmer =AZ1+MDP/2.0
=AZ1+MDP-A2 1 1170035 Copilot Standard Copilot Standard 1XCAN RPM 1XCAN 360° 1XEND Kwant-Controls =AZ1+MDP/6.0
=AZ1+MDP-A2 1 1169701 Kabelsatz X3.1 control panel cable set X3.1 Weidmüller =AZ1+MDP/6.0
=AZ1+MDP-AX1 1 1169693 Übergabeelement X1 control panel interface module X1 GESAS =AZ1+MDP/2.0
=AZ1+MDP-AX1 1 1169698 Kabelsatz X1 control panel cable set X1 Halmer =AZ1+MDP/2.0
=AZ1+MDP-AX9 1 1169705 Kabelsatz X91 Anzeige Azimut/RPM cable set X91 Halmer =AZ1+MDP/7.0
=AZ1+MDP-P41 1 1155994 Schubrichtungsanzeige thrust direction indicator CAN S/G H/G BELEUCHTET Dr. Horn =AZ1+MDP/7.0
=AZ1+MDP-P51 1 1180944 Drehzahlanzeige SW/GE speed indicator bk/ye EAD96X96 S5- Dr. Horn =AZ1+MDP/7.4
=AZ1+MDP-X30 1 1121725 Doppelklemme ZDK 2,5/1,5 terminal ZDK 2,5/1,5 ZDK 2,5/1,5 Weidmüller =AZ1+MDP/5.3
=AZ1+MDP-X30 1 1121726 Abschlußplatte für 1121725 cover plate for 1121725 ZAP Weidmüller =AZ1+MDP/5.3
=AZ1+MDP-X30 1 1126844 Endwinkel safety angle WEW 35/2 Weidmüller =AZ1+MDP/5.3
=AZ1+MDP-X30 1 1069768 Gruppenbezeichnung name plate for terminal row WGB 5 Weidmüller =AZ1+MDP/5.3
=AZ1+MDWP-2A10 1 1163274 Warnpanel Warning panel WAP GESAS =AZ1+MDWP/2.1
=AZ1+MDWP-2A10 1,5 1101794 Geflechtschlauch 30mm fine braided tubing 30mm PP-FG B-30 Hellermann =AZ1+MDWP/2.1
=AZ1+MDWP-X21 1 1161797 Mehrstock-Reihenklemme ZDLD 2.5-2N terminalZDLD 2.5-2N ZDLD 2.5-2N Weidmüller =AZ1+MDWP/2.2
=AZ1+MDWP-X21 1 1161798 Abschlußplatte für 1161797 cover plate for 1161797 ZAP Weidmüller =AZ1+MDWP/2.2
=AZ1+MDWP-X21 1 1126844 Endwinkel safety angle WEW 35/2 Weidmüller =AZ1+MDWP/2.2
=AZ1+MDWP-X21 1 1069768 Gruppenbezeichnung name plate for terminal row WGB 5 Weidmüller =AZ1+MDWP/2.2
=AZ1+ENR-4A3 1 1156514 Schubrichtungsanzeige kompl. IP 56 thrust dir. indicator compl. IP 56 ANZEIGE MIT ABDECKUNG Dr. Horn =AZ1+ENR/3.1
=AZ1+ENR-4A3 1 1156410 Befestigungswinkel holder for 1 indicator BEFESTIGUNGSWINKEL Dr. Horn =AZ1+ENR/3.1
=AZ1+SRP-5B1 1 HY in Hydraulikstückliste in hydr. parts list SCHOTTEL =AZ1+SRP/3.6
=AZ2+SCS-A1 1 1126105 Stromversorgung power supply QUINT-PS/ 3AC/24DC/20 Phönix GmbH =AZ2+SCS/4.7
Date 15.08.2014 = PARTS 9/ 17

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Parts List
Id.Nr.
=AZ2+SCS-A40 1 1179940 DCM CP-ANZEIGE DCM CP-INDICATOR DCM CP-ANZEIGE SCHOTTEL =AZ2+SCS/24.1
=AZ2+SCS-A81 1 1167526 DCM externe Systeme DCM external systems DCM EXTERNESYSTEME 1BUS SYSTEM GESAS =AZ2+SCS/34.0
=AZ2+SCS-A83 1 1174848 Trennverstärker Bipolar converter bipolar 857-409 Weidmüller =AZ2+SCS/36.1
=AZ2+SCS-1A1.0 1 1167520 WAGO Fahrstandswahl 1BUS system desk control DIO modul 1 Bus SCHOTTEL =AZ2+SCS/11.0
=AZ2+SCS-1A1.0 1 1192755 Parameterliste parameter list SCHOTTEL =AZ2+SCS/11.0
=AZ2+SCS-2A0.0 1 1167520 WAGO Fahrstandswahl 1BUS system desk control DIO modul 1 Bus SCHOTTEL =AZ2+SCS (AZ2 Schaltschrank.S1)
=AZ2+SCS-2A1.0 1 1193931 WAGO Port Erweiterung WAGO Port Extension =AZ2+SCS/39.0
=AZ2+SCS-2A1.5 0 1155228 Digitalausgang 8xDO 0,5A digital output 8xDO 0,5A 750-530 WAGO =AZ2+SCS (AZ2 Schaltschrank.S1)
=AZ2+SCS-2A1.7 0 1155225 Busendklemme bus terminal 750-600 WAGO =AZ2+SCS (AZ2 Schaltschrank.S1)
=AZ2+SCS-2A10 1 1163274 Warnpanel Warning panel WAP GESAS =AZ2+SCS/38.2
=AZ2+SCS-2A10 8 1130139 Scheibe 4,3 disc B 4,3 DIN 125 A2 DIN =AZ2+SCS/38.2
=AZ2+SCS-2A10 8 1066247 Federscheibe M4 4,2 SCHOTTEL =AZ2+SCS/38.2
=AZ2+SCS-2A10 8 1000977 Sechskantmutter M4 nut M4 SCHOTTEL =AZ2+SCS/38.2
=AZ2+SCS-3A1 1 1167522 DCM RPM control DCM RPM control DCM RPM 1BUS SYSTEM GESAS =AZ2+SCS/19.1
=AZ2+SCS-3A2 1 1148645 Trennverstärker Programmierbar galvanic isolated output MAZ DC / DC SELECT Weidmüller =AZ2+SCS/47.5
=AZ2+SCS-3A4 1 1172147 Rampengenerator ramp generator 113640000 GESAS =AZ2+SCS/23.2
=AZ2+SCS-4A1 1 1167524 DCM steering DCM steering DCM STEUERUNG 1BUS SYSTEM GESAS =AZ2+SCS/27.1
=AZ2+SCS-4A2 1 1168411 DPV DPV DPV 1BUS SYSTEM GESAS =AZ2+SCS/27.4
=AZ2+SCS-4A3 1 1179008 DPV Zeitabhängige Steuerung DPV NFU control steering GESAS =AZ2+SCS/24.6
=AZ2+SCS-5A3 1 1115903 Motoransteuerung amplifier MSV 1.0 SPEEDRONIC SCHOTTEL =AZ2+SCS/33.0
=AZ2+SCS-B1 1 1196882 Temperaturregler Öffner thermostat NC TRO 60 RÜBSAMEN & HERR =AZ2+SCS/44.5
=AZ2+SCS-F1 1 1121648 Leistungsschalter 3,5-5A power switch 3,5-5A 3RV10 11-1FA10 Siemens =AZ2+SCS/4.6
=AZ2+SCS-F1 1 1121644 Hilfsschalter Leistungsschalter auxiliary switch circuit breaker 3RV1901-1E Siemens =AZ2+SCS/4.6
=AZ2+SCS-F2 1 1121651 Leistungsschalter 1,8-2,5A power switch 1,8-2,5A 3RV10 11-1CA10 Siemens =AZ2+SCS/4.8
=AZ2+SCS-F3 1 1127605 Phasenüberwachung Phase control 3UG45 13-1BR20 Siemens =AZ2+SCS/4.6
Date 15.08.2014 = PARTS 10 / 17

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Parts List
Id.Nr.
=AZ2+SCS-4F3 1 1098223 Sicherungsklemme terminal for fuse Weidmüller =AZ2+SCS/24.6
=AZ2+SCS-4F3 4 1139809 Glassicherung fuse 5X20/2,0A(F) Weidmüller =AZ2+SCS/24.6
=AZ2+SCS-4F3 1 1069764 Abschlußplatte safety plate WAP 2,5...10 Weidmüller =AZ2+SCS/24.6
=AZ2+SCS-GND 1 1126844 Endwinkel safety angle WEW 35/2 Weidmüller =AZ2+SCS/1.2
=AZ2+SCS-GND 1 1069768 Gruppenbezeichnung name plate for terminal row WGB 5 Weidmüller =AZ2+SCS/1.2
=AZ2+SCS-GND 1 1130041 Abschlußplatte für 1130039 cover plate for 1130039 ZAP Weidmüller =AZ2+SCS/1.2
=AZ2+SCS-1K2.1 1 1151646 Relais relay MY2 IN1 24VDC OMRON =AZ2+SCS/9.4
=AZ2+SCS-1K2.1 1 1151647 Stecksockel plug socket PYF 08S OMRON =AZ2+SCS/9.4
=AZ2+SCS-1K2.1 1 1151648 Haltebügel zu MY clip PYCM 08S OMRON =AZ2+SCS/9.4
=AZ2+SCS-1K2.1 1 1151649 Sockelbrücke socket bridge PYDM-08SB OMRON =AZ2+SCS/9.4
=AZ2+SCS-1K5 1 1166167 Stromstoßrelais impulse relay 15522 Merlin Gerin =AZ2+SCS/9.8
Date 15.08.2014 = PARTS 11 / 17

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Parts List
Id.Nr.
Date 15.08.2014 = PARTS 12 / 17

0 1 2 3 4 5 6 7 8 9
Parts List
Id.Nr.

=AZ2+SCS-5K3 1 1121646 Schütz, 7A, 24V DC relay, 7A, 24V DC 3RT10 15-1BB41 Siemens =AZ2+SCS/33.3
=AZ2+SCS-L+ 1 1126844 Endwinkel safety angle WEW 35/2 Weidmüller =AZ2+SCS/1.2
=AZ2+SCS-L+ 1 1069768 Gruppenbezeichnung name plate for terminal row WGB 5 Weidmüller =AZ2+SCS/1.2
=AZ2+SCS-L+ 1 1130041 Abschlußplatte für 1130039 cover plate for 1130039 ZAP Weidmüller =AZ2+SCS/1.2
=AZ2+SCS-1M0 1 1196880 Filterlüfter LV250 24V DC filter fan LV 250 24V DC RÜBSAMEN & HERR =AZ2+SCS/7.2
=AZ2+SCS-1M0 1 1196881 Austrittsfilter GV250 exhaust filter GV 250 RÜBSAMEN & HERR =AZ2+SCS/7.2
=AZ2+SCS-1M0 1 1196882 Temperaturregler Öffner thermostat NC TRO 60 RÜBSAMEN & HERR =AZ2+SCS (AZ2 Schaltschrank.S1)
=AZ2+SCS-P1 1 1187576 LCD Systemanzeige LCD display LCD DISPLAY BEIJER =AZ2+SCS/12.2
=AZ2+SCS-P1 2 1186019 Kabel LCD Display cable LCD display Weidmüller =AZ2+SCS/12.2
=AZ2+SCS-S1 2 1121639 Klemmenabdeckung für 1121638 cover plate for 1121638 3LD9221-1A Siemens =AZ2+SCS/4.1
=AZ2+SCS-S3 1 1130230 Leucht Drucktaste push button with lamp EAO 61-1100.0 Lumitas =AZ2+SCS/16.7
=AZ2+SCS-S3 1 1130224 Druckhaube / rot front part EAO 61-9681.2 Lumitas =AZ2+SCS/16.7
=AZ2+SCS-S3 1 1131114 Schaltelement SP/2S lower part EAO 61-8420.12 Lumitas =AZ2+SCS/16.7
=AZ2+SCS-S3 1 1130219 Frontrahmenset front set EAO 61-9931.0 Lumitas =AZ2+SCS/16.7
=AZ2+SCS-S3 1 1158756 LED 28V 14mA LED EAO 10-2313.3139 Lumitas =AZ2+SCS/16.7
=AZ2+SCS-1S1 1 1130416 Schutzklappe Flacher Einbau front set EAO 61-9922.0 Lumitas =AZ2+SCS/9.1
=AZ2+SCS-1S1 1 1130225 Druckhaube / grün front part EAO 61-9681.5 Lumitas =AZ2+SCS/9.1
=AZ2+SCS-1S2 1 1130223 Druckhaube / gelb fornt part EAO 61-9681.4 Lumitas =AZ2+SCS/14.3
=AZ2+SCS-1S2 1 1130219 Frontrahmenset front set EAO 61-9931.0 Lumitas =AZ2+SCS/14.3
Date 15.08.2014 = PARTS 13 / 17

0 1 2 3 4 5 6 7 8 9
Parts List
Id.Nr.
=AZ2+SCS-SP 1 1103169 Einbausteckdose 220V socket BBC =AZ2+SCS/4.4
=AZ2+SCS-SWBOX 1 1053244 Schaltschrank 800x1000x300 switch box AE1180 Rittal-Werk =AZ2+SCS/53.5
=AZ2+SCS-SWBOX 1 1135768 Türfeststeller switch box door holder 2519.000 Rittal-Werk =AZ2+SCS/53.5
=AZ2+SCS-SWBOX 4 1085605 Tragschiene 35x15 supporting bar TS35X15 Weidmüller =AZ2+SCS/53.5
=AZ2+SCS-SWBOX 1 1170070 Handlauf hand rail GN 667-30-300-SW GANTER =AZ2+SCS/53.5
=AZ2+SCS-SWBOX 3 1178897 Tragschienenhalter holder 1201604 =AZ2+SCS/53.5
=AZ2+SCS-SWBOX 1 1184645 SCHOTTEL Logo 100x100 SCHOTTEL LOGO SCHOTTEL LOGO Halmer =AZ2+SCS/53.5
=AZ2+SCS-SWBOX 1 1161920 Kabeleinführungsflansch switch box cable entry 2563.100 Rittal-Werk =AZ2+SCS/53.5
=AZ2+SCS-4V1 1 1133067 Diodenklemme doppelt diode terminal ZDK 2.5/1.5/D/6 Weidmüller =AZ2+SCS/28.8
=AZ2+SCS-X1 1 1126367 Schutzleiterklemme 16mm² earth terminal 16mm² ZPE 16 Weidmüller =AZ2+SCS/4.2
Date 15.08.2014 = PARTS 14 / 17

0 1 2 3 4 5 6 7 8 9
Parts List
Id.Nr.

=AZ2+SCS-X10 1 1121723 Durchgangs-Reihenklemme ZDU 2.5 terminal ZDU 2,5 ZDU 2.5 Weidmüller =AZ2+SCS (AZ2 Schaltschrank.S1)
=AZ2+SCS-X12 1 1121722 Abschlußplatte für 1121721 cover plate for 1121721 ZAP Weidmüller =AZ2+SCS (AZ2 Schaltschrank.S1)
=AZ2+SCS-X12 1 1126844 Endwinkel safety angle WEW 35/2 Weidmüller =AZ2+SCS (AZ2 Schaltschrank.S1)
Date 15.08.2014 = PARTS 15 / 17

0 1 2 3 4 5 6 7 8 9
Parts List
Id.Nr.
=AZ2+SCS-X51.V1 1 1194625 LED-Reihenklemme, grün LED terminal WDK 2.5 LD GR 1R 24VDC =AZ2+SCS/20.7
=AZ2+SCS-X51.V1 1 1114133 Abschlußplatte, Doppelklemme safety plate WAP/WDK 2.5 Weidmüller =AZ2+SCS/20.7
Date 15.08.2014 = PARTS 16 / 17

0 1 2 3 4 5 6 7 8 9
Parts List
Id.Nr.
=AZ2+SCS-XC 1 1128985 Übergabeelement connector D-SUB 9 Weidmüller =AZ2+SCS/11.6
=AZ2+MDP-A1 1 1168785 Bedienpanel Fix Pitch PS control panel Fix Pitch PS FSP-FP PS SRP/STP GESAS =AZ2+MDP/2.0
=AZ2+MDP-A1 1 1170467 Platine gebohrt panel drilled STANDARD Halmer =AZ2+MDP/2.0
=AZ2+MDP-A1 1 1170073 Montageplatte AFT mounted plate aft Montageplatten =AZ2+MDP/2.0
=AZ2+MDP-A1 8 1025675 Sechskantmutter M4 nut DIN 934 M4 A4-80 DIN =AZ2+MDP/2.0
=AZ2+MDP-A1 8 1066247 Federscheibe M4 4,2 SCHOTTEL =AZ2+MDP/2.0
=AZ2+MDP-A1 8 1130139 Scheibe 4,3 disc B 4,3 DIN 125 A2 DIN =AZ2+MDP/2.0
=AZ2+MDP-A1 1,5 1101794 Geflechtschlauch 30mm fine braided tubing 30mm PP-FG B-30 Hellermann =AZ2+MDP/2.0
=AZ2+MDP-A1 1 1171571 Winkel Kabelbefestigung groß angle cable fixing Halmer =AZ2+MDP/2.0
=AZ2+MDP-A2 1 1170035 Copilot Standard Copilot Standard 1XCAN RPM 1XCAN 360° 1XEND Kwant-Controls =AZ2+MDP/6.0
=AZ2+MDP-A2 1 1169701 Kabelsatz X3.1 control panel cable set X3.1 Weidmüller =AZ2+MDP/6.0
=AZ2+MDP-AX9 1 1169705 Kabelsatz X91 Anzeige Azimut/RPM cable set X91 Halmer =AZ2+MDP/7.0
=AZ2+MDP-P41 1 1155994 Schubrichtungsanzeige thrust direction indicator CAN S/G H/G BELEUCHTET Dr. Horn =AZ2+MDP/7.0
=AZ2+MDP-P51 1 1180944 Drehzahlanzeige SW/GE speed indicator bk/ye EAD96X96 S5- Dr. Horn =AZ2+MDP/7.4
=AZ2+MDP-X30 1 1121726 Abschlußplatte für 1121725 cover plate for 1121725 ZAP Weidmüller =AZ2+MDP/5.3
=AZ2+MDP-X30 1 1126844 Endwinkel safety angle WEW 35/2 Weidmüller =AZ2+MDP/5.3
=AZ2+MDP-X30 1 1069768 Gruppenbezeichnung name plate for terminal row WGB 5 Weidmüller =AZ2+MDP/5.3
=AZ2+MDWP-2A10 1 1163274 Warnpanel Warning panel WAP GESAS =AZ2+MDWP/2.1
=AZ2+MDWP-2A10 1,5 1101794 Geflechtschlauch 30mm fine braided tubing 30mm PP-FG B-30 Hellermann =AZ2+MDWP/2.1
=AZ2+MDWP-X21 1 1161798 Abschlußplatte für 1161797 cover plate for 1161797 ZAP Weidmüller =AZ2+MDWP/2.2
=AZ2+MDWP-X21 1 1126844 Endwinkel safety angle WEW 35/2 Weidmüller =AZ2+MDWP/2.2
=AZ2+MDWP-X21 1 1069768 Gruppenbezeichnung name plate for terminal row WGB 5 Weidmüller =AZ2+MDWP/2.2
=AZ2+ENR-4A3 1 1156514 Schubrichtungsanzeige kompl. IP 56 thrust dir. indicator compl. IP 56 ANZEIGE MIT ABDECKUNG Dr. Horn =AZ2+ENR/3.1
=AZ2+ENR-4A3 1 1156410 Befestigungswinkel holder for 1 indicator BEFESTIGUNGSWINKEL Dr. Horn =AZ2+ENR/3.1
Date 15.08.2014 = PARTS 17 / 17

0 1 2 3 4 5 6 7 8 9
Cable Drawings
Date 06.02.2014 = CABLE 1/ 59

Ed. ROM CONFIDENTIAL Cable Drawings 1201903 + YARD
0 1 2 3 4 5 6 7 8 9
Cable Drawings
cable identifier cable type total cores cross-section cable length remarks
=AZ1-W200 MPRXCX 3 1,5 K2*
target item from target item to
function text Page / path label Connection conductor label Connection
point point
AC feedline switch box +SCS/4.0 =MSB+SCS-400VX1 1 BK +SCS-X1 1
AC feedline switch box =MSB+SCS-400VX1 2 BU +SCS-X1 2
AC feedline switch box =MSB+SCS-400VX1 3 BN +SCS-X1 3
AC feedline switch box -W200 SH SH +SCS-SH
Date 15.08.2014 = CABLE 2/ 59

Ed. MSC CONFIDENTIAL =AZ1-W200 Cable Drawings 1201903 + YARD
0 1 2 3 4 5 6 7 8 9
Cable Drawings
=AZ1-W201 MPRXCX 2 2,5 K2*
point point
earth connection +SCS/4.3 =MSB+SCS-220VX1 1 BK +SCS-X1 5
earth connection =MSB+SCS-220VX1 2 BU +SCS-X1 6
earth connection -W201 SH SH +SCS-SH
Date 15.08.2014 = CABLE 3/ 59

0 1 2 3 4 5 6 7 8 9
Cable Drawings
=AZ1-W202 MPRXCX 1 16 K1*
point point
earth connection +SCS/4.2 +SCS-X1 4 BK +SCS-SH PE
SH
Date 15.08.2014 = CABLE 4/ 59

0 1 2 3 4 5 6 7 8 9
Cable Drawings
point point
feedline switch cabinet 24V DC +SCS/5.0 =ESB+SCS-24-X1 1 BK +SCS-X2 1
feedline switch cabinet 24V DC =ESB+SCS-24-X1 2 BU +SCS-X2 2
feedline switch cabinet 24V DC -W203 SH SH +SCS-SH
Date 15.08.2014 = CABLE 5/ 59

0 1 2 3 4 5 6 7 8 9
Cable Drawings
=AZ1-W204 MPRXCX 2 2,5
point point
feedline indicators +SCS/5.3 =ESB+SCS-24-X1 3 BK +SCS-X2 3
feedline indicators =ESB+SCS-24-X1 4 BU +SCS-X2 4
feedline indicators -W204 SH SH +SCS-SH
Date 15.08.2014 = CABLE 6/ 59

0 1 2 3 4 5 6 7 8 9
Cable Drawings
=AZ1-W210 TCX(C) 2x2 0,75 K3*
point point
feedback unit steering +SCS/13.6 +SCS-X41 5 1.1 +SRP-4A4 6
feedback unit steering +SCS-X41 6 1.2 +SRP-4A4 7
feedback unit steering -W210 SH SH +SCS-SH
Date 15.08.2014 = CABLE 7/ 59

0 1 2 3 4 5 6 7 8 9
Cable Drawings
=AZ1-W211 TCX(C) 2x2 0,75 K4*
point point
CAN BUS Indicator +SCS/24.0 +SCS-X41 1 1.1 +SRP-4A4 1
CAN BUS Indicator +SCS-X41 2 1.2 +SRP-4A4 2
CAN BUS Indicator -W211 SH SH +SCS-SH
Date 15.08.2014 = CABLE 8/ 59

0 1 2 3 4 5 6 7 8 9
Cable Drawings
=AZ1-W212 TCX(C) 2x2 0,75 K3*
point point
shaft speed pick up control system +SCS/20.4 +SCS-X51 1 1.1 +SRP-X5 1
shaft speed pick up control system +SCS-X51 2 1.2 +SRP-X5 2
+SCS-X51.V1 + 2.2 +SRP-X5 9
shaft speed pick up control system -W212 SH SH +SCS-SH
Date 15.08.2014 = CABLE 9/ 59

0 1 2 3 4 5 6 7 8 9
Cable Drawings
=AZ1-W213 TCX(C) 2x2 0,75 K3*
point point
shaft speed pick up indication +SCS/25.6 +SCS-X51 4 1.1 +SRP-X5 4
shaft speed pick up indication +SCS-X51 5 1.2 +SRP-X5 5
2.2
shaft speed pick up indication -W213 SH SH +SCS-SH
Date 15.08.2014 = CABLE 10 / 59

0 1 2 3 4 5 6 7 8 9
Cable Drawings
=AZ1-W214 TCX(C) 4x2 0,75 *K3
point point
hydr. oil pressure max +SCS/43.6 +SCS-X21 8 1.1 +SRP-X2 11
lube oil level min +SCS-X21 9 1.2 +SRP-X2 12
lube oil temp. max +SCS-X21 10 2.1 +SRP-X2 16
lub oil filter dirty +SCS-X21 11 2.2 +SRP-X2 18
lub oil flow min +SCS-X21 12 3.1 +SRP-X2 20
3.2
4.1
4.2
SH
Date 15.08.2014 = CABLE 11 / 59

0 1 2 3 4 5 6 7 8 9
Cable Drawings
=AZ1-W216 MPRXCX 3 1,5 *K3
point point
+SCS/4.5 SH
service plug +SCS-X10 1 +SRP-M1
Date 15.08.2014 = CABLE 12 / 59

0 1 2 3 4 5 6 7 8 9
Cable Drawings
=AZ1-W220 MPRXCX 10 1,5 K2*
point point
clutch disengaging +SCS/33.1 +SCS-X52 1 1 +CLU-X5 1
clutch disengaging +SCS-X52 2 2 +CLU-X5 2
clutch engaging +SCS-X52 3 3 +CLU-X5 3
supressing lube flow +SCS-X52 5 5 +CLU-X5 5
clutch engaged +SCS-X52 6 6 +CLU-X5 6
clutch air pressure min +SCS-X52 8 8 +CLU-X5 8
10
clutch disengaging -W220 SH SH +SCS-SH
Date 15.08.2014 = CABLE 13 / 59

0 1 2 3 4 5 6 7 8 9
Cable Drawings
=AZ1-W240 MPRXCX 10 1,5 K3*
point point
steering valves +SCS/32.0 +SCS-X42 1 1 +HYP-X4 14
steering valves +SCS-X42 2 2 +HYP-X4 15
failure extern system +SCS-X21 1 5 +HYP-X2 1
hydr. oil level min +SCS-X21 2 6 +HYP-X2 2
hydr. oil pressure min +SCS-X21 3 7 +HYP-X2 4
hydr. oil temperature max +SCS-X21 5 8 +HYP-X2 6
hydr. oil pressure max +SCS-X21 7 10 +HYP-X2 10
steering valves -W240 SH SH +SCS-SH
Date 15.08.2014 = CABLE 14 / 59

0 1 2 3 4 5 6 7 8 9
Cable Drawings
=AZ1-W241 TCX(C) 2x2 0,75 K3*
point point
overload power plant steering +SCS/28.5 +SCS-X42 8 1.1 +ENR-4B1.1 1
overload power plant steering +SCS-X42 9 1.2 +ENR-4B1.1 3
speed pickup hydraulic pump +SCS-X42 10 2.1 +ENR-4B1.1 4
2.2
overload power plant steering -W241 SH SH +SCS-SH
Date 15.08.2014 = CABLE 15 / 59

0 1 2 3 4 5 6 7 8 9
Cable Drawings
=AZ1-W242 TCX(C) 4x2 0,75 K4*
point point
thrust direction indicator hydraulic aggregate +SCS/24.4 +SCS-X44 1 1.1 +ENR-4A3 1
thrust direction indicator hydraulic aggregate +SCS-X44 2 1.2 +ENR-4A3 2
4.1
4.2
thrust direction indicator hydraulic aggregate -W242 SH SH +SCS-SH
Date 15.08.2014 = CABLE 16 / 59

0 1 2 3 4 5 6 7 8 9
Cable Drawings
=AZ1-W248 TCX(C) 2x2x 0,75 *K3
point point
min hydr. oil level +ENR/2.1 +HYP-X2 1 +HYT-2S1
min hydr. oil level +HYP-X2 2 +HYT-2S1
Date 15.08.2014 = CABLE 17 / 59

0 1 2 3 4 5 6 7 8 9
Cable Drawings
=AZ1-W300 MPRXCX 4 2,5 K3*
point point
feedline control panels +SCS/6.0 +SCS-X12 1 BK +MDP-AX1 1
feedline control panels +SCS-X12 2 BU +MDP-AX1 2
instrument light +SCS-X12 3 BN +MDP-AX1 3
instrument light +SCS-X12 4 WH +MDP-AX1 4
feedline control panels -W300 SH SH +SCS-SH
Date 15.08.2014 = CABLE 18 / 59

0 1 2 3 4 5 6 7 8 9
Cable Drawings
point point
feedline indicators +SCS/5.3 +SCS-X12 5 BK +MDP-AX9 1
feedline indicators +SCS-X12 6 BU +MDP-AX9 2
BN
Date 15.08.2014 = CABLE 19 / 59

0 1 2 3 4 5 6 7 8 9
Cable Drawings
=AZ1-W302 MPRXCX 19 1,5 K3*
point point
NFU systems +SCS/6.5 +SCS-X12 7 1 +MDP-AX1 7
NFU systems +SCS-X12 8 2 +MDP-AX1 8
NFU control ON / OFF +SCS-X12 9 3 +MDP-AX2 14
indication NFU steering ON +SCS-X12 11 5 +MDP-AX2 13
thruster turning ccw +SCS-X12 13 7 +MDP-AX2 44
thruster turning cw +SCS-X12 14 8 +MDP-AX2 54
NFU RPM control in service +SCS-X12 16 9 +MDP-AX1 10
+SCS-X12 17 10 +MDP-AX2 24
+SCS-X12 18 11 +MDP-AX2 34
12
13
14
15
16
17
18
19
NFU systems -W302 SH SH +SCS-SH
Date 15.08.2014 = CABLE 20 / 59

0 1 2 3 4 5 6 7 8 9
Cable Drawings
=AZ1-W303 TCX(C) 2x2 0,75 K4*
point point
control bus +SCS/11.4 +SCS-X12 22 1.1 +MDP-AX3 1
control bus +SCS-X12 23 1.2 +MDP-AX3 2
control bus -W303 SH SH +SCS-SH
Date 15.08.2014 = CABLE 21 / 59

0 1 2 3 4 5 6 7 8 9
Cable Drawings
=AZ1-W304 TCX(C) 2x2 0,75 K4*
point point
CAN BUS Indicator +SCS/24.7 +SCS-X12 26 1.1 +MDP-AX9 3
CAN BUS Indicator +SCS-X12 27 1.2 +MDP-AX9 4
Date 15.08.2014 = CABLE 22 / 59

0 1 2 3 4 5 6 7 8 9
Cable Drawings
=AZ1-W305 TCX(C) 2x2 0,75 K3*
point point
propeller RPM indicator +SCS/26.6 +SCS-X12 30 1.1 +MDP-AX9 13
propeller RPM indicator +SCS-X12 31 1.2 +MDP-AX9 14
propeller RPM indicator -W305 SH SH +SCS-SH
Date 15.08.2014 = CABLE 23 / 59

0 1 2 3 4 5 6 7 8 9
Cable Drawings
=AZ1-W380 MPRXCX 5 1,5 K3*
point point
feed line warning panel +SCS/40.3 +SCS-X22 5 1 +MDWP-X21 5
feed line warning panel +SCS-X22 6 2 +MDWP-X21 7
feed line warning panel -W380 SH SH +SCS-SH
Date 15.08.2014 = CABLE 24 / 59

0 1 2 3 4 5 6 7 8 9
Cable Drawings
=AZ1-W381 TCX(C) 2x2 0,75 K4*
point point
CAN BUS warning panel +SCS/40.1 +SCS-X22 1 1.1 +MDWP-X21 1
CAN BUS warning panel +SCS-X22 2 1.2 +MDWP-X21 2
CAN BUS warning panel -W381 SH SH +SCS-SH
Date 15.08.2014 = CABLE 25 / 59

0 1 2 3 4 5 6 7 8 9
Cable Drawings
=AZ1-W710 TCX(C) 7x2 0,75 K3*
point point
Feedline signals +SCS/20.0 +SCS-X3 1 1.1 =YARD+PM-AZ1-X1 1
Propulsion motor OFF +SCS-X3 2 1.2 =YARD+PM-AZ1-X1 2
Propulsion motor ON +SCS-X3 3 2.1 =YARD+PM-AZ1-X1 3
Propulsion motor in idle +SCS-X3 4 2.2 =YARD+PM-AZ1-X1 4
overload +SCS-X3 5 3.1 =YARD+PM-AZ1-X1 5
3.2
lever in idle +SCS-X3.K3 11 4.1 =YARD+PM-AZ1-X1 6
clutch engaged +SCS-X3.K12 11 5.1 =YARD+PM-AZ1-X1 8
6.1
6.2
7.1
7.2
Feedline signals -W710 SH SH +SCS-SH
Date 15.08.2014 = CABLE 26 / 59

0 1 2 3 4 5 6 7 8 9
Cable Drawings
=AZ1-W711 TCX(C) 2x2 0,75 K3*
point point
speed value +SCS/47.4 +SCS-X3 13 1.1 =YARD+PM-AZ1-X1 10
speed value +SCS-X3 14 1.2 =YARD+PM-AZ1-X1 11
2.1
2.2
speed value -W711 SH SH +SCS-SH
Date 15.08.2014 = CABLE 27 / 59

0 1 2 3 4 5 6 7 8 9
Cable Drawings
=AZ1-W720 TCX(C) 4x2 0,75 K3*
point point
Autopilot system ready for service +SCS/49.1 +SCS-X5 1 1.1 =YARD+AP-X1 1
Autopilot system ready for service +SCS-X5 2 1.2 =YARD+AP-X1 2
+SCS-X5.K1 14 2.1 =YARD+AP-X1 3
+SCS-X5.K1 11 2.2 =YARD+AP-X1 4
Autopilot mode in service +SCS-X5 3 3.1 =YARD+AP-X1 5
setpoint steering value from AP system +SCS-X5 4 3.2 =YARD+AP-X1 6
4.1
4.2
Autopilot system ready for service -W720 SH SH +SCS-SH
Date 15.08.2014 = CABLE 28 / 59

0 1 2 3 4 5 6 7 8 9
Cable Drawings
=AZ1-W820 TCX(C) 2x2 0,75 K3*
point point
failure AC / DC converter +SCS/48.3 =YARD+SWU-X1 1 1.1 +SCS-X4.K1 11
failure AC / DC converter =YARD+SWU-X1 2 1.2 +SCS-X4.K1 14
failure 24V DC feedline =YARD+SWU-X1 3 2.1 +SCS-X4.K2 11
failure SCHOTTEL warning unit -W820 SH SH +SCS-SH
Date 15.08.2014 = CABLE 29 / 59

0 1 2 3 4 5 6 7 8 9
Cable Drawings
=AZ2-W200 MPRXCX 3 1,5 K2*
point point
AC feedline switch box +SCS/4.0 =MSB+SCS-400VX1 4 BK +SCS-X1 1
AC feedline switch box =MSB+SCS-400VX1 5 BU +SCS-X1 2
AC feedline switch box =MSB+SCS-400VX1 6 BN +SCS-X1 3
AC feedline switch box -W200 SH SH +SCS-SH
Date 15.08.2014 = CABLE 30 / 59

0 1 2 3 4 5 6 7 8 9
Cable Drawings
=AZ2-W201 MPRXCX 2 2,5 K2*
point point
earth connection +SCS/4.3 =MSB+SCS-220VX1 3 BK +SCS-X1 5
earth connection =MSB+SCS-220VX1 4 BU +SCS-X1 6
earth connection -W201 SH SH +SCS-SH
Date 15.08.2014 = CABLE 31 / 59

0 1 2 3 4 5 6 7 8 9
Cable Drawings
point point
earth connection +SCS/4.2 +SCS-X1 4 BK +SCS-SH PE
SH
Date 15.08.2014 = CABLE 32 / 59

0 1 2 3 4 5 6 7 8 9
Cable Drawings
point point
feedline switch cabinet 24V DC +SCS/5.0 =ESB+SCS-24-X1 5 BK +SCS-X2 1
feedline switch cabinet 24V DC =ESB+SCS-24-X1 6 BU +SCS-X2 2
feedline switch cabinet 24V DC -W203 SH SH +SCS-SH
Date 15.08.2014 = CABLE 33 / 59

0 1 2 3 4 5 6 7 8 9
Cable Drawings
point point
feedline indicators +SCS/5.3 =ESB+SCS-24-X1 7 BK +SCS-X2 3
feedline indicators =ESB+SCS-24-X1 8 BU +SCS-X2 4
Date 15.08.2014 = CABLE 34 / 59

0 1 2 3 4 5 6 7 8 9
Cable Drawings
=AZ2-W210 TCX(C) 2x2 0,75 K3*
point point
feedback unit steering +SCS/13.6 +SCS-X41 5 1.1 +SRP-4A4 6
feedback unit steering -W210 SH SH +SCS-SH
Date 15.08.2014 = CABLE 35 / 59

0 1 2 3 4 5 6 7 8 9
Cable Drawings
=AZ2-W211 TCX(C) 2x2 0,75 K4*
point point
CAN BUS Indicator +SCS/24.0 +SCS-X41 1 1.1 +SRP-4A4 1
Date 15.08.2014 = CABLE 36 / 59

0 1 2 3 4 5 6 7 8 9
Cable Drawings
=AZ2-W212 TCX(C) 2x2 0,75 K3*
point point
shaft speed pick up control system +SCS/20.4 +SCS-X51 1 1.1 +SRP-X5 1
+SCS-X51.V1 + 2.2 +SRP-X5 9
shaft speed pick up control system -W212 SH SH +SCS-SH
Date 15.08.2014 = CABLE 37 / 59

0 1 2 3 4 5 6 7 8 9
Cable Drawings
=AZ2-W213 TCX(C) 2x2 0,75 K3*
point point
shaft speed pick up indication +SCS/25.6 +SCS-X51 4 1.1 +SRP-X5 4
2.2
shaft speed pick up indication -W213 SH SH +SCS-SH
Date 15.08.2014 = CABLE 38 / 59

0 1 2 3 4 5 6 7 8 9
Cable Drawings
=AZ2-W214 TCX(C) 4x2 0,75 *K3
point point
hydr. oil pressure max +SCS/43.6 +SCS-X21 8 1.1 +SRP-X2 11
lube oil level min +SCS-X21 9 1.2 +SRP-X2 12
lube oil temp. max +SCS-X21 10 2.1 +SRP-X2 16
lub oil filter dirty +SCS-X21 11 2.2 +SRP-X2 18
lub oil flow min +SCS-X21 12 3.1 +SRP-X2 20
3.2
4.1
4.2
SH
Date 15.08.2014 = CABLE 39 / 59

0 1 2 3 4 5 6 7 8 9
Cable Drawings
=AZ2-W216 MPRXCX 3 1,5 *K3
point point
+SCS/4.5 SH
Date 15.08.2014 = CABLE 40 / 59

0 1 2 3 4 5 6 7 8 9
Cable Drawings
=AZ2-W220 MPRXCX 10 1,5 K2*
point point
clutch disengaging +SCS/33.1 +SCS-X52 1 1 +CLU-X5 1
clutch disengaging +SCS-X52 2 2 +CLU-X5 2
supressing lube flow +SCS-X52 5 5 +CLU-X5 5
clutch air pressure min +SCS-X52 8 8 +CLU-X5 8
10
clutch disengaging -W220 SH SH +SCS-SH
Date 15.08.2014 = CABLE 41 / 59

0 1 2 3 4 5 6 7 8 9
Cable Drawings
=AZ2-W240 MPRXCX 10 1,5 K3*
point point
steering valves +SCS/32.0 +SCS-X42 1 1 +HYP-X4 14
failure extern system +SCS-X21 1 5 +HYP-X2 1
hydr. oil level min +SCS-X21 2 6 +HYP-X2 2
hydr. oil pressure min +SCS-X21 3 7 +HYP-X2 4
hydr. oil pressure max +SCS-X21 7 10 +HYP-X2 10
steering valves -W240 SH SH +SCS-SH
Date 15.08.2014 = CABLE 42 / 59

0 1 2 3 4 5 6 7 8 9
Cable Drawings
=AZ2-W241 TCX(C) 2x2 0,75 K3*
point point
overload power plant steering +SCS/28.5 +SCS-X42 8 1.1 +ENR-4B1.1 1
overload power plant steering +SCS-X42 9 1.2 +ENR-4B1.1 3
speed pickup hydraulic pump +SCS-X42 10 2.1 +ENR-4B1.1 4
2.2
overload power plant steering -W241 SH SH +SCS-SH
Date 15.08.2014 = CABLE 43 / 59

0 1 2 3 4 5 6 7 8 9
Cable Drawings
=AZ2-W242 TCX(C) 4x2 0,75 K4*
point point
thrust direction indicator hydraulic aggregate +SCS/24.4 +SCS-X44 1 1.1 +ENR-4A3 1
4.1
4.2
thrust direction indicator hydraulic aggregate -W242 SH SH +SCS-SH
Date 15.08.2014 = CABLE 44 / 59

0 1 2 3 4 5 6 7 8 9
Cable Drawings
=AZ2-W248 TCX(C) 2x2x 0,75 *K3
point point
min hydr. oil level +ENR/2.1 +HYP-X2 1 +HYT-2S1
min hydr. oil level +HYP-X2 2 +HYT-2S1
Date 15.08.2014 = CABLE 45 / 59

0 1 2 3 4 5 6 7 8 9
Cable Drawings
=AZ2-W300 MPRXCX 4 2,5 K3*
point point
feedline control panels +SCS/6.0 +SCS-X12 1 BK +MDP-AX1 1
feedline control panels +SCS-X12 2 BU +MDP-AX1 2
instrument light +SCS-X12 3 BN +MDP-AX1 3
instrument light +SCS-X12 4 WH +MDP-AX1 4
feedline control panels -W300 SH SH +SCS-SH
Date 15.08.2014 = CABLE 46 / 59

0 1 2 3 4 5 6 7 8 9
Cable Drawings
point point
feedline indicators +SCS/5.3 +SCS-X12 5 BK +MDP-AX9 1
feedline indicators +SCS-X12 6 BU +MDP-AX9 2
BN
Date 15.08.2014 = CABLE 47 / 59

0 1 2 3 4 5 6 7 8 9
Cable Drawings
=AZ2-W302 MPRXCX 19 1,5 K3*
point point
NFU systems +SCS/6.5 +SCS-X12 7 1 +MDP-AX1 7
NFU systems +SCS-X12 8 2 +MDP-AX1 8
thruster turning ccw +SCS-X12 13 7 +MDP-AX2 44
thruster turning cw +SCS-X12 14 8 +MDP-AX2 54
NFU RPM control in service +SCS-X12 16 9 +MDP-AX1 10
+SCS-X12 17 10 +MDP-AX2 24
+SCS-X12 18 11 +MDP-AX2 34
12
13
14
15
16
17
18
19
NFU systems -W302 SH SH +SCS-SH
Date 15.08.2014 = CABLE 48 / 59

0 1 2 3 4 5 6 7 8 9
Cable Drawings
=AZ2-W303 TCX(C) 2x2 0,75 K4*
point point
control bus +SCS/11.4 +SCS-X12 22 1.1 +MDP-AX3 1
control bus -W303 SH SH +SCS-SH
Date 15.08.2014 = CABLE 49 / 59

0 1 2 3 4 5 6 7 8 9
Cable Drawings
=AZ2-W304 TCX(C) 2x2 0,75 K4*
point point
CAN BUS Indicator +SCS/24.7 +SCS-X12 26 1.1 +MDP-AX9 3
Date 15.08.2014 = CABLE 50 / 59

0 1 2 3 4 5 6 7 8 9
Cable Drawings
=AZ2-W305 TCX(C) 2x2 0,75 K3*
point point
propeller RPM indicator +SCS/26.6 +SCS-X12 30 1.1 +MDP-AX9 13
propeller RPM indicator -W305 SH SH +SCS-SH
Date 15.08.2014 = CABLE 51 / 59

0 1 2 3 4 5 6 7 8 9
Cable Drawings
=AZ2-W380 MPRXCX 5 1,5 K3*
point point
feed line warning panel +SCS/40.3 +SCS-X22 5 1 +MDWP-X21 5
feed line warning panel -W380 SH SH +SCS-SH
Date 15.08.2014 = CABLE 52 / 59

0 1 2 3 4 5 6 7 8 9
Cable Drawings
=AZ2-W381 TCX(C) 2x2 0,75 K4*
point point
CAN BUS warning panel +SCS/40.1 +SCS-X22 1 1.1 +MDWP-X21 1
CAN BUS warning panel -W381 SH SH +SCS-SH
Date 15.08.2014 = CABLE 53 / 59

0 1 2 3 4 5 6 7 8 9
Cable Drawings
=AZ2-W710 TCX(C) 7x2 0,75 K3*
point point
Feedline signals +SCS/20.0 +SCS-X3 1 1.1 =YARD+PM-AZ2-X1 1
Propulsion motor OFF +SCS-X3 2 1.2 =YARD+PM-AZ2-X1 2
Propulsion motor ON +SCS-X3 3 2.1 =YARD+PM-AZ2-X1 3
Propulsion motor in idle +SCS-X3 4 2.2 =YARD+PM-AZ2-X1 4
overload +SCS-X3 5 3.1 =YARD+PM-AZ2-X1 5
3.2
6.1
6.2
7.1
7.2
Feedline signals -W710 SH SH +SCS-SH
Date 15.08.2014 = CABLE 54 / 59

0 1 2 3 4 5 6 7 8 9
Cable Drawings
=AZ2-W711 TCX(C) 2x2 0,75 K3*
point point
speed value +SCS/47.4 +SCS-X3 13 1.1 =YARD+PM-AZ2-X1 10
speed value +SCS-X3 14 1.2 =YARD+PM-AZ2-X1 11
2.1
2.2
speed value -W711 SH SH +SCS-SH
Date 15.08.2014 = CABLE 55 / 59

0 1 2 3 4 5 6 7 8 9
Cable Drawings
=AZ2-W720 TCX(C) 4x2 0,75 K3*
point point
Autopilot system ready for service +SCS/49.1 +SCS-X5 1 1.1 =YARD+AP-X2 1
Autopilot system ready for service +SCS-X5 2 1.2 =YARD+AP-X2 2
+SCS-X5.K1 14 2.1 =YARD+AP-X2 3
+SCS-X5.K1 11 2.2 =YARD+AP-X2 4
Autopilot mode in service +SCS-X5 3 3.1 =YARD+AP-X2 5
setpoint steering value from AP system +SCS-X5 4 3.2 =YARD+AP-X2 6
4.1
4.2
Autopilot system ready for service -W720 SH SH +SCS-SH
Date 15.08.2014 = CABLE 56 / 59

0 1 2 3 4 5 6 7 8 9
Cable Drawings
=AZ2-W780 TCX(C) 4x2 0,75 *K3
point point
FIFI Mode possible +SCS/50.5 =YARD+FIFI-AZ2-X1 1 1.1 +SCS-X8.K41 14
FIFI Mode possible =YARD+FIFI-AZ2-X1 2 1.2 +SCS-X8.K41 11
feed line =YARD+FIFI-AZ2-X1 3 2.1 +SCS-X8 41
feed line =YARD+FIFI-AZ2-X1 4 2.2 +SCS-X8 42
FIFI MODE ON =YARD+FIFI-AZ2-X1 5 3.1 +SCS-X8 43
3.2
4.1
4.2
FIFI Mode possible -W780 SH SH +SCS-SH
Date 15.08.2014 = CABLE 57 / 59

0 1 2 3 4 5 6 7 8 9
Cable Drawings
=AZ2-W820 TCX(C) 2x2 0,75 K3*
point point
failure AC / DC converter +SCS/48.3 =YARD+SWU-X1 5 1.1 +SCS-X4.K1 11
failure AC / DC converter =YARD+SWU-X1 6 1.2 +SCS-X4.K1 14
failure SCHOTTEL warning unit -W820 SH SH +SCS-SH
Date 15.08.2014 = CABLE 58 / 59

0 1 2 3 4 5 6 7 8 9
Cable Drawings
=WH-W10 TCX(C) 2x2 0,75 K4*
point point
spare =AZ2+MDP/5.2 =AZ1+MDP-X30 1 1.1 =AZ2+MDP-X30 1
spare =AZ1+MDP-X30 2 1.2 =AZ2+MDP-X30 2
=AZ2+MDP-SH SH -W10 SH
Date 15.08.2014 = CABLE 59 / 59

Ed. MSC CONFIDENTIAL =WH-W10 Cable Drawings 1201903 + YARD

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SERVICE MANUAL

Rudderpropeller SRP 1515 FP

Key Word: BONNY 39

Distribution and Duplication Disclaimer

TTD-db 14338705-1 19 May 2015 1/2

Rev. Revision Chapter Description Document Document Document Document

TTD-db 14338705-1 19 May 2015 2/2

3 Operating, Mounting and Maintenance Instructions

4 Spare Parts Catalogue

en TTD-db Table of Contents 14338705-1 19 May 2015 1/2

5 Documents from Suppliers

Installation, Operation and Maintenance of Airflex VC Marine Clutches

Operating Instructions Gear pump KF 2,5...200 ......................................................2012-09-25 .......... KRACHT

Compact Cooler Instruction Manual P Type Heat Exchanger

Operating Instructions Shell - and - Tube Heat Exchanger

6.1 Pneumatic Diagrams

6.2 Hydraulic Diagrams

6.3 Wiring Diagrams

SSS XXXX YY Z/Z

Bsp. R/R Right/Right

FP Fixed Pitch Propeller

Bsp. 1515 Size

SCHOTTEL propulsion unit

2/2 TTD-db Table of Contents 14338705-1 19 May 2015 en

TWO (2) SCHOTTEL RUDDERPROPELLER

TYP SRP 1515 FP

AS MAIN PROPULSION UNITS

SCHOTTEL Project no. : TUG-110244-06

Rev. No Issue Date Issue Description Originator/Dpt.

1. SCOPE OF SUPPLY ........................................................................................................... 4

1.1 List of components supplied by SCHOTTEL

1.2 Additional agreements

Type of construction : Z-drive

Propeller Arm /Stem length : 3200 mm

Weight excl oil & auxiliaries : 25,5 t (approximately)

Note: The final weight will be determined in the installation proposal.

Gear Reduction Ratio : 6,554

Nozzle : WAG 19A modified

Lay out material : G-CuAI10Fe5Ni5-C (CU 3)

Design Type &

Type : SCHOTTEL Steering-System SST 612

Starter supply : SCHOTTEL

Lubrication system : by electrical lube oil pump

Propeller-, steering shaft sealing type : standard

2.2. PRIME MOVER

Type : CAT 3516C

2.3. POWER TRANSMISSION

Shaftline length :6335 mm

3. DESIGN & CONSTRUCTION

3.1 GENERAL DESIGN FEATURES

Thrust direction transmitter

Connection between upper and lower gear's power transmission is achieved by a

Structure of the nozzle is designed for speeds up to max 13 knots“.

3.2 STEERING SYSTEM

SCHOTTEL installation instructions for hydraulic systems have to be observed.

Maximum environmental temperature

Maximum environmental operation conditions:

 24 V DC (+30% /-25%) with a max. ripple of 1 V (max. 300 W) for emergency

6. COATING AND PAINT STRUCTURE

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