Marine Propulsion Systems

TECHNICAL MANUAL
- INTRODUCTION FOR
CONTROLLABLE PITCH PROPELLER SYSTEM

MODEL CPP KH-850

Niveko

" DORA"
1

CPP KH-850

A- Section
CONTENTS
A- INTRODUCTION ............................................................................................................5
A.1 - Storage Instructions...............................................................................................................5
A.2- Responsibility and Warranty...................................................................................................6
A.3- Customer and ZF Reference Data...........................................................................................7
A.4- Main Technical Data ................................................................................................................8
A.5.1- Mechanical System ...................................................................................................9
A.5.2- Hydraulic System ......................................................................................................10
A.5.3- Electric and Electronic System ..................................................................................12

B MECHANICAL INSTALLATION.......................................................................................15
B.1- General recommendations......................................................................................................15
B.1.1- Assembly drawing .....................................................................................................17
B.2- Propeller Shaft Installation Procedure ..................................................................................18
B.2.1- Shaft seal installation Type IHC ..............................................................................22
B.2.1.1- Rear end shaft seal ................................................................................................22
B.2.1.2- Front end shaft seal................................................................................................25

B.2.1.3- Checks on mounted SUPREME seals...................................................................27

B.2.1.4- Seal Lubrication......................................................................................................28
B.2.1.5- Stern tube seal - Start-up instructions .....................................................................29
B.2.2- Coupling flange installation Hydraulic press-fit ........................................................30
B.3- Propeller blade installation .....................................................................................................32
B.4- Shaft-to-gearbox connection ..................................................................................................35
B.5- OD-box installation..................................................................................................................39

C - HYDRAULICS INSTALLATION ........................................................................................43

C.1- Hydraulic control system - Type KH-850 / PVT ......................................................................44
C.2- Stern tube tank installation .....................................................................................................50

D ELECTRICAL INSTALLATION RECOMMENDATIONS .........................................................53

D.1- General recommendations......................................................................................................53
D.2- Power devices .........................................................................................................................54
D.3- Control devices........................................................................................................................59

E REFERENCE VALUES, SPECIFICATIONS AND REQUIREMENTS ..........................................61

E.1- General engineering units.......................................................................................................61
E.2- Setting data, torque values and electrical specifications ......................................................63
E.3- Hydraulic operating data .........................................................................................................66
E.4- Lubrication specifications.......................................................................................................67
E.4.1- Propeller system specifications..................................................................................67
E.4.2- Stern tube specifications............................................................................................70
E.4.3- Shaft seal lubrication .................................................................................................71
E.5- Gap and sag specifications.....................................................................................................72

F- ELECTRONIC CONTROL SYSTEM MRCS 08/90............................................................89

Terminology: .......................................................................................................................89
List of Abbreviations ............................................................................................................90
Safety Instructions ...............................................................................................................91
F.1.1- General Description of the Scope of Supply ..............................................................93
F.1.1.1- Power supply..........................................................................................................94
F.1.1.2- Failure ....................................................................................................................95
F.1.2- CPP Control System MRCS 08/90.............................................................................96
F.1.3- Technical Specification for the installed equipment : ..................................................97
F.1.4- Operating Instructions................................................................................................107
F.1.5- Commissioning Instructions .......................................................................................110
F.1.5.1- Parameter Input......................................................................................................111
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CPP KH-850
F.1.5.2- Input Procedure ......................................................................................................112
F.1.5.3- Parameter of Control Transmitters and Feedback Transmitters...............................113
F.2- MRCS 08/90 Electronic Unit - General Information ................................................................114
F.2.1- General Description of the System.............................................................................114
F.2.2- Basic Description.......................................................................................................117
F.2.3- Technical Specifications ............................................................................................121
F.2.4- Construction ..............................................................................................................122
F.2.4.A- Mechanical Construction ........................................................................................122
F.2.4.B- Electrical Construction............................................................................................125
F.2.4.C- Power Supply.........................................................................................................126
F.2.4.D- Main-CU ................................................................................................................132
F.2.4.E- Shaft Speed-CU .....................................................................................................140
F.2.4.F- Amplifier-CU...........................................................................................................148
F.2.4.G- Parameter Setting PCB..........................................................................................155
F.2.5- Parameter In/Output ..................................................................................................158
F.2.6- Parameter List ...........................................................................................................161
F.2.7- Error List - Error message and treatment ...................................................................168
F.3- Terminal Connecting Plan .......................................................................................................172
X1 Terminal strip W/H Panel................................................................................................173
X2 Terminal strip ECR Panel ...............................................................................................174
X3 Terminal strip Wing Panel STB.......................................................................................175
X4 Terminal strip Wing Panel PORT ....................................................................................176
X5 Terminal strip ECR .........................................................................................................177
X6 Terminal strip ECR .........................................................................................................181
X7 Terminal strip ECR .........................................................................................................183
X9 Terminal strip ER Control Box ........................................................................................183
X10 Terminal strip ER Control Box ......................................................................................184
X11 Terminal strip ER Control Box ......................................................................................185
List of Cable-b .....................................................................................................................187

G- START-UP AND COMMISSIONING ...................................................................................219

G.1- Start-up ....................................................................................................................................219
G.2- Special start-up instructions ..................................................................................................221
G.2.1- Special instructions: electronic control system ...........................................................221
G.2.2- Special instructions: hydraulic control unit .................................................................221
G.2.3- Sepcial instructions: shaft seal assemblies................................................................222
G.3- Start-up check list ...................................................................................................................223
G.4- Sea Trials and Commissioning...............................................................................................224

H- OPERATING INSTRUCTIONS ..........................................................................................228

H.1- Responsibility and Warranty...................................................................................................229
H.2- Storage instructions................................................................................................................230
H.3- Operating instructions ............................................................................................................231
H.3.1- Control panel operation .............................................................................................231
H.4- Emergency operation (Come-home procedure).....................................................................237
H.5- Regular maintenance ..............................................................................................................238
H.5.1- Propeller system maintenance schedule....................................................................238
H.5.2- Special maintenance instructions: Hydraulic control unit ............................................240
H.5.3- Special maintenance instructions: Shaft seal boxes...................................................241
H.5.4- Hydraulic control unit / Fluid specifications.................................................................243
H.5.4- Stern tube oil specifications.......................................................................................245
H.5.6- Stern tube fore end seal / Lubrication specifications ..................................................245
H.6- Spare parts ..............................................................................................................................246
H.7- ZF Worldwide...........................................................................................................................255

DORA - 01/2004 -

CPP KH-850
release

date

00
01

04.2004
04.2004

comments
initial version DORA
updating information: hydraulic control unit KH-850; Gap/Sag calculation (06-5-2004)

DORA - 01/2004 -

CPP KH-850

A- INTRODUCTION
A.1 - Storage Instructions
1. The material has been shipped in good condition,
protected against mechanical damage and
corrosion by appropriate packaging. The
consignee/shipyard shall inspect the material
upon delivery and make sure that:
- all items have been delivered as shown on the
transport documents
- no item has suffered any damage during
transportation and handling
- all parts are free of corrosion.
Once the consignee/shipyard has accepted the
delivery of the goods, the consignee/shipyard will
have to make sure the goods are stored in good
conditions to prevent mechanical damage to and/or
corrosion of the goods. No dirt, dust, humidity or any
other matter must be allowed to penetrate into the
mechanical devices and/or electric or electronic
components.

2. Hydraulic machinery:
Hydraulic devices (pumps, servos, valves, etc.)
have been tested before delivery. Therefore, they
benefit from a natural internal oil film protection.
However, this protection will last no more than 3
months in a dry and sheltered environment. If the
hydraulic units have been stored for more than 3
months, they will have to be run under no-load
conditions, with fresh oil, to flush the entire system
before the actual start-up. Oil and oil filter will then
be changed before start-up!
3. If the hydraulic machinery is laid up for an
extended period of more than 1 month, an anticorrosion compound, such as Rust Veto Concentrate by E.F.Hougton & Co. of Philadelphia, USA,
(or equivalent additive) should be added to the
tank oil, and the system run without load for some
length of time, sufficient to circulate the added oil
through the entire system.

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CPP KH-850

A.2- Responsibility and Warranty

Purpose of this manual
The following manual contains the information required for installers and users of ZF Marine Propulsion
Systems equipment. These include, but are not
limited to, ships staff, shipping company superintendents, land based support staff, shipbuilders and
dry-dock supervisory staff.

This manual is intended to provide the information

necessary for the safe installation, onboard operation
and routine ships maintenance. The manual also
contains spare parts ordering information.
ZF Marine Propulsion Systems provide this manual as
a guide only, it is not intended to, nor does it, replace
all, or in part, any directives from a customer, or end
user, or their appointed third party representative(s). It
is appreciated by ZF Marine Propulsion Systems that
regional law, insurance, shipping company and
shipyard regulations as well as ships design specific
considerations, etc, may result in the necessity to
modify, or change the techniques, practices and
procedures described herein. Please be advised,
however, that any modification, or change of
techniques, practices and/or procedures may
invalidate the manufacturer warranty, unless prior
written agreement has been received, in writing, from
ZF Masson. Limitations of liability, end user customer
and manufacturer responsibility
The following statements do not take precedence over
any existing contractual obligations, real or implied.
REPAIR WORK
Due to continuing development of our products,
manufacturing technology and procedures future
repair work may require the application of work
practices, test or adjustment data that are not covered
by this manual at the time of issue. We therefore
recommend that repair work carried out on your ZF
product is performed only by skilled technicians who
have undergone practical and theoretical skills

training, (ZF training includes refresher and

assessment courses), and is conducted at approved
ZF training centres.
The ZF group has installed a network of fully staffed
Sales and Service Organisation Centres, (SSOCs), at
strategic locations throughout the world so that our
customers receive field support close to their geographical location. Repair work carried out at ZF SSOCs
will be guaranteed in accordance with the prevailing
contractual conditions.
Note : Damage resulting from work performed by nonZF personnel and which is deemed by ZF to have
been conducted in an improper manner, including all
follow-on remedial work, the costs thereof, loss of
vessel operational time and any associated loss of
revenue including any and all third party liabilities,
(consequential damages) are, in their entirety,
excluded from the ZF contractual guarantee.
WARNING
Installation and Operation of the equipment, including
unauthorised modification, that is outwith the
parameters described in this manual, (plus any
pertinent ZF Marine Propulsion Systems technical
data and the sales contract , including any relevant
amendments/revisions), may result in irreparable
damage to, and/or malfunction of the equipment. Such
actions may result in invalidation and rejection of
existing warranty and any warranty claims, solely at
the manufacturers discretion.
ADVISORY
Should any installation, operation, maintenance
and/or modification work be considered by end users,
or any third party then ZF Marine Propulsion Systems
strongly recommends that such work only be
undertaken in full agreement with the express
permission, in writing, of the manufacturer, ZF
Masson S.A.

ZF Marine Propulsion Systems, Division ZF Masson may be contacted per the below :
Postal address
Telephone :
(33) 386 95 62 33
Office address
ZF Masson S.A.
Telefax :
(33) 386 95 62 96
ZF Masson S.A.
B.P 716
5, rue Henri-Cavallier
F89107 SENS Cedex (FRANCE)
89107 St. Denis les Sens (FRANCE) Website :
www.zf-marine.com
--------Service department

0033 386 956233
ZF Masson S.A.
services.zfmasson@zf.com
Service department

0033 386 951378
guy.geoffroy@zf.com
F-89100 Sens (France)

DORA - 01/2004 -

CPP KH-850

A.3- Customer and ZF Reference Data

Client:
Vessel name:

NIVEKO

DORA
ZF reference number:
ZF serial number:
Classification society (CPP system):

98567
CPP00027
BV-AUT-UMS-1D

Propeller type:
Propeller rotation:

KH-850
Right hand

Scope of supply (ZF)

CPP assembly Propeller shaft assembly Stern tube assembly Stern tube seal assy., fore Stern tube seal assy., aft Stern tube gravity tank 80L
Od-box with pitch indicator
Hydraulic power pack
Hydraulic control accessories CPP electronic control unit -

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CPP KH-850

A.4- Main Technical Data

DORA
Propeller data
Propeller type:
Number of blades:
Propeller hub size:
propeller diameter:
Propeller hub material:
Propeller blade material:
Propeller weight:
hub + shaft:
one blade:
total inertia ( in air ):

KH 850
4
850 mm
3500 mm
G-CuAl 10 Ni
G-CuAl 10 Ni

=
=

33,5 inch
137,8 inch

5151 kg
659 kg
3012 kgm

=
=

5833 mm

229,6 inch

320 mm
300 mm
280 mm
OMC

=
=
=

12,6 inch
11,8 inch
11,0 inch

=
=
=

98,6 inch
17,6 gal (GB)
21,1 gal (US)

=
=

semi split with 4 th ring

std supreme - non split

Propeller shaft data

Propeller shaft length:
coupling flange to axis of blade
rotation:
Propeller shaft diameter:
Aft bearing dia:
Fwd bearing dia:
Dia at coupling flange:
Propeller shaft coupling type
Stern tube data
Stern tube mounting:
Stern tube length:
Stern tube oil tank capacity:

chockfast
2505 mm
80 litres

Stern tube temperature transducer,

type:
AFT stern tube seal :
FWD stern tube seal :

PT100
IHC size: 355
IHC size: 330

11355,8 lbs
1452,8 lbs

Miscellaneous
none

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CPP KH-850
A.5.1- Mechanical System
The KH type propeller system includes a hydraulically operated controllable pitch propeller and hollow propeller
shaft or "line shaft", through which it is mechanically linked to a propulsion gearbox.
OD-box

gearbox

coupling flange
shaft
pitch control
oil piping

stern tube
shaft seal, fore
stern tube flange
(hydraulic
connection)
stern tube
bearing, fore

stern tube

stern tube
bearing, aft
stern tube
shaft seal, aft

propeller blades
propeller hub

The gearbox output shaft is rigidly linked to the line shaft, which is a monoblock part running all the way through
the stern tube to the propeller hub. The propeller hub (i.e. the propeller) is bolted to the propeller shaft.
A hydraulic actuator piston inside the propeller hub moves back and forth to swivel the propeller blades so as to
change the propeller pitch, through a yoke and crank assembly.
The line shaft and gearbox shaft are hollow to allow oil pressure for propeller pitch adjustment to run through the
shafts, from the OD box at the front end of the propulsion gearbox to the actuator cylinder located inside the
propeller hub. The central feeding pipe moves fore and aft with the actuator piston, so that, at the same time, it
provides an accurate indication of the propeller pitch.
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CPP KH-850
A.5.2- Hydraulic System
Propeller actuation is provided through hydraulic pressure acting on the piston inside the propeller hub.
A main oil tank containing the hydraulic fluid supplies the operating fluid to the system. Operating pressure is
supplied by an independent, electrically driven variable displacement oil pump (P1) fitted as a part of the
hydraulic control unit. An identical stand-by oil pump assembly (P2) is installed in parallel with the main
operating pump and is controlled through a pressure switch connected to the CPP main hydraulic control block.
Emergency actuation is possible by means of a hand pump (PM).
A pressure regulator (LP1) placed parallel to the oil filter (FLT) sets the maximum operating pressure limit. Oil
exiting from the oil filter passes through a flow control valve (LD1) before it reaches the distributor solenoid
valves (D1). The flow control valve determines the speed of the propeller adjustment. It has been set in our
factory.
The distributor solenoid valves are energised with 24 V DC to direct oil under operating pressure through
pressure outlets (A) or (B) to the propeller pitch servo, as requested by the operator, until the desired propeller
pitch is reached.

hydraulic control
unit

hand pump

electric motor

pump coupling
bell housing

PVT-oil pump

Hydraulic pressure is carried to the servo chambers through the propeller shaft, where two concentric channels
are formed in the centre of the shaft. Both channels open at the front end of the propulsion gearbox output shaft,
into the manifold or O.D. box. In this way, oil under pressure can be supplied from the engine room to either of
the servo chambers in the propeller hub.

electric
junction
box

filler
plug

main oil
tank

DORA - 01/2004 -

10

CPP KH-850
CPP hydraulic circuit diagram:

FLT
CaP

M1

PV2

M1

NV

P1

P1

C1

75b
NE

XP1

C3

PM

PM

G1

LD1

XP2

FA

PPA
75b

D1

C2
P2

LP1

T Y

CP1
SC1

T
VV

M2

X P

100b

CP2

P2

PPB

PV1
TH1

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11

CPP KH-850
A.5.3- Electric and Electronic System
The main cabinet and switchboard is supplied with alternating current. All control and monitoring devices (such
as solenoid valves, pressure switches and so forth) are connected to a 24V direct current source, preferably
including an independent back-up source (such as a 24V battery).
For a detailed description and data concerning the electric and electronic propeller pitch control system, refer to
the manufacturer's documentation in sections D and F in this manual.
Electronic Pitch Control System - Block Diagram
W/H

W IN G PO RT

W/H

W IN G S TB

21

21

21

PITC H

PITC H

S HAF T RPM
(OP TIO N )

X 4 Term .

PITC H
S HAF T RPM
(OP TIO N )

X 1 Term .

EC R

X 3 Term .
3

EC R
S 08 / 90

S HAF T
RPM

2 4 V DC Supply

2 4 V DC Supply

Alarm M onit. S ys tem

N ote:
S creened C able:
O nly one side of the

S HAF T
RPM

PITC H
Term inals X 5,X 6,X 7

X 2 Term .
C AB IN ET

8
Propuls ion
S ensor/ Actuator
1 .value pitch
2 .lim it pic k up z ero
3 .valve group
4 .lim it pic k up ahead
5 .lim it pic k up as tern
6 .local/ re m ote s w itch engine
7 .speed s etting to gove rnor
8 .fuel rac k pos ition
9 .engine s peed s ignal
1 0:load re duc tion 4 0 %
1 1.em stop/ pitch to zero
1 2.overload
1 3.engine rpm control
1 9.pick up shaft rpm
2 1s election sw itch EC R W / H to engine
2 2acce pt rem ote to e ngine
* EH Supply
**ZF Supply
*** Engine M aker S upply

8a

M ain Sw itchboard

Term inals X 9,X 10

ER

S afety
1 0 S ys te m

Em . C ontr. B ox
C PP
TERM IN AL
BOX

12

11

X3

mA
*
19

**
1

**
2

**
4

**
5

**
3

***
6

mA
*
***
*
7 13 22

13

14

15

X 15

X 55

X 51

mA mA
*** *** ***
8
9 12

*** ***
10 11

*
21

H ydr.
U nit

CPP Control System MRCS 08/90 General description

The Manual Control of CPP is possible from the local side. Automatic control is possible from the ECR Panel,
from Wheelhouse Panels as well as from the WING via a Control Lever.
Change-over from ECR to the Wheelhouse is made by a selector switch LOCAL/REMOTE on the Engine. The
change over between ECR, W/H Panel and Wings is made by pushbuttons incorporated in the control panels.
This change over is interlocked by the control lever positions UP / DOWN, which must be in similar positions.
The CPP control is possible only if the engine is running (system without clutch), indicated by a lamp installed in
the control panels. Zero position of the CPP is indicated in the panels and will interlock Engine start.
The Electronic Unit is to be installed in the Engine Control Room Console and contains all electronic PCBs for
the CPP Control System MRCS 08/90 .
The Microprocessor controlled System will activate the Hydraulic Solenoid Valves for AHEAD and ASTERN
movement of the CPP. The feedback from the CPP position transmitter is supplied to the control system and
regulates the position of the CPP.
The control of CPP is monitored by an incorporated overload detection with Automatic Slow Down.
In the wheelhouse panels a Back-Up control of the CPP is provided by Joystick, which can be activated by a
covered switch.
Indicators for Shaft RPM and CPP angle are installed in or near the Control Panels.
The Engines are to be started locally. After Starting of the Hydraulic System for the CPP, the Engine and CPP
can be operated manually in the Engine Room.
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12

CPP KH-850
After changing the LOCAL/REMOTE Switch to Remote, the Control can be taken over by one of the Control
Panels or the Wings, provided that the relevant Control Lever is at Zero Position, the Engine is running and the
CPP Hydraulic Pressure is available. Take Over is executed by pressing the relevant pushbutton ECR, W/H or
WING.
For exact values, please refer to section A.4- Technical Data and relevant information in section E.1- Assembly
- Lubrication
values and setting data! For lubricants and oil specifications, please refer to section E.2
specifications!

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13