009 Propulsion Azimuth Thruster - S

Operation & Maintenance Manual
for
MP/01680.M1AT-OMM
Hyundai Heavy Industries Co. Ltd. - P136
Product: LMT
Date:
Version:
Made by:
29 November 2012
a2
Wrtsil Netherlands B.V.
Lib Version: a2
Wrtsil Netherlands B.V. hereby presents you with the Operation & Maintenance Manual - O&MM (formerly
known as Instruction Manual).
The O&MM is intended to provide you with necessary and useful information for operation, maintenance
and troubleshooting.
The O&MM contains information such as instructions, advice, specifications, technical data and drawings
of equipment included in the scope of supply as well as recommended / general installation drawings
(controls excluded). Most information is given by means of drawings. These drawings can be found in each
chapter. Deviations from the instructions is only allowed after consulting Wrtsil Netherlands B.V..
If additional information is necessary that is not known or available at the time of the release of this O&MM
edition, this will be sent on by means of updates.
Make sure you study the O&MM carefully and inform us about any remarks you have as soon as possible.
If you require more technical information, you can contact our service department.
THIS PUBLICATION IS DESIGNED TO PROVIDE AS ACCURATE AND AUTHORITATIVE INFORMATION REGARDING THE SUBJECTS COVERED AS
WAS AVAILABLE AT THE TIME OF WRITING. HOWEVER, THE PUBLICATION DEALS WITH COMPLICATED TECHNICAL MATTERS AND THE DESIGN
OF THE SUBJECT AND PRODUCTS IS SUBJECT TO REGULAR IMPROVEMENTS, MODIFICATIONS AND CHANGES. CONSEQUENTLY, THE PUBLISHER AND COPYRIGHT OWNER OF THIS PUBLICATION CANNOT TAKE ANY RESPONSIBILITY OR LIABILITY FOR ANY ERRORS OR OMISSIONS
IN THIS PUBLICATION OR FOR DISCREPANCIES ARISING FROM THE FEATURES OF ANY ACTUAL ITEM IN THE RESPECTIVE PRODUCT BEING
DIFFERENT FROM THOSE SHOWN IN THIS PUBLICATION. THE PUBLISHER AND COPYRIGHT OWNER SHALL NOT BE LIABLE UNDER ANY CIRCUMSTANCES, FOR ANY CONSEQUENTIAL, SPECIAL, CONTINGENT, OR INCIDENTAL DAMAGES OR INJURY, FINANCIAL OR OTHERWISE,
SUFFERED BY ANY PART ARISING OUT OF, CONNECTED WITH, OR RESULTING FROM THE USE OF THIS PUBLICATION OR THE INFORMATION
CONTAINED THEREIN.
COPYRIGHT 2011 WRTSIL NETHERLANDS B.V.
ALL RIGHTS RESERVED. NOTHING FROM THIS PUBLICATION MAY BE REPRODUCED, OR TRANSMITTED IN ANY FORM OR BY ANY MEANS,
ELECTRONIC OR MECHANICAL, INCLUDING PHOTOCOPYING, RECORDING OR ANY INFORMATION STORAGE OR RETRIEVAL SYSTEM WITHOUT
PRIOR WRITTEN APPROVAL OF WRTSIL NETHERLANDS B.V..
ALSO FOR USING ONE OR MORE PARTS OF THIS PUBLICATION IN PAPERS, READERS AND OTHER COLLECTED WORKS, YOU MUST CONTACT
WRTSIL NETHERLANDS B.V..
MP/01680.M1AT-OMM - a2
29 November 2012
iii

Table of Contents
Table of Contents
1.
General information ..................................................................................................................................

1.1
Content overview ..............................................................................................................................
1.2
Target groups ...................................................................................................................................
1.3
Liability and warranty ........................................................................................................................
1.4
Safety information ............................................................................................................................
1.4.1
Intended use ...................................................................................................................
1.4.2
General safety ................................................................................................................
1.4.3
Notational convention .....................................................................................................
1.4.4
Personal protection .........................................................................................................
1.4.5
Warnings ........................................................................................................................
1.4.6
Cautions .........................................................................................................................
1.5
Technical data ..................................................................................................................................
1.5.1
Technical specification ....................................................................................................
1.5.2
Storage conditions ..........................................................................................................
1-1
1-1
1-1
1-2
1-3
1-3
1-3
1-5
1-8
1-8
1-9
1-11
1-11
1-14
2.
Description ................................................................................................................................................
2.1
System overview ..............................................................................................................................
2.2
The propeller arrangement ...............................................................................................................
2.2.1
The fixed pitch propeller .................................................................................................
2.2.2
The cathodic protection ..................................................................................................
2.3
The shaft arrangement .....................................................................................................................
2.3.1
The floating shaft arrangement ......................................................................................
2.3.2
The shaft brake ..............................................................................................................
2.4
The gearbox arrangement ................................................................................................................
2.4.1
The propeller gearbox ....................................................................................................
2.4.2
The propeller shaft seal ..................................................................................................
2.4.3
The upper gearbox .........................................................................................................
2.5
The stem section ..............................................................................................................................
2.5.1
The steering motor-unit ..................................................................................................
2.5.2
The azimuth feedback unit .............................................................................................
2.5.3
The cover .......................................................................................................................
2.5.4
The steering hub ............................................................................................................
2.5.5
The slewing bearing with integrated spur gear ...............................................................
2.5.6
The stem box ..................................................................................................................
2.5.7
The lubrication oil return pipe .........................................................................................
2.5.8
The steering pipe seal ....................................................................................................
2.5.9
The steering pipe bearing ..............................................................................................
2.5.10
The steering pipe ...........................................................................................................
2.5.11
The lubrication oil ...........................................................................................................
2.5.12
Operation of the stem section ........................................................................................
2.5.13
The vertical intermediate-shaft arrangement .................................................................
2.5.14
The azimuth feedback unit .............................................................................................
2.6
The steering system .........................................................................................................................
2.6.1
General ...........................................................................................................................
2.6.2
Description .....................................................................................................................
2.7
The pneumatic system .....................................................................................................................
2.7.1
The brake air control-panel ............................................................................................
2.7.2
The static-pressure air control-panel ..............................................................................
2.8
The electrical system .......................................................................................................................
2.8.1
The electrical system ......................................................................................................
2.8.2
The starter cabinet of the prime mover ..........................................................................
2.8.3
The starter cabinet of the lubrication pump-unit .............................................................
2.8.4
The starter cabinet of the pitch pump-unit ......................................................................
2.9
The propulsion control system .........................................................................................................
2.10 The prime mover ..............................................................................................................................
2.11 Drawings ..........................................................................................................................................
2-1
2-1
2-1
2-1
2-2
2-2
2-2
2-3
2-5
2-5
2-8
2-9
2-12
2-12
2-13
2-13
2-13
2-13
2-13
2-13
2-13
2-14
2-14
2-14
2-14
2-15
2-16
2-18
2-18
2-18
2-20
2-20
2-22
2-24
2-24
2-24
2-24
2-29
2-34
2-34
2-34
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Table of Contents
3.
Operation ...................................................................................................................................................
3.1
Performance limitations ....................................................................................................................
3.1.1
The gearbox arrangement ..............................................................................................
3.1.2
The stem section ............................................................................................................
3.1.3
The lubrication system ...................................................................................................
3.1.4
The static pressure system ............................................................................................
3.1.5
The pneumatic system ...................................................................................................
3.2
Checklist steering gear .....................................................................................................................
3.3
Start the thruster ..............................................................................................................................
3.3.1
Start after a short stop ...................................................................................................
3.3.2
Start after an emergency stop ........................................................................................
3.4
Operate the thruster .........................................................................................................................
3.4.1
Steering behaviour .........................................................................................................
3.4.2
Unwanted thruster positions ...........................................................................................
3.4.3
Sailing ............................................................................................................................
3.4.4
Crash stop of the vessel .................................................................................................
3.5
Stop the thruster ...............................................................................................................................
3.5.1
Stop the thruster when sailing ........................................................................................
3.5.2
Normal stop of the thruster .............................................................................................
3.5.3
Emergency stop of the thruster ......................................................................................
3.6
External controls ..............................................................................................................................
3.6.1
Introduction .....................................................................................................................
3.6.2
The AutoPilot system .....................................................................................................
3.6.3
The joy-stick system .......................................................................................................
3.6.4
The Dynamic Positioning system ...................................................................................
3.7
Cold weather operation ....................................................................................................................
3.7.1
Sailing in cold water .......................................................................................................
3.7.2
Sailing in ice ...................................................................................................................
3.8
Emergency operation .......................................................................................................................
3.8.1
Sail with a failed lubrication pump ..................................................................................
3.8.2
Sail with a failed seal ......................................................................................................
3.8.3
Sail with a failed heat exchanger ....................................................................................
3.8.4
How to steer by hand .....................................................................................................
3.9
Shut down the thruster .....................................................................................................................
3.10 How to operate for maintenance purposes ......................................................................................
3.10.1
Operate the lubrication system .......................................................................................
3.10.2
Operate the steering system ..........................................................................................
3.10.3
Operate the static pressure system ................................................................................
3-1
3-1
3-1
3-1
3-1
3-2
3-2
3-3
3-6
3-6
3-6
3-7
3-7
3-7
3-8
3-9
3-10
3-10
3-11
3-12
3-12
3-12
3-12
3-13
3-13
3-14
3-14
3-14
3-15
3-15
3-17
3-18
3-22
3-24
3-25
3-25
3-26
3-26
4.
General maintenance ................................................................................................................................

4.1
Torque tables ...................................................................................................................................
4.1.1
Metric fasteners ..............................................................................................................
4.2
Consumable installation materials ....................................................................................................
4.2.1
Cleaning agent ...............................................................................................................
4.2.2
Locking adhesive ............................................................................................................
4.2.3
Bonding adhesives .........................................................................................................
4.2.4
Sealant ...........................................................................................................................
4.2.5
Liquid gasket ..................................................................................................................
4.2.6
Anti-seize compound ......................................................................................................
4.2.7
Preservation fluids ..........................................................................................................
4.3
Table of lubricants ............................................................................................................................
4.3.1
Lubrication system .........................................................................................................
4.3.2
Hydraulic steering system ..............................................................................................
4.3.3
Universal shafts ..............................................................................................................
4.4
Cleaning instructions for piping ........................................................................................................
4.4.1
Introduction .....................................................................................................................
4.4.2
Cleaning of the piping - Class 01 and 02 .......................................................................
4.4.3
Cleaning of the piping - Class 02 and 03 .......................................................................
4.4.4
Contamination in service ................................................................................................
4-1
4-1
4-2
4-3
4-3
4-3
4-3
4-3
4-3
4-4
4-4
4-4
4-5
4-5
4-5
4-5
4-5
4-6
4-8
4-8
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Table of Contents
4.5
Assembly instructions for piping .......................................................................................................

4.5.1
Piping material ...............................................................................................................
4.5.2
Bending specifications ....................................................................................................
4.5.3
Welded connections .......................................................................................................
4.5.4
Cone connection and cutting ring (DIN 3861/ISO 8434-1) .............................................
4.5.5
Pressure tests ................................................................................................................
Cleaning instructions for tanks .........................................................................................................
4.6.1
Required tools and materials ..........................................................................................
4.6.2
Preparation .....................................................................................................................
4.6.3
Clean the oil tank ............................................................................................................
4.6.4
Do an inspection of the oil tank ......................................................................................
4.6.5
Assemble the oil tank .....................................................................................................
4.6.6
After installation test .......................................................................................................
4.6.7
Job close up ...................................................................................................................
4.6.8
After care ........................................................................................................................
4-9
4-9
4-9
4-9
4-10
4-16
4-16
4-16
4-17
4-19
4-19
4-19
4-20
4-20
4-21
Preventive maintenance ...........................................................................................................................

5.1
Introduction .......................................................................................................................................
5.1.1
Preventive maintenance at progressive intervals ...........................................................
5.1.2
Preventive maintenance for class demanded inspections ..............................................
5.2
Maintenance intervals for the thruster ..............................................................................................
5.2.1
General condition ...........................................................................................................
5.2.2
Inspection for oil and grease leaks .................................................................................
5.2.3
Inspection for water leaks ...............................................................................................
5.2.4
Inspection for air leaks ...................................................................................................
5.2.5
Inspection for wear, damage and installation .................................................................
5.2.6
Inspection for signs of corrosion and pitting ...................................................................
5.2.7
Inspection for cleanliness ...............................................................................................
5.2.8
Lubrication and grease application .................................................................................
5.2.9
Preventive replacement of parts .....................................................................................
5.2.10
Functional test and adjustment ......................................................................................
5.2.11
Cleaning .........................................................................................................................
5.3
Maintenance intervals for parts kept in storage ................................................................................
5.3.1
Corrosion protection .......................................................................................................
5.3.2
Visual inspection ............................................................................................................
5.3.3
5.3.4
Shelf life ..........................................................................................................................
5.4
Maintenance checklists for the thruster ............................................................................................
5.4.1
General condition ...........................................................................................................
5.4.2
Inspection for oil and grease leaks .................................................................................
5.4.3
Inspection for water leaks ...............................................................................................
5.4.4
Inspection for air leaks ...................................................................................................
5.4.5
Inspection for wear, damage and installation .................................................................
5.4.6
Inspection for signs of corrosion and pitting ...................................................................
5.4.7
Inspection for cleanliness ...............................................................................................
5.4.8
Lubrication and grease application .................................................................................
5.4.9
Preventive replacement of parts .....................................................................................
5.4.10
5.4.11
Cleaning .........................................................................................................................
5.5
Maintenance checklists for parts kept in storage .............................................................................
5.6
Drain the lubrication system .............................................................................................................
5.6.1
5.6.2
Preparation .....................................................................................................................
5.6.3
Drain the lubrication system ...........................................................................................
5.6.4
Drain the header tank .....................................................................................................
5.6.5
Drain the propeller gearbox and the stem section ..........................................................
5.6.6
Drain the upper gearbox .................................................................................................
5.6.7
Drain the gearbox of the steering motor .........................................................................
5.6.8
Job close up ...................................................................................................................
5-1
5-1
5-1
5-2
5-3
5-3
5-3
5-3
5-4
5-4
5-4
5-5
5-5
5-5
5-6
5-7
5-8
5-8
5-8
5-8
5-8
5-9
5-9
5-11
5-13
5-14
5-15
5-18
5-20
5-22
5-23
5-25
5-27
5-28
5-30
5-30
5-31
5-32
5-32
5-33
5-34
5-34
5-35
4.6
5.
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Table of Contents
6.
Inspection, Test and Adjustment .............................................................................................................

6.1
The inspection for oil and grease leaks ............................................................................................
6.1.1
6.1.2
Preparation .....................................................................................................................
6.1.3
Do an inspection of the oil pipes, hoses and connections ..............................................
6.1.4
Do an inspection of the oil level ......................................................................................
6.1.5
Do an inspection of the Input shaft seal .........................................................................
6.1.6
Do an inspection of the steering pipe seal .....................................................................
6.1.7
Do an inspection of the propeller shaft seal ...................................................................
6.1.8
Job close up ...................................................................................................................
6.2
The inspection for water leaks ..........................................................................................................
6.2.1
6.2.2
Preparation .....................................................................................................................
6.2.3
Do an inspection of the water pipes, hoses and connections ........................................
6.2.4
Job close up ...................................................................................................................
6.3
The inspection for air leaks ..............................................................................................................
6.3.1
6.3.2
Preparation .....................................................................................................................
6.3.3
Do an inspection of the pneumatic air pipes, hoses and connections ............................
6.3.4
Job close up ...................................................................................................................
6.4
The inspection for wear, damage and installation ............................................................................
6.4.1
6.4.2
Preparation .....................................................................................................................
6.4.3
Do an inspection of the pipes, hoses and connections ..................................................
6.4.4
Do an inspection of the electrical wiring, cabinets and cable protection. .......................
6.4.5
Do an inspection of the holding brake and disc ..............................................................
6.4.6
Do an inspection of the prime mover ..............................................................................
6.4.7
Do an inspection of the pump-units ................................................................................
6.4.8
Do an inspection of the steering motor-units ..................................................................
6.4.9
Do an inspection of the mounting materials and sealants ..............................................
6.4.10
Do an inspection of the anodes (cathodic protection) ....................................................
6.5
The inspection for signs of corrosion and pitting ..............................................................................
6.5.1
6.5.2
Preparation .....................................................................................................................
6.5.3
Do an inspection of the electrical bonding ......................................................................
6.5.4
Do an inspection of the locking materials .......................................................................
6.5.5
Do an inspection of the painted areas ............................................................................
6.5.6
Do an inspection of the bare metal surface of the shafts ...............................................
6.5.7
Do an inspection of the propeller blade and hub surface ...............................................
6.5.8
Do an inspection of the propeller gearbox surface .........................................................
6.5.9
Do an inspection of the locking materials (strips, welds, wire) .......................................
6.6
The inspection for cleanliness ..........................................................................................................
6.6.1
6.6.2
Preparation .....................................................................................................................
6.6.3
Do an inspection of the oil pump motor(s) ......................................................................
6.7
Get an oil sample and get an oil analysis .........................................................................................
6.7.1
Introduction .....................................................................................................................
6.7.2
6.7.3
Preparation .....................................................................................................................
6.7.4
How to sample the lubrication system ............................................................................
6.7.5
How to sample the steering system ...............................................................................
6.7.6
Job close up ...................................................................................................................
6.8
The functional test of the steering system ........................................................................................
6.8.1
6-1
6-1
6-1
6-1
6-2
6-3
6-4
6-5
6-5
6-6
6-6
6-6
6-6
6-7
6-7
6-7
6-8
6-8
6-8
6-9
6-9
6-9
6-10
6-11
6-11
6-11
6-12
6-12
6-12
6-13
6-13
6-13
6-14
6-14
6-15
6-16
6-16
6-17
6-17
6-18
6-18
6-19
6-19
6-19
6-20
6-21
6-21
6-22
6-22
6-23
6-25
6-27
6-27
6-27
7.
Troubleshooting ........................................................................................................................................
7.1
Introduction .......................................................................................................................................
7.2
Safety information ............................................................................................................................
7.3
Reference information ......................................................................................................................
7-1
7-1
7-1
7-1
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Table of Contents
7.3.1
Operational modes .........................................................................................................
7.3.2
Hydraulic and lubrication systems ..................................................................................
7.3.3
Electrical systems ...........................................................................................................
Follow up of alarms ..........................................................................................................................
Troubleshoot the gearbox related problems .....................................................................................
7.5.1
The propeller gearbox ....................................................................................................
7.5.2
The upper gearbox .........................................................................................................
7.5.3
The lubrication system ...................................................................................................
Troubleshoot the propulsion related problems ..................................................................................
7.6.1
The propulsion system ...................................................................................................
Troubleshoot the steering related problems .....................................................................................
7.7.1
The steering system .......................................................................................................
Drawings ..........................................................................................................................................
7-1
7-2
7-2
7-2
7-5
7-6
7-8
7-9
7-12
7-13
7-13
7-13
7-17
Removal / Installation ...............................................................................................................................

8.1
Remove the lubrication filter element ...............................................................................................
8.1.1
8.1.2
Preparation .....................................................................................................................
8.1.3
Remove the filter element ..............................................................................................
8.1.4
Job close up ...................................................................................................................
8.2
Remove the rope guard ....................................................................................................................
8.2.1
8.2.2
Preparation .....................................................................................................................
8.2.3
Remove the rope guard ..................................................................................................
8.2.4
Job close up ...................................................................................................................
8.3
Remove the steering filter element ...................................................................................................
8.3.1
8.3.2
Preparation .....................................................................................................................
8.3.3
Remove the filter element ..............................................................................................
8.3.4
Job close up ...................................................................................................................
8.4
Remove the steering motor-unit .......................................................................................................
8.4.1
8.4.2
Preparation .....................................................................................................................
8.4.3
Disconnect the steering lines .........................................................................................
8.4.4
Drain the lubrication system ...........................................................................................
8.4.5
Remove the steering motor-unit .....................................................................................
8.4.6
Job close up ...................................................................................................................
8.5
Install the lubrication filter element ...................................................................................................
8.5.1
8.5.2
Preparation .....................................................................................................................
8.5.3
Install the filter element ..................................................................................................
8.5.4
Job close up ...................................................................................................................
8.6
Install the rope guard ........................................................................................................................
8.6.1
8.6.2
Preparation .....................................................................................................................
8.6.3
Install the rope guard ......................................................................................................
8.6.4
Do the after installation test ............................................................................................
8.6.5
Job close up ...................................................................................................................
8.7
Install the steering filter element ......................................................................................................
8.7.1
8.7.2
Preparation .....................................................................................................................
8.7.3
Install the filter element ..................................................................................................
8.7.4
Job close up ...................................................................................................................
8.8
Install the steering motor-unit ...........................................................................................................
8.8.1
8.8.2
Preparation .....................................................................................................................
8.8.3
Install the steering motor-unit .........................................................................................
8.8.4
Fill the oil systems ..........................................................................................................
8.8.5
Do the after installation tests ..........................................................................................
8.8.6
Job close up ...................................................................................................................
8-1
8-1
8-1
8-1
8-2
8-3
8-3
8-3
8-4
8-4
8-5
8-6
8-6
8-7
8-7
8-9
8-9
8-9
8-10
8-11
8-12
8-12
8-16
8-16
8-16
8-17
8-17
8-19
8-19
8-19
8-20
8-21
8-22
8-22
8-23
8-23
8-23
8-24
8-26
8-26
8-26
8-27
8-29
8-35
8-35
8-35
7.4
7.5
7.6
7.7
7.8
8.
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Table of Contents
8.8.7
After care ........................................................................................................................
Drawings ..........................................................................................................................................
8-35
8-35
Storage and transport ..............................................................................................................................

9.1
Introduction .......................................................................................................................................
9.2
Receipt of parts ................................................................................................................................
9.3
Lifting ................................................................................................................................................
9.4
Long term storage of equipment ......................................................................................................
9.5
Drawings ..........................................................................................................................................
9-1
9-1
9-2
9-2
9-2
9-3
10. Spare parts catalogue ..............................................................................................................................

10.1 Drawings ..........................................................................................................................................
10-1
10-1
8.9
9.
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Table of Contents
List of Drawings
DAAK018950 C
General arrangement of the thruster .................................................................................. 2-35
DAAK101429 C
Block diagram thruster installation ..................................................................................... 2-36
DAAK101812 B
I/O and settings list thruster installation mechanical parts ................................................. 2-37
DAAK102649 Paint specification .............................................................................................................. 2-43
DAAK018296 A
Anode plan ......................................................................................................................... 2-45
DAAK100216 Brake - Pneumatic control panel ........................................................................................ 7-18
DAAK100217 A
Pneumatic head pressure panel ........................................................................................ 7-19
DAAK101350 A
Coolers - diagram / specification ........................................................................................ 7-20
DAAK100253 Cooler - assembly .............................................................................................................. 7-21
DAAK100255 A
Steering system - hydraulic diagram .................................................................................. 7-22
DAAK100254 A
Steering system - power pack ............................................................................................ 7-23
DAAK015662 Steering system - Counter balance block .......................................................................... 7-24
DAAK100265 Steering system - Junction manifold ................................................................................. 7-25
DAAK101348 B
Lubrication system - Diagram ............................................................................................ 7-26
DAAK100246 Lubrication system - Oil pump upper gearbox ................................................................... 7-27
DAAK100247 Lubrication system - Filter manifold upper gearbox ........................................................... 7-28
DAAK100266 A
Lubrication system - Header tank upper gearbox .............................................................. 7-29
DAAK100257 Lubrication system - Oil pump lower gearbox .................................................................... 7-30
DAAK100310 A
Lubrication system - Header tank lower gearbox ............................................................... 7-31
DAAK103317 A
Hydraulic connections ........................................................................................................ 7-32
DAAK100645 A
Starter - Steering pump ..................................................................................................... 7-35
DAAK100646 A
Starter - Lubrication oil pump ............................................................................................. 7-39
DAAK100647 A
Starter - Lubrication oil pump(s) ........................................................................................ 7-41
DAAK100256 Electrical connections steering power pack ....................................................................... 7-44
DAAK008012 A
Wiring diagram terminal box JB12 ..................................................................................... 7-45
W084843587 B
Terminal box JB12 ............................................................................................................. 7-46
PAAI003138_D01 - Water separator 1/3 ........................................................................................................... 7-47
DAAK103528 B
Floating shaft arrangement ................................................................................................ 8-37
DAAK103528 B
Coupling - instruction sheet ............................................................................................... 8-38
PAAI064158 Brake assembly .................................................................................................................. 8-39
T003001371 O
Upper gearbox - Assembly ................................................................................................. 8-40
PAAI031938 B
Flange and speed pick-up assembly (starboard) ............................................................... 8-41
PAAI031938 B
Flange and speed pick-up assembly (port-side) ................................................................ 8-42
DAAK102321 C
Steering section arrangement ............................................................................................ 8-43
DAAK011368 A
Steering motor assembly ................................................................................................... 8-44
T002014339 P
Azimuth feedback unit ........................................................................................................ 8-45
T002010530_D01 MDiagram azimuth feedback unit .......................................................................................... 8-46
T003005755 L
Intermediate shaft .............................................................................................................. 8-47
PAAI002732 A
Shank assembly ................................................................................................................. 8-48
DAAK004540 E
Propeller gearbox assembly ............................................................................................... 8-49
DAAK018911 B
Propeller assembly ............................................................................................................ 8-50
DAAK103614 Calculation sheet keyless propeller fit ................................................................................ 8-51
DAAK104633 Transport parts stem section with upper gearbox ..............................................................
9-4
DAAK018944 A
Transport parts propeller gearbox ......................................................................................
9-5
DBAC426812 Spare parts catalogue - MP/01680.M1AT11P ................................................................... 10-2
DBAC426812 Spare parts catalogue - MP/01680.M1AT12P ...................................................................10-101
29 November 2012

1. General information
1.
General information
This section gives an introduction to this manual, information about the liability and warranty, safety information, technical specifications and a reference to the spare parts catalogue.
1.1
Content overview
This manual is applicable to the Wrtsil installation as specified on the first page of this manual. The
manual contains several chapters which only cover the equipment that is part of our scope of supply. The
chapters are identified as:
GENERAL INFORMATION
This chapter gives an introduction, safety information, classification and technical

data.
DESCRIPTION
This chapter gives a general overview of the functionality of the system. This
chapter provides background information necessary for operation, maintenance
and troubleshooting of the system.
OPERATION
This chapter gives the instructions for the operation of the system. The instructions
include the start, stop and emergency procedures.
GENERAL MAINTENANCE
This chapter gives the general maintenance instructions, lubrication and other
consumable material tables. The instructions include e.g. the lubrication and the
cleaning procedures.
PREVENTIVE MAINTENANCE
This chapter gives the maintenance intervals and checklists for on-board equipment
and spare parts. Also given are the procedures for lubrication, cleaning, filling and
draining.
INSPECTION, TEST AND ADJUST- This chapter gives the detailed inspection, test and adjustment procedures which
MENT
can be a result of the preventive maintenance tasks.
1.2
TROUBLESHOOTING
This chapter is meant to give help with the fault isolation and recovery. The chapter
includes safety instructions and troubleshooting charts.
REMOVAL / INSTALLATION
This chapter gives, in alphabetical order, the removal and installation procedures
for the equipment which is part of the system.
STORAGE AND TRANSPORT
This chapter gives the information about the storage and transport requirements,
recommendations and instructions.
SPARE PARTS CATALOGUE
This chapter gives the spare parts information for the equipment which is part of
this system. The spare parts catalogue gives ordering and technical information
which is supported by exploded views.
Target groups
NOTE!
Persons who have not read and understood all instructions relevant for the work is not qualified
to execute the procedure. Persons are assumed to be qualified if they have the skill, knowledge,
materials, tools and equipment available, to operate or maintain the system and if they finished
a safety training about the (residual) hazards of the system with a certificate.
Persons are assumed to be well-trained if they have finished their general education with a
certificate.
For thruster specific training, the relevant training modules offered by Wrtsil must be successfully completed with a certificate.
This manual is intended for use by operational and maintenance staff of the vessel.
Operations may only performed by qualified and well trained operational staff who are familiar with
the construction and operation of the system.
Mechanical work may only be performed by qualified and well-trained persons who are familiar with
the mechanical repair and service procedures and who obey the specific regulations and requirements
set by the authorities, manufacturer, employer and owner of the system.
29 November 2012
1-1

1.3
Electrical work may only be performed by qualified and well-trained persons who are familiar with the
electrical repair and service procedures and who obey the specific regulations and requirements set
by the authorities, manufacturer, employer and owner of the system.
Inspections by divers may only be performed by qualified and well-trained persons with valid certificates
and who are familiar with the diving, inspection and service procedures and who obey the specific
regulations and requirements set by the authorities, manufacturer, employer and owner of the system.
Liability and warranty

Wrtsil Netherlands B.V. has taken reasonable precautions to avoid mistakes and typing errors, but does
not accept responsibility for mistakes or typing errors in this manual.
Wherever this manual refers to 'owner', 'purchaser' or 'shipyard' in connection with responsibility, work to
be carried out, or goods to be supplied, these words are to be read as 'contracting party'.
If work that is not fully described in this manual is carried out without the supervision of Wrtsil service
personnel, the contractual agreed warranty lapses.
Warranty conditions are contained in the relevant contract.
Warranty claims can be rejected in the following situations:
Installation, operation, or maintenance of the equipment not in accordance with Wrtsil Netherlands B.V. instructions.
Modification(s) to the equipment without prior consent of Wrtsil Netherlands B.V..
Oils used not in accordance with our recommendations as listed in this manual.
Applied power, data and characteristics not in accordance with those quoted on the name plate of
the installation.
Wrtsil Netherlands B.V. is not responsible for vibration problems resulting from the overall system.
Wrtsil Netherlands B.V. does not, therefore, accept any responsibility for any complaints or damage
caused by such vibration.
1-2
29 November 2012

1.4
Safety information
1.4.1 Intended use

The steerable thruster is intended for use in Main propulsion, Bollard pull, Station keeping and Manoeuvring.
The steerable thruster may only be used in accordance with the limitations as given in the classification
data sheet, the technical specification which is part of the contract, the instructions for installation as given
in the Installation Planning Instructions (IPI) and the instructions for use and long term storage in the Operating and Maintenance Manual (OMM).
1.4.2 General safety

Please carefully read this manual before you do any work on the system, the sub-systems or its parts. Make
sure, that you have read and are aware of all the safety warnings and instructions. Also take notice of the
safety instructions that are related to the thruster system.
The persons who operate, maintain or repair the equipment, and the persons located in the near vicinity of
the equipment must be informed of the possible dangerous situations. This advice, in no way supersedes
any instruction issued from a higher authority or contained in any (safety) standard.
Introduction to safety
The operation and maintenance procedures can give dangerous situations if you do not obey the safety
precautions. We have done, to the best of our abilities and knowledge at the time to tell and warn you, as
accurately and as fully as possible, about the possible dangerous situations when you use the thruster
system, but the human element can never be completely eliminated.
You are responsible for the supervision and the implementation of the instructions as given in this manual.
This chapter gives an indication of the dangerous areas of the equipment, and instructions on how to avoid
accidents or damage to equipment when you operate or maintain the thruster system.
In some cases the information may seem irrelevant, but it is to your advantage to know of all possible
dangerous situations. The possibility of (serious) injury depends, among other things, on the following
factors:
the professional skill of operating and maintenance persons;
the knowledge of these persons about the possible dangerous situations;
the degree of concentration of these persons during their work;
the type of work.
Lock-out - Tag-out procedure

This procedure gives the minimum requirements for the lock-out of the energy sources (Electrical, hydraulic
and pneumatic power, etc) that can cause injury to persons. If available, the employer's and manufacturer's
safety instructions prevail.
Make the system safe

1. Inform the ship's staff that a lock-out of the system (or a part of the system) is necessary.
2. After approval, shutdown the system by the usual stop and shutdown procedure.
3. At each propulsion and local control panel, attach a warning sign: "Do not operate the system - Maintenance in progress".
4. Set the applicable switch(es) to the OFF position and make them safe with a padlock.
5. In the controls cabinet, find and set the switch ISOLATION STEERING VALVES to the ON position.
6. For pressurized systems, if necessary, release the pressure from the system (part) under maintenance.
Return the system into operation

1. Make sure, the work is finished by all persons.
2. Remove all tools, materials and equipment from the work area.
29 November 2012
1-3

3. Make sure, it is safe to energize the system. Unsafe circuits can cause (Serious) injury to persons.
4. If applicable, fill and pressurize the system.
5. Remove the padlock.
6. After approval, start the system by the usual start procedure.
7. Do a functional test to make sure, that the system operates as normal.
8. At each propulsion and local control panel, remove the warning sign: "Do not operate the system Maintenance in progress".
9. Return the system to the ship's staff and for record purposes, make a note in maintenance logbook.
Access and escape routes

The access to the operating area, the maintenance area and the escape routes should be kept clear of
obstacles at all times.
The access should be available at suitable places and should be accessible from the escape routes. It
should be possible to open the access panels and covers without any effort.
Material and equipment

Storage
The material and the equipment which has no association with the system should not be stored in the operating area. The flammable materials, the gases and the dangerous chemicals should be stored in an appropriate area according to the manufacturer's instructions as stated in the related material safety datasheet (MSDS).
Disposal
Dispose of the materials, the equipment, the waste and the discarded parts in an environmental safe
manner in accordance with the manufacturer's instructions and the international (maritime) regulations.
Lifting
DISCLAIMER
The next procedures are meant as guidelines because the weight and shape of the parts vary. The lifting
operation is always under the directions and responsibility of the appointed person who supervises the
lifting operation. Wrtsil Netherlands B.V declines any responsibility.
Wrtsil Netherlands B.V nor any of her employees, servants or agents shall be liable for any loss,
damage or expense whatever sustained by any person or company due to any act, omission, inaccuracy,
or error or whatever nature in consequence of any information as given in these guidelines.
WARNING!
The parts can be heavy. The weight depends on the size. Only use validated, sufficiently rated and approved lifting equipment and procedures that are supervised by a responsible person. Lifting equipment
and procedures that are not validated, approved and supervised can be unsafe. Lifting equipment and
procedures that are unsafe can cause (serious) injury or death to persons.
CAUTION!
Only use the applicable lifting facilities. Do not attach lifting tools to machined surfaces, shaft ends,
piping work or other externally mounted equipment other than the attached lifting facilities for handling
by crane or forklift truck.
1-4
29 November 2012

1. Do a visual inspection of the lifting equipment.
Make sure, the equipment is valid, free of any signs of wear and damage. Equipment that has signs of
serious wear or damage are regarded as unsafe.
2. Make sure, free access and a free loading area are available.
3. Determine the weight of the part(s) which are lifted.
4. Determine the center of gravity and take notice of the working and safe load limitations (WLL and SWL).
5. Lift the parts by the instructions of the appointed person who supervises the lifting operation.
Diving
DISCLAIMER!
The next instructions are meant as a minimum guideline. The diving operation is always under the directions and responsibility of the appointed person who supervises the diving operation. Wrtsil Netherlands
B.V declines any responsibility.
or error or whatever nature in consequence of any information as given in the next instructions.
NOTE!
A diving operation, to work under water, is always dangerous.
1. Make sure:
the diving equipment is valid, ready and safe for use;
the safe diving measurements are taken;
the rescue measurements are valid and ready for immediate use;
a standby diver is available and ready for immediate deployment.
2. Lock out the applicable systems and equipment.

3. Make sure, the vessel and the thrusters can not start any movement.
4. Install the warning signs: "Do not operate - Diver in the water".
5. Inform all persons involved in the operation about the safety, the diving and the maintenance or inspection
tasks.
6. With a diver in the water, the diving supervisor becomes the commanding officer of the operation.
1.4.3 Notational convention

Warning, caution, note
WARNING!
Failure to obey the warning can result in (serious) injury or death of persons.
CAUTION!
Failure to obey the caution can result in (serious) damage to equipment or environment.
NOTE!
A note gives additional information for clarification.
29 November 2012
1-5

NOTE!
Environmental remark
An environmental remark gives additional information for clarification with respect to environmental issues.
Orientation
The orientation is defined as: Looking in Direction of sailing means the thruster(s) are set to 0.
1-6
Orientation
Description
Location
Direction of sailing
FWD
Forward side, front
Bow
RH
Right hand side, right
Starboard
AFT
Aft side, rear, back
Stern
LH
Left hand side, left
Port side
29 November 2012

Direction of rotation
The direction of rotation is, unless otherwise specified, defined as: 'Looking at' or 'in forward direction'.
29 November 2012
Direction
Description
Location
Clockwise
CW, turning right
as looking at the clock

as looking at the compass rose
Counterclockwise
CCW, turning left
as looking at the clock

as looking at the compass rose
Inward over the top
port side = CW
starboard = CCW
as looking at the hub
Outward over the top port side = CCW

starboard = CW
as looking at the hub
Electric motor
as looking at the fan
CW, turning right

CCW, turning left
1-7

Pumps, Gearboxes
as looking at the input

shaft
1.4.4 Personal protection

WARNING!
The use of personal protective equipment does not mean that you can ignore the normal safety precautions. The best protection against (serious) personal injury is care and attention when you do the work.
In spite of the many safety precautions taken, accidents can still occur. Always use the applicable Personal
Protective Equipment (PPE) when you work on the installation. PPE is meant to protect your health and
well-being. Incorrect use or maintenance of the PPE can result in (serious) injury to persons.
When you have to work in a possible dangerous situation, do the work with two persons, of which one is
in command.
Summary
This summary gives, but is not limited to the most common PPE:
hard hat (safety helmet), to give protection for your head from injury by falling materials, tools and
equipment, weather and electric shock;
safety goggles or face shield, to give protection for your eyes and/or face when you work with
chemical agents or when you do any hot works (welding/grinding);
safety shoes or boots; to give protection for your feet (toes) against materials, tools and equipment
that fall and protect you against falling when you walk on slippery surfaces;
safety gloves to give protection for your hands (fingers) against consumable materials, hot or sharp
objects (edges) or to give more grip when handling parts;
hearing protection, to give protection for your ears from permanent damage when you are exposed
to excessive noise levels;
fall protection harness, to give protection against falling when working on height;
protective clothing to give protection for your body against general hazards or environmental conditions
(cold or hot weather);
high visibility jacket, to give protection for possible accidents because other persons can see you
better (in poorly lighted areas or closing daylight).
1.4.5 Warnings
Group
1-8
Content
Always be careful when you work around rotating components.
Check the equipment frequently to prevent possible dangerous conditions.
Follow the directions in the manual.
29 November 2012

Group
Content
Only use validated, sufficiently rated and approved lifting equipment and procedures that are
supervised by a responsible person.
The parts can be heavy, be aware the weight depends on the size.
Make sure that equipment can neither tilt nor move during lifting.
Make sure there is sufficient space and that persons are in safe positions.
Make sure that you shut off the prime movers and all pumps, disconnect the electric power
supply and close all relevant valves when you work on equipment.
Make sure that the prime mover cannot be accidentally started.
Put warning signs in position.
Make sure that no one is working on the equipment before starting the prime mover.
Do not, under any circumstances, start the prime mover or operate equipment when a warning
sign is attached.
Make sure that high pressurised oil can not leak. Place protective guards in position.
Always wear safety glasses and protective clothing when you work on equipment.
Oil pipes or hoses of insufficient strength can burst under pressure. Severe injury can result.
Do not disconnect hydraulic pipes or hoses when pumps are operating.
Make sure that all protective guards and covers are correctly installed.
Make sure that rotation by gravity is not possible.
Make sure that uncontrolled rotation of the hub and propeller shaft is not possible during
launching and outfitting.
Do not mix metric fasteners with other (standard) fasteners.

Mismatched or incorrect fasteners will cause damage to or malfunction of equipment or can
result in injury.
Disconnect the mains and back up power supplies when you work on the remote control and
put warning signs in position.
The propulsion control system is always under live voltage.
Disconnect interface circuits that are under voltage from other power supplies.
If handled improperly, compressed (pneumatic) air systems can be hazardous to your health.
Cleaning with compressed air is dangerous.

Do not use compressed air for cleaning unless no alternative method of cleaning is available.
Always wear safety glasses and hearing protection when working with compressed air systems.
Assembly, handling and repair of compressed air systems should be performed by qualified
personnel only.
1.4.6 Cautions
Group
Content
Only use the applicable lifting facilities, always attach lifting equipment to the lifting points or
to places indicated on the (transport) drawings. Use shackles or slings.
Do not attach lifting tools to machined surfaces, shaft ends, piping work or other externally
mounted equipment other than the attached lifting facilities for handling by crane or forklift
truck.
Make sure that you place sufficiently sized oil or fluid catch tank(s).
Always collect and removed spilled oil or fluid from (dis) assembly procedures.
Make sure that you drain system oil or fluid before equipment disassembly.
29 November 2012
1-9

Group
1-10
Content
Make sure there is no dirt or foreign materials in the hydraulic or circulation systems. This can
cause extensive damage to equipment.
Do not use alkaline or chemical detergents to clean, rubber, synthetic or painted components.
They can cause damage to equipment. Wipe with a dry cloth only.
If pressure pumps are installed in parallel, make sure the hydraulic system is designed for such
purpose.
Check the hydraulic system first.
Simultaneously running of pumps can cause serious damage to equipment.
Always earth screened cables exclusively at cabinet side, never at panel nor component side.
Electric welding introduces spikes.
Always disconnect the mains and back up power supplies to the electronic cabinet or to
components close to the welding area.
Do not use control panels or electrical cabinets as an earth point when welding, this can cause
damage to electrical components.
When welding, always connect to a good earth point close to the welding area to avoid damage
to equipment surfaces.
When welding, protect the surroundings from welding spatters.
Never attempt to stop or repair an air leak while the leaking portion is still under pressure.
Always isolate (lock out) and release all residual air pressure and tag out the portion of the
system which needs repair.
Do not use compressed air for cleaning unless no alternative method of cleaning is available.
29 November 2012

1.5
Technical data
1.5.1 Technical specification

FS2510-2500WO
General thruster data

Table 1.1 General thruster data
Description
Specification
Type
LMT
Application
Main propulsion
Input power (MCR) [kW]
2000
Input speed [rpm]
790
Direction of rotation (input shaft)
Port CW / Starboard CCW
Reduction ratio
4.6782
Steering speed [calculated - rpm]
2.0
Table 1.2 Classification data
Description
NOTE!
Specification
The publication of the classification data sheet is beyond the scope of this manual. For your reference, a
summary of the class notation is given. For the complete and validated classification data sheet, please
refer to the classification certificates that came with the approval of the vessel.
Class bureau A
Det Norske Veritas
Class notation A
+1A1 E0 DYNPOS AUT IMO DP-1
Class bureau B
Indian Register of Shipping
Class notation B
+ SUL, deck strengthened for 5t/m, IY, DP(1), IBS, SYJ
Ice class
None
Table 1.3 Cooling water
Description
Specification
Quality
Fresh water
Temperature [max. C]
38
Pressure [max. bar]

Flow rate steering system [calculated -
3
dm3/min]
Flow rate lubrication system [calculated -
dm3/min]
44
109
Table 1.4 Colour scheme
Description
Specification
Inboard
see paint specification
Outboard
see paint specification
The propeller arrangement

Table 1.5 Propeller data
Description
Specification
Type
Fixed pitch propeller
Speed
169
Classification [ISO class]
ISO 484 class S
Surface classification [ISO class]
ISO 484 class S
29 November 2012
1-11

Description
Specification
Material
Propeller: CuNiAl
Number of blades
Diameter [mm]
3200
Table 1.6 Cathodic protection
Description
Specification
Material of the anodes
Zinc
Designed lifetime of the anodes
The shaft arrangement

Table 1.7 Floating shaft
Description
Specification
Length [mm]
1000
Table 1.8 Brake
Description
Specification
Operation
Air operated
The gearbox arrangement

Table 1.9 Propeller gearbox
Description
Specification
Type / Size
F-2510
Reduction ratio
2.615
Table 1.10 Upper gearbox
Description
Specification
Type
2500
Reduction ratio
1.789
Table 1.11 Seals
Description
Specification
Aft Seal
JMT-Refer to drawing
Aft seal material
Viton
Aft seal liner
Ceramic coated stainless steel
The steering system

Table 1.12 Steering system
Description
Specification
Type
Open loop
Number of steering motors
Redundancy of pumps [%]
1x100 (2 systems)
Pump power [kW]
60.6
Pump drive
Oil content - power pack tank [calculated Oil quality (cleanliness)
1-12
Electrical
dm3]
800
ISO4406:1999; contamination rate 19 / 16 / 13 (NAS1638
class 7)
29 November 2012

Description
Specification
Oil temperature, minimum [C]
Refer to the technical data sheet of the oil in use.
Oil temperature, maximum [C]
Refer to the technical data sheet of the oil in use.
The lubrication system

Table 1.13 Lubrication system
Description
Specification
Pump power [kW]
UGB 7.5, LGB 2.8 + 1.4
Pump drive
Electric
Oil content - upper gearbox [calculated - dm3]
350
Oil content - Header tank [calculated - dm3]
UGB 800, LGB 800
Oil content - Lubrication oil tank [calculated - dm3]
UGB 1,400, LGB 400
Oil content - Stembox [calculated - dm3]
Refer to diagram
Oil quality (cleanliness)
ISO4406:1999; contamination rate 21 / 19 / 16 (NAS1638

class 10)
Oil temperature, minimum [C]
Refer to the technical data sheet of the oil in use

recommendation: 0
Oil temperature, maximum [C]
Refer to the technical data sheet of the oil in use

recommendation: 80
The electrical system

Table 1.14 The electrical system
Description
Specification
Mains voltage [V]
440
Mains frequency [Hz]
60
Controls voltage [V]
230 V ac
Emergency power
230 V ac
Ambient conditions
Temperature [C]: 0 - 55
Relative humidity: No condensation allowed
The pneumatic system

Table 1.15 Compressed air
Description
Specification
Quality
Dry and clean air according to ISO 8573-1, class 3.4.3
Vessel pressure [max. bar]
10
Brake system pressure [max. bar]
6-7
Static pressure system - air pressure [max. bar]
Refer to diagram
Air consumption brake [calculated - dm3/cycle
Refer to drawing
The prime mover

Table 1.16 Prime mover
Description
Specification
Starter type
Shipyard supply
Power [kW]
2000
29 November 2012
1-13

1.5.2 Storage conditions

Table 1.17 Mechanical parts
Description
Specification
Packaging
Original packaging, free of damage and contamination
Environment
Indoor, dry and well ventilated
Temperature [minimum C]
Temperature [maximum C]
+50
Relative humidity
<60%, no condensation allowed
Table 1.18 Electrical and electronic parts
Description
Specification
Packaging
Environment
Indoor, dry and well ventilated
-25
+70
Relative humidity
Table 1.19 Seals and rubber parts
1-14
Description
Specification
Packaging
Environment
Indoor, dry with a minimum of ventilation
+5
+25
Relative humidity
UV radiation
Protect against direct sun and artificial light
29 November 2012

2. Description
2.
Description
2.1
System overview
This section gives a general physical description of the thruster system. Unless otherwise specified, for
more detailed information,, please refer to the related system descriptions.
The main function of the thruster system is to move the vessel or to keep the vessel at station in a controlled
manner.
2.2
The propeller arrangement

The function of the propeller arrangement is to move the vessel in the selected direction.
The propeller arrangement has:
the fixed pitch propeller, to move the vessel;
the cathodic protection, to protect the under water parts of the thruster.
2.2.1 The fixed pitch propeller

Refer to figure :2.1 Fixed pitch propeller - Component information (typical) .
The function of the propeller is to move the vessel. The propulsion power is selected by the output speed
of the prime mover. The propeller blades and the hub are manufactured in one piece with a design that is
specific for the vessel and its purpose.
The fixed pitch propeller has:
the propeller blades (1), to give the thrust force to move the vessel;
the solid hub (3), to hold the propeller blades and taper fit connection;
the taper fit connection (2), to attach the propeller to the propeller shaft of the propeller gearbox.
29 November 2012
2-1

2. Description
Figure 2.1 Fixed pitch propeller - Component information (typical)
2.2.2 The cathodic protection

The primary function of the cathodic protection is to protect the under water parts of the thruster system.
The thruster system will only be equipped with the first set of anodes by Wrtsil when ordered or mentioned
in our scope of supply.
The thruster system is provided with anodes to protect the thruster system for a specific period of time
against galvanic corrosion, provided that the rest of the ship is sufficiently protected by a system fully
compatible with the anodes used on the thruster system.
The drawing Anode Plan gives, for the applicable thruster system, the following information:
2.3
the number and used type of anodes;
the mass of the anodes;
the period of protection of the thruster system;
the material of the anodes;
the position of the anodes.
The shaft arrangement
2.3.1 The floating shaft arrangement

Refer to figure 2.2, The floating shaft arrangement - Component information (typical).
The function of the floating shaft arrangement is to bring the output power from the prime mover to the
upper gearbox.
The floating shaft arrangement has:
2-2
a solid shaft (1), to overcome a distance between the prime mover and the upper gearbox;
29 November 2012

2. Description
a torsional stiff flexible coupling (2) on the two ends of the shaft, to connect the shaft.
Optionally the floating shaft arrangement has:
a dual shaft arrangement, to overcome an extended distance between prime mover and upper gearbox;
a brake, to prevent 'windmilling' of the propeller;
a bulkhead seal, to a prevent a water flow from one compartment, through the shaft opening in a
bulkhead, to an adjacent compartment.
The dual shaft arrangement

The function of the dual shaft arrangement is to to overcome an extended distance between prime mover
and upper gearbox.
The dual floating shaft arrangement has:
two separate floating shafts, to overcome an extended distance passing through a bulkhead;
a solid interconnecting shaft with connecting flange at one side, to connect to one of the two shafts
and to support the two shafts in between;
a clamping hub, to make the connection to the second shaft;
a split cylindrical roller bearing, to support the interconnecting shaft;
an integrated bulkhead seal, to a prevent a water flow from one compartment, through the shaft
opening in a bulkhead, to an adjacent compartment.
Figure 2.2 The floating shaft arrangement - Component information (typical)
2.3.2 The shaft brake

Refer to figure 2.3, The shaft brake- Component information (typical).
29 November 2012
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2. Description
The function of the shaft brake is to prevent free movement of the propeller when the prime mover is shut
down.
The shaft brake has:
the pivot base (1), to hold the keep plate and the arms with the brake pads;
the brake arms (2), to hold the brake pad assembly and tension spring;
the tension springs (3), to open the brake arms when the pneumatic air pressure is released;
the actuator rod (4), to move the brake arms and to apply brake force;
the grease nipples (5), to apply grease to the brake arm shafts for a smooth movement;
the spring clips (6), to attach the brake pad assembly to the brake arm;
the pressure plate (7), to hold the brake pads;
the brake pads (8), to hold the brake disc which prevents free movement of the propeller;
the pneumatic actuator (9), to apply the brake force via the brake pads to the brake disc;
the air connection (10), to connect the pneumatic air supply.
The shaft brake optionally has:
the keep plate, to keep the brake pad assembly at the correct position;
the adjustment bolts, to adjust the space between the brake pads and the brake disc;
the stabilization rod assembly, to make sure the two brake arms operate equally (vertical installation).
Figure 2.3 The shaft brake- Component information (typical)
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2. Description
Operation of the shaft brake

The shaft brake is applied by pneumatic power and released by the tension springs. The shaft brake is a
holding device which only can be applied when the speed of the shaft is below a preset value in the control
software.
When pneumatic power is applied, the pneumatic actuator rod moves the brake arms to press the brake
pads against the brake disc. The brake disc is held by pressure and friction between the brake pads and
disc.
When pneumatic power is removed, the pneumatic actuator releases the force on the brake arms. The
tension springs open the brake arms to release the pressure on the brake pads. The brake disc can now
move freely because the brake pads are no longer in contact with the brake disc.
For a reliable operation it is important to apply dry, clean pressurized air and to keep the installation free
of contamination (oil/grease). Oil and grease on the brake pads or brake disc causes excessive slip and
loss of brake force. For the air quality, please refer to the technical specification.
2.4
The gearbox arrangement
2.4.1 The propeller gearbox

Refer to figure 2.4, The PGB - Component information (typical).
The primary functions of the propeller gearbox are to change a vertical into a horizontal movement and to
reduce the speed from the prime mover to the propeller. The secondary function of the propeller gearbox
is to hold the propeller shaft and the lubrication oil.
The propeller gearbox has:
the housing (1), to hold the transmission parts and the lubrication oil;
the lubrication oil, to minimize the wear of the gears and bearings and to keep static pressure onto
the seals;
the input shaft (2), to transmit the power from the vertical intermediate shaft, through a bevel gear, to
the propeller shaft;
the propeller shaft (6), to transmit the power from the input shaft to the propeller;
the input shaft bearings arrangement (9 & 10), to support the input shaft;
the propeller shaft bearings arrangement (4 & 7), to support the propeller shaft and to transfer the
propeller thrust to the vessel;
the propeller shaft seal (8), to keep the oil filled inside separated from the surrounding (sea)water at
the outside;
the lubrication oil pipes and connections (11), to create a lubrication oil flow through the propeller
gearbox.
The housing
The primary function of the housing is to hold the transmission parts and the lubrication oil.
The housing has:
the main housing, to transmit the propeller thrust to the stem section;
the cover, to close the front end of the housing;
the bearing seats, to hold the bearings;
the inspection cover, to allow for an inspection of the equipment inside the housing.
Optionally the housing has:
the rope guard, to prevent damage of thruster by a fishing net, ropes or lines.
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2. Description
The lubrication oil

The primary function of the lubrication oil is to minimize the wear of the gears and the bearings by lubrication,
dissipation of heat, and transport of contamination. The secondary function of the lubrication oil is to reduce
the noise level. The lubrication oil is also used to keep a static pressure onto the steering pipe and propeller
shaft seals.
The propeller gearbox is fully filled with lubrication oil which is circulated by a lubrication pump-unit. Note
that a failure of the lubrication pump-unit does not affect the lubrication of the gears and bearings. A failure
of the lubrication pump-unit stops the circulation and therefore the filtration. A lack of filtration can cause
a build up of contamination which finally will cause a system failure.
For detailed information about the lubrication circuit, please refer to the section Description and operation
- The lubrication system.
The input shaft

The primary function of the input shaft (pinion shaft) is to transmit the power from the vertical intermediate
shaft to the propeller shaft.
The input shaft has:
a single-piece shaft (2) and pinion (3), to transmit the torque to the propeller shaft;
the bearing collars, to install the bearings.
The propeller shaft

The primary function of the propeller shaft is to transmit the power from the input shaft to the propeller.
The propeller shaft has:
the single-piece shaft with a tapered cone, to connect and drive the propeller;
the bearing collars, to install the bearings;
the gearwheel hub, to connect the crown gearwheel to the propeller shaft;
the crown gearwheel bolted to the hub, to transmit the power from the input shaft to the propeller
shaft;
the liner, to give a runway for the lip seals of the propeller shaft seal.
The bearings
The primary function of the bearings is to give the propeller thrust to the vessel. The secondary function is
to support the input shaft and the propeller shaft.
The bearings are:
a set of input shaft spherical-roller bearings at the two sides of the pinion wheel , to reduce the shaft
deflection caused by the radial forces of the tooth load;
the input shaft self-aligning thrust-bearings, to absorb the axial forces caused by the axial forces of
the tooth load;
the propeller shaft thrust-bearings at the propeller side, to give the thrust load to the vessel;
the propeller shaft spherical-roller bearing at the gearwheel side, to support the propeller shaft at the
aft end.
The propeller shaft seal

The function of the propeller shaft seal is to prevent water ingress in the lubrication oil and oil leakage into
the surrounding (sea)water.
For detailed information of the propeller shaft seal, please refer to the section Description - The propeller
shaft seal.
The lubrication oil pipes and connections

The primary function of the lubrication oil pipes and connections is to create a lubrication oil flow through
the propeller gearbox.
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2. Description
The lubrication oil pipes and connections have:
the steering pipe, to allow the lubrication oil to flow (by gravity) from the stem section into the propeller
gearbox.
the return pipe, to allow the lubrication pump to take the oil from the lowest location in the propeller
gearbox.
Operation of the propeller gear box

Refer to figure 2.4, The PGB - Component information (typical).
The input shaft (2) receives the power from the prime mover. The paired gearwheel set, the pinion (3) and
the crown wheel (5), reduce the input speed to the propeller speed.
The lubrication oil flows freely from the stem section, through the steering pipe and input shaft bearings (10),
into the propeller gearbox. For the circulation of the lubrication oil, a lubrication pump-unit takes, through
the return pipe, the lubrication oil from the lowest location into the header tank.
The alignment of the input shaft (2) is kept by a set of input shaft spherical-roller bearings (9). When input
power is applied, these bearings take the radial forces caused by the tooth load. The axial forces are taken
by the self-aligning thrust-bearings (10) at top (in the steering pipe).
The alignment of the propeller shaft is kept by the propeller shaft spherical-roller bearing (4). When power
is applied, this bearing takes the radial forces caused by the tooth load. The axial and thrust forces are
taken by the thrust-bearings (7). This bearing set transfers the thrust power to the vessels' structure.
The propeller shaft is sealed by a propeller shaft seal (8) with lip seals that run on a liner. The lip seal (oil
side) is pushed against the liner by the static pressure of the lubrication oil. To prevent (sea)water to enter
the propeller gearbox, the static pressure is slightly higher than the pressure from the surrounding
(sea)water. The other two lip seals (water side) are pushed against the liner by the pressure from the surrounding (sea)water.
For detailed information about:
the static pressure of the lubrication oil, please refer to the section Description and operation - The
lubrication system;
the steering pipe configuration and seal, please refer to the section Description and operation - The
stem section.
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2. Description
Figure 2.4 The PGB - Component information (typical)
2.4.2 The propeller shaft seal

Refer to figure 2.5 The propeller shaft seal - Component information (typical).
The function of the propeller shaft seal is to prevent water ingress in the lubrication oil and oil leakage into
the surrounding (sea)water.
The propeller shaft seal has:
the housing, to hold the lip-seals (1) and to install the propeller shaft seal onto the propeller gearbox;
the liner (2), to give a smooth surface to limit the wear of the lip-seals;
the spring-loaded oil lip-seal (3), to keep the lubrication oil into the propeller gearbox;
the spring-loaded water lip-seals (4, 5), to keep the (sea)water outside the propeller gearbox.
Optionally the propeller shaft seal has:
the second spring-loaded oil lip-seal, a final defense to keep the lubrication oil into the propeller
gearbox;
the spring-loaded UNNET seal (6, 7 and 8), a first defense to protect the lip-seals against damage by
foreign objects (fishing nets, lines, ropes, etc.).
Operation of the propeller shaft seal

The propeller shaft is sealed by the propeller shaft seal with lip-seals (3, 4, 5) that run on a liner (2). The oil
lip-seal (3) is pushed against the liner (2) by the static pressure of the lubrication oil. To prevent (sea)water
to enter the propeller gearbox, the static pressure is slightly higher than the pressure from the surrounding
(sea)water. The two water lip-seals (4, 5) are pushed against the liner (2) by the pressure from the surrounding
(sea)water. The outer water lip-seal (5) operates as a dirt deflector and first defense against water ingress
into the lubrication oil. The center water lip-seal (4) is the final defense against water ingress.
2-8
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2. Description
Operation of the UNNET seal

The UNNET seal ring (7) turns with the propeller shaft and runs into its own housing (8). The first defense
against foreign objects (fishing nets, lines, ropes, etc.) is the fin (6) at the spring-loaded seal ring (7). The
foreign object that winds around the liner (2) is blocked by the fin (6) at the seal ring (7). The fin (6) prevents
that the foreign object is caught between the UNNET seal ring (7) and the liner (2) of the propeller shaft
seal. If a larger volume is caught, the seal ring (7) is pressed against the housing (8) which prevents the
foreign object to get into the propeller shaft seals (3-5).
Figure 2.5 The propeller shaft seal - Component information (typical)
2.4.3 The upper gearbox

Refer to figure 2.6, The upper gearbox - Component information (typical).
The primary functions of the Upper gearbox (UGB) are to change a horizontal into a vertical movement and
to reduce the speed from the prime mover to the input shaft of the propeller gearbox.
The upper gearbox has:
the housing (1), to hold the transmission parts and the lubrication oil;
the input shaft oil seal (2), to prevent oil leakage along the input shaft;
the input shaft (3), to transmit the power from the prime mover, through a bevel gear, to the output
shaft;
the input shaft bearing-arrangement (4), to support the input shaft;
the output shaft bearing-arrangement (5), to support the output shaft;
the output shaft (6), to transmit the torque from the bevel gear, to the propeller gearbox input shaft;
the output shaft oil seal (7), to prevent oil leakage along the output shaft;
the lubrication oil, to minimize the wear of the gears and bearings;
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2. Description
the lubrication pipes and connections, to distribute the lubrication oil to the upper gearbox.
Optionally, the upper gearbox has:
a non-reverse rotation mechanism, to prevent reverse rotation of the propeller;
a brake unit at the input shaft, to prevent free rotation of the propeller (known as windmilling);
a clutch at the input shaft, to connect and disconnect the propeller to the prime mover.
The housing
The primary function of the housing is to hold the transmission parts and the lubrication oil.
The housing has:
the housing, to hold the mechanical power parts;
the bearing seat at the input shaft, to hold the bearing-arrangement and to close the housing;
the bearing seat at the the output shaft, to hold the bearing-arrangement and to close the bottom of
the housing;
the inspection cover, to allow for an inspection of the equipment inside the housing.
The lubrication oil

The primary function of the lubrication oil is to minimize the wear of the gears and the bearings by lubrication,
dissipation of heat, and transport of contamination. The secondary function of the lubrication oil is to reduce
the noise level.
At standstill the upper gearbox is fully filled with lubrication oil. During operation the lubrication oil level is
kept at an operational level by the level pump-unit. Note that when the level pump fails, the upper gearbox
is automatically fully filled with oil which causes the oil to foam and to heat up fast. If the level pump fails,
the thruster can be operated in an emergency mode.
For detailed information about the emergency operation, please refer to the section Operational instructions
- Emergency operation.
For detailed information about the lubrication circuit, please refer to the section Description and operation
- Lubrication system.
The input shaft

The primary function of the input shaft is to transmit the power from the prime mover, through a bevel gear,
to the output shaft.
The input shaft has:
a single-piece shaft and pinion wheel, to transmit the torque to the propeller shaft;
the cylindrical shaft end, to install a flange for the connection of a shaft line to the prime mover.
The output shaft

The primary function of the output shaft is to transmit the torque from the bevel gear through the vertical
intermediate shaft to the input shaft of the propeller gearbox.
The output shaft has:
a solid shaft and hub, to transmit the torque from the crown wheel, which is bolted to the hub, to the
vertical intermediate shaft;
the cylindrical shaft end, to install the hub of the vertical intermediate shaft.
The input shaft bearing-arrangement

The primary function of the input shaft bearing-arrangement is to support the input shaft.
The input shaft bearing-arrangements has:
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2. Description
the input shaft (spherical) roller bearings at both sides of the gear, to absorb the radial forces caused
by the tooth load;
the input shaft thrust bearings, to absorb the axial forces caused by the tooth load;
The output shaft bearing-arrangement

The primary function of the output shaft bearing-arrangement is to support the output shaft.
The output shaft bearing-arrangement has:
the output shaft (spherical) roller bearings at both sides of the gear, to absorb the radial forced caused
by the tooth load;
the output shaft thrust bearings, to absorb the axial forces caused by the tooth load.
The input shaft oil-seal

The primary function of the input shaft oil-seal is to prevent oil leakage along the input shaft.
The input shaft oil-seal has:
the lip seal(s), to prevent oil leakage along the input shaft;
the liner, to give a runway for the lip seals.
The lubrication oil pipes and connections

The primary function of the lubrication oil pipes and connections is to create a lubrication oil flow through
the upper gearbox.
The lubrication oil pipes and connections have:
the oil distribution panel, to maintain, during operation, a forced flow of lubrication oil to the gears
and bearings.
Operation of the upper gearbox

Refer to figure 2.6, The upper gearbox - Component information (typical).
The upper gearbox is a single-stage 90 degrees angle drive to transmit the power from the prime mover to
the input shaft of the propeller gearbox.
The paired gearwheel set, the pinion and the crown wheel, reduce the input speed for the propeller gearbox.
The alignment of the input shaft (3) is kept by a set of input shaft (spherical) roller bearings (4). When input
power is applied, these bearings take the radial forces caused by the tooth load. The axial forces are taken
by the self-aligning thrust-bearings.
The alignment of the output shaft (6) is kept by the output shaft spherical-roller bearing (5). When power is
applied, this bearing takes the radial forces caused by the tooth load. The axial forces are taken by the
thrust-bearings.
The input shaft (3) is sealed by an oil seal (2) which is running on a liner.
The output shaft (6) is sealed by an oil seal (7) which is running on a liner.
The upper gearbox has a lubrication system. When in operation, a circulation pump gives a continuous oil
flow to the bearing and gears. When stopped, the upper gearbox is automatically filled with oil to prevent
corrosion.
For a detailed description of the lubrication system, please refer to the section Description and operation
- Lubrication system.
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2. Description
Figure 2.6 The upper gearbox - Component information (typical)
2.5
The stem section

Refere to figure 2.7, The stem section - Component information (typical).
The primary function of the stem section is to hold the steering system and to offer a structure to connect
the thruster to the vessel.
The stem section has:
the steering motor-unit (1), to turn the slewing bearing with integrated spur gear into the required
direction;
the azimuth feedback unit (2), to change mechanical steering positions into electrical signals for use
by the control system;
the cover (3), to close the stem box and to offer a structure to hold the steering units, the azimuth
feedback unit and other related equipment;
the steering hub (4), to connect the slewing bearing to the steering pipe;
the slewing bearing (5) with integrated spur gear, to transmit the rotational force from the steering
units to the steering pipe and to support the steering hub;
the stem box (6), to hold the steering system and the lubrication oil;
the lubrication oil pump suction pipe (7);
the steering pipe bearing (8), to support the steering pipe and to take the radial forces caused by the
propeller thrust;
the steering pipe seal (9), to separate the oil filled inside from the surrounding (sea)water at the outside;
the steering pipe (10), to connect the steering hub to the propeller gearbox;
the automatic vent valve assembly, to automatically release the trapped air from the lubrication system;
the lubrication oil, to minimize the wear of the gears and bearings and to keep static pressure onto
the steering pipe seals
2.5.1 The steering motor-unit

The primary function of the steering motor-unit is to turn the slewing bearing with integrated spur gear into
the required direction.
For detailed information about the steering motor-unit, please refer to the section System description Steering system.
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2. Description
2.5.2 The azimuth feedback unit

The primary function of the azimuth feedback unit is to change mechanical steering positions into electrical
signals for use by the control system.
For detailed information about the azimuth feedback unit, please refer to the section System description Stem section - Azimuth feedback unit
2.5.3 The cover

The primary function of the cover is to close the stem box and to offer a structure to hold the steering units,
the azimuth feedback unit and other related equipment.
The cover has:
the cover, to close the stem section.
2.5.4 The steering hub

The primary function of the steering hub is to connect the outer race-way of the slewing bearing to the
steering pipe.
The steering hub has:
the steering hub, to connect the slewing bearing outer race-way to the steering pipe.
2.5.5 The slewing bearing with integrated spur gear

The primary function of the slewing bearing with integrated spur gear is to transmit the rotational force from
the steering units to the steering pipe and to support the steering hub.
The slewing bearing with integrated spur gear has:
the bearing unit, to absorb the axial and radial forces;
the integrated spur gear at the outer race-way, to transmit the rotational force from the steering units
to the steering pipe.
The inner race-way of the bearing unit is bolted onto the bottom seat of the top cover of the stem section.
The the outer race-way is bolted on to the steering hub.
2.5.6 The stem box

The primary function of the stem box is to hold the steering system and the lubrication oil.
The stem box has:
the cone shaped housing, to create a passage through the hull.
2.5.7 The lubrication oil return pipe

The primary function of the lubrication oil return pipe is to create a lubrication oil flow through the stem
section.
The lubrication oil return pipe has:
the return pipe, to allow the lubrication pump to take the oil from the lowest location in the stem
section.
2.5.8 The steering pipe seal

The primary function of the steering pipe seal is to keep the oil filled inside separated from the surrounding
(sea)water at the outside.
The steering pipe seal has:
a lip seal (oil side), to prevent oil leakage from the stem section;
a lip seal (centre), a second defence to prevent (sea)water to enter the stem section;
a lip seal (water side), the first defence to prevent damage by dirt and (sea)water to enter the stem
section.
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2. Description
Optionally the steering pipe seal has:
a lip seal (oil side), to prevent, as second defence oil leakage from the stem section.
2.5.9 The steering pipe bearing

The primary function of the steering pipe bearing is to support the steering pipe and to take the radial forces
caused by the propeller thrust.
The steering pipe bearing has:
the rollers, to transmit the forces from the rotating inner ring to the standing outer ring of the bearing;
the raceways, to provide the hardened track for the rollers to run on with a minimum of wear for a
reliable operation;
the grease, to reduce the friction in the bearing and thus reduce the wear of the bearing.
2.5.10 The steering pipe

The primary function of the steering pipe is to transmit the rotational force from the steering hub to the
propeller gearbox.
The steering pipe has:
the liner, to offer a lower wear running surface for the seals;
the double row, spherical roller bearing, to support and keep the steering pipe in place;
the flange, to connect the propeller gearbox to the steering pipe.
2.5.11 The lubrication oil

The primary function of the lubrication oil is to minimize the wear of the gears and the bearings and to keep
static pressure onto the steering pipe seals.
For detailed information about the lubrication circuit, please refer to the section System description - Lubrication system.
2.5.12 Operation of the stem section

The primary function of the Stem section is to hold the steering system and to offer a structure to connect
the thruster to the vessel.
A steering hub, bolted onto top of the steering pipe, makes it possible to steer the thrust of the propeller
in any direction. The hub runs on a slewing bearing with an integrated spur gear. The steering force, required
to rotate the hub, comes from the hydraulic steering units. The hydraulic steering units have a pinion at the
output shaft. The pinions mesh with the spur teeth of the slewing bearing.
The hull penetration is accomplished by a through-hull cone shaped housing welded into an opening formed
in the hull. The bottom side of the cone shaped housing accommodates a double row roller bearing which
supports the steering pipe and holds it in place.
A steering pipe seal at the bottom of the cylindrical part of the through-hull housing separates the oil filled
inside from the surrounding (sea)water at the outside.
An azimuth feedback unit, installed on the top cover of the stem section, gives the direction of the thrust
of the propeller to the propulsion control system. The feedback unit also contains a mechanical indicator
which is used for local manual (emergency) operation.
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2. Description
Figure 2.7 The stem section - Component information (typical)
2.5.13 The vertical intermediate-shaft arrangement

Refer to figure 2.8, The vertical intermediate-shaft arrangement - Component information (typical).
The function of the vertical intermediate-shaft arrangement is to connect the input shaft of the propeller
gearbox with the output shaft of the upper gearbox.
The vertical intermediate-shaft arrangement has:
the shaft connection with splines (1), to connect the vertical intermediate shaft to the output shaft of
the upper gearbox;
the shaft (2), to transmit the power from the output shaft of the upper gearbox to the input shaft of
the propeller gearbox;
the geared coupling (3), to connect the vertical intermediate shaft to the input shaft of the propeller
gearbox and to give compensation for vibration and slight misalignment of the shaft.
The vertical intermediate shaft runs inside the steering pipe.
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2. Description
Figure 2.8 The vertical intermediate-shaft arrangement - Component information (typical)
2.5.14 The azimuth feedback unit

Refer to figure 2.9: The azimuth feedback unit - Component information (typical)
NOTE!
This description discusses all possible options of the azimuth feedback unit. It is possible that
some of the options are not installed on your vessel. For detailed information, please refer to
the connection diagram which is part of this manual.
The function of the azimuth feedback unit is to translate mechanical steering positions into electrical signals
for use by the control system.
The azimuth feedback unit has:
the housing (1), to protect the potentiometers and the terminal strip;
the potentiometer R12 (B), to give a signal to the propeller position indicator;
the potentiometer R10 (A), to give a signal to the follow up control system;
the terminal strip (2), to make the electrical connections to the azimuth feedback unit;
the visual indicator (5), to show the actual propeller position;
the mounting plate (3), to attach the azimuth feedback unit to stem section;
the azimuth feedback gear (4), to mesh with the spur teeth of the outer bearing ring.
The azimuth feedback unit has optionally:
2-16
the potentiometer R6 (C), to give a signal to the joystick of the propulsion control system;
the potentiometer R8 (C), to give a signal to the Dynamic Positioning (DP) control system.
29 November 2012

2. Description
Operational description
Refer to figure 2.9: The azimuth feedback unit - Component information (typical)
The azimuth feedback unit gets a mechanical input from the steering gear wheel. The mechanical input
comes through the azimuth feedback gear (4) and is internally connected to all installed potentiometers (A,
B and C).
The potentiometer R12 (B) transfers the mechanical position information into a change of resistance of the
potentiometer and therefore the value of the electrical signal which is used by the propeller position indicator on the bridge.
The potentiometer R10 (A) transfers the mechanical position information into a change of resistance of the
potentiometer and therefore the value of the electrical signal which is used by the follow-up control system
which is part of the steering system.
The visual indicator (5) gets the mechanical position information from the spur gear. Change of the mechanical position is directly shown on the indicator.
A movement of the azimuth feedback gear (4) at the azimuth feedback box turns the potentiometer R6 (C)
and R8 (C) at the same time. The potentiometer R6 (C) transfers the mechanical position information into
a change of resistance of the potentiometer and therefore the value of the electrical signal which is used
by the joystick of the propulsion control system.
The potentiometer R8 (C) transfers the mechanical position information into a change of resistance of the
potentiometer and therefore the value of the electrical signal which is used by the DP control system.
For detailed operation of the control system, please refer to the documentation set that came with the applicable control system.
Figure 2.9 The azimuth feedback unit - Component information (typical)
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2. Description
2.6
The steering system
2.6.1 General
The steerable thruster contains a hydraulic system for the azimuth rotation of the thruster.
The azimuth rotation of the thruster is executed by hydraulic motors, which allow the thruster to rotate
360 degrees around its Z-axis. The hydraulic motors are supplied with oil by a Hydraulic Power Pack (HPP).
2.6.2 Description
The steering system has a Hydraulic Power Pack (HPP), a counter balance manifold and steering motorunits which are connected with the related piping and hoses.
Depending on specifications, one or two hydraulic pumps provide flow to actuate the steering motors. The
proportional control valve directs the oil flow from the pumps to the steering motors.
Depending on the steering command to the proportional control valve, the oil flow is lead to the related
port of the steering motor.
The Hydraulic Power Pack (HPP)

The primary function of the HPP is to supply pressurized oil to the components in the system.
The HPP has:
The oil
The primary function of the oil is to transmit the hydraulic power to the steering equipment.
The oil has additives for:
oxidation and thermal stability;
corrosion inhibition.
The service life of the oil is dependent on the operational and storage temperature, particle contamination
and water ingress. The oxidation additives attach to the particles and are removed from the oil by the filter
element, or they sink to the bottom of the tank. You can decrease the oxidation of the oil when the operating
and storage temperature are obeyed and the particle contamination is limited by correct filtration. For detailed
information on the oil in use, please refer to the manufacturer's product and safety data sheets.
The power pack tank

The primary function of the power pack tank is to hold the oil.
The the power pack tank has:
the tank, to hold the oil;
a dip-stick, to inspect the oil level;
a level sensor, to give oil level information to the propulsion control and the integrated automation
system;
a breather element, to keep ambient pressure to the tank;
a drain connection, to remove the oil from the tank;
the return filter, to maintain the required oil cleanliness;
the heat exchanger, to keep the oil at the required operational temperature;
the steering manifold with related control equipment, to control the operation of the HPP;
the junction box, to make the electrical connections.
The steering manifold is equipped with a connection to fill (or top up) the power pack tank. You must use
this connection to make sure the oil gets filtered by the return filter before it enters the power pack tank.
The return filter

The function of the return filter is to maintain the required oil cleanliness.
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2. Description
The return filter has:
the return filter element, to remove the contamination from the oil;
the clogging indicator, to show if the filter element is full with contamination;
the alarm sensor, to give a warning when the filter element is full with contamination;
the internal by-pass valve, to allow the flow around the fully contaminated filter element.
Optionally the return filter is installed in a duplex filter configuration. This configuration allows for maintenance
to one return filter while the other filters the oil. Selection of the filter in use is made by a selection handle.
The pump-unit
The primary function of the pump-unit is to supply oil to the components in the system.
The the pump-unit has:
the (variable displacement) pump, to create the flow to the steering motors;
the pump motor, to drive the pump;
the starter cabinet, to control the electrical operation of the pump motor.
The heat exchanger

The function of the heat exchanger is to keep the oil at the required operational temperature.
The heat exchanger has:
the oil inlet and outlet connection, to connect the oil pipes;
the water inlet and outlet connections, to connect the cooling water pipes to the vessel's cooling
water system;
the heat exchange bodies, to transfer the heat from the oil to the water;
the internal or external by-pass valve, to protect against a too high oil pressure.
The steering manifold

The primary function of the steering manifold is to distribute the oil and to hold the related control equipment.
The secondary function of the steering manifold is to give a connection to fill (or top up) the power pack
tank with filtered oil.
The steering manifold has:
the manifold body, to hold the related control equipment and to distribute the oil to the steering system;
the directional control valve, to allow for steering in Non-Follow-up (back-up) mode;
the proportional control valve, to allow for steering in Follow-up mode;
the valves and switches, to give an interface between the hydraulic system, external systems and
human control;
the measurement connections, to connect (external) maintenance tools.
The steering motor-unit

The primary function of the steering motor-unit is to turn the propeller gearbox with propeller into the required
direction.
The steering motor-unit has:
the hydraulic motor, to convert the hydraulic power into torque and rotation;
the planetary reduction gear, to convert an input rotation into an output rotation;
the pinion at the output shaft, to drive the crown (slewing) gear at the steering pipe.
29 November 2012
2-19

2. Description
The counter balance block

The primary function of the counter balance block is to prevent cavitation of the steering motor-units. The
secondary function of the counter balance block is to prevent unwanted (uncontrolled) movement of the
thruster as a result of negative loads.
The counter balance block has:
2.7
the manifold body, to hold the related control equipment and to distribute the oil to the steering system;
the pilot operated counter balance valves, to allow for a smooth and controlled steering movement
and to prevent unwanted steering movements by external forces;
the safety valve, to prevent the build up of a too high oil pressure;
the non-return valves, to control the distribution of the oil flow in the counter balance block;
the measurement connections, to connect (external) maintenance tools.
The pneumatic system

NOTE!
This description details the installation which is part of the scope of supply and starts from the
air-intake at the air service unit. For a description of the vessel's pneumatic system, please refer
to the documentation that came with the vessel's pneumatic system.
The primary function of the pneumatic system is to reduce the vessel's air pressure to the work pressure
for the connected equipment.
The pneumatic system has:
the brake air control-panel, to prepare and control the compressed air supply for use by the brake.
for the connected equipment..
the static-pressure air control-panel, to prepare and control the compressed air supply for use by the
static pressure system.
for the connected equipment.
the brake air control-panel, to prepare and control the compressed air supply for use by the brake;
the static-pressure air control-panel, to prepare and control the compressed air supply for use by the
static pressure system.
2.7.1 The brake air control-panel

Refer to figure 2.10, The brake air control-panel - Component information (typical).
The primary function of the air control-panel is to prepare and control the compressed air supply for use
by the brake.
The primary components of the air control-panel are:
the air preparation unit (1), to reduce the air pressure and to remove the contamination and condensate
from the compressed air;
the brake control valve (2), to engage or disengage the brake.
The secondary component of the air control-panel is:
2-20
the brake engaged/disengaged switch (a), to give an electrical signal to the propulsion control system.
29 November 2012

2. Description
The air preparation unit

The primary function of the air preparation unit is to reduce the compressed air pressure and to remove
the contamination and condensate from the compressed air.
The air preparation unit has:
the pressure regulator, to set and reduce the air pressure;
the pressure gauge, to show the air pressure;
the filter elements, to remove the contamination and condensate from the compressed air;
the condensate bowls, to hold the filter element, to collect and (automatically) drain the condensate
for the compressed air.
The brake control valve

The primary function of the brake control valve is to engage or disengage the brake.
The brake control valve has:
the valve block, to control the compressed air supply to the brake;
the solenoid, to energize the valve;
the manual override, to disengage the valve when there is an electrical or control failure;
the silencer(s), to reduce the sound of the released air.
Operation of the air control-panel

Refer to figure 2.10, The brake air control-panel - Component information (typical).
The compressed air supply from the vessel enters the air control-panel at the air preparation unit (1). In the
air preparation unit (1), the air pressure is reduced to the operating pressure of the brake. The air in the filter
bowl rotates (by centrifugal forces) which allows the filter element to remove the contamination and condensate (water) from the compressed air. The water flows to the bottom of the bowl where it is drained
automatically or by hand.
The clean and dry air enters the brake control valve (2). When the engage command is given, the air flows
through the brake control valve (2) to the brake. Between the brake control valve (2) and the brake, a pressure
switch, the brake engaged/disengaged switch (a), is installed to give feedback to the control system. High
pressure indicates that the brake is engaged, low pressure indicates that the brake is released.
29 November 2012
2-21

2. Description
Figure 2.10 The brake air control-panel - Component information (typical)
2.7.2 The static-pressure air control-panel

Refer to figure 2.11, The static-pressure air control-panel - Component information (typical).
The primary function of the air control-panel is to prepare and control the compressed air supply for use
by the static pressure system.
The primary components of the static-pressure air control-panel are:
the air preparation unit (1), to remove the contamination and condensate from the compressed air;
the shut-off valve (2), to shut-off the vessel's air supply;
the pressure regulator (3), to reduce the compressed air pressure.
The secondary components of the static-pressure air control-panel are:
the pressure safety valve (a), to relieve the air pressure when the preset value is exceeded;
the pressure transmitter (b), to give pressure feedback to the propulsion control system;
the junction box (c), to make the electrical connections;
the non-return valve (d), to keep the system pressure when the air supply varies or fails.
The air preparation unit

The primary function of the air preparation unit is to remove the contamination and condensate from the
compressed air.
The air preparation unit has:
2-22
the filter element, to remove the contamination and condensate from the compressed air;
the condensate bowl, to hold the filter element, to collect and (automatically) drain the condensate
for the compressed air.
29 November 2012

2. Description
The pressure regulator

The primary function of the pressure regulator valve is to reduce the compressed air pressure.
The pressure regulator has:
the valve block, to set and reduce the air pressure;
the pressure gauge, to show the air pressure;
Operation of the air control-panel

Refer to figure 2.11, The static-pressure air control-panel - Component information (typical).
The compressed air supply from the vessel enters the air control-panel at the shut-off valve (2) through the
non-return valve (d) to the filter bowl of the air preparation unit (1). The air in the filter bowl rotates (by
centrifugal forces) which allows the filter element to remove the contamination and condensate (water) from
the compressed air. The water flows to the bottom of the bowl where it is drained automatically or by hand.
The clean and dry air enters the pressure regulator (3) where the air pressure is reduced to the required
pressure. The air passes a pressure transmitter (b) which is installed to give feedback to the control system.
The compressed air pressure and the static oil pressure from the header tank give the required static
pressure for the propeller shaft and steering pipe seals.
The air control panel has also a pressure safety valve (a). The pressure safety valve (a) releases the air when
the air pressure becomes too high. Too high pressure can cause damage to the seals.
Figure 2.11 The static-pressure air control-panel - Component information (typical)
29 November 2012
2-23

2. Description
2.8
The electrical system
2.8.1 The electrical system

NOTE!
This description details the electrical system that is part of the thruster system. The electrical
power supply from the vessel is beyond the scope of this manual. For information of the vessel's
electrical power supply and distribution, please refer to the manual that came with vessel's
system.
The primary function of the electrical system is to give an interface between the vessel's electrical power
supply and the thruster system. The secondary function is to protect the electrical system of the thruster
and to give feedback of the status.
The primary components of the electrical system are:
the starter cabinet for the prime mover, to supply and control the electrical power to the main drive
motor;
the starter cabinet for the lubrication pump-unit, to supply and control the electrical power to the
pump motor;
the starter cabinet for the steering pump-unit, to supply and control the electrical power to the pump
motor.
NOTE!
This description details the electrical system that is part of the thruster system. The electrical
power supply from the vessel is beyond the scope of this manual. For information of the vessel's
electrical power supply and distribution, please refer to the manual that came with vessel's
system.
The primary function of the electrical system is to give an interface between the vessel's electrical power
supply and the thruster system. The secondary function is to protect the electrical system of the thruster
and to give feedback of the status.
The primary components of the electrical system are:
the starter cabinet for the prime mover, to supply and control the electrical power to the main drive
motor;
the starter cabinet for the lubrication pump-unit, to supply and control the electrical power to the
pump motor;
the starter cabinet for the steering pump-unit, to supply and control the electrical power to the pump
motor;
the starter cabinet for the pitch pump-unit, to supply and control the electrical power to the pump
motor.
2.8.2 The starter cabinet of the prime mover

The function of the starter cabinet is to supply and control the electrical power to the prime mover.
For detailed information, please refer to the documentation that came with the starter cabinet of the prime
mover.
2.8.3 The starter cabinet of the lubrication pump-unit

Refer to figure 2.12, The starter cabinet of the lubrication pump-unit - Component information (typical).
The function of the starter cabinet is to supply and control the electrical power to the pump motor.
The starter cabinet has:
the local control switches:

-
2-24
the MAIN switch, to connect or disconnect the vessel's power supply to the starter cabinet;
29 November 2012

2. Description
-
the L-0-R switch, to set the control over the starter cabinet to Local, 0ff or Remote (bridge) operation.
the local indicators:

-
the Ampere meter, to show the current that is consumed by the pump motor;
the POWER ON indicator, to show that the main switch is set to on and that the electrical circuit
is energized;
the OVERLOAD indicator, to show that the pump motor consumes more electrical power than
necessary as a result of an electrical failure or a mechanical overload;
the RUNNING indicator, to show that the pump motor runs (normal operation);
the STOPPED indicator, to show that the pump motor does not run (normal operation).
the circuit breakers (a), to protect persons against electrical shock and the electrical circuits against
short circuits;
the transformer (b), to change main electrical power into electrical power for the controls;
the main contactor (c) for the pump motor, to connect the electrical power directly (Direct-On-Line)
to the pump motor;
the control signal relays (d), to give a signal to the local indicators and, if applicable, to the vessel's
integrated automation and propulsion control system;
the thermal overload relay (e), to trigger the alarm system when the pump motor suffers from an
overheat condition as a result of an electrical failure or mechanical overload;
the mains switch (f), to connect or disconnect the vessel's power supply to the starter cabinet;
the terminal strip (g), to make the electrical connections.
29 November 2012
2-25

2. Description
Figure 2.12 The starter cabinet of the lubrication pump-unit - Component information (typical)
2-26
29 November 2012

2. Description
Inputs and outputs

The input signals are:
the REMOTE STOPPING signal, to energize the stop relay;
the REMOTE STARTING signal, to energize the start relay.
The output signals are:
the OVERLOAD signal, to indicate that the pump motor consumes more electrical power than necessary;
the CONTROL POWER FAILURE signal, to indicate that the power supply to the control cabinet has
failed;
the RUNNING signal, to indicate that the pump motor is in operation;
the STOPPED signal, to indicate that the pump motor is stopped.
The optional inputs are:
the POWER MOTOR HEATING signal, to indicate that the heating element is in operation;
the EXTERNAL STOP signal, to energize the stop relay.
The optional outputs are:
the PHASE FAILURE signal, to indicate that one or more phases of the electrical power are missing;
the TO MOTOR HEATING power supply, to feed the heating element of the motor with electrical
power.
The electrical power supply comes from the vessel's electrical power grid and is connected to the body of
the main switch. For detailed information about the specifications, please refer to the section General Technical data.
Operation of the starter cabinet

Refer to figure 2.13, The starter cabinet of the lubrication pump-unit - Schematic diagram (typical).
NOTE!
This description details a typical circuit of the starter cabinet which is used in the lubrication
system. For the electrical diagrams for the thruster system as installed on your vessel, please
refer to the schematic diagrams that are part of this section. For the electrical power specifications, please refer to the section General - Technical data.
Local operation
When the main switch is set to on, main electrical power is supplied to the starter cabinet and to the main
contacts of the contactor which energize the pump motor. Also the POWER ON indicator comes on.
Electrical power to the controls equipment comes, through separate circuit breakers (main and control
power), from a transformer. With the L-0-R switch set to the L- or 0-position, the pump motor is in local
control which means that remotely given commands from the vessel's integrated automation and propulsion
control system are ignored.
Start and run

When the L-0-R switch is set to the L-position and the main switch is set to on, the main contactor
gets energized and the pump motor comes on direct-on-line (DOL). Also the RUNNING indicator
comes on and the STOPPED indicator goes off.
Stop
When the L-0-R switch is set to the 0-position and the main switch is set to on, the main contactor
gets de-energized and the pump motor goes off. Also the RUNNING indicator goes off and the
STOPPED indicator comes on.
Overload condition
When the pump motor has an overload condition, the power consumption rises beyond the set value
of the thermal overload relay. The pump motor and the RUNNING indicator stay on and the OVERLOAD
29 November 2012
2-27

2. Description
indicator comes on. The pump motor only stops after a human stop-command or a fatal failure of the
pump motor itself.
Short circuit / Earth leak condition

When there is a short circuit or an earth leak in the main power circuit, the main circuit breaker trips
and the power is removed from the starter cabinet and all indicators go off. Because the main contactor gets de-energized, the pump motor also stops.
Operation by the vessel's integrated automation and propulsion control system

power), from a transformer. With the L-0-R switch set to the R-position, the pump motor is in remote control
which means that remotely given commands from the vessel's integrated automation and propulsion control
system are executed.
2-28
Start and run

When a start command is received from a remote control panel, the start relay is energized. The start
contact of the start relay closes and the main contactor gets energized and the pump motor comes
on direct-on-line (DOL). Also the RUNNING indicator comes on and the STOPPED indicator goes off.
Stop
When a stop command is received from a remote control panel, the start relay gets de-energized.
The stop relay gets energized which de-energizes the start relay. The start contact of the start relay
opens and the main contactor gets de-energized and the pump motor stops. Also the RUNNING indicator goes off and the STOPPED indicator comes on.
Overload condition
pump motor itself.

29 November 2012

2. Description
Figure 2.13 The starter cabinet of the lubrication pump-unit - Schematic diagram (typical)
2.8.4 The starter cabinet of the pitch pump-unit

Refer to 2.14, The starter cabinet of the pitch pump-unit - Component information (typical).
The function of the starter cabinet is to supply and control the electrical power to the pump motor
The starter cabinet has:
the local control switches:

-
the MAIN switch, to connect or disconnect the vessel's power supply to the starter cabinet;
the L-0-R switch, to set the control over the starter cabinet to Local, 0ff or Remote (bridge) operation.
the local indicators:

-
the Ampere meter, to show the current that is consumed by the pump motor;
the POWER ON indicator, to show that the main switch is set to on and that the electrical circuit
is energized;
the OVERLOAD indicator, to show that the pump motor consumes more electrical power than
necessary as a result of an electrical failure or a mechanical overload;
the RUNNING indicator, to show that the pump motor runs (normal operation);
the STOPPED indicator, to show that the pump motor does not run (normal operation).
the circuit breakers (a), to protect persons against electrical shock and the electrical circuits against
short circuits;
the transformer (b), to change main electrical power into electrical power for the controls;
29 November 2012
2-29

2. Description
2-30
the main contactor (c) for the pump motor, to connect the electrical power directly (Direct-On-Line)
to the pump motor;
the control signal relays (d), to give a signal to the local indicators and, if applicable, to the vessel's
integrated automation and propulsion control system;
the thermal overload relay (e), to trigger the alarm system when the pump motor suffers from an
overheat condition as a result of an electrical failure or mechanical overload;
the mains switch (f), to connect or disconnect the vessel's power supply to the starter cabinet;
the terminal strip (g), to make the electrical connections.
29 November 2012

2. Description
Figure 2.14 The starter cabinet of the pitch pump-unit - Component information (typical)
29 November 2012
2-31

2. Description
Inputs and outputs

The input signals are:
the REMOTE STOPPING signal, to energize the stop relay;
the REMOTE STARTING signal, to energize the start relay.
The output signals are:
the OVERLOAD signal, to indicate that the pump motor consumes more electrical power than necessary;
the CONTROL POWER FAILURE signal, to indicate that the power supply to the control cabinet has
failed;
the RUNNING signal, to indicate that the pump motor is in operation;
the STOPPED signal, to indicate that the pump motor is stopped.
The optional inputs are:
the POWER MOTOR HEATING signal, to indicate that the heating element is in operation;
the EXTERNAL STOP signal, to energize the stop relay.
The optional outputs are:
the PHASE FAILURE signal, to indicate that one or more phases of the electrical power are missing;
the TO MOTOR HEATING power supply, to feed the heating element of the motor with electrical
power.
The electrical power supply comes from the vessel's electrical power grid and is connected to the body of
the main switch. For detailed information about the specifications, please refer to the section General Technical data.
Operation of the starter cabinet

Refer to figure 2.15, The starter cabinet of the pitch pump-unit - Schematic diagram (typical).
NOTE!
This description details a typical circuit of the starter cabinet which is used in the pitch system.
For the electrical diagrams for the thruster system as installed on your vessel, please refer to
the schematic diagrams that are part of this section. For the electrical power specifications,
please refer to the section General - Technical data.
Local operation
power), from a transformer. With the L-0-R switch set to the L- or 0-position, the pump motor is in local
control which means that remotely given commands from the vessel's integrated automation and propulsion
control system are ignored.
2-32
Start and run

When the L-0-R switch is set to the L-position and the main switch is set to on, the main contactor
gets energized and the pump motor comes on direct-on-line (DOL). Also the RUNNING indicator
comes on and the STOPPED indicator goes off.
Stop
When the L-0-R switch is set to the 0-position and the main switch is set to on, the main contactor
gets de-energized and the pump motor goes off. Also the RUNNING indicator goes off and the
STOPPED indicator comes on.
Overload condition
29 November 2012

2. Description
pump motor itself.

Operation by the vessel's integrated automation and propulsion control system

power), from a transformer. With the L-0-R switch set to the R-position, the pump motor is in remote control
which means that remotely given commands from the vessel's integrated automation and propulsion control
system are executed.
Start and run

When a start command is received from a remote control panel, the start relay is energized. The start
contact of the start relay closes and the main contactor gets energized and the pump motor comes
on direct-on-line (DOL). Also the RUNNING indicator comes on and the STOPPED indicator goes off.
Stop
When a stop command is received from a remote control panel, the start relay gets de-energized.
The stop relay gets energized which de-energizes the start relay. The start contact of the start relay
opens and the main contactor gets de-energized and the pump motor stops. Also the RUNNING indicator goes off and the STOPPED indicator comes on.
Overload condition
pump motor itself.

29 November 2012
2-33

2. Description
Figure 2.15 The starter cabinet of the pitch pump-unit - Schematic diagram (typical)
2.9
The propulsion control system

The propulsion control system transmits orders from the control station in command to the vessel's integrated
automation system and the thruster installation.
The detailed description and operation of the propulsion control system is beyond the scope of this
manual, please refer to the technical documentation that came with the propulsion control system.
2.10 The prime mover

The function of the prime mover is to change the electrical energy into mechanical power to drive the propeller.
The prime mover has:
the E-motor with variable speed, to change the electrical energy into mechanical power;
the starter cabinet, to control the operation of the electric motor and to communicate with the vessel's
integrated automation system and propulsion control system.
The detailed description and operation of the prime mover is beyond the scope of this manual, please refer
to the technical documentation that came with the prime mover.
2.11 Drawings
DAAK018950 C
DAAK101429 C
DAAK101812 B
DAAK102649 DAAK018296 A
2-34
General arrangement of the thruster .................................................................... 2-35

Block diagram thruster installation ....................................................................... 2-36
I/O and settings list thruster installation mechanical parts ................................... 2-37
Paint specification ................................................................................................ 2-43
Anode plan ........................................................................................................... 2-45
29 November 2012

DAAK018950 C - General arrangement of the thruster
Approved
29 November 2012
2-35

DAAK101429 C - Block diagram thruster installation
jge008 Gerrits
jge008 Gerrits
25.01.2012
25.01.2012
Approved
2-36
29 November 2012
29 November 2012
2012.09.21
DAAK101812
Geerten Paulussen
: Hyundai Heavy Industries Co., Ltd.

: Hyundai Heavy Industries Co., Ltd.
: P136
Thruster type :
Class :
: MP/01680.M1T11+T12
G.P.
FK
Initials
FS2510-/2500 WO
DNV + IRS, +1A1 E0 DYNPOS AUT, NAUT-AW, Comf. V(3) and C(3), DK(+) IRS & SUL,
IY, DP(1), IBS, SYJIMO DP-1
Description
Added (final) pressure setting Pneumatic panel head pressure. Added information from supplier. Removed 273.04 at
Steering power pack.
Clarified I/O-list regarding steering power pack.
Definitions and conventions

This list only describes components that are on mechanical parts of the thruster
1
All contacts are potential-free and suitable for, at least, 24 VDC/500 mA
2
By default all alarm contacts are closed when there is no alarm situation
3
Galvanic isolation according specifications of control system
4
In case switches are connected with Red - White - Blue shielded cables:
Red wire to be connected to "common" terminal at sensor side
5
White cable to be connected to closed contact at non loaded condition
Blue cable to be connected to open contact at non loaded condition
LGB = propeller (out board) gear box, UGB = upper (inboard) gear box
6
D.W. (in column Junction box no.) = Direct Wired (no junction box supplied)
7
For information about process codes see DMYI000073
8
Yard
Owner
N.B. no.
WRTSIL ORDER no.
2012.05.09
Date
Engineering
2012.01.19
Revision
Revision control
Department:
Creation date:

Document Owner:
Rev. No:
B
Document No:
I/O and settings list thruster installation mechanical parts
Document title:

DAAK101812 B - I/O and settings list thruster installation mechanical parts
2-37
2-38
Y201B-A
Y206A-A
Y206B-A
243.2-A
271-A
273.01-A
273.03-A
273.05-A
273.06-A
298-A
Y201A-A
Position
code
PZ
LSAL
PSAH
PSL
PSAH
PSAL
TSAH
Steering power pack A
Function
Clockwise steering actuation
Valve solenoid
(follow up)
Counter clockwise steering actuation
(follow up)
Valve solenoid
Valve solenoid
Valve solenoid
Press. safety valve Steering actuation
Level switch
Oil level
Pressure switch
Clogged filter
Pressure primary pump available
Pressure switch
Pressure switch
Filter external by-pass
Pressure switch
System pressure
Temperature switch Oil temperature
Process
code
Description
Components on :
Open when level low

Open when pressure drop over filter too high
Closed when pump running
Open when filter is set to by-pass
Open when pressure too low
Open when temperature too high
Proportional 12 VDC / 2.5 A

24 VDC / 1,29 A / 31 W
24 VDC / 1.29 A / 31W
Type / Range
Closed when pressure is available

Sin/Cos
Sin/Cos
Triangle
Triangle
Sin/Cos
Type / Range
Function
Head pressure PGB
Lub. oil pressure UGB available
Low lub. oil pressure UGB
Lub. oil temperature UGB
Feed back actual steering angle
Feed back steering angle (indicator)
Feed back steering angle (indicator)
Description
Press. safety valve
Pressure switch
Pressure switch
Temperature switch
Potentiometer
Potentiometer
Potentiometer
Potentiometer
Potentiometer
Position
code
427.04
460.01
460.02
475.02
R6
R8
R10
R12
R13
Process
code
PZ
PSL
PSAL
TSAH
GC
GC
GC
GC
GC
Thruster (on steering gear cover or UGB)
Components on :
1,2
8
3
6
65
24
24
172
bar
bar
bar
bar
C
V
V
bar
Set
point
/
Value Uom
Set
point
/
Value Uom
3,0 bar
0.4 bar
0.6 bar
70 C
2
k
2
k
2.5
k
2.5
k
2
k
12
12
12
7
7
7
7
7
Alarm
Alarm
Controls
Alarm
Alarm
Alarm
Controls
Controls
Controls
Controls
9A
9A
9A
9A
9A
9A
9A
9A
9A
9A
Input for:
/
Junction
Output from: box no.
Controls
Alarm
Alarm
JS-system
DP-system
Controls
Controls
Controls
Input for:
/
Junction

29 November 2012
29 November 2012
PZ
LSAL
PSAH
PSL
PSAH
PSAL
TSAH
Position
code
427.02
427.03
461.01
461.02
461.03
461.04
463.01
463.02
475.01
475.03
Process
code
PZ
PZ
PSL
PSAL
PSL
PSAL
PSAH
PSAH
TSAH
TT
Steering power pack B
Description
Press. safety valve
Press. safety valve
Pressure switch
Pressure switch
Pressure switch
Pressure switch
Pressure switch
Pressure switch
Temperature switch
Temp. transmitter
Open when level low

Closed when pump running
Open when filter is set to by-pass

24 VDC / 1,29 A / 31 W
24 VDC / 1.29 A / 31W
Type / Range
Function
Primary lub oil pump set
Secondary lub oil pump set
Lub. oil press. primary pump avail.
Lub. oil press. primary pump too low
Lub. oil press. second. pump avail.
Lub. oil press second. pump too low
Clogged filter primary pump set
Clogged filter secondary pump set
Lub. oil temperature LGB
Starting condition primary pump set
1,2
8
3
6
65
24
24
172
bar
bar
bar
bar
C
V
V
bar
Set
point
/
Value Uom
Set
point
/
Type / Range
Value Uom
9 bar
8 bar
0,3 bar
0,3 bar
0,3 bar
0,3 bar
Open when pressure drop over filter too high 3,5 bar
70 C
4 - 20 mA
45 C
Lubrication system lower gear box
Function
Valve solenoid
(follow up)
Valve solenoid
(follow up)
Valve solenoid
Valve solenoid
Press. safety valve Steering actuation
Oil level
Level switch
Clogged filter
Pressure switch
Pressure primary pump available
Pressure switch
Filter external by-pass
Pressure switch
System pressure
Pressure switch
Temperature switch Oil temperature
Process
code
Description
Components on :
Y201B-B
Y206A-B
Y206B-B
243.2-B
271-B
273.01-B
273.03-B
273.05-B
273.06-B
298-B
Y201A-B
Position
code
Components on :
9B
9B
9B
9B
9B
9B
9B
9B
9B
9B
Controls
Alarm
Controls
Alarm
Alarm
Alarm
Alarm
Controls
10
10
10
10
10
10
10
10
Input for:
/
Junction
Alarm
Alarm
Controls
Alarm
Alarm
Alarm
Controls
Controls
Controls
Controls
Input for:
/
Junction

2-39
2-40
Function
Type / Range
Max. head pressure
Head pressure
Head pressure level detection (for alarm) 4 - 20 mA
Description
Press. safety valve
Pressure control
Pressure transm.
Position
code
427.07
438
466.02
Process
code
PZ
PC
PT
Pneumatic panel head pressure
Components on :
Type / Range
Open when level too low
Function
Oil level
Process
code
Description
LSAL
Level switch
Position
code
450.02
Open when level too low
Type / Range
Lubrication oil tank upper gear box
Process
code
Description
Function
PZ
Press. safety valve Pneumatic head pressure
Oil level
LSAL
Level switch
Components on :
Position
code
427.05
450.01
Lubrication oil tank lower gear box
Set
point
/
Value Uom
0,5 bar
0,3
bar
Set
point
/
Value Uom
Set
point
/
Value Uom
0,5 bar
Set
point
/
Value Uom
Type / Range
10 bar
Lubrication system upper gear box
Process
code
Description
Function
PZ
Press. safety valve Lub oil pump pressure
PSAH
Pressure switch
Clogged filter
Sensors and actuators on :
Position
code
434
464.01
Components on :
12
D.W.
Controls
14
Input for:
/
Junction
Input for:
/
Junction
Alarm
D.W.
Alarm
Input for:
/
Junction
Alarm
Input for:
/
Junction

29 November 2012
29 November 2012
Position
code
JB5.2
JB7
JB9A/B
JB10
JB12
JB14
D.W.
Jensen
Default functions
Shaft speed detection, brake allowance
Azimuth feed back
Steering power pack / pump set
Pump set LGB lubrication
Main
Pneumatic head pressure panel
Direct wired components
Water separator
JUNCTION BOXES & WIRING
7
0.4
bar
bar
Set
point
/
Value Uom
Steering gear cover

Power pack / pump set
Pump set
On thruster
On tank or loose delivery
D.W.
12
12
Input for:
/
Junction
Alarm
Jensen
Controls
Controls
Controls
Input for:
/
Junction
Controls
D.W.
Wiring diagram
PAAI031938
DAAK000920
DAAK100256
DAAK100259
DAAK018233
DAAK100217
DAAK018232
Set
point
/
Value Uom
Type / Range
2
bar
Position on installation
Function
Clogged filter
Position
code
464.05
Process
code
Description
PSAH
Pressure switch
Water separator (Jensen)
Components on :
Open when brake engaged

12 pulses per revolution
12 pulses per revolution
Type / Range
24 VDC / 1.2 W
Function
Engage brake
Supply pressure towards brake
Brake engage pressure detection
Shaft speed detection, brake allowance
Shaft speed detection (redundant)
Position
code
Y601
622
654
656.01
656.02
Process
code
Description
Valve solenoid
PC
Pressure regulator
PSH
Pressure switch
GS
Proximity switch
GS
Proximity switch
Shaft brake (control panel and speed pickups)
Components on :

2-41
2-42
Function
Primary steering pump
E-motor stand still heating
Secondary steering pump
Water separator oil heater(s)
Lubrication pump UGB
Primary lub oil pump LGB
Secondary lub oil pump LGB
Water separator pump
0,042
1,65
7,5
0,04
2,8
0,026
1,4
0,025
0,21
0,042
Power S1 [kW]
Power S6 [kW]
60,6
N.A.
60,6
N.A.
N.A.
N.A.
N.A.
N.A.
N.A.
N.A.
N.A.
N.A.
Voltage [V]
440
230
440
230
N.A.
440
230
440
230
440
230
440
Position
code
240.01A
240.01B
422.01
422.02
422.03
423.01
425
PUMPS
Function
Primary steering pump
Secondary steering pump
Lubrication pump UGB
Primary lub oil pump LGB
Secondary lub oil pump LGB
Water separator pump
UGB level pump
Actual flow per pump [dm3/min]

179
179
110
36
11
1,8
15,5
Remarks:
For E-motor used in S1 duty only, the S6 power will normally not be stated.
For E-motors used in S6 duty the Inom current is valid for the S6 duty only
For E-motors started with / sequence, the starting current is stated for the stage only
Water separator has common input for power supply to E-motor and heaters
208.01A
208.01AS
208.01B
208.01BS
401
403.01
403.01S
403.02
403.02S
403.03
403.03S
406
Position
code
E-MOTORS (or other components requiring electric power)
60
60
60
60
60
60
60
60
60
60
60
60
Frequency [Hz]
Connection
acc.
Inom [A]
70
N.A.
0,183
70
N.A.
0,183
N.A.
2,16
11,9
N.A.
0,017
5,5
N.A.
0,113
3
N.A.
0,109
N.A.
0,54
Istart [A]
497
N.A.
497
N.A.
N.A.
91,63
N.A.
33,55
N.A.
18,9
N.A.
1,9

29 November 2012

DAAK102649 - - Paint specification
Paint Specification
All rights reserved. Nothing from this publication may be reproduced, or disclosed without prior written approval of Wrtsil Propulsion Netherlands B.V.
Document owner: D. Nas
Issue Date
Page
Doc. no.
Rev.
12.03.2012
1/2
DAAK102649
--
1.1 Pre-treatment.
Surface treatment
Activity
Cleaning and de-greasing
Remove all oil, grease, salt and other contamination.
Blasting
SA 2,5 according ISO 8501-1
Surface roughness / blast profile
50 Rz micron (minimum)
Remove blast dust
Removal of all present blast residue & dust.
General(not to be blasted): stainless steel, bronze/brass, rubber/synthetic/plastic, machined
surfaces / areas as well fit and sliding surfaces.
All items indicated by a red dot (sticker) should not be blasted and painted.(initiated by eng. Dept.)
All items otherwise indicated by Wartsila, Wartsila representative or as stated on drawings.
Always protect seals and sensitive equipment during blasting and coating operations.
No masking tape used during blasting shall be used during coating operations.( apply new tape )
Consult coating application & safety data sheets before start of coating operations.
1.2 Coating.
Dry parts (inboard parts) & Hydraulic equipment incl. systems.
Layer
1
2
Coating manufacturer & Type

International Intergard 7600 KUA763/A
Pure epoxy universal primer
International Interthane 990 PHG360/A
Polyurethane Finish
Colour & Colour no.

Grey
DFT min.
75
DFT max.
150
Aquamist blue
50
100
125
250
Colour & Colour no.

Red Aluminium
DFT min.
200
DFT max.
300
Light Grey
100
150
Red
125
200
Brown
125
200
550
850
3
N/A
4
N/A
Total DFT (microns)
Wet parts (outboard parts)

Layer
1
2
Coating manufacturer & Type

International Intergard 7600 KUA760
Pure epoxy universal primer
International Intergard 263 FAJ034
Epoxy tie coat
International Intersmooth 7460HS SPC
BEA757
TBT Free, low friction, self polishing
copolymer A/F
International Intersmooth 7460HS SPC
BEA754
TBT Free, low friction, self polishing
copolymer A/F
5
N/A
6
N/A
Total DFT (microns)
29 November 2012
2-43

DAAK102649 - - Paint specification
Paint Specification
All rights reserved. Nothing from this publication may be reproduced, or disclosed without prior written approval of Wrtsil Propulsion Netherlands B.V.
Document owner: D. Nas
Issue Date
Page
Doc. no.
Rev.
12.03.2012
2/2
DAAK102649
--
1.3 Coating contractor information.
Apply stripe coat on all edges, bolt pockets, bolts, nuts, underneath anodes, locking wire, etc, and always
according best coating practise.
Applied coating must be free of any coating defect and should have a good cosmetic appearance.
Dry Film Thickness (DFT) according the minimum requirement as stated in section 1.2
Method of application: Airless spray equipment.
Thinning of the product(s): According manufacturer datasheet
Check application & safety data sheets before the start of the blast and coating operations.
Inspection and witness of the preparation and coating works can be carried out by Wrtsil and
stakeholders at all times.
Anodes, propeller, and stainless steel to be masked off during blast and coating operations.
Extreme caution must be taken when blasting around seal areas. (seals to be protected)
Always refer to manufacturers data, application and safety sheets.
1.4 Information for yard and owner.
Due to positioning, hoist and handling operations at coating contractors site or during transportation
small areas could be affected / damaged. (Scratches, rubbing marks) especially on anti-fouling coatings.
1.5 Preservation Fluid. (coating contractor)
2-44
Apply preservation fluid on all non coated metal parts. (preservation fluid suitable for 1 year outdoor
preservation)
29 November 2012

DAAK018296 A - Anode plan
29 November 2012
2-45
This page intentionally left blank
2-46
29 November 2012

3. Operation
3.
Operation
This chapter gives the instructions for the operation of the system. The instructions include the start, stop
and emergency procedures.
3.1
Performance limitations
This section gives the operational limitations after a failure of a system or a part of that system.
3.1.1 The gearbox arrangement

Failed equipment
Limitation
The propeller shaft seal
Reduce the propeller speed to limit water Increase the static pressure of the lubricingress in the lubrication oil.
ation oil.
Take an oil sample.
What to do / remarks
3.1.2 The stem section

Failed equipment
Limitation
The steering pipe seal
Reduce the steering movements to limit Increase the static pressure of the lubricwater ingress in the lubrication oil.
ation oil.
Take an oil sample.
The azimuth feedback unit - Con- Use of the Follow-Up mode is not pos- Use the Non Follow-Up mode.
trols potmeter failure
sible.
Control by the Dynamic Positioning, Auto
Pilot or Joy-stick system is not possible
(if installed).
3.1.3 The lubrication system

Failed equipment
Limitation
The lubrication circulation pump
Limitation of the propeller speed by the Reduce the speed, higher speeds generoil temperature.
ate more heat.
Take an oil sample.
The upper gearbox is, possibly, fully filled
with lubrication oil
There is no circulation, filtration and
cooling of the lubrication oil. The
(sea)water that surrounds the propeller
gearbox is the only source to cool the
lubrication oil.
You can not start the prime mover as
usual.
Override the start condition: 'Lub oil

pressure available' is not valid.
The lubrication level pump
ate more heat.
The upper gearbox is, possibly, fully filled
with lubrication oil.
Take an oil sample.
The oil filter element
No limitations.
The heat exchanger
ate more heat.
The (sea)water that surrounds the propeller gearbox is the only source to cool
the lubrication oil.
29 November 2012
The lubrication oil gets not filtered anymore.
3-1

3. Operation
3.1.4 The static pressure system

Failed equipment
Limitation
The static-pressure air-control

panel
Limitation of the propeller speed to re- Reduce the speed.

duce the risk of water ingress in the lub- Static pressure of the lubrication oil is
rication oil.
too low.
Take an oil sample.
3.1.5 The pneumatic system

NOTE!
The main air-supply system is beyond the scope of this operation and maintenance manual.
For detailed information, please refer to the documentation that came with the main air-supply
system. Only the result of a main air failure for the thruster system is given, be aware that more
equipment can fail as a result of a main air supply failure.
Failed equipment
Limitation
Main air supply
The brake disengages and can not engage by remote control commands.
When the thruster is stopped, the propeller can turn freely by external forces.
Limitation of the propeller speed to re- Static pressure of the lubrication oil is
duce the risk of water ingress in the lub- too low.
rication oil.
Take an oil sample.
3-2
The brake air control-panel
Brake disengages and can not engage

by remote control commands.
When the thruster is stopped, the propeller can turn freely by external forces.
The static-pressure air controlpanel
Limitation of the propeller speed to re- Stop the thruster.

duce the risk of water ingress in the lubrication oil.
29 November 2012

3. Operation
3.2
Checklist steering gear

You can use this checklist to test the steering system as given in the departure requirements of SOLAS
chapter V, regulation 26; Steering gear. For future reference, put a copy of the completed checklist in the
vessel's operation logbook.
Name
Signature
Date
NOTE!
Interval
The cooling water supply-system is beyond the scope of this manual, for detailed instructions,
please refer to the documentation that came with the cooling water supply-system.
Description
Task summary
OK / Not OK /
Not done
Required action
(Make a note of any anomaly)
Do a visual inspection Do an inspection for leaks, correct oil

of the steering system. level, damage, correct installation and
signs of corrosion. Do any necessary
work.
Do an inspection of
Do an inspection of the oil level in the
the lubrication system. header tank. A correct level in the header
tank indicates that the slewing bearing
and gearbox of the steering motor are
filled with lubrication oil. Do any necessary work.
Do a visual inspection Do an inspection for water leaks. Make
of the heat exchanger. sure, the water flows through the heat
exchanger. Do any necessary work.
Start the steering sys- Make sure it is safe to start the steering
tem.
system.
No alarms are given.
The clogging indicator on the filter unit
stays green.
29 November 2012
3-3

3. Operation
Description
Task summary
Turn the thruster.
Make sure, it is safe to turn the thruster.

At the bridge, on each propulsion control
panel, select Non-Follow-Up and turn
the thruster 360 in CW direction.
Make sure, the indicator follows the
steering command correctly.
OK / Not OK /
Not done
Required action

panel, select Non-Follow-Up and turn
the thruster 360 in CCW direction.
Bring the thruster in the 0 position.
panel:
select Follow-Up;
turn the thruster 90 in the CW

direction;
allow the thruster to stop at the

requested position.
Repeat for the 180, 270 and 360 positions.

Bring the thruster in the 0 position.
panel:
select Follow-Up;
turn the thruster 90 in the CCW

direction;
allow the thruster to stop at the

requested position.
Repeat for the 180, 270 and 360 positions.

On each local control panel, turn the
thruster 360 CW.
On each local control panel, turn the
thruster 360 CCW.
On the engine control panel, in Non-Follow-Up mode, turn the thruster 360 in
the CW direction.
On the engine control panel, in Non-Follow-Up mode, turn the thruster 360 in
the CCW direction.
3-4
29 November 2012

3. Operation
Description
Task summary
OK / Not OK /
Not done
Required action
Do a inspection of the Ask the navigational officer on duty to

indicator on the aziturn the thruster to 0 and make sure,
muth feedback unit.
the indicator shows 0.
Ask the navigational officer on duty to
turn the thruster to 90 in CW direction
and make sure, the indicator follows the
Allow the thruster to stop at the requested position.
Repeat for the 180, 270 and 360 positions
Do any necessary work.
29 November 2012
3-5

3. Operation
3.3
Start the thruster
3.3.1 Start after a short stop

WARNING!
Make sure, it is safe to start the thruster. It is unsafe to start the thruster if there is maintenance in progress or if
there are persons in the water. Unsafe conditions can cause (serious) injury to persons and damage to equipment.
Start the thruster:
1. Start the lubrication pump.

2. Start the steering pump.
3. Make sure, there are no alarms.
4. Do an operational test of the steering system. Make sure, the system operates
correctly.
5. Disengage the brake.
6. Start the prime mover.
3.3.2 Start after an emergency stop

An emergency stop is regarded as an uncontrolled stop of the prime mover (activation of the emergency
stop button). After an emergency stop it is assumed that there is no damage to the thruster.
Make the system safe:
1. Remove the cause of the emergency stop.

2. If necessary, engage the brake.
3. Reset the emergency stop circuit.
4. Make sure, it is safe to restart the thruster. Do any necessary work.
WARNING!
Make sure, it is safe to start the thruster. It is unsafe to start the thruster if there is maintenance in progress or if
there are persons in the water. Unsafe conditions can cause (serious) injury to persons and damage to equipment.
Start the thruster:
1. If necessary, start the lubrication pump.

2. If necessary, start the steering pump.
3. Make sure, there are no alarms.
4. Do an operational test of the steering system. Make sure, the system operates
correctly.
5. Disengage the brake.
6. Start the prime mover.
For a quick inspection:
3-6
Make sure:
there are no signs of a leak;
there are no unusual noises;
there are no unusual vibrations;
there are no unusual alarms;
the indicators/gauges show a correct value.
29 November 2012

3. Operation
3.4
Operate the thruster
3.4.1 Steering behaviour

The thrusters are used as a propulsion device which is also used as a rudder. If you want to steer to port
side or starboard, allow the vessel a few moments to respond to the steering command. The response time
to the steering command varies with the mass of the vessel and the propeller speed of each thruster.
Pay special attention to the azimuth indicators. The azimuth indicators show the position of the related
thruster with respect to the vessel and not necessarily the direction you want to go to. The thrusters, installed
astern, (main propulsion) act in the same way as a twin outboard-engine.
For nominal operation of the thrusters, make sure no turbulent water (water wash from another thruster)
enters the thruster. Turbulent water decreases the thrust and affects the steering behaviour. Turbulent
water that enters a thruster also causes propeller cavitation. Cavitation results in less thrust than expected,
a lot of noise and in the long term, in serious damage of the outboard parts and surface of the vessel.
To prevent unexpected steering behaviour and unnecessary damage, make sure turbulent water can not
enter the thruster. To keep out turbulent water and for a smooth steering behaviour it is advised to limit the
steering actions to a maximum of 30 with respect to direction of sailing. With the two thrusters installed
next to each other, the maximum steering angle is approximately 45. Beyond 45, turbulent water is likely
to enter the other thruster because the water has had no time to 'straighten' itself.
Sail to port
Sail ahead
Sail to starboard
Maximum azimuth
3.4.2 Unwanted thruster positions

Turbulent water caused by the water wash of a thruster decreases the thrust of another
thruster, affects the steering behaviour and can cause serious damage. For this reason,
do not turn the thrusters towards each other.
If you turn the thrusters towards each other:
the water wash (thrust) from thruster A blocks the thrust of thruster B and vice
versa.
the water wash of the thrusters generate an excessive mechanical load to the
vessel and the thrusters which will finally result in structural damage;
there will be no significant change in the vessel's speed.
29 November 2012
3-7

3. Operation
3.4.3 Sailing
Berthing
In the given situation, berthing is done with thruster A in use for berthing operation and
thruster B is in standby to support thruster A.
If installed, the transverse thruster in the bow is used as required to complete the
berthing operation.
Do not turn thruster A and B in the same direction because the water wash from thruster B
will affect the performance of thruster A.
3-8
29 November 2012

3. Operation
3.4.4 Crash stop of the vessel

WARNING!
NEVER turn the thrusters towards each other. The water wash from thruster A will remove all thrust from
thruster B and vice versa. If you turn the thrusters towards each other, you will loose all control and
power at the moment you need it most. Incorrect crash stop manoeuvres can cause (serious) injury to
people and damage to equipment or environment.
Reference information
A crash stop is a human action to slow down and stop the vessel as quickly as possible, to prevent (serious)
injury to persons and damage to equipment or environment (e.g. a quay, loss of oil, etc.).
A crash stop means decrease the speed [rpm] of the prime movers and change the direction of the thrusters
by hand. This means that you must take over control to the control panel which is in front of you.
A crash stops means that you need control and thrust at any moment during the stop. Quick means do not
unnecessarily decrease the speed (loss of thrust) and do not create excessive loads (turn the thrusters
correctly).
A crash stop is usually done with the use of the two thrusters that are next to each other. All other propulsion
equipment must only be decreased in speed as quick as possible or shut down.
Crash stop procedure

Summary
Procedure
Take control.
Take over the control to the propulsion control panel in

front of you.
Decrease the speed to 70%.
Simultaneously, decrease the speed to 70%, 50% is better

but not always possible by the make of the prime mover.
The make of the prime mover can force you to turn the
thruster at a higher speed.
In a short period of time, you will need as quick as the Emotor allows, the full 100%
Turn the thrusters outwards.
Simultaneously, turn the thrusters outwards to avoid loss

of thrust when the wash hits the other thruster.
Turn the thrusters to 180.
Wait for the azimuth indicators to respond. If response is

visible, simultaneously turn the thrusters to 180.
With the thrusters at 135 and 225,

increase engine speed to 100%.
If the azimuth indicators show 135 and 225, simultaneously, increase the speed to 100%, but do not stall the
engines.
If stopped and safe,

cut the engine speed to 0%.
If the vessel is at zero speed or at a safe distance from the

dangerous situation, cut the engine speed to 0%.
Evaluate the situation and prepare for further actions.
As a result of the operational decision by the commanding

officer, do any procedure as required for the situation.
29 November 2012
3-9

3. Operation
Crash stop procedure
3.5
Never !
Stop the thruster
3.5.1 Stop the thruster when sailing

CAUTION!
Do not sail with a stopped thruster in 0 (ahead). The propeller of a stopped thrusters in 0 can reach a
trailing speed beyond the allowed speed. A (trailing) propeller speed beyond the allowed speed will cause
(serious) damage to the gears and the bearings.
CAUTION!
Before you sail with a thruster not in use, get a confirmation from the manufacturer of the prime mover
that you can sail without the risk of mechanical, thermal or electrical damage of the prime mover. A
thruster that is set to off (with a trailing propeller) can cause overheating of the bearings or let the prime
mover operate as a generator.
NOTE!
3-10
If sailing with a thruster not in operation, as a result of the external forces of the surrounding
water,
the propeller can turn freely. To prevent damage to the gears and bearings, the lubrication
system must stay on.
the thruster can turn freely in azimuth. To prevent unexpected movements, the steering
system must stay on.
29 November 2012

3. Operation
Stop the thruster:
1. If in command, disconnect the external propulsion control system (e.g. the

autopilot system).
2. Turn the thruster, with respect to the direction of sailing, to the 90 position.
3. Stop the prime mover.
4. If sailing, leave:
Stop the thruster:
the lubrication system in operation, to prevent damage to the gears and

bearings.
the steering system in operation, to hold the thruster in the 90 position.

dynamic positioning system).
Stop the thruster:

bearings.

joystick system).

bearings.
3.5.2 Normal stop of the thruster

@@@
NOTE!
The pneumatic system is beyond the scope of this manual. For detailed instructions, please
refer to the documentation that came with the pneumatic system.
Stop the thruster:
1. If in control, disconnect the external control system.

2. If applicable, set the brake to standby.
4. Make sure, the brake is engaged.
For the steering system:
1. Stop the steering system.
For the lubrication system:
1. Stop the lubrication system.
For the pneumatic system:
1. Leave the pneumatic system in operation, to hold:
29 November 2012
the brake engaged. The brake disengages automatically when the

pneumatic air supply gets too low;
the static pressure correct for the propeller shaft seal and the steering
pipe seal. Water ingress into the lubrication oil is possible when the
pneumatic air supply gets too low.
3-11

3. Operation
3.5.3 Emergency stop of the thruster

If the emergency stop button is pressed, the prime mover shuts down automatically to create a safe situation.
Depending on the configuration of the control circuits and drives, the auxiliary systems can stop also. For
detailed information, refer to the documentation that came with the propulsion control system or the vessel's
safety system.
3.6
Stop the thruster:

autopilot system).
Stop the thruster:

dynamic positioning system).
Stop the thruster:

joystick system).
External controls
3.6.1 Introduction
The propulsion control system has two main operational modes. They are:
Follow-Up (FU) - Daily operation:

The FU mode is used for the daily operation of the thruster system. In the FU mode, the thruster
system is controlled from the remote control panels which are a part of the propulsion control system.
The remote control panels are regarded as the control panels which are not installed in the thruster
room. In the FU mode, a set point, the demand as given by the operator in command, is compared
with the feedback signal that comes from the feedback unit on the thruster itself (the current position).
Here is automatically reacted upon by the propulsion control system to match the set point (demand)
and the feedback signal (current position).
Non Follow-up (NFU) - Back-up:

The NFU mode is used for the back-up operation of the thruster system. In the NFU mode, the
solenoids on the thruster system are no longer controlled by the control software but directly with a
open/close command which is electrically given by the operator. The operation of the NFU-back-up
mode is done from any propulsion control panel either by push buttons or a jog switch and human
decisions. In the NFU mode, the only feedback to the thruster system is the human interaction.
Non Follow-up (NFU) - Emergency operation:

This mode is only used when communication with the (remote) control panels is no longer valid. In
this mode it is possible to operate the hydraulic control valves by hand on the solenoids itself. When
this mode is active at least two persons are required, one engineer who operates the hydraulic control
valves itself and one navigation officer (in command) who tells the engineer what to do. Be aware,
the engineer is with respect to navigation of the vessel completely blind and must rely on the decisions
and commands of the navigation officer. This mode can also be used for maintenance activities.
3.6.2 The AutoPilot system

NOTE!
For a smooth and safe transfer under all circumstances the control levers on all control stations
are set to the neutral position. With the levers in the neutral position, you can always transfer
command without any unexpected (dangerous) movement of the vessel.
The propulsion control system has an interface with the AutoPilot system (AP). The AP commands are executed as given by the AP system. Before you can engage the AutoPilot system:
3-12
the Bridge Control Station (BCS) is in command;
the thruster system is operated in FU mode;
29 November 2012

3. Operation
the thruster system has no active alarms;
on all control stations, the control levers are set to the zero position;
the AutoPilot system itself is ready to take command.
If the AutoPilot system has a communication failure with the Lipstronic control system:
the AutoPilot system is disconnected;
an alarm is given;
the thruster settings for steering, return automatically to the zero position.
For a detailed description and (emergency) instruction, please refer to the manual that came with:
the propulsion control system;
the AutoPilot system.
3.6.3 The joy-stick system

NOTE!
The propulsion control system has an interface with the joy-stick system (JS). The joy-stick commands are
executed as given by the joy-stick system. Before you can engage the joy-stick system:
the joy-stick system itself is ready to take command.
If the joy-stick system has a communication failure with the Lipstronic control system:
the joy-stick system is disconnected;
an alarm is given;
the thruster settings are frozen in the current position.
the joy-stick system.
3.6.4 The Dynamic Positioning system

NOTE!
The propulsion control system has an interface with the Dynamic Positioning system (DP). The DP commands
are executed as given by the DP system.
Before you can engage the Dynamic Positioning system:
29 November 2012
3-13

3. Operation
if applicable, the DP back-up system is ready and healthy;
the Dynamic Positioning system itself is ready to take command.
If the Dynamic Positioning system has a communication failure with the Lipstronic control system:
the Dynamic Positioning system is disconnected;
an alarm is given;
the thruster settings are frozen in the current position.
3.7
the Dynamic Positioning system.
Cold weather operation

This section is meant to give background information for the cold weather operation of the thruster(s). The
content of this section does not replace any directives from your Class society or (inter)national rules and
standards.
Support for sailing in ice and cold weather can be offered by the relevant national authority. Their ice and
cold weather regime gives the environmental conditions and the ice management gives operational guidance.
The environmental information can include the ambient temperature, the water temperature, the ice thickness,
the ice pressure, the degree of ice ridging, the duration of the ice season, the wind and weather conditions,
the tides, the currents and the presence of land-fast ice. The operational guidance can include the
icebreaker assistance, the availability of ice forecasts and related routing advice.
3.7.1 Sailing in cold water

NOTE!
Instruction for sailing in cold water is beyond the scope of this manual. For detailed instructions,
please refer to the documentation from the ship yard and classification society that came with
the vessel.
There are no significant differences for sailing worldwide or sailing in cold water (not covered with any ice).
However there are some issues that need some attention.
If the thruster is shut down, the temperature of the lubrication oil in the propeller gearbox will decrease
until the surrounding water temperature is reached. Low temperatures of the lubrication oil increases the
viscosity, the oil gets thicker and more difficult to pump through the system. In a cold start of the thruster,
you will get a 'clogged filter' alarm to tell you that the lubrication oil does not go through the filter element
but that it is by-passed. This means that the lubrication oil is not filtered until the lubrication oil is warm
enough to go through the filter again. This phenomenon is normal. After some time, when the oil is warm,
the chief engineer should check the installation for correct operation.
The lubrication oil system is designed for a seamless operation when the cold start temperature of the oil
stays above 10C for the thruster room installed parts and above 0C for the under water installed parts
(propeller gearbox).
At a cold start of the thruster, make sure the prime mover runs at at least 30% of the nominal speed [rpm].
At this speed, the churning losses caused by the gears, will generate sufficient heat to bring the lubrication
oil to a temperature which allows for normal operation.
For detailed information about the viscosity and operational temperatures of the lubrication oil, please refer
to the technical data sheets of the lubrication oil. These data sheets and the material safety data sheets
are available from the oil manufacturer or distributor.
3.7.2 Sailing in ice

NOTE!
3-14
Instruction for sailing in ice is beyond the scope of this manual. For detailed instructions, please
refer to the documentation from the ship yard and classification society that came with the
vessel.
29 November 2012

3. Operation
The risk of damage to the thruster of a vessel that sails in ice conditions is a combination of factors such
as the ice sheet thickness, the pressure in the ice sheet, collisions with ice ridges and large ice pieces,
manoeuvring actions and the speed of the vessel.
In addition to 3.7.1 Sailing in cold water, special care and attention are needed when you enter an ice field.
When you sail in broken ice, careful control is necessary to make sure that the thruster (which is your rudder
and propeller) does not get damaged. A vessel that sails in ice fields has different characteristics for draft,
stability and steering behavior with respect to sailing in open water.
The strength of the ice depends on different factors. First-year sea ice is generally softer than second-year
or multi-year sea ice (also known as old ice) because it still contains salts. But if the water has by nature
already has a lower percentage of salt, the lack of salt makes the ice purer and therefore stronger.
In old ice, the salts are extracted by a longer exposure to the environment. The lack of salts makes the ice
purer and therefore much stronger.
When you estimate the load on the thruster, please mind the mixture of the ice with respect to a milling or
an impact load on the propeller. Be aware, a propeller operated in ice can suffer from cavitation more
easily than when you sail in open water. Cavitation limits the performance of the propeller and causes extra
mechanical stress and damage to the propeller and hull.
Table 3.1 Sea ice descriptions by the World Meteorological Organization (WMO)
Ice description
Classification
New ice
< 10
Nilas; ice rind
0-10
Young ice
10-30
Grey ice
10-15
Grey-white ice
15-30
First-year ice
30-200
Thin first-year ice
30-70
Thin first-year ice first stage
30-50
Thin first-year ice second stage
50-70
Medium first-year ice
70-120
1.
Thick first-year ice
120-200
4.
7.
Old ice
3.8
Thickness [cm]
Second-year ice
8.
Multi-year ice
9.
Ice of land origin
Undetermined or unknown
Emergency operation
3.8.1 Sail with a failed lubrication pump

CAUTION!
Make sure the temperature of the lubrication oil stays below the maximum temperature. Oil which becomes
too hot, starts to degrade rapidly and finally fails to lubricate the system properly. Degraded lubrication
oil which fails to lubricate properly can cause (serious) damage to equipment and costly downtime for
repair.
When the lubrication pump-unit fails:
you can not start the prime mover as usual. For a normal start the lubrication system must be operational;
the upper gearbox is, possibly, fully filled with lubrication oil;
29 November 2012
3-15

3. Operation
you can operate the thruster with limitations;
there is no circulation, filtration, reliable temperature/pressure reading and cooling of the lubrication
oil;
the (sea)water that surrounds the propeller gearbox is the only source to cool the lubrication oil.
for a safe operation of the thruster, extra attention is required to prevent damage to equipment.
Sail the vessel

CAUTION!
During emergency operation, only sail the vessel in close communication and with extra attention of the
engineer in charge. During emergency operation, start allowances that are overruled and incorrect response to alarm messages can cause damage to equipment.
NOTE!
Be aware, because the lubrication pump does not operate, a low pressure alarm is given. This
is normal behavior when sailing with a failed lubrication system.
1. Ask the chief engineer to by-pass the signal "Lub oil pressure available", for detailed information refer
to the documentation that came with the controls (cabinet).
2. Set the lubrication pump set to off and make sure, the level pump is stopped to prevent damage to the
bearings in the upper gearbox.
3. At the related propulsion control panels, install a warning sign: "thruster in emergency operation - control
signals are by-passed".
4. Ask the chief engineer permission to start the thruster from a propulsion control panel at the bridge.
5. To limit the heat generation and to keep the temperature of the lubrication oil within limits, operate the
thruster as usual but at a reduced load (maximum 50%).
6. Stay in close and continuous communication with the engineer in charge.
7. Frequently, inspect the operation of the thruster for anomalies.
Maintain the thruster

1. Make a note in the maintenance logbook:
in the controls cabinet, the signal "Lub oil pressure available" is by-passed with a jumper;
the lubrication pump-unit has failed.
2. Take an oil sample and get an oil analysis (type, contamination and viscosity) from the manufacturer,
refer to the section: Inspection, test and adjustment.
NOTE!
When the lubrication pump fails, there is no circulation of the lubrication oil which means
that the reading at the temperature gauge is false. For a proper measurement you can make
use of an infrared thermometer (gun).
3. Frequently, inspect the lubrication oil temperature of the upper gearbox. Make sure, the lubrication oil
temperature stays below 70C.
Return to normal operation

1. Install a new lubrication-unit pump as soon as possible.
2. Remove the jumper (by-pass) of the signal "Lub oil pressure available", for detailed information refer to
the documentation that came with the controls (cabinet).
3. When the new lubrication pump-unit is installed, after approximately 300 hours of operation:
3-16
29 November 2012

3. Operation
2. Install a new lubrication oil filter-element, refer to the section: Removal / Installation.
4. Compare the results of the oil analysis before and after the failure of the lubrication pump-unit.
5. Do any necessary work.
3.8.2 Sail with a failed seal

NOTE!
This procedure is applicable to the propeller shaft seal and the steering pipe seal.
The lubrication oil is used to keep the static pressure onto the seals. Aim is to keep the oil inside and the
(sea)water outside of the thruster.
There is water in the oil

Water can only get in the lubrication oil when:
the propeller shaft or steering pipe seal (water seal) has a failure;
the heat exchanger has an internal leak;
the static pressure from the surrounding (sea) water is higher than the static oil pressure.
NOTE!
Water in the oil causes acid compounds in the oil which will lead to contamination (e.g. sludge,
varnish deposits) and deterioration of the oil. Too much water in the oil means less lubrication,
a shorter service life of the oil and a higher risk of corrosion and a reduced life-time of bearings
and gear wheels.
1. Make sure:
1. The valves at the thruster are in the correct position.
2. The pneumatic air pressure is available and set to the correct value.
3. The static oil pressure caused by the header tank can get into the stem section and propeller gearbox.
2. In stopped condition, do an inspection of the oil level. The level must be between the marks.
3. Do an inspection for oil and air leaks, do any necessary work and add oil, as specified in the section
technical data, to get to the correct level.
4. If operational conditions allow, shut down the thruster, if not - reduce the propeller speed to limit water
ingress in the lubrication oil.
5. Take an oil sample and get an oil analysis (type, contamination and viscosity) from the manufacturer.
6. Increase the pneumatic air pressure to the header tank with 0.1 bar at the time.
ENVIRONMENTAL REMARK!
If you increase the pneumatic air pressure, the static pressure from the lubrication oil will increase to push the
seal more against the liner. Aim is to keep the oil inside and the (sea) water outside of the thruster.
7. At regular intervals do an inspection of the oil level and air pressure, Do any necessary work.
8. When in port, do an inspection of the seals (by diver) and do any necessary work.
NOTE!
As a temporary solution to bring the vessel to a nearby shipyard and to limit the possible damage
to the gears and bearings, you can install a temporary water separator/purifier unit to keep the
amount of water in the lubrication oil as limited as possible. Mind that this temporary solution
offers a possibility to limit the (collateral) damage, it certainly does not solve the problem and
that a repair is necessary.
29 November 2012
3-17

3. Operation
There is oil in the (sea)water

Oil can only get in the (sea)water if
the propeller shaft or steering pipe seal (oil seal) has a failure;
the static pressure from the surrounding (sea) water is lower than the static oil pressure.
1. Make sure:
1. The valves at the thruster are in the correct position.
2. The pneumatic air pressure is available and set to the correct value.
3. The static oil pressure caused by the header tank can get into the stem section and propeller gearbox.
2. Do an inspection of the oil level. The level must be between the marks.
3. If operational conditions allow, shut down the thruster.
4. Take an oil sample and get an oil analysis (type, contamination and viscosity) from the manufacturer.
5. Lower the pneumatic air pressure to the header tank with 0.1 bar at the time.
ENVIRONMENTAL REMARK!
If you lower the pneumatic air pressure, the static pressure from the lubrication oil will decrease with respect to
the (sea)water pressure which will push the water seal more against the liner. Aim is to keep the oil inside and the
(sea) water outside of the thruster..
6. At regular intervals do an inspection of the oil level and air pressure, Do any necessary work.
7. When in port, do an inspection of the seals (by diver) and do any necessary work.

1. Repair or install a new seal as soon as possible.
2. Make sure, the static pressure is set correctly, for detailed information, refer to the diagrams.
3. When the new seal is installed, at preventive maintenance interval MR:
4. Compare the results of the oil analysis before and after the failure of the seal.
3.8.3 Sail with a failed heat exchanger

Sailing with a failed heat exchanger for the lubrication system
NOTE!
The vessels' cooling water system is beyond the scope of our delivery. For a detailed description
of the vessels' cooling water system, refer to the documentation that came with the cooling
water system.
The water circuit is blocked

CAUTION!
Make sure the temperature of the lubrication oil stays below the maximum temperature. Oil which becomes
too hot, starts to degrade rapidly and finally fails to lubricate the system properly. Degraded lubrication
oil which fails to lubricate properly can cause (serious) damage to equipment and costly downtime for
repair.
3-18
29 November 2012

3. Operation
If the cooling water circuit is blocked:
there is no cooling of the lubrication oil;
the (sea)water that surrounds the propeller gearbox is the only source to cool the lubrication oil.
CAUTION!
engineer in charge.
NOTE!
Be aware, because the heat exchanger does not operate correctly, a temperature alarm is
possible. This is normal behavior when sailing with a failed heat exchanger.
2. To limit the heat generation and to keep the temperature of the lubrication oil within limits, operate the
thruster as usual but at a reduced speed (maximum 75%).
3. At regular intervals do an inspection of the lubrication oil temperature, the oil temperature must stay
below 70C.
5. At regular intervals do an inspection of the thruster for anomalies.
the lubrication pump-unit is in operation and cooling by the heat exchanger is not possible.;
for the propeller and upper gearbox, keep a record of the lubrication oil temperature [C] with respect
to speed [rpm] and oil pressure [bar].

Water can only get in the lubrication oil when:
the propeller shaft or steering pipe seal (water seal) has a failure;
the heat exchanger has an internal leak;
the static pressure from the surrounding (sea) water is higher than the static oil pressure.
NOTE!
varnish deposits) and deterioration of the oil. Too much water in the oil means less lubrication,
a shorter service life of the oil and a higher risk of corrosion.
1. Do an inspection of the oil level. The level must read between the marks.
2. If operational conditions allow, shut down the thruster, if not - (if possible) reduce the cooling water
pressure to limit water ingress in the lubrication oil. Mind that a reduction of the cooling water pressure
gives less cooling as usual.
below 70C.
4. At regular intervals do an inspection of the oil level and do any necessary work.
the lubrication pump-unit is in operation and cooling by the heat exchanger is limited.;
29 November 2012
3-19

3. Operation
for the propeller and upper gearbox, keep a record of the lubrication oil temperature [C] with respect
to speed [rpm] and oil pressure [bar].
NOTE!
to the gears and bearings, you can install a temporary water separator/purifier unit to keep the
amount of water in the lubrication oil as limited as possible. Mind that this temporary solution
offers a possibility to limit the (collateral) damage, it certainly does not solve the problem and
that a repair is necessary.
There is oil in the water

Oil from the lubrication system of the thruster can only get in the cooling water when the heat exchanger
has an internal leak.
2. Refer to the documentation that came with the cooling water system for further (detailed) instructions.
below 70C.

1. Repair or install a new heat exchanger as soon as possible.
2. If the new heat exchanger is installed, at preventive maintenance interval MR:
3. Compare the results of the oil analysis before and after the failure of the heat exchanger.
Sailing with a failed heat exchanger for the steering system

NOTE!
The vessels' cooling water system is beyond the scope of our delivery. For a detailed description
of the vessels' cooling water system, refer to the documentation that came with the cooling
water system.
The water circuit is blocked

CAUTION!
Make sure the temperature of the steering oil stays below the maximum temperature. Oil which becomes
too hot, starts to degrade rapidly and finally fails to actuate and lubricate the system properly. Degraded
steering oil which fails can cause (serious) damage to equipment and costly downtime for repair.
If the cooling water circuit is blocked:
there is no cooling of the steering oil;
CAUTION!
3-20
29 November 2012

3. Operation
engineer in charge.
NOTE!
Be aware, because the heat exchanger does not operate correctly, a temperature alarm is
possible. This is normal behavior when sailing with a failed heat exchanger.
2. At regular intervals do an inspection of the steering oil temperature, the oil temperature must stay below
70C.
4. At regular intervals do an inspection of the thruster for anomalies.
the steering pump-unit is in operation and cooling by the heat exchanger is not possible;
keep a record of the steering oil temperature [C].

Water can only get in the steering oil when the heat exchanger has an internal leak.
NOTE!
varnish deposits) and deterioration of the oil. Too much water in the oil means less actuation
power and lubrication, a shorter service life of the oil and a higher risk of corrosion.
2. If operational conditions allow, shut down the thruster.
NOTE!
to the hydraulic equipment, you can install a temporary water separator/purifier unit to keep the
amount of water in the oil as limited as possible. Mind that this temporary solution offers a
possibility to limit the (collateral) damage, it certainly does not solve the problem and that a repair
is necessary.
There is oil in the water

Oil from the steering system of the thruster can only get in the cooling water when the heat exchanger has
an internal leak.
2. Refer to the documentation that came with the cooling water system for further (detailed) instructions.
below 70C.

1. Repair or install a new heat exchanger as soon as possible.
2. If the new heat exchanger is installed, at preventive maintenance interval MR:
2. Install the new steering oil filter-elements, refer to the section: Removal / Installation.
29 November 2012
3-21

3. Operation
3. Compare the results of the oil analysis before and after the failure of the heat exchanger.
3.8.4 How to steer by hand

Refer to figure 3.1, The steering control valves - Operation by hand.
Refer to SOLAS Chapter 5, Regulation 26, Steering gear: Testing and drills.
This procedure describes how to steer the thruster by hand if only the related propulsion control system
fails and the steering system is still operational.
LIMITATION!
The maximum steering movement is limited to 15.
Operate the steering control valves for the maximum of one second at the time (the thruster turns
15/second).
Be aware, if operated by hand, the steering behavior of the vessel is different from normal operation.
CAUTION!
Keep the communication between the bridge and the engineer open at all times. The commanding officer
is the 'eyes and ears' of the engineer in the thruster room who operates the thruster by hand. Communication that fails can cause (serious) damage to the vessel or the environment by unexpected movement
of the vessel..
NOTE!
If operated by hand, there is no control over the steering speed. The thruster turns approximately
15 per second! This means if you operate the steering control valve for one second, the thruster
turns 15 (counter)clockwise.
1. On the propulsion control panels, turn the thruster to 0.

2. On the bridge, appoint a commanding officer who is responsible for communication with the engineer
in the thruster room and the navigation officer.
4. Install a warning sign: "Do not switch/operate - thruster in emergency operation".
5. On the steering pump, find the steering control valves/solenoids Y201 A/B.
6. Clean the area to prevent contamination of the connector pins.
7. Disconnect the connectors from the steering control valves.
8. Install blanking caps on the electrical connector(s) to prevent contamination.
9. On the cover of the stem section find the azimuth feedback unit.
10. Communicate the position of the azimuth feedback indicator to the navigation officer.
11. Make sure, hydraulic pressure is available.
12. Ask the commanding officer:
1. To reduce the speed of the vessel (safety).
2. For permission to test the response of the thruster for steering by hand.
13. Test the manual steering and make a note of the steering response in forward direction (counterclockwise or clockwise).:
1. Carefully operate the steering control valve Y201A for 0.5 seconds (approximate turn of 7).
3-22
29 November 2012

3. Operation
2. Carefully operate the steering control valve Y201B for 0.5 seconds (approximate turn of 7).
3. Verify the position on the azimuth feedback indicator with the actual direction.
14. Tell the commanding officer that you are ready to steer the thruster by hand at the officer's commands.
How to steer by hand with two thrusters (main propulsion)

This procedure describes how to steer the vessel by hand when: thruster 1 is full functional and for the
other thruster has a propulsion control system failure:
the thruster 1 is full functional and in operation;
for the thruster 2, the related propulsion control system fails and the steering system is still operational.
NOTE!
If you decide to shut down the failed thruster,
the steering system is kept in operation to prevent the thruster to turn freely by external
forces;
the lubrication system is kept in in operation to prevent mechanical damage to the gearbox.
1. Prepare the failed thruster for steering by hand. Refer to the procedure: How to steer by hand.
2. Ask the commanding officer for permission to turn the thruster to 0 (neutral position).
3. Carefully operate the valve to turn and keep the thruster to 0.
4. At request of the commanding officer, carefully operate the valve to turn the thruster to the requested
position.
5. At the bridge, use the other thruster to steer the vessel.

1. Ask the commanding officer for permission to turn the thruster to 0.
2. Turn the thruster to 0.
3. Remove the blanking caps.
4. Connect and lock the connectors Y201A/B to the related steering control valves.
5. Make sure, on all propulsion control panels, the azimuth direction is set to 0.
6. In the controls cabinet, set the switch ISOLATION STEERING VALVES to the OFF position.
7. Clean the work area.
8. Make sure all connections are made and tools, materials and (service) equipment are removed from the
work area.
9. Do a functional test of the steering system.
29 November 2012
3-23

3. Operation
Figure 3.1 The steering control valves - Operation by hand
3.9
Shut down the thruster

NOTE!
The pneumatic system is beyond the scope of this manual. For detailed instructions, please
refer to the documentation that came with the pneumatic system.
Stop the thruster:
1. If in control, disconnect the external control system.

2. If applicable, set the brake to standby.
4. Make sure, the brake is engaged.
For the steering system:
1. Stop the steering system.

2. On the starter cabinet:
1. Set the L-0-R switch to 0.
2. Set the MAIN switch to 0.
3. Make sure, the oil level is correct. Do any necessary work.
For the lubrication system:
1. Stop the lubrication system.

2. On the starter cabinet:
1. Set the L-0-R switch to 0.
2. Set the MAIN switch to 0.
3. Make sure, the oil level is correct. Do any necessary work.
For the pneumatic system:
For when the vessel is in the water

1. Leave the pneumatic system in operation, to hold:
the brake engaged. Be aware, the brake disengages automatically when

the pneumatic air supply gets too low;
the static pressure correct for the propeller shaft seal and the steering
pipe seal. Water ingress into the lubrication oil is possible when the
pneumatic air supply gets too low.
2. Make sure, the pneumatic air pressure is correct. Do any necessary work.
For when the vessel is in dry-dock
1. For general safety reasons, leave the brake engaged. Be aware, the brake
disengages automatically when the pneumatic air supply gets too low.
2. On the static-pressure air control-panel, close the pneumatic air supply.
Be aware that the static pressure on the propeller shaft and steering pipe seal
is too low. When the vessel is lowered into the water, do not forget to set the
pneumatic air supply to the correct pressure.
3-24
29 November 2012

3. Operation
3.10 How to operate for maintenance purposes

3.10.1 Operate the lubrication system
Required tools and materials
Table 3.2 Required materials
Description
Specification
Quantity
Not applicable
Table 3.3 Special tools
Description
Specification
Quantity
Warning signs
"Do not operate - System is in local control"
Warning signs
"Do not operate - Maintenance in progress"
Specification
Quantity
Table 3.4 Consumable materials
Description
Not applicable
Table 3.5 Expendable parts
Description
Specification
Quantity
Not applicable
Table 3.6 Spare parts
Description
Specification
Quantity
Not applicable
Table 3.7 Referenced procedures
Description
Specification
Not applicable

NOTE!
When the control over the lubrication system is taken over by the starter cabinet, the commands
from the remote (propulsion) control panels are ignored. In this situation, it is normal behaviour
that you can not start the thruster (or the lubrication system) from the remote (propulsion) control
panels.
Start the lubrication system

WARNING!
Make sure it is safe to energize (pressurize) the system. The system must be clean and free of leaks.
Unsafe systems can cause (serious) injury or death to persons.
Stop the lubrication system

CAUTION!
29 November 2012
3-25

3. Operation
With the thruster in operation, do not stop the lubrication pump unnecessarily. If you stop the lubrication
system, the thruster can operate at limited conditions, there is no longer cooling and filtration of the
lubrication oil. Sailing without circulation of the lubrication oil can cause (serious) damage to equipment.
Return the lubrication system into service

NOTE!
This procedure assumes that the lubrication system is serviceable and locally set to off.
3.10.2 Operate the steering system

Description
Specification
Quantity
Not applicable
Description
Specification
Quantity
Warning signs
Warning signs
Description
Specification
Quantity
Not applicable
Description
Specification
Quantity
Not applicable
Description
Specification
Quantity
Not applicable
Description
Specification
Stop the thruster
Refer to section: Operation - Stop the thruster
3.10.3 Operate the static pressure system

NOTE!
The static pressure uses the lubrication oil from the lubrication system to create the static
pressure onto the seals.

Description
Specification
Quantity
Not applicable
3-26
29 November 2012

3. Operation
Description
Specification
Quantity
Warning signs
Warning signs
"Do not operate - Maintenance work in progress"
Description
Specification
Quantity
Not applicable
Description
Specification
Quantity
Not applicable
Description
Specification
Quantity
Not applicable
Description
Specification
Stop the lubrication system
Refer to the section Operation - Operate the lubrication system
Start the lubrication system
Refer to the section Operation - Operate the lubrication system

CAUTION!
Do not unnecessarily set the pneumatic air supply to the header tank to off. If the vessel is in the water
and the pneumatic air supply to the header tank is set to off, the lubrication oil system is vulnerable for
ingress of (sea)water because the (sea)water pressure gets higher than the static oil pressure. (Sea)water
in the lubrication oil system can cause (serious) damage to equipment.
1. On the bridge:
1. Ask the commanding officer for any deviations during normal operation.
2. Make sure, there are no propulsion alarms present.
3. Let the commanding officer stop the lubrication system.
2. On each propulsion control panel:
1. Install the warning sign: "Do not operate - System is in local control".
3. Make sure, free access is available.
4. On the starter cabinet of the lubrication system, shut down the lubrication system. For detailed instructions, please refer to Stop the lubrication system.
5. At the header tank, on the static-pressure air control-panel:
1. Close the air-supply shut-off valve.
2. On the pressure indicator, note that the pneumatic air pressure drops.
3. Install the warning sign: "Do not operate - Maintenance work in progress".
29 November 2012
3-27

3. Operation
Start the static pressure system

For routine maintenance
Action
Result
At the header tank, do an inspection of the oil level.
Make sure the oil level is correct.
Make sure, the vessel's pneumatic air supply is available. The pneumatic air supply is available.
On the static-pressure air control-panel, open the airsupply shut-off valve.
On the static-pressure air control-panel:
the pressure indicator shows the static air pressure.
In the lubrication system:
Do an inspection of the lubrication system.
the static pressure onto the seals becomes available.
no leaks are seen;
no unusual noises are heard;
the oil level in the header tank stays correct.
After repair
For detailed information about the valves and numbering, please refer to the lubrication oil diagram.
Action
Result
In the lubrication system, set the valves in the correct po- For the header tank:
sition.
the drain valve (435.6) is closed;
the shut-off valve (431.2) is open.
Make sure, the vessel's pneumatic air supply is available. The pneumatic air supply is available.
On the static-pressure air control-panel, open the airsupply shut-off valve.
the pressure indicator shows the static air pressure.
no leaks are seen;
Stop the static pressure system

CAUTION!
3-28
29 November 2012

3. Operation
Action
Result
On the static-pressure air control-panel, close the airsupply shut-off valve.
the pressure indicator shows that the static air

pressure drops;
the static-pressure transmitter gives a signal to the

vessel's control system.
Shut-down the static pressure system

CAUTION!
Action
Result
On the static-pressure air control-panel, close the airsupply shut-off valve.
For maintenance activities, if necessary:
set the pressure regulator to 0 bar;
close the oil supply line to the stem section.
the pressure indicator shows that the static air

pressure drops;
the static-pressure transmitter gives a signal to the

vessel's control system.
The static pressure is no longer available.
Return the static pressure system into service

Action
Result
Make sure, it is safe to return the static pressure system

into service.
no leaks were seen;
no unusual noises were heard;
the oil level in the header tank is correct;
the clogging indicator on the filter unit is green;
On the starter cabinet of the static pressure pump, set the The main electrical power is available.
MAIN switch to the I position.
On the starter cabinet of the static pressure pump, set the On the starter cabinet of the static pressure pump:
ON/OFF switch to the ON position.
the RUNNING indicator comes on.

Start the lubrication system.
29 November 2012
the static pressure pump pump comes on;
the lubrication circulation pump comes on;
the circulation and filtration of the oil is available.
3-29

3. Operation
Action
Result
no leaks are seen;
Remove all warning signs and report to the commanding The system is returned into service.
officer that the static pressure system is available and in
operation..
3-30
29 November 2012

4. General maintenance
4.
General maintenance
This chapter gives the general maintenance instructions, lubrication and other consumable material tables.
The instructions include e.g. the lubrication and the cleaning procedures.
4.1
Torque tables
The next tables give information on the torque values for metric fasteners to which anti-seize or locking
compound is applied or not. Please note that there is a table for Nm and for lbf/ft
(1 Nm = 0.102 kgm = 0.738 lbf/ft).
NOTE!
Surfaces of the fastener and the equipment you want to attach, must be clean and free
of damage and signs of corrosion. Also inspect the surface below the head and in the nut
or threaded hole. Before installation, you must de-grease the contact surfaces of the
equipment and the fastener.
Dry is identified as:

Friction coefficient = 0.14 (clean surface, lightly oiled or with locking compound applied
to the thread and the contact surface).
With anti-seize compound is identified as:

Friction coefficient = 0.10 (clean surface, with anti-seize compound applied to the thread
and the contact surface).
On the drawings, there are symbols added to the item numbers which give the letter and
the group number. With this data you can look up the correct torque value that you must
apply.
Stainless steel must comply with ISO3506, Mechanical properties of corrosion-resistant

stainless steel fasteners,
M14 corresponds to property class 70 (yield 450 N/mm2)
> M14 corresponds to property class 80 (yield 600 N/mm2)
The symbol on the drawing and the corresponding torque from the table are valid and are
above the property class marking on the fastener.
EXAMPLE 1
K1 (M20x2.5, stainless steel), dry mounted:
the table Metric fasteners [Nm] gives 350 Nm;
the table Metric fasteners [lbf/ft] gives 260 lbf/ft.
EXAMPLE 2
K1 (M20x2.5, stainless steel), with anti-seize compound:
the table Metric fasteners [Nm] gives 265 Nm;
the table Metric fasteners [lbf/ft] gives 195 lbf/ft.
29 November 2012
4-1

4.1.1 Metric fasteners

Table 4.1 Metric fasteners [Nm]
Fastener
Dry installation
With anti-seize compound
Letter
Thread
[DIN13]
Group Group 1 Group 2

Grade 8.8 Stainless Grade
steel
10.9
Group 3
Grade
12.9

steel
10.9
Group 3
Grade
12.9
M3x0.5
1,25
0,87
1,75
0,9
0,66
1,3
1,55
M4x0.7
2,85
4.8
2,1
1,5
3,6
M5x0.8
5,6
3,9
7,8
9.4
4,2
2,95
5,8
M6x1
9,7
6,8
13,5
16.5
7,3
5,2
10
12
M8x1.25
23,5
16,5
33
39
17
12,5
24
29
M10x1.5
47
33
66
79
35
25
49
59
M12x1.75
81
57
115
135
60
43
86
100
M14x2
130
90
180
215
95
68
135
160
M16x2
195
185
275
330
145
135
200
240
M18x2.5
270
255
380
460
200
190
280
340
M20x2.5
380
350
530
640
280
265
390
480
M24x3
650
610
920
1100
490
460
690
800
M27x3
950
890
1350
1600
700
660
1000
1200
M30x3.5
1300
1200
1800
2200
950
910
1350
1600
M36x4
2250
2100
3200
3800
1650
1550
2400
2800
M39x4
2900
2700
4100
4900
2150
2000
3000
3600
M42x4.5
3600
3400
5100
6100
2700
2500
3800
4500
M48x5
5400
5100
7600
9100
4000
3800
5700
6800
Table 4.2 Metric fasteners [lbf/ft]
Fastener
4-2
Dry
With anti-seize compound
Letter
Thread
[DIN13]

steel
10.9
Group 3
Grade
12.9

steel
10.9
Group 3
Grade
12.9
M3x0.5
0,9
0,64
1,3
1,55
0,68
0,49
1,15
M4x0.7
2,1
1,45
2,9
3,5
1,6
1,11
2,2
2,6
M5x0.8
4,1
2,9
5,8
6,9
3,1
2,18
4,4
5,2
M6x1
7,1
10
12
5,3
3,9
7,5
M8x1.25
17
12
24
29
13
9,2
18
22
M10x1.5
35
24
49
58
26
18
37
44
M12x1.75
60
42
85
100
45
32
64
75
M14x2
95
66
135
160
70
50
100
120
M16x2
145
135
200
240
110
100
150
180
M18x2.5
200
185
280
340
150
140
210
260
M20x2.5
280
260
390
470
210
195
290
350
M24x3
480
450
670
800
360
340
500
600
M27x3
700
660
1000
1200
525
490
750
900
M30x3.5
950
900
1350
1600
710
670
1000
1200
M36x4
1650
1550
2300
2800
1240
1150
1700
2100
M39x4
2150
2000
3000
3600
1600
1450
2200
2700
M42x4.5
2600
2500
3700
4500
1950
1850
2800
3400
M48x5
4000
3700
5600
6700
3000
2800
4200
5000
29 November 2012

4.2
Consumable installation materials

NOTE!
This section gives an overview, for the use on propulsion installations, of installation related
chemical agents. The symbols refer to the symbols on the drawings where they tell you which
locking adhesive must be used during the installation task. For the detailed technical specifications and safety instructions, please refer to the manufacturer's (safety) documentation.
4.2.1 Cleaning agent

Symbol
Part no.
Product ID
Product name
Colour
Use
T003000506 7063
Super Clean
Transparent
Cleaner for fastener and surface.
Product name
Colour
Use
T001048197 243
Nutlock
Blue
Locking adhesive for mild steel fasteners.
T002005540 2701
Studlock, M20 Green
Locking adhesive for stainless steel

fasteners.
W005903954 275
Studlock > M20 Green
Locking adhesive for stainless steel

fasteners.
Product name
Colour
Use
4.2.2 Locking adhesive

Symbol
Part no.
Product ID
4.2.3 Bonding adhesives

Symbol
Part no.
Product ID
T002005542 406
Super bonder
Transparent
Bonding adhesive for O-rings and synthetic materials
T002005545 307
High
Strength adhes- Transparent

ive
Bonding adhesive for metals (e.g. mild

steel, bronze).
W084815378 641
Retaining com- Green

pound
Bonding adhesive for cylindrical assemblies (e.g. bearings)
Symbol
Part no.
Product name
Use
T002005541 290
4.2.4 Sealant
Product ID
Colour
Penetrating Ad- Green

hesive
Light brown
Sealant for existing connections (eg. pipe

fittings).
T002007114 577
Pipe sealant
T002014693 Molykote 111
Silicone sealant Transparent
Sealant and lubricant for valves.
Sealant for pipe fittings and joints.
Product ID
Product name
Colour
Use
T002014948 Loctitie 574
Master Gasket
Orange
Liquid gasket for machined surfaces.
4.2.5 Liquid gasket

Symbol
Part no.
29 November 2012
4-3

4.2.6 Anti-seize compound

Symbol
Part no.
Product ID
Product name
Colour
Use
W005903853 Chesterton 725 Anti-seize spray Gray

/ paste
Anti-seize compound for metals (e.g.

mild steel, bronze).
U000000403 Unasco
Anti-seize tape
(PTFE)
Anti-seize compound for stainless steel

(BSP-threads).
T003000768 Copaslip
Anti-seize com- Orange-brown

pound
Gray
High temperature anti-seize compound,

oxidation and corrosion inhibitor for
metal mounting parts (e.g. bolts, nuts)
4.2.7 Preservation fluids

Table 4.3 Recommended fluids for preservation purposes
Brand
Fluid type
Used for
SHELL
Ensis 30
Oil pipe assemblies
Ensis Fluid R
Bare metal surfaces of machined or

partly machined parts
< 6 months
Ensis Fluid RX

< 9 months
Ensis Fluid S

< 12 months
Ensis Fluid SX

< 24 months
VSI 8235
Corrosion inhibitor for lubrication and

steering oil
Osyris DWX 3000

< 6 months
Osyris DWX 5000

< 9 months
Osyris DWX 7000

< 12 months
Osyris DWX 9000

< 24 months
Tectyl T 286

< 6 months
Tectyl T 275

< 9 months
Tectyl 502 C

< 12 months
Tectyl 506 WD

< 24 months
TOTAL
Valvoline
4.3
Life time
Table of lubricants
This part of the manual gives a recommendation for the oil and grease as used in the thruster installation.
WARNING!
For the use, storage, transport, disposal and safety information of the recommended oil and grease
types, please refer to the latest Material Safety Data Sheet (MSDS). The latest MSDS is available from
the manufacturer. Incorrect execution of the instructions in the MSDS can cause (serious) injury to persons
or damage to equipment and environment.
4-4
29 November 2012

4.3.1 Lubrication system

Table 4.4 Recommended oil for the lubrication system
Brand
Oil type
Agip
Blasia 150
ARAL
Degol BG 150
Degol BMB 150
BP
Energol GR-XP 150 (ISO)
Castrol
Alpha SP 150
Chevron
Non-leaded gear compound EP 150
EXXON
Spartan EP 150
FINA
Giran 150
Kuwait
Goya 150
Mobil
Mobilgear 600 XP 150
SHELL
Omala 150
TEXACO
Meropa 150
4.3.2 Hydraulic steering system

Table 4.5 Recommended oil for the hydraulic steering system
Brand
Oil type
(engine-room temperature > 10C)
Oil type
(engine-room temperature < 10C)
Agip
OSO 46
OSO 32
ARAL
Vitam DE 46
Vitam HF 46
Vitam DE 32
Vitam HF 32
BP
Energol SHF-HV 46
Energol SHF-HV 32
Castrol
Hyspin AWS 46
Hyspin AWH 46
Hyspin AWS 32
Hyspin AWH 32
Chevron
EP Hydraulic oil 46
EP Hydraulic oil 32
EXXON
Nuto H46
Nuto H32
FINA
Hydran 46
Hydran 32
Kuwait
Hadyn 46
Hadyn 32
Mobil
DTE ISO 46
DTE ISO 32
SHELL
Tellus T46
Tellus T32
TEXACO
Rando oil HD 46
Rando oil HD 32
4.3.3 Universal shafts

Table 4.6 Recommended lubrication for universal shafts
4.4
Brand
Grease type
SHELL
Alvania Grease EP (LF) 2
Cleaning instructions for piping
4.4.1 Introduction
This specification is applicable for the piping (pipes, hoses and connection parts) of the hydraulic, the lubrication, the pneumatic and the water systems.
29 November 2012
4-5

Table 4.7 Piping classifications
Class
System
Description
01
High pressure oil system
Steering system.
Pitch actuation.
02
Low pressure oil system
Lubrication system.
03
Air systems
Pneumatic air actuators, valves and switches.
Water systems
Bilge water systems.

Cooling water systems.
Contaminated piping causes damage to or failure of the used equipment which can result in a failure of the
complete system. To prevent damage and failure of the equipment, it is mandatory to clean the piping
(pipes, hoses and connection parts) before the system is put into operation.
NOTE!
The (assembled) equipment, closed by the appropriate end caps or plugs, that is supplied by
Wrtsil Netherlands B.V. is cleaned in the shop.
4.4.2 Cleaning of the piping - Class 01 and 02

NOTE!
This procedure is applicable for the high and low pressure oil piping. Cleaning of the piping
means to flush the piping internally with a suitable fluid as specified in the procedure.
Introduction
Flushing is a procedure which is vital for a reliable operation and life of a fluid system. Flushing is necessary
to minimize the risk of early equipment failures and unscheduled (costly) downtime.
The aim of flushing is to remove contamination from the inside of the pipes and the equipment that might
got into the system during assembly. Flushing is done at a much higher flow rate than during normal operation.
The equipment ready for assembly into the system is in a clean condition, protected with preservative oil
and all openings sealed. Temporary sealing devices, plugs etc., shall only be removed during the installation
of the part into the system.
The piping ready for assembly into the system is free from scale, rust, flux etc. The piping that is not ready
for installation must be cleaned before installation or rejected.
The set up
CAUTION!
Work clean. Make sure the work area, the tools, the flushing fluid and the equipment are clean. Contamination of the piping can cause (severe) damage to the equipment.
The piping that connects the different equipment must be disconnected and connected with temporary
piping to make several loops of the piping. If the piping cannot be disconnected after installation, you have
to connect the temporarily piping in a different manner. You can use a by-pass for the equipment that
causes a restriction to the required flow or equipment that is vulnerable to damage.
The equipment, which may have been flushed on assembly, include the reservoirs (tanks), the pumps, the
motors, the dead-end components such as cylinders, servo valves, flow regulators and other valves that
have small orifices.
The flushing equipment

CAUTION!
4-6
29 November 2012

Do not use the pumps of the oil system for flushing purposes. The capacity of these pumps is not sufficient
to obtain the required flow.
Give special attention to large piping. It is likely, that large piping does not meet the requirements for
cleanliness. Extra care during flushing is required to get the correct level of cleanliness.
Flush the piping with the use of a special flushing unit which at least can give a flow rate of twice the system'
s flow rate. The required flow rate for the each pipe diameter is determined and given by the piping manufacturer.
The flushing unit must have flushing pumps, oil tanks, heaters, filters and hose connections.
The flushing pumps must have adjustable relief valves which are set at a pressure above the required
pressure to pass the full pump flow through the system.
The oil tank must have a capacity that is at least equal to three times the pump rate and preferably larger
than the system volume.
The heaters must be able to heat and maintain the flushing fluid temperature at 60 C.
The filter units have a cleanable or disposable filter element. Duplex filter units are preferred as they permit
the change over to a clean filter element without interrupting the flushing procedure. Each filter unit should
have a clogging indicator, preferably with an audible alarm. An automatic filter bypass is not preferred. The
filter has a generous dirt-holding capacity and the size should be able to pass the specified pump rate at
a low pressure drop.
The flushing fluid

Use a special flushing fluid with a low viscosity and classified level of cleanliness for the flushing process.
The flushing fluid must be compatible with the fluid, specified for the system and the system materials,
especially the seals. For detailed information on the compatibility of the flushing fluid, please ask the manufacturer for detailed information and instructions.
Flushing fluids are often refined distillates with rust inhibitors and additives to remove contamination such
as water, rust preventative compounds and sludges. Do not use flushing fluids that have petroleum solvents
such as kerosene or non-petroleum solvents such as carbon tetrachloride, water, caustic compounds or
other active materials.
If the use of a special flushing fluid is not possible, select an appropriate fluid from the table of lubricants.
For the flushing process, always use fresh and clean fluid that meets the specified level of cleanliness.
The level of cleanliness of the flushing fluid, is for each class defined in the table below and before use, the
level of cleanliness must be confirmed by a fluid sample.
Table 4.8 Fluid classifications
Class
System
Classification
01
ISO4406, class 17/15/12

(equals approximately NAS1638, class 6
02
ISO4406, class 19/17/14

(equals approximately NAS1638, class 8
The flushing fluid must be pre-heated to at least 60C.
The flushing procedure

With the system prepared as described, fill the system by feeding the flushing fluid to the flushing unit so
that the fluid is filtered before entering the system. Fresh and clean fluid directly taken from the oil drum
does often not meet the required system level of cleanliness.
Circulate the flushing fluid and bleed the system to remove the trapped air. Heat and keep the flushing
fluid to the required temperature.
Flush the system for a period of half an hour, change the filter element as the filter clogging indicator comes
on or as indicated by the filter pressure drop. At each filter element change, reverse the flow through the
system by interchanging the supply and return lines from the flushing unit.
29 November 2012
4-7

Continue flushing and reverse the flow periodically, until the system operates for several hours without interruptions caused by clogged filter elements or pressure drops. Take the fluid samples as required and
make sure that the required level of cleanliness is maintained.
If the system comprises several loops, change the flushing unit connections to another loop and repeat the
above procedure.
When the system has attained the required level of cleanliness, drain the system completely, clean the
outside of the connections and disconnect the flushing unit and remove the bypass pipes. Examine the
exposed openings and if any section is found to be unsatisfactory, it must be removed for separate cleaning
or replaced, and the flushing procedure must then be repeated.
New system oil

As soon as possible, to prevent internal corrosion, fill the system, through a filter, with fresh, new and clean
system oil. Bleed the system and start the pump to move the oil around. Operate the system unitil the
cleaned surfaces are properly protected against corrosion.
Flushing of systems in normal operation is not required unless a major overhaul is done or if the result of
an oil analysis advices to do so. Operation of a system with a contaminated fluid will cause (severe and
costly) damage to the equipment.
4.4.3 Cleaning of the piping - Class 02 and 03

The prescribed cleaning method by flushing the system can be very time consuming and expensive.
Moreover class 02 and 03 piping may not need to be as thoroughly cleaned as class 01 piping (although
you must make sure that the piping is clean).
In some cases cleaning can be done with the use of special foam plugs.
Prerequisites for alternative cleaning

The foam plug cleaning method can be used:
1. For piping that was manufactured and stored in a clean environment.
2. If piping is made from seamless precision pipe (acc. DIN 2445 or DIN 2462).
Never use the foam plug cleaning method:
1. for Class 01 piping. The piping used in the closed loop steering systems and pitch actuation must be
flushed.
2. for welded or heat treated piping.
Foam plug cleaning procedure

1. The pipes should at least be visually clean and free of loose parts.
2. First blow the pipes with dry and clean air.
3. Blow a foam plug through the pipe and repeat this until the plug stays clean.
4. Finally blow a new, clean plug through the pipe and make sure the plug comes out clean.
Repeat the cleaning procedure until the final check shows a clean plug.
Job close up
If applicable, after the piping is cleaned, apply a conservation fluid.
Re-install all piping to its original place or cap, mark and store the pipes for later use.
4.4.4 Contamination in service

For the confirmation and severity of the contamination, it is advised to do an oil analysis first.
For fresh water contamination only, the (temporarily) use of a purifier is usually sufficient to remove the
contamination.
In case of severe sea water contamination or contamination with harmful foreign material, it may be necessary
to remove the system oil and to clean and flush the system.
In case of minor contamination the applicable steps of the flushing procedure should be done.
4-8
29 November 2012

In cases of severe contamination -not including sea water- the complete flushing procedure must be done.
Modifications of flushing time and circulation temperature should be made depending upon the circumstances
of the contamination.
Sea water contamination requires a very special procedure. After removal of the sea water, the use of corrosion inhibitors, specifically developed for this type of contamination is mandatory. Careful cleaning and
flushing procedures must be done to get the required level of cleanliness.
4.5
Assembly instructions for piping
4.5.1 Piping material

Table 4.9 Piping material
Class
System
Material
01
Steel: St 37.4 according to DIN 2445/2
02
03
Air systems
Water systems
As specified by the shipyard.
4.5.2 Bending specifications

The minimum bending radius is 3.5 x pipe diameter with a tolerance of 0.5 x pipe diameter.
4.5.3 Welded connections

WARNING!
Be careful when you use consumable materials. Obey the manufacturer's material safety instructions.
Failure to obey the material safety instructions can cause (serious) injury to persons or damage to
equipment and environment.
After welding:
1. Clean the pipe with a 10% Hydrochloric acid (HCL).
2. Clean the pipe again with a lime solution (e.g. Calcium oxide) to neutralize the Hydrochloric acid.
3. Finally clean the pipe thoroughly with fresh water or steam.
4. Use clean and dry compressed air to remove residual fluid from the pipe.
5. Make sure the inside is free of contamination.
6. Let the pipe dry on the air.
7. Flush the piping with an approved fluid.
For detailed information, please refer to the cleaning specification for piping.
8. If applicable, treat the inside with an approved preservation fluid.
For detailed information, please refer to the table of preservation fluids.
9. Close the pipe ends airtight with blanking caps or suitable tape.
10. Paint the outside with an approved paint or coating.
For detailed information, please refer to the paint specifications.
29 November 2012
4-9

4.5.4 Cone connection and cutting ring (DIN 3861/ISO 8434-1)

Assembling in fitting body (steel and copper)
Cut the pipe
NOTE!
The use of pre-assembly bodies, VOMO or pre-assembly tools is strongly recommended for all
assemblies.
Stainless steel pipe and fittings must be pre-assembled in a VOMO body or pre-assembly tool.
For detailed instructions, please refer to paragraph "Assembling in hardened pre-assembly body
(VOMO)".
Maximum height [H] for straight pipe

end.
The portion of straight pipe [H} must
not deviate from roundness and
straightness to the extent that the
pipe tolerances in DIN2391 are exceeded.
Minimum length [L] for short pipe
section.
LL
04 05 06 08 06 08 10 12 15 18 22 28 35 42 06 08 10 12 14 16 20 25 30 38
[H] 24 25 25 25 31 31 33 33 36 36 42 42 48 48 35 35 37 37 43 43 50 54 58 65
[L]
30 32 32 33 39 39 42 42 45 48 53 53 60 60 44 44 47 47 54 54 63 68 73 82
Saw off the pipe at an angle of 90.

Tolerance: 0.5.
Use a guide to make the job more
easy.
Do not use pipe cutting tools.

Top: To cut gives heavy bevel / burrs.
Bottom: To saw gives no bevel /
burrs.
4-10
29 November 2012

Hold the pipe with the opening down.

Remove any burrs from the inside
and outside edge.
If required, make a bevel up to
0.2x45.
If necessary, use a support sleeve.
Prepare the fitting

Put the fitting, that corresponds to
the pipe size, in a vice.
Apply a light layer of oil to:
the thread and cone of the

coupling;
the cutting ring;
the thread of the nut.
Prepare the connection

Make sure the pipe is free of burrs,
nicks and contamination.
Move the nut over the pipe.
Move the cutting ring in the correct
position over the pipe. The high end
of the ring must face the nut.
Make sure the cutting ring can move
freely.
Top: Correct
Bottom: Wrong
Pre-assemble the connection

Put the pipe into the fitting until it
touches the shoulder of the coupling.
Hold the pipe and move the cutting
ring towards the fitting.
Move the nut towards the fitting and
tighten the nut by hand.
29 November 2012
4-11

Use a marker to put a mark on the

nut and the pipe.
Hold the pipe firmly and tighten the
nut, with a correct sized spanner, by
1.5 turn.
Inspect the connection

CAUTION!
To prevent leaks, after disassembly of the pipe connection, make sure that during assembly the same
pipe is fitted into the same cone of the fitting.
Hold the pipe and carefully loosen

the nut.
Remove the pipe from the fitting.
Make sure, a visible collar fills the
space between the pipe and the cutting ring.
If not:
Repeat the procedure "Assemble the
connection" and carefully tighten the
nut slightly more.
NOTE!
It does not matter if you

can turn the cutting ring.
Final assembly of the connection

CAUTION!
4-12
29 November 2012

Make sure:
the pipe is free of burrs and

contamination;
the connection has a light layer

of oil on the thread and cutting
ring.

Use a correct sized spanner to tighten the nut until you feel a clear resistance.
Stop and tighten the nut extra by a
0.5 turn.
Assembling in hardened pre-assembly body (VOMO)

For frequent assembly of stainless steel pipe and hose standpipe fittings, pre-assembly must take place
exclusively in the pre-assembly bodies 'VOMO" or with pre-assembly tools and machines.
Inspection of pre-assembled bodies (VOMO)

NOTE!
The cones of the pre-assembly bodies (VOMO) are subject to normal wear. This means that
regular inspection and calibration with cone gauges is required.
Inspect the pre-assembly bodies

after every 50 pre-assemblies for
signs of wear, damage and corrosion..
Pre-assembly bodies that do not
pass the inspection must be discarded to prevent faulty connections.
Use of the cone gauges:
Good:
The rear of the cone gauge must
protrude from from the top face of
the 24 cone.
Fair:
The rear of the cone gauge is flush
with the top face of the 24 cone.
Bad:
The rear of the cone gauge lies under
the top face of the 24 cone.
Cut the pipe

Saw off the pipe at an angle of 90.
Tolerance: 0.5.
Use a guide to make the job more
easy.
29 November 2012
4-13

Do not use pipe cutting tools.

Top: To cut gives heavy bevel / burrs.
Bottom: To saw gives no bevel /
burrs.
Hold the pipe with the opening down.

Remove any burrs from the inside
and outside edge.
If required, make a bevel up to
0.2x45.
If necessary, use a support sleeve.
Prepare the pre-assembly body

Put the pre-assembly body, that
corresponds to the pipe and fitting
size, in a vice.
Apply a light layer of oil to:
the thread and taper of the

VOMO;
the cutting ring;
the thread of the nut.
Prepare the pipe

Make sure the pipe is free of burrs,
nicks and contamination.
Move the nut over the pipe.
Move the cutting ring in the correct
position over the pipe. The high end
of the ring must face the nut.
Make sure the cutting ring can move
freely.
Top: Correct
Bottom: Wrong
4-14
29 November 2012

Pre-assemble the connection

Put the pipe into the pre-assembly
body until it touches the stop of the
body.
Hold the pipe and move the cutting
ring towards the pre-assembly body
Move the nut towards the pre-assembly body and tighten the nut by
hand.
Use a marker to put a mark on the
nut and the pipe.
Hold the pipe firmly and tighten the

nut, with a correct sized spanner, by
1.5 turn.
Inspect the pre-assembly

Hold the pipe and carefully loosen
the nut.
Remove the pipe from the pre-assembly body
Make sure, a visible collar fills the
space between the pipe and the cutting ring.
Use a partly cut pre-assembly body
to make sure that the pipe touches
the stop of the pre-assembly body.
If not:
Repeat the procedure "Assemble the
connection" and carefully tighten the
nut slightly more.
NOTE!
It does not matter if you

can turn the cutting ring.
Final assembly of the connection

CAUTION!
29 November 2012
4-15

Make sure:
the pipe is free of burrs, nicks

and contamination;
the connection has a light layer

of oil on the thread and cutting
ring.

Use a correct sized spanner to tighten the nut until you feel a clear resistance.
Stop and tighten the nut extra by a
0.5 turn.
4.5.5 Pressure tests

The pressure test medium is oil.
Table 4.10 Piping pressure test
4.6
Class
System
Test pressure
01
1.5 x the value of the safety valve setting, during 30

minutes.
02
0.5 bar, during 6 hours.
Cleaning instructions for tanks

CAUTION!
Fill the lubrication system as quick as possible with the specified lubrication oil. A thruster with a drained
lubrication system is vulnerable for corrosion because of the absence of lubrication oil. Internal (signs
of) corrosion can cause (serious) damage to the gears and the bearings.
CAUTION!
Take the header tank back into service as quick as possible. The static pressure is removed from the
seals when the header tank is drained. Seals that have no static oil-pressure can leak (sea)water into the
lubrication system. (Sea)water in the lubrication system can cause (serious) damage to the gears and
the bearings.
4.6.1 Required tools and materials

4-16
Description
Specification
Quantity
Cleaning cloth
Lint-free
As required
29 November 2012

Description
Specification
Quantity
Oil catch tank
Refer to the technical specification for the oil content
As required
Warning signs
Oil drain-set
Self priming service pump-unit, hoses, connection pieces 1
Oil sample kit
To take an oil sample from the header tank
1 set
Specification
Quantity
Description
Oil absorption grain (litter)
To clean up the spilled oil
As required
Cleaning agent
White spirit or kerosine
As required
Description
Specification
Quantity
Not applicable
Table 4.15 Spare parts - Lubrication system
Description
Specification
Quantity
Oil filter element
Refer to the spare parts catalogue
Gasket, tank cover
Table 4.16 Spare parts - Steering system
Description
Specification
Quantity
Oil filter element
Low pressure, refer to the spare parts catalogue
Oil filter element
High pressure, refer to the spare parts catalogue
Gasket, tank cover
Table 4.17 Spare parts - Static air supply
Description
Specification
Quantity
Air filter element
Air service unit
Description
Specification
Stop the lubrication pump
Refer to section Operation - Stop the lubrication system
Stop the steering pump
Refer to section Operation - Stop the steering system
Stop the compressed air supply
Refer to section Operation - Stop the static pressure system.
Drain the lubrication system
Refer to section - Preventive maintenance - Drain the lubrication system
Fill the lubrication system
Refer to section - Preventive maintenance - Fill the lubrication system
Drain the steering system
Refer to section - Preventive maintenance - Drain the steering system
Fill the steering system
Refer to section - Preventive maintenance - Fill the steering system
Preventive maintenance - MR
Refer to section - Preventive maintenance
4.6.2 Preparation
Get access
1. Get permission from the commanding officer to do the maintenance job.
2. Make sure free access is available.
29 November 2012
4-17


WARNING!
Be careful and use the applicable Personal Protective Equipment (PPE). The oil system is pressurized
and hot. The incorrect use of the PPE and the pressurized and hot oil can cause (serious) injury to persons.
For the lubrication system

1. Install the warning signs: "Do not operate - Maintenance in progress".
2. Lock-out the starter cabinet of the lubrication pump(s):
1. Set the L-0-R switch in the 0 position.
2. Set the MAIN switch in the 0 position.
3. Install the personal safety padlock.
4. Make sure the pump-unit is off.
NOTE!
The pneumatic air supply is beyond the scope of this manual. For detailed instructions, refer
to the documentation that came with the pneumatic air-supply system.
3. Lock-out the pneumatic air supply to the header tank:

1. Set the pressure regulator in the 0 position.
2. If present, close the air supply valve.
4. Make sure the pressure is 0 bar.
4. Let the lubrication oil cool down.
For the steering system
2. Lock-out the starter cabinet of the steering pump(s):
3. Let the steering and lubrication oil cool down.
4. Release the steering oil pressure:
1. On the steering control valve, operate the solenoid by hand to release the hydraulic pressure.
2. At the steering pressure gauge, make sure the hydraulic pressure is released.
Take an oil sample

1. For future reference, take an oil sample from the header tank and get an oil analysis (type, contamination
and viscosity) from the manufacturer. For detailed instructions, refer to the procedure: Take an oil sample.
4-18
29 November 2012

1. For future reference, take an oil sample from the steering oil tank and get an oil analysis (type, contamination and viscosity) from the manufacturer. For detailed instructions, refer to the procedure: Take an
oil sample.
Drain the oil tank

1. Drain the header tank.
For detailed instructions, refer to the procedure: Drain the lubrication system.
1. Drain the steering oil tank.
For detailed instructions, refer to the procedure: Drain the steering system.
4.6.3 Clean the oil tank

1. Make sure, free access to the cover of the tank is available.
2. Clean the outside of the cover to prevent contamination to enter the system.
3. Remove the accessories from the cover.
4. Remove the mounting materials that attach the cover to the tank.
5. Remove the cover from the tank.
6. Keep the removed parts in a clean location.
7. Install a blind plug into the supply line to prevent contamination to enter the system.
8. Clean the inside of the tank from the top to the bottom.
9. If installed, remove and clean the inside and outside of the sight-glass.
4.6.4 Do an inspection of the oil tank

1. Do an inspection of the inside for signs of damage and corrosion.
1. Make sure all welds are in good condition.
2. Do an functional test of the valves for correct operation.
4.6.5 Assemble the oil tank

1. If installed, install the sight-glass.
2. Remove all tools, materials and equipment from the inside of the oil tank.
3. Make sure the inside of the oil tank is absolutely clean.
4. Install the cover on the oil tank with the gasket and mounting materials.
5. Install the accessories, make sure, all openings are closed (breather valve, dip-stick, etc. are installed)
to prevent contamination to enter the system.
6. Install a new filter element. For detailed instructions, refer to the section: Removal / Installation.
7. Set the valves in the correct position for operation.
8. Fill the oil tank with the specified oil (type and cleanliness) to get the correct oil level. For detailed instructions, refer to the section: Preventive maintenance.
9. Make sure, no signs of oil leaks are seen. If you see an oil leak, take corrective action and clean up any
spilled oil.
29 November 2012
4-19

4.6.6 After installation test

WARNING!
Inform other persons and make sure, it is safe to start or pressurize the equipment. Unexpected movement
of the equipment can cause (serious) injury or death to persons.

1. Start the lubrication system. For detailed instructions, refer to the section Operation.
2. Let the system run for at least 5 minutes. Make sure:
no unusual noise is heard,
no excessive vibration is felt,
no signs of oil leaks are seen,
the oil runs through the filter unit (becomes warm).
3. Stop the lubrication system. For detailed instructions, refer to the section Operation.
5. Add the specified oil (type and cleanliness) to get the correct oil level.
1. Make sure, the steering pump and motor unit are filled with steering oil.
2. Start the steering system. For detailed instructions, refer to the section Operation.
3. Let the system run for at least 5 minutes. Make sure:
no unusual noise is heard,
no excessive vibration is felt,
no signs of oil leaks are seen,
the oil runs through the filter unit (becomes warm).
4. Stop the steering system. For detailed instructions, refer to the section Operation.
6. Add the specified oil (type and cleanliness) to get the correct oil level.
4.6.7 Job close up

CAUTION!
Set the by-pass valve in the correct position. If the oil flows through the by-pass, the oil does not get
filtered. Contaminated oil can cause (serious) damage and (costly) downtime to the equipment.
1. Remove all tools, materials and equipment from the work area. Make sure the area is safe and clean.
2. Dispose of the waste and discarded parts in an environmental safe manner in accordance with the
manufacturer's instructions and international regulations.
3. If required, make a note of the deviation in the maintenance logbook.
4. Return the system into operation.
4-20
29 November 2012

3. If required, make a note of the deviation in the maintenance logbook.
4.6.8 After care

1. Do the preventive maintenance task with interval MR. Refer to the section: Preventive maintenance.
29 November 2012
4-21
4-22
29 November 2012

5. Preventive maintenance
5.
Preventive maintenance
This chapter gives the maintenance intervals and checklists for on-board equipment and spare parts and
the related preventive maintenance procedures.
5.1
Introduction
This chapter gives the maintenance intervals and related checklists for the preventive maintenance tasks
for the Wrtsil scope of supply. The maintenance intervals are meant as an advice and a help for the
planning of the preventive maintenance tasks either in dry dock, on-board or for parts kept in storage. For
future reference and trend monitoring, put a copy of the completed maintenance checklists in the maintenance logbook. If a task can only be done by the manufacturer or an approved service station, please make
an appointment with the Wrtsil service organization, well in advance.
The given maintenance intervals, in calendar time or service hours are the result of condition-based maintenance analyses and give a minimum level of maintenance. For the best possible, operational reliability,
you need to review and revise the maintenance intervals in accordance with the operational use and conditions. If in doubt, please ask the Wrtsil service organization for advice
For the best results of the 3 and 5 year inspections and the overhaul tasks, it is recommended that a
Wrtsil service engineer is present to execute or supervise the given tasks. Note that some of the overhaul
tasks are typical shop tasks. If you require a Wrtsil service engineer, please let us know well in advance.
NOTE!
Use calendar time or service hours, whichever comes first, to determine the applicable maintenance interval.
The maintenance intervals are defined as:

Symbol
Interval
Description
Calendar Hours
D
Daily
24
When the thruster is in use.
Monthly
750
At least one time in a month.
Quarterly
2000
At least one time in 3 months.
6M
1/2 Year
4000
At least one time in 6 months.
Annually
8000
At least one time in 12 months (1 year).
3Y
3 Year
24000
At least one time in 3 year, Once in 2.5 years for class demanded inspections.
5Y
5 Year
40000
At least one time in 5 year.

For the best results, it is recommended that a Wrtsil service engineer is present
to execute or supervise the given tasks.
MR
300
After commissioning or
after an overhaul of the steerable thruster, or when the oil system was opened for
inspection and repair (known as major repair).
The maintenance locations are defined as:

The maintenance task is possible if the vessel is in the water.
The maintenance task is only possible if the vessel is in dry dock.
The maintenance task is only possible if the equipment is removed from the vessel and sent to an approved
work shop.
5.1.1 Preventive maintenance at progressive intervals

Preventive maintenance at progressive intervals means that you do the preventive maintenance of the
nearest intervals during the (un)scheduled maintenance or repair of the vessels equipment.
29 November 2012
5-1

The preventive maintenance intervals tell you which inspections and tests must at least be done at which
moment. However there can be unscheduled moments in between these intervals. If the vessel is in drydock for whatever reason, it is recommended and cost efficient to do the (dry-dock) indicated inspections
and tests at that unscheduled moment, but make sure, the given inspections and tests are done at least
one time per interval.
5.1.2 Preventive maintenance for class demanded inspections

For vessels that operate under class restrictions, it can happen that the given maintenance interval does
not meet the maintenance requirements from the classification bureau. In these events the maintenance
interval as demanded by the classification bureau prevails. For detailed information and instructions, please
refer to the maintenance requirements as issued by your classification bureau.
5-2
29 November 2012

5.2
Maintenance intervals for the thruster
5.2.1 General condition

Description
Maintenance interval
D
6M
3Y
5Y
MR
3Y
5Y
MR
Response of the steering actuation system.

Vibration levels.
Noise.
Oil filter element.
Filler/Breather.
Oil temperature.
Cooling water temperature.
Oil pressure.
Brake air pressure.
Header tank air pressure.
Oil condition (samples).
5.2.2 Inspection for oil and grease leaks

Description
D
6M
Oil pipes, hoses and connections.

Oil level.
Input shaft seal.
Steering pipe seal.
Propeller shaft seal.
5.2.3 Inspection for water leaks

NOTE!
29 November 2012
5-3

Description
D
6M
3Y
5Y
MR
3Y
5Y
MR
3Y
5Y
MR
3Y
5Y
MR
Water pipes, hoses and connections.
5.2.4 Inspection for air leaks

Description
D
6M
Air pipes, hoses and connections.

Air control panels / air service units.
Shaft brake membrane.
5.2.5 Inspection for wear, damage and installation

Description
D
6M
Pipes, hoses and connections.

Electrical wiring, cabinets and cable protection
Mounting and locking materials, gaskets and sealants.
Holding brake and disc.
Prime mover.
Steering motor-unit.
Lubrication pump-unit.
Geared coupling.
5.2.6 Inspection for signs of corrosion and pitting

Description
D
6M
Propeller surface.
Propeller gearbox surface.
Locking materials (strips, welds, wire).
Painted areas.
5-4
29 November 2012

Description
D
6M
3Y
5Y
MR
3Y
5Y
MR
Bare metal surface of the shafts.

Holding brake and disc.
Electrical bonding.
5.2.7 Inspection for cleanliness

Description
D
6M
Oil pump electric motor(s).

Hoses and connections.
Prime mover.
Air control panel.
Oil tanks and equipment.
Inside of the electrical cabinets.
Equipment environment.
Input seal environment.
Propeller arrangement.
Propeller gearbox.
5.2.8 Lubrication and grease application

Description
D
6M
3Y
5Y
MR
Add the specified oil to get the correct oil level.

Geared coupling.
Brake actuator / brake arm shafts.
5.2.9 Preventive replacement of parts

As a result of preventive maintenance inspections or tasks, in some cases it is required to remove the used
part and install a new part or add oil/grease.
Only use Wrtsil approved:
29 November 2012
5-5

spare parts, as specified in the spare parts catalogue;
oil and grease, as specified in the technical data and table of lubricants.
Description
D
6M
3Y
5Y
MR
3Y
5Y
MR
Filter element(s).
Drain and fill the lubrication system with fresh, clean, new oil.
Drain and fill the steering system with fresh clean, new oil.
Oil hoses.
Flexible coupling of the oil pump-units.
Brake pads.
Filter element of the air control panel.
The PLC backup battery.
The active, electrical equipment in the starter cabinets.
5.2.10 Functional test and adjustment

Description
D
6M
Get an oil sample and get an oil analysis (type, contamination and
viscosity) from the manufacturer.
Steering system - SOLAS Chapter V, regulation 26 compliance.
Steering system - valves, sensors and switches.
Lubrication system - valves, sensors and switches.
Alarm system(s).
Lamp and indicator test.
Main circuit breaker test (for the electrical motors).
Thermal circuit breaker test (for the electrical motors).
Local control panels.
Propulsion control panels.
Air pressure.
5-6
29 November 2012

5.2.11 Cleaning
Description
D
6M
3Y
5Y
MR
Oil tank(s).
Heat exchanger(s) - steering system.
Heat exchanger(s) - lubrication system.
Brake
29 November 2012
5-7

5.3
Maintenance intervals for parts kept in storage

NOTE!
The spare parts are preserved up to 6 months. After this period the spare parts need inspections
and maintenance to keep the part serviceable.
5.3.1 Corrosion protection

Description
D
Silica gel.
Preservation fluid.
Ambient conditions.
6M
3Y
5Y
MR
3Y
5Y
MR
3Y
5Y
MR
5.3.2 Visual inspection

Description
D
6M
Signs of corrosion.
Signs of damage.
Packaging.

Description
D
Proper movement.
6M
X
5.3.4 Shelf life

NOTE!
The shelf life of parts and consumable materials kept in storage depends strongly on the storage
conditions and the used materials of the parts. The given intervals are a guideline. For detailed
information, please refer to the technical data and material safety data sheets of the parts and
consumable materials which are available from the manufacturer.
Description
D
Seals and O-rings (NBR).

Seals and O-rings (Viton).
Other parts that have a limited shelf life.
5-8
6M
3Y
5Y
MR
X
X
At any time as indicated on label.
29 November 2012

5.4
Maintenance checklists for the thruster

The maintenance checklists are meant to help the engineer and to give a summary of the required task.
For future reference, put a copy of the completed maintenance checklists in the maintenance logbook.
5.4.1 General condition

Name
Signature
Date
Interval
WARNING!
Be careful when you work near moving or turning equipment. Make the work area safe. Moving or turning
equipment can pull you in the installation which can cause (serious) injury or death to persons.
NOTE!
At the heat exchanger, the inlet - outlet oil temperatures can change strongly. This is a normal
reaction to environment and load conditions. The measured values are meant as a reference
and therefore not as an alarm.
You can do the next maintenance tasks if the vessel is in the water.
Description
Task summary
OK / Not OK /
Not done
Required action
(Make a note of any deviation)
Response of the steer- Before sailing, do the steering response Follow-Up

ing actuation system. test in the 'Follow-Up' and 'Non FollowUp' mode of the propulsion control system.
Non Follow-Up
Make sure, on all propulsion control
panels, the vessel's response is correct.
Vibration levels.
During normal operation, make sure, no

unusual vibrations are felt.
Noise.
During normal operation, make sure, no

unusual noise is heard.
Oil filter element.
Use the visual indicator to determine the Lubrication oil:

status. If necessary, install a new filter
element.
Steering oil:
Filler/breather.
Make sure, the filler/breather is in good Header tank:

condition and dry.
If necessary, install a new filler/breather.
Steering oil tank:
Oil temperature [C].
During normal operation, with the temper- Lubrication oil:

ature stabilized:
measure or read the temperature indicator.
Steering oil:
Make a note and compare the result with
previous inspections.
29 November 2012
5-9

Description
Task summary
OK / Not OK /
Not done
Required action
(Make a note of any deviation)
Cooling water temper- During normal operation, with the temper- Lubrication sysature [C].
ature stabilized:
tem:
measure or read the pressure indicator.
Steering system:
Oil pressure [bar].
Condition: temperature stabilized:

Lubrication oil:
measure or read the temperature indicator.
Make a note and compare the result with Steering oil:
Brake air pressure

[bar].
During normal operation, with the brake

disengaged:
Read the pressure from the indicator.
Header tank air pres- During normal operation:

sure [bar].
Read the pressure from the indicator.
Oil condition
(samples).
5-10
Take an oil sample and get an oil analysis (type, contamination and viscosity)
from the manufacturer or approved
laboratory.
29 November 2012

5.4.2 Inspection for oil and grease leaks

Name
Signature
Date
Interval
WARNING!
Make sure, it is safe to work on the oil system. Do not get oil onto your skin or in your eyes. Use the
applicable Personal Protective Equipment (PPE). Pressurized oil can cause (serious) injury or death to
persons.
CAUTION!
To limit oil contamination, repair a leak as soon as possible: where oil can get out, dirt can get in the
system. Oil leaks will result in a low oil level or contaminated oil that can cause (serous and costly) system
failures.
Description
Task summary
OK / Not OK /
Not done
Oil pipes, hoses and

connections.
Make sure, no signs of oil leaks are seen.

If you see an oil leak, take corrective action and clean up any spilled oil.
Oil level.
In stopped condition, inspect the oil

Lubrication syslevel. The level must be between the
tem:
marks.
If necessary do an inspection for oil
leaks, do any necessary work and add Steering system:
oil, as specified in the section technical
data, to get to the correct level.
Input shaft seal.

Required action
WARNING!
Lock-out and tag-out the installation. Make sure:
the oil pumps are locked and tagged out;
the prime mover is locked and tagged out;
the propeller can not turn by hand (manual operation);
the thruster can not move by external forces.
Unexpected movement of the equipment can cause (serious) injury or death to persons.
Unless otherwise specified, you can do the next maintenance tasks if the vessel is in dry dock.
29 November 2012
5-11

5-12
Description
Task summary
Steering pipe seal.

Propeller shaft seal.

OK / Not OK /
Not done
Required action
29 November 2012

5.4.3 Inspection for water leaks

Name
Signature
Date
NOTE!
Interval
Description
Task summary
Water pipes, hoses

and connections.
Make sure, no signs of water leaks are

seen. If you see a water leak, take corrective action and clean up any spilled
water.
29 November 2012
OK / Not OK /
Not done
Required action
5-13

5.4.4 Inspection for air leaks

Name
Signature
Date
Interval
WARNING!
Make sure, it is safe to work on the compressed air system. Use the applicable Personal Protective
Equipment (PPE). Pressurized air can cause (serious) injury or death to persons.
CAUTION!
Air leaks cause a lower air pressure than specified. Air operated equipment can not operate correctly
when the air pressure is too low. Low air pressure causes excessive wear of the equipment and finally
(serious and costly) system failures.
Description
Task summary
Air pipes, hoses and

connections.
Listen carefully and make sure, no signs

of air leaks are heard. If you hear an air
leak, take corrective action.
OK / Not OK /
Not done
Required action
Air control panels / air Listen carefully and make sure, no signs
service units.
Shaft brake membrane.
5-14
Listen carefully and make sure, no signs

29 November 2012

5.4.5 Inspection for wear, damage and installation

Name
Signature
Date
Interval
CAUTION!
Do not re-tighten mounting parts that are installed with the use of a locking agent. Mounting parts that
are not installed with a lock washer are often locked with a locking agent (Loctite). If you re-tighten
mounting parts that are installed with the use of a locking agent, (serious) damage or loss of equipment
can occur.
Description
Task summary
OK / Not OK /
Not done
Required action
Pipes, hoses and con- Make sure:

nections.
no signs of wear and damage are

seen;
the equipment is correctly attached to the mounting surface.
If you see damage, make a note of the

location and condition or do any necessary work.
Electrical wiring, cabin- Make sure:
ets and cable protec
tion
seen;

Holding brake and
disc.
Make sure:

seen;
If you see (or smell) damage, make a

note of the location and condition or do
any necessary work.
Prime mover
Make sure:

seen;
If you see (or smell) damage, make a

note of the location and condition or do
any necessary work.
29 November 2012
5-15

Description
Task summary
Steering motor-unit.
Make sure:

seen;
OK / Not OK /
Not done
Required action

Lubrication pump-unit. Make sure:

seen;

Geared coupling.
Make sure:

seen;
If you see excessive wear or damage,

make a note of the location and condition or do any necessary work.
WARNING!
Description
Task summary
Mounting materials
and sealants.
(Inspection by diver)
Make sure:

seen;
OK / Not OK /
Not done
Required action

5-16
29 November 2012

Description
Task summary
OK / Not OK /
Not done
Required action
Anodes (cathodic pro- (Inspection by diver)

tection).
Make sure:
no signs of wear and damage or

loss are seen;
the anodes are correctly attached

to the mounting surface.

29 November 2012
5-17

5.4.6 Inspection for signs of corrosion and pitting

Name
Signature
Date
Interval
You can do the next maintenance tasks when the vessel is in the water.
Description
Task summary
Electrical bonding.
Clean the surface.

Make sure, no signs of corrosion and
damage are seen.
If corrosion is seen, do a bonding check
and repair failed connections.
Locking materials
(strips, welds, wire).
Clean the surface.

If you see excessive corrosion or damage, make a note of the location and
condition or do any necessary work.
Painted areas.
Clean the surface.

damage are seen.
OK / Not OK /
Not done
Required action
Bare metal surface of Clean the surface.

the shafts.
damage are seen.
Holding brake disc.
Clean the surface.

damage are seen.
WARNING!
5-18
29 November 2012

Description
Task summary
Propeller surface.
Clean the surface.

Make clear and detailed photographs of
the surface and sent them to the Wrtsil
service organization for an assessment
of the condition.
OK / Not OK /
Not done
Required action
Propeller gearbox sur- Clean the surface.

face.
cavitation damage are seen.
Locking materials
(strips, welds, wire).
29 November 2012
Clean the surface.

cavitation damage are seen.
5-19

5.4.7 Inspection for cleanliness

Name
Signature
Date
Interval
Description
Task summary
OK / Not OK /
Not done
Required action
Oil pump electric mo- Make sure:

tor(s).
a free flow of air is available;
the ventilation openings are not

blocked;
the cooling surface is clean.
If you see contamination, make a note

of the location and condition or do any
necessary work.
Hoses and connections
Make sure, that the hoses and connections are clean and free of excessive oil
damp at the outside.
necessary work.
Prime mover
Make sure:
a free flow of air is available;
the ventilation openings are not

blocked;

necessary work.
Air control panel.
Make sure, the air service unit (bowl) is

clean and dry. If applicable, drain the
condensate.
necessary work.
Oil tanks and equipment.
Make sure, that the outside of the oil

tanks and piping are clean and free of
excessive oil damp.
necessary work.
Inside of the electrical Isolate the electrical power and make

cabinets.
sure, the inside of the cabinet is free of
excessive contamination (dust). If installed, do an inspection of the cabinet
filters.
necessary work.
5-20
29 November 2012

Description
Task summary
Equipment environment.
Make sure, access and escape routes

are free of obstacles and contamination.
If you see excessive contamination,
Input seal environment.
Make sure the input seal environment is

free of grease, oil and other contamination.
OK / Not OK /
Not done
Required action
WARNING!
Description
Task summary
OK / Not OK /
Not done
Required action
Propeller arrangement. (Inspection by diver)

Make sure, the equipment is free of foreign objects and contamination (e.g.
from sea life).
Propeller gearbox.
29 November 2012
(Inspection by diver)
Make sure, the equipment is free of foreign objects and contamination (e.g.
from sea life).
5-21

5.4.8 Lubrication and grease application

Name
Signature
Date
Interval
WARNING!
Always wear the applicable personal protective equipment when you work with oil or grease. Do not get
the oil or grease onto your skin or in your eyes. Oil and grease can cause (serious) injury to persons.
CAUTION!
Clean the work area before you do any work. A clean area prevents contamination to enter the system.
Contamination that enters with oil or grease application will result in (serious, costly) damage of equipment.
Description
Task summary
Add the specified oil

to get the correct oil
level.
Use oil, as specified in the section technical data, to fill the system to the correct
level.
Dispose of the waste in an environmental
safe manner.
Geared coupling.
Use grease, as specified in the section

technical data, to maintain the system
as given in the maintenance instructions.
safe manner.
OK / Not OK /
Not done
Required action
Brake actuator / brake Use grease, as specified in the section

arm shafts.
technical data, to maintain the system
as given in the maintenance instructions.
safe manner.
5-22
29 November 2012

5.4.9 Preventive replacement of parts

Name
Signature
Date
Interval
WARNING!
Always wear the applicable Personal Protective Equipment (PPE) when you work with oil or grease. Do
not get the oil or grease onto your skin or in your eyes. Oil and grease can cause (serious) injury to persons.
CAUTION!
Clean the work area before you do any work. A clean area prevents contamination to enter the system.
Contamination that enters with oil or grease application will result in (serious, costly) damage of equipment.
NOTE!
As a result of preventive maintenance inspections or tasks, in some cases it is required to remove

the used part and install a new part or add oil/grease.
Only use Wrtsil approved:
spare parts, as specified in the spare parts catalogue;
oil and grease, as specified in the technical data and table of lubricants.
Description
Task summary
Filter element(s).
Remove the used filter element. Clean

the inside of the oil filter unit and install
a new oil filter element.
Add the specified oil to get to the correct
oil level.
After installation, set the external bypass
valve in the correct position.
OK / Not OK /
Not done
Required action
Drain and fill the lubric- Use the specified oil to fill the system to
ation system with
the correct level.
fresh, clean, new oil. Make sure, you carefully remove the air
from the system.
safe manner.
Drain and fill the steer- Use the specified oil to fill the system to
ing system with fresh, the correct level.
clean, new oil.
Make sure, you carefully remove the air
from the system.
safe manner.
29 November 2012
5-23

Description
Task summary
Hydraulic hoses.
Remove the old hoses and install the

new hoses. Make sure, no leaks are
seen.
For future reference, make a note for the
date of installation in the maintenance
logbook.
Flexible coupling of
the oil pump-units.
Remove all Flexible coupling discs and

carefully clean the area. Do any necessary work and install new elements.
OK / Not OK /
Not done
Required action
Filter element of the air Remove the filter element and clean the
control panel.
bowl. Do any necessary work. Install a
new filter element and make sure, the air
flows and the work pressure is correct.
If installed, make sure the (automatic)
drain valve operates correctly.
The PLC backup bat- With the PLC set to ON, remove the
tery.
backup battery from the PLC and install
the new backup battery.
The active, electrical
equipment in the
starter cabinets.
As result of functional test and operational hours, remove the main contactor(s)
and thermal relay(s) from the cabinet(s)
and install the new equipment as given
in the manufacturer's maintenance instructions.
WARNING!
Description
Task summary
OK / Not OK /
Not done
Required action
Anodes (cathodic pro- Remove the used anodes and carefully

tection).
clean the area. Do any necessary work
and install the new anodes.
5-24
29 November 2012


Name
Signature
Date
Interval
WARNING!
Inform other persons and make sure,it is safe to start or pressurize the equipment. Unexpected movement
of the equipment can cause (serious) injury or death to persons.
Description
Task summary
OK / Not OK /
Not done
Required action
Get an oil sample and Sent the oil sample in a clean, new
get an oil analysis
sample bottle, to the oil manufacturer for
(type, contamination an oil type analysis.
and viscosity) from the
manufacturer.
Steering system SOLAS Chapter V,
regulation 26 compliance.
Do a test of the emergency steering

system. Make sure, the procedure is
known and the emergency steering system operates correctly.
Steering system valves, sensors and

switches.
Do a functional test of the steering system. Make sure all valves, sensors and
switches operate correctly.
Lubrication system valves, sensors and

switches.
Do a functional test of the lubrication

system. Make sure all valves, sensors
and switches operate correctly.
Alarm system(s).
Do a functional test of the oil level alarm

and make sure, the alarm comes on.
Adjust the alarm setting if necessary.
Do a functional test of the oil temperature alarm and make sure, the alarm
comes on.
Do a functional test of the oil pressure
alarm and make sure, the alarm comes
on.
Safety equipment.
Do a functional test of the safety equipment (e.g. fuses, relief valves) and make
a note of the results.
Lamp and indicator

test.
Do a lamp and indicator test. Make sure,

the lamp comes on and the indicators
give an indication. Remove defective
lamp bulb and install a new bulb as necessary.
29 November 2012
5-25

Description
Task summary
OK / Not OK /
Not done
Required action
Main circuit breaker

At the applicable starter cabinet(s), find
test (for the pump mo- the main circuit breaker. Press the test
tors).
button and make sure, the circuit breaker
trips. Reset the circuit breaker and make
sure, the electrical power is available to
the starter cabinet.
Thermal circuit breaker At the applicable starter cabinet(s), find
test (for the electrical and test the thermal circuit breaker that
motors).
protects the motor. Make sure, the set
value is correct.
5-26
Local control panels.
In Non Follow-Up (NFU) mode, do a

functional test from the local control
panels.
Do a functional test of the indicator at
the azimuth feedback unit.
Propulsion control
panels.
Do a functional test of the propulsion

control panels.
Air pressure.
Adjust the air pressure to the required

value (as indicated on the drawing set).
29 November 2012

5.4.11 Cleaning
Name
Signature
Date
Interval
WARNING!
Be careful if you use the consumable material(s). Obey the local and manufacturers health and safety
instructions. Use the applicable Personal Protective Equipment (PPE). Incorrect use can cause (serious)
injury to persons and damage to the environment.
Description
Task summary
Clean the oil tank(s).
Drain the oil and clean the inside of the Lubrication systank(s).
tem
Do an inspection of the inside for signs
of damage and corrosion. Do any necesSteering system
sary work.
safe manner.
Heat exchanger(s) of
the steering system.
Drain the oil and water.

Oil side
Clean the inside of the heat exchanger(s).
of wear, damage and corrosion. Do any Water side
necessary work.
safe manner.
Heat exchanger(s) lubrication system.
Drain the oil and water.

Oil side:
Clean the inside of the heat exchanger(s).
of wear, damage and corrosion. Do any Water side
necessary work.
safe manner.
Brake.
Drain the condensate (water) from the

pneumatic actuator.
Clean the outside of the brake and disc.
Remove all contamination and excessive
grease to prevent slip and loss of brake
power. Do any necessary work.
safe manner.
29 November 2012
OK / Not OK /
Not done
Required action
5-27

5.5
Maintenance checklists for parts kept in storage

Name
Signature
Date
Interval
WARNING!
Be careful if you use the consumable material(s). Obey the local and manufacturers health and safety
instructions. Use the applicable Personal Protective Equipment (PPE). Incorrect use can cause (serious)
injury to persons and damage to the environment.
Description
Task summary
OK / Not OK /
Not done
Ambient conditions.
Make sure, the equipment is stored as

specified in the section Technical data
Measure the ambient temperature and
make a note.
Mechanical
parts
Required action
C
Electrical parts
C
Rubber based
parts
C
5-28
Silica gel.
In the bag or box of the parts in storage,

inspect the anti-corrosion material and
add sufficient new material. Close the
bag or box air-tight to prevent for ingress
of moisture.
Preservation fluid.
Add new preservation fluid to get the

correct storage conditions. For information, refer to the Table of lubricants.
Signs of corrosion.
Inspect the part for signs of corrosion. If

you see signs of corrosion, carefully remove the preservation fluid and corrosion. Clean the surface and apply a new
layer of preservation fluid.
Signs of damage.
Inspect the part for signs of damage. If

you see damage, make a note and do
any necessary work.
Packaging.
Inspect the packaging for signs of damage. If the packaging is damaged or

opened, inspect the content for completeness and usability.
Proper movement.
On all rotating and moving parts, make

sure, proper movement into another position is possible.
If you fail to rotate or move the part,
make a note and do any necessary work.
29 November 2012

Description
Task summary
Shelf life time
For parts with a shelf/service life time,

inspect the date. If the life time is exceeded, discard the parts in an environmental safe manner and order new parts.
OK / Not OK /
Not done
Required action
For consumable materials with a

shelf/service life time, inspect the date.
If the life time is exceeded, discard the
consumable materials in an environmental safe manner and order new consumable materials.
29 November 2012
5-29

5.6
Drain the lubrication system

CAUTION!
of) corrosion can cause serious damage to the gears and the bearings.
NOTE!
You can not drain the lubrication system when the vessel is in the water because the lubrication
oil is also used to keep the static pressure onto the propeller shaft and steering pipe seals. When
the static pressure decreases or even is lost, the lubrication system is vulnerable for water ingress
because the (sea)water pressure becomes higher than the static oil pressure.
This procedure assumes that the vessel is in dry dock and made safe for maintenance activities.

Description
Specification
Quantity
Cleaning cloth
Lint-free
As required
Specification
Quantity
Description
Oil catch tank
Refer to the technical specification for the oil volume
As required
Warning signs
Oil drain-set
Self priming service pump-unit, hoses, connection pieces 1
Description
Specification
Quantity
Oil absorption grain (litter)
To clean up the spilled oil
As required
Specification
Quantity
Description
Not applicable
Description
Specification
Quantity
Not applicable
5-30
Description
Specification
Stop the lubrication pump
Refer to section: Operation - Stop the lubrication pump.
Stop the steering pump
Refer to section: Operation - Stop the steering pump.
Stop the compressed air supply
Refer to section: Operation - Stop the static pressure system.
Lubrication diagram
Refer to the section: Troubleshooting - Drawings.
Flush instructions
Refer to the section: General maintenance - Cleaning instruction for piping.
Clean the header tank
Refer to the section: General maintenance - Clean the header tank.
29 November 2012

5.6.2 Preparation
WARNING!
Use the applicable Personal Protective Equipment (PPE). Incorrect use can cause (serious) injury to
persons and damage to the environment.
Get access
WARNING!
Only use validated and approved access platform(s). Access platform(s) that are not validated and approved can be unsafe. Access platforms that are unsafe can cause (serious) injury or death to persons.

2. Turn the thruster to the maintenance position to make sure, the thruster will not turn by gravity forces
when the the steering oil pressure is released.
4. Install the access platform(s).
5. Make sure, the access platforms are validated and approved.

WARNING!
Let the oil cool down. Oil systems that operate, generate heat. Hot oil and surfaces can cause (serious)
burns to the skin.
1. At the control panels, install the warning signs: "Do not operate - Maintenance in progress".
2. Stop and lock-out the steering pump-unit.
For detailed instructions, please refer to the procedure: Stop the steering pump.
WARNING!
Be careful if you release the steering oil pressure. A thruster without steering oil pressure will turn
uncontrolled to its rest position caused by gravity forces. A thruster that turns uncontrolled can cause
(serious) injury to persons or damage to equipment.
4. Release the hydraulic pressure:
5. Stop the compressed air supply to the header tank.
For detailed instructions, please refer to the procedure Stop the static pressure system.
6. Stop and lock-out the lubrication pump-unit.
For detailed instructions, please refer to the procedure: Stop the lubrication pump.
7. If installed, stop and lock-out the water separator/purifier.
For detailed instructions, please refer to the documentation that came with the water separator/purifier.
8. If necessary, let the lubrication oil cool down.
29 November 2012
5-31

Take an oil sample

1. For future reference, take an oil sample and get an oil analysis (type, contamination and viscosity) from
the manufacturer or approved laboratory.
5.6.3 Drain the lubrication system

NOTE!
This procedure is applicable if you want to drain the lubrication system completely. It is possible
to drain parts of the lubrication system separately as given in the separate instructions that follow.
For the upper gearbox

1. Drain the upper gearbox. For detailed instructions, please refer to 5.6.6, Drain the upper gearbox.
For the header tank
1. Remove and keep the filler cap.
2. Make sure, the drain valve is closed and the shut-off valve is open.
For the propeller gearbox and the stem section
1. Drain the propeller gearbox and the stem section. For detailed instructions, please refer to 5.6.5, Drain
the propeller gearbox and the stem section.
For the steering motor-unit
1. Drain the gearbox of the steering motor-unit. For detailed instructions, please refer to 5.6.7, Drain the
gearbox of the steering motor.
If installed; For the water separator/purifier
1. Drain the water separator/purifier, For detailed instructions, refer to the manufacturer's documentation
that came with the water separator/purifier.
5.6.4 Drain the header tank

WARNING!
persons.
NOTE!
You can use this procedure if you only need to drain the header tank. If you need to drain the
complete lubrication system, best practice is to use the drain port of the propeller gearbox.
Refer to figure 5.1,, The header tank - Drain procedure (typical).

1. At the header tank, find the drain connection (a).
2. In between the stem section and the header tank, find the shut-off valve (1).
3. Turn the shut-off valve (1) in the closed position.
4. Clean the work area and the drain connection (a).
5. Connect the lubrication oil drain-set (3) to the drain connection (a) and the oil catch tank (4).
6. Keep all removed parts (blanking caps, etc.) in a safe and clean location.
7. Put the oil catch tank in the correct position.
8. Open the drain connection (2) and let the lubrication oil flow into the oil catch tank (4).
9. When ready, close the drain connection (4).
5-32
29 November 2012

10. Do an inspection of the header tank, for detailed instructions, refer to the section Preventive maintenance,
procedure: Cleaning.
Figure 5.1 The header tank - Drain procedure (typical)
Be aware, some parts and connections are omitted for clarity.
5.6.5 Drain the propeller gearbox and the stem section

WARNING!
persons.
1. At the bottom of the propeller gearbox, find the drain plug.

2. Put the oil catch tank, of sufficient size, in the correct position.
3. At the header tank, remove the filler/breather valve to vent the header tank.
4. Carefully, remove and discard the drain plug and seal to let the lubrication oil flow into the oil catch tank.
5. At the cover of the stem section, find the breather valve of the stem section.
6. When the sight glass is empty, remove the breather valve to drain the oil more easily.
29 November 2012
5-33

5.6.6 Drain the upper gearbox

WARNING!
persons.
NOTE!
Under normal circumstances, the header tank can hold the oil content of the upper gearbox. In
this procedure the lubrication oil is pumped into the header tank to allow you to drain the oil
either from the drain connection at the header tank or via the stem section through the drain
port of the propeller gearbox.
1. In between the stem section and the header tank, find the shut-off valve.
2. Turn the shut-off valve in the closed position.
3. Make sure, the oil level in the header tank is almost at minimum.
4. Start the lubrication system and monitor the oil level in the header tank. The level pump brings the lubrication oil from the upper gearbox into the header tank.
5. When the lubrication oil from the upper gearbox is in the header tank, stop the lubrication system.
6. Make the system safe to work on and lock out the lubrication system.
7. Find the inspection hatch. Make sure, free access is available.
8. Around the inspection hatch, clean the outside of the upper gearbox.
9. Clean the hoses of the oil drain set internally and externally.
10. Remove the inspection hatch and make sure, no contamination can enter the upper gearbox.
11. Feed the suction hose of the service pump-unit, through the inspection hatch to the bottom of the upper
gearbox.
12. Feed the output hose of the service pump-unit into an oil catch tank.
13. Make sure, the output hose can not fall from the oil catch tank.
14. Use the service pump-unit to get the last amount of lubrication oil from the upper gearbox into the oil
catch tank.
5.6.7 Drain the gearbox of the steering motor

NOTE!
The gearbox of the steering motor-unit gets oil from the lubrication system.
1. At the steering motor-unit, find the drain plug and level eye.
2. Make sure:
the steering motor can not start (steering system is depressurized);
the thruster is in the rest position and can not turn by gravity forces.
3. Install an oil catch tank under the drain plug.

4. Remove the drain plug and keep it in a clean location.
5. Remove and keep a vent plug, to drain the oil more easy.
6. When the gearbox is empty, flush the gearbox. For detailed instructions, refer to the procedure: Flush
instructions.
5-34
29 November 2012

5.6.8 Job close up

1. Leave the warning signs in place and remove the tools, materials and equipment from the work area.
Make sure the area is clean.
2. To prevent contamination to enter the system, temporarily, install:
1. the inspection hatch to the upper gearbox.
2. the breather valves on the header tank and stem section.
3. the removed plugs in the steering motor-units.
4. As quick as possible, fill the thruster with the specified lubrication oil.
29 November 2012
5-35
5-36
29 November 2012

6. Inspection, Test and Adjustment
6.
Inspection, Test and Adjustment

This chapter gives the detailed inspection, test and adjustment procedures which can be a result of the
preventive maintenance tasks.
6.1
The inspection for oil and grease leaks

Description
Specification
Quantity
Cleaning cloth
Lint-free
As required
Scraper
Carbon-reinforced fiber; to remove the contamination

(sea life) from the under water parts
Description
Specification
Quantity
Warning signs

"Do not operate - Diver in the water"
4
4
Inspection mirror
Flash light
Watertight (for outboard inspections)
Filter set
To add oil to the system
Photo camera
Description
Specification
Quantity
Cleaning agent
To remove oil deposit
As required
Oil
Refer to the General maintenance - Table of lubricants

Refer to General information - Technical data
As required
Grease

As required
Specification
Quantity
Description
Not applicable
Description
Specification
Quantity
Not applicable
Description
Specification
Stop the thruster
6.1.2 Preparation
Get access
29 November 2012
6-1


WARNING!
1. Lock out the applicable system.

3. If necessary, let the system cool down.
Make the system safe for divers

DISCLAIMER!
1. Do an inspection of the diving equipment. (responsibility diving supervisor)

2. A diving operation, to work under water, is always dangerous. (responsibility diving supervisor)
Make sure:

6. Inform all persons involved in the diving operation about the safety, the diving and the inspection tasks.
6.1.3 Do an inspection of the oil pipes, hoses and connections

WARNING!
Do not move your hands over the oil pipes, hoses and connections to do an inspection for leaks. The
oil system is pressurized and hot. Pressurized and hot oil can cause (serious) injury to persons.
CAUTION!
Do not mix the lubrication oil with the (hydraulic) steering oil. The lubrication oil and the (hydraulic)
steering oil are different. The use of the wrong type of oil will cause (serious) damage to equipment and
costly downtime for repair.
6-2
29 November 2012

1. Clean the inspection areas.
2. Clean the outside of the rubber based hydraulic hoses. Oil on the outside of the rubber based hydraulic
hoses shortens the service life.
3. Do an inspection for oil leaks of the oil pipes, hoses and connections.
4. Make sure:
1. there is no strain on connections and hoses;
2. there are no signs of an oil leak.
5. If you see signs of an oil leak,
1. Make sure, contamination can not enter the oil system.
2. Take any required corrective action. Be aware, if you tighten a connection too much, the connection
can get damaged.
3. Clean up any spilled oil.
4. Do an inspection of the oil level.
5. Use a filter set to add the specified oil to get to the correct oil level.
6.1.4 Do an inspection of the oil level

CAUTION!
Do not mix the lubrication oil with the (hydraulic) steering oil. The lubrication oil and the (hydraulic)
steering oil are different. The use of the wrong type of oil will cause (serious) damage to equipment and
costly downtime for repair.

1. Make sure, the lubrication pump-unit is set to off (locked out).
2. Allow the oil to fill the upper gearbox. This can take up to 20 minutes.
3. Clean the inspection area.
4. Do an inspection of the oil level alarm sensor.
5. Make sure, the electrical wiring and connections show no signs of damage.
7. Make sure, the oil level is just above the minimum mark.
8. If the oil level is too low:
2. For future reference, make a note of the quantity you have added.
9. Do a general inspection of the oil. Make sure, the oil:
has no burnt smell (oil temperature too high);
has no dark color ((oil temperature too high);
has no milky color (water in the oil).
10. If you feel the oil is not correct, take an oil sample and get an oil analysis (type, contamination and viscosity) from the manufacturer or approved laboratory.
29 November 2012
6-3

WARNING!
Be careful when you are near operating (rotating, moving) equipment. Do not wear loose clothing
and use the applicable Personal Protective Equipment (PPE). Operating (rotating, moving) equipment
can cause (serious) injury to persons.
11. Set the lubrication pump-unit to on.

12. Allow the level pump (part of the lubrication pump) to bring the oil from the upper gearbox to the header
tank.
13. Do an inspection of the oil level again.
14. Make sure, the oil level is just below the maximum mark.
15. Set the lubrication pump-unit to off and do any necessary work.

1. Make sure, the steering pump-unit is set to off (locked out).
3. Do an inspection of the oil level alarm sensor.
4. Make sure, the electrical wiring and connections show no signs of damage.
6. Make sure, the oil level is between the minimum and maximum mark.
7. If the oil level is too low:
2. For future reference, make a note of the quantity you have added.
8. Do a general inspection of the oil. Make sure, the oil:
has no burnt smell (oil temperature too high);
has no dark color ((oil temperature too high);
has no milky color (water in the oil).
9. If in doubt about the oil quality, take an oil sample and get an oil analysis (type, contamination and viscosity) from the manufacturer or approved laboratory.
10. Set the steering pump-unit to on.
6.1.5 Do an inspection of the Input shaft seal

NOTE!
The housing of the upper gearbox is made of cast iron. The housing of the upper gearbox can
feel 'tacky' which is caused by an oil film. This is a normal situation because cast iron is a slightly
porous material. This phenomenon is not classified as an oil leak, but you need to keep the
surface as clean as possible.
1. Make sure, the prime mover is set to off (locked out).

2. On the upper gearbox, clean the inspection area.
3. Do an inspection for oil leaks.
1. Make sure, contamination can not enter the upper gearbox.
can get damaged.
6-4
29 November 2012

4. Do an inspection of the oil level in the header tank.
5. Use a filter set to add the specified lubrication oil to get to the correct oil level.
6.1.6 Do an inspection of the steering pipe seal

You can do the next maintenance task best if the vessel is in dry-dock.
As alternative (with maybe less result), the inspection can be done in the water by sufficiently
trained and skilled divers. For inspections by diver, special safety measures must be taken.
1. Make sure, the prime mover and other moving equipment are set to off (locked out).
2. Do an inspection of the oil level in the header tank. Do any necessary work.
3. On the steering pipe,
1. Make clear photographs of the inspection area.
1. Make sure, contamination can not enter the thruster's lubrication system.
2. Make clear photographs of the suspected area.
3. Take any required corrective action.
5. Do an inspection of the lubrication oil level.
6.1.7 Do an inspection of the propeller shaft seal

1. Make sure, the prime mover and other moving equipment are set to off (locked out).
2. Do an inspection of the oil level in the header tank. Do any necessary work.
3. On the propeller gearbox,
1. Make clear photographs of the inspection area.
1. Make sure, contamination can not enter the thruster's lubrication system.
2. Make clear photographs of the suspected area.
3. Take any required corrective action.
5. Do an inspection of the lubrication oil level.
29 November 2012
6-5

6.1.8 Job close up

1. Remove all tools, materials and equipment from the work area. Make sure the area is clean.
2. Discard the contaminated cloth(s) in an environmentally safe manner in accordance with the manufacturer's instructions and (inter)national regulations.
3. Complete the maintenance checklist and insert the check list in the maintenance logbook.
4. Return the systems into operation.
6.2
The inspection for water leaks

NOTE!
The vessel's water supply is beyond the scope of this manual, for detailed instructions, refer to
the documentation that came with the water supply system.

Description
Specification
Quantity
Cleaning cloth
Lint-free
As required
Description
Specification
Quantity
Warning signs
Inspection mirror
Flash light
Description
Specification
Cleaning agent
Quantity
As required
Description
Specification
Quantity
Not applicable
Description
Specification
Quantity
Not applicable
Description
Specification
Stop the thruster
6.2.2 Preparation
Get access
6-6
29 November 2012


WARNING!
1. Lock out the applicable thruster system.

2. Make sure, there is a water flow through the heat exchanger(s).
6.2.3 Do an inspection of the water pipes, hoses and connections

1. Clean the inspection areas on the heat exchanger of:
the steering system;
the lubrication system.
2. Clean the outside of the rubber based hoses. Oil on the outside of the rubber based hoses shortens the
service life.
3. Do an inspection for water leaks of the water pipes, hoses and connections.
4. Make sure:
there is no strain on connections and hoses;
there are no signs of a water leak.
5. If you see signs of a water leak,
make sure, contamination can not enter the system;
take any required corrective action.

Be aware, if you tighten a connection too much, the connection can get damaged;
clean up any spilled water;
if you suspect the heat exchanger of an internal leak, take an oil sample and get an oil analysis (type,
contamination and viscosity) from the manufacturer.
6.2.4 Job close up

2. Discard the contaminated cloth(s) in an environmentally safe manner in accordance with the manufacturer's instructions and (inter)national regulations.
3. Return the systems into operation and make a note in the maintenance logbook.
6.3
The inspection for air leaks

NOTE!
The vessel's pneumatic air supply is beyond the scope of this manual, for detailed instructions,
refer to the documentation that came with the pneumatic air supply.
29 November 2012
6-7


Description
Specification
Quantity
Cleaning cloth
Lint-free
As required
Description
Specification
Quantity
Warning signs
Inspection mirror
Flash light
Description
Specification
Cleaning agent
Quantity
As required
Description
Specification
Quantity
Not applicable
Description
Specification
Quantity
Not applicable
Description
Specification
Stop the thruster
6.3.2 Preparation
Get access

WARNING!
1. Lock out the applicable thruster system.

2. Make sure, the vessel's air supply is available at the correct rate.
6.3.3 Do an inspection of the pneumatic air pipes, hoses and connections

1. Clean the inspection areas on the pneumatic air parts.
service life.
6-8
29 November 2012

3. Do an inspection for leaks of the pneumatic air pipes, hoses and connections.
4. Make sure:
1. there is no strain on connections and hoses;
2. there are no signs of a pneumatic air leak.
5. If you note signs of a pneumatic air leak,
1. Make sure, contamination can not enter the system.
can get damaged.
3. If you suspect a part of an internal pneumatic air leak, do a functional test of that part to confirm the
pneumatic air leak.
6.3.4 Job close up

2. Discard the contaminated cloth(s) in an environmentally safe manner in accordance with the manufacturer's instructions and (inter)national regulations .
3. Return the systems into operation and make a note in the maintenance logbook.
6.4
The inspection for wear, damage and installation

Description
Specification
Quantity
Cleaning cloth
Lint-free
As required
Scraper
Carbon, reinforced fiber; to remove the contamination

Description
Specification
Quantity
Warning signs

4
4
Inspection mirror
Flash light
Photo camera
Description
Specification
Quantity
Cleaning agent
As required
Specification
Quantity
Description
Not applicable
Description
Specification
Quantity
Not applicable
29 November 2012
6-9

Description
Specification
Stop the thruster
6.4.2 Preparation
Get access

WARNING!


This procedure is only applicable and valid for outboard inspections with the vessel in the
water.
DISCLAIMER!
1. Do an inspection of the diving equipment. (responsibility driving supervisor)

2. A diving operation, to work under water, is always dangerous. (responsibility driving supervisor)
Make sure:

6-10
29 November 2012

6.4.3 Do an inspection of the pipes, hoses and connections

NOTE!
This inspection is applicable to the (oil, water and oil) pipes, hoses and connections (e.g. tube
fittings).

service life.
3. Do a visual inspection of the pipes, hoses and connections.
4. Make sure, the pipes, hoses and connections show:
1. no signs of (abrasive) wear.
2. no signs of strain on the connections and the hoses.
3. no twists / distortion of the hoses.
4. no signs of damage, pay special attention to the sleeves.
5. no loose/missing clamps, heat shields (for hoses), etc.
6.4.4 Do an inspection of the electrical wiring, cabinets and cable protection.

NOTE!
This inspection is applicable to the electrical wiring, the cable protection hoses, the glands, the
starter cabinets, the junction boxes, the control cabinets and propulsion control panels.

2. Do a visual inspection of the electrical wiring, cabinets and cable protection.
3. Make sure, the electrical wiring, cabinets and cable protection show:
2. no strain on connectors and cable glands.
3. no signs of damage, pay special attention to the isolation.
4. no loose/missing covers, strain reliefs, clamps, etc.
6.4.5 Do an inspection of the holding brake and disc

2. Do a visual inspection of the brake pads.
3. Make sure, the brake pads:
1. are clean and free of signs of oil mist.
2. show no signs of excessive wear.
3. show no signs of damage.
4. show no loose/missing (installation) materials.
4. Do a visual inspection of the brake disc.
5. Make sure, the brake disc:
1. is clean and free of signs of oil mist.
2. show no signs of excessive wear.
29 November 2012
6-11

3. show no signs of damage.
4. show no loose/missing (installation) materials.
6.4.6 Do an inspection of the prime mover

2. Do a visual inspection of the prime mover.
3. Make sure, the prime mover is correctly attached to:
1. the mounting surface.
2. the shaft (flexible coupling).
4. Make sure, the prime mover and the related electrical wiring and cable protection show:
6.4.7 Do an inspection of the pump-units

WARNING!
NOTE!
This maintenance task is applicable to the lubrication pump-unit and the steering pump-unit.

2. Do a visual inspection of the pump-unit.
3. Make sure, the pump-unit is correctly attached to the mounting surface.
4. Make sure, the pump-unit and the related electrical wiring and cable protection show:
6.4.8 Do an inspection of the steering motor-units

WARNING!
6-12
29 November 2012

2. Do a visual inspection of the steering motor-units.
3. Make sure:
1. the hydraulic motor is correctly attached to the planetary gearbox.
2. the planetary gearbox is correctly attached to the mounting surface.
6.4.9 Do an inspection of the mounting materials and sealants


2. Do a visual inspection of the mounting materials.
3. Make sure:
1. the mounting materials are in place.
2. the locking materials (strips) are in place.
4. Make sure, the materials show:
1. no signs of excessive wear.
2. no signs of damage.
6.4.10 Do an inspection of the anodes (cathodic protection)


2. Do a visual inspection of the anodes, which are installed on the thruster.
3. Make sure, the anodes show:
1. no signs of excessive wear.
2. no damage.
3. no loose/missing parts.
4. Do a visual inspection of the anode area.
5. Make sure, the area shows no signs of excessive wear as a result of a failure of the anode(s).
6. Install new anodes if the volume of the anode is less than 50%.
6.5
The inspection for signs of corrosion and pitting

Corrosion is the deterioration of materials by chemical interaction with their environment.
Pitting corrosion, or pitting, is a form of extremely localized corrosion of a metal surface confined to a point
or small area, that takes the form of cavities. Pitting is one of the most damaging forms of corrosion.
29 November 2012
6-13


Description
Specification
Quantity
Cleaning cloth
Lint-free
As required
Scraper
Carbon-reinforced fiber; to remove the contamination

Description
Specification
Quantity
Warning signs

4
4
Inspection mirror
Flash light
Photo camera
Description
Specification
Quantity
Cleaning agent
As required
Specification
Quantity
Description
Not applicable
Description
Specification
Quantity
Not applicable
Description
Specification
Stop the thruster
6.5.2 Preparation
Get access

WARNING!

6-14
29 November 2012


water.
DISCLAIMER!

Make sure:

6.5.3 Do an inspection of the electrical bonding

NOTE!
The function of the electrical bonding, the intended electrical connection of all metal surfaces
to a grounding surface, is to prevent persons from electrical shock. In case of a failed electrical
insulation, all metal objects in the area have the same electrical potential, so it is hardly possible
that a person can touch different metal objects with a different electrical potential.
This procedure is only applicable and valid for inboard inspections.
1. Make sure, it is safe to work on (electrical) installations.

remove oil and grease, etc. with suitable cleaning agent;
remove salt and other contamination with fresh water and if necessary mild soap.
3. Do a visual inspection of the electrically bonded equipment.

4. Make sure, the electrically bonds are:
in place and correctly attached;
in good condition, no signs of damage and corrosion are visible.
29 November 2012
6-15

5. If corrosion is visible, do a bonding check and repair failed connections. If time or place does not allow
for immediate repair, take measures to prevent failure of the inspected electrical bonds.
6.5.4 Do an inspection of the locking materials

NOTE!
The function of the locking materials is to keep the fasteners correctly attached and prevent
unintentionally loosening and loss because of vibration or other external forces. The use of
locking materials allows for rapid and easy visual inspections. Fasteners that are not properly
locked can fail and result in (serious) damage of the equipment.
The locking materials are referred to mechanical means as welds, strips, wire, lock washers,
cotter pins, etc.
2. Do a visual inspection of the locking materials.

3. Make sure, the locking materials are:
4. Do any necessary work. If time or place does not allow for immediate repair, take measures to prevent
failure of the inspected locking materials.
6.5.5 Do an inspection of the painted areas

NOTE!
The function of the paint is to protect the surfaces against ambient conditions which can cause
corrosion of the material.
Damage of the paint is referred to as discoloration, cracks, blisters, loose paint (chips), visible
primer, etc.
2. Do a visual inspection of the painted areas.

3. Make sure, the paint:
is correctly applied at the required locations;
shows no signs of damage and corrosion;
shows no degraded paint surfaces.
4. Do any necessary work. If time or place does not allow for immediate repair, take measures to stop
excessive corrosion or to do an emergency repair of the damage. For detailed instructions, refer to the
technical data and application instructions of the paint manufacturer.
6-16
29 November 2012

water.
CAUTION!
Only use plastic or wooden scrapers to remove the contamination from the surface. Sharp or metal
scrapers and tools can cause damage to the surface. Damaged surfaces will degrade the performance
of the equipment which can result in costly repair.
remove the sea life and other contamination as much as possible.
2. Do a visual inspection of the painted areas.

3. Make sure, the paint:
is correctly applied at the required locations;
shows no signs of damage and corrosion;
shows no degraded paint surfaces;
shows no signs of any (oil) leaks.
4. If you see excessive corrosion or damage, make a note of the location and condition.
6.5.6 Do an inspection of the bare metal surface of the shafts

NOTE!
The function of the preservation fluid is to protect the surfaces against ambient conditions which
can cause corrosion of the material.
1. Clean the inspection area, but do not remove the a continuous layer of preservation fluid which is already
applied.
2. Do an inspection of the bare metal surface of the shafts.
3. Make sure, the bare metal surfaces:
are protected by a continuous layer of preservation fluid;
show no signs of damage and corrosion.
technical data and application instructions of the preservation-fluid manufacturer.
6.5.7 Do an inspection of the propeller blade and hub surface


1. Make sure:
the propeller can not turn by mechanical or gravity force;
the thruster can not turn by mechanical or gravity force.
29 November 2012
6-17

CAUTION!
remove the sea life and other contamination as much as possible;
2. Make clear and detailed photographs and sent them to the Wrtsil service organization for an assessment and advice. If time or place does not allow for immediate repair, take measures to do an emergency
repair of the damage as per Wrtsil instructions.
6.5.8 Do an inspection of the propeller gearbox surface

CAUTION!
1. Do an inspection of the propeller gearbox surface for signs of oil leaks.

2. If signs of oil leaks are visible, make clear and detailed photographs and sent them to the Wrtsil service
organization for an assessment and advice.
remove the sea life and other contamination as much as possible;
technical data and application instructions of the paint manufacturer.
6.5.9 Do an inspection of the locking materials (strips, welds, wire)

remove the sea life and other contamination as much as possible.
2. Do a visual inspection of the locking materials.

3. Make sure the locking materials are:
6-18
29 November 2012

4. Do any necessary work. If time or place does not allow for immediate repair, take measures to prevent
failure of the inspected locking materials.
6.6
The inspection for cleanliness

Description
Specification
Quantity
Cleaning cloth
Lint-free
As required
Scraper
Carbon, reinforced fiber; to remove the contamination

Description
Specification
Quantity
Warning signs

4
4
Inspection mirror
Flash light
Photo camera
Description
Specification
Quantity
Cleaning agent
Kerosine, white spirit, mild soap solution
As required
Specification
Quantity
Description
Not applicable
Description
Specification
Quantity
Not applicable
Description
Specification
Stop the thruster
6.6.2 Preparation
Get access

WARNING!
29 November 2012
6-19


water.
DISCLAIMER!

Make sure:

6.6.3 Do an inspection of the oil pump motor(s)

NOTE!
The cleanliness of oil pump motor(s) is important for the service life of that motor. Motors that
are externally and internally clean will suffer less from overheating and thermal failures.
1. Do a visual inspection for cleanliness.

2. Make sure:
the external cooling ribs are clean and allow for a free flow of air;
the ventilation openings are open and allow for a free flow of air;
Make sure:
6-20
a free flow of air is available,;
the ventilation openings are not blocked;
29 November 2012

If you see contamination, make a note of the location and condition or do any necessary work.
6.7
Get an oil sample and get an oil analysis
6.7.1 Introduction
Safety instructions
WARNING!
Be careful when you use consumable materials.
Obey the owner's, marine and manufacturer's application and safety instructions;
Use the applicable Personal Protective Equipment (PPE);
Always refer to the latest Material Safety Data Sheet as issued by the manufacturer;
Immediately, clean up any spilled consumable material.
If you fail to obey the instructions, (serious) injury to persons or damage to equipment can occur.
WARNING!
persons.
WARNING!
Let the system parts sufficiently cool down. System parts that operate, generate heat. Hot surfaces can
cause (serious) burns to the skin.
Why to get an oil sample

Oil analysis is most effective as a diagnostic tool when the oil samples are taken at regular intervals from
the same locations, with use of the same procedures and tools. An oil analysis schedule, when correctly
implemented, helps you to increase the equipment reliability and to decrease the total cost of owner ship
(maintenance cost).
If an oil sample is correctly taken, the degree of oil deterioration is a measure for the amount of mechanical
wear of the equipment and the chemical wear of the oil. Based on the results and recommendations of the
laboratory, you are able to do preventive maintenance within the preventive maintenance schedule and
when it is convenient.
When to get an oil sample

NOTE!
Be aware, oil analysis and intervals can be regulated by your classification society. The demands
of the classification society are regarded as mandatory and prevail over the instructions as given
in this manual.
Basically, oil analysis is done at regular intervals as indicated in the preventive maintenance schedules to
get a credible performance history.
Additionally, oil analysis is done at maintenance events if you suspect that the oil is contaminated (dirt,
metal particles, water) or before and after an oil system is opened for maintenance and repair (removal/installation of filter elements is excluded).
29 November 2012
6-21

Where to get an oil sample

Best location to get an oil sample is to take the oil from:
the oil line before the filter unit;
approximately 10 cm (4 inches) above the lowest point of a gearbox / tank.

Description
Specification
Quantity
Cleaning cloth
Lint-free
As required
Description
Specification
Quantity
Oil sample kit
As delivered by laboratory
1 set
Drain hose
As required
dm3
Oil catch tank
Warning signs
Description
Specification
Quantity
Cleaning agent
White spirit or Kerosine
As required
Description
Specification
Quantity
Not applicable
Description
Specification
Quantity
Not applicable
Description
Specification
Not applicable
6.7.3 Preparation
Oil sample kit
Prepare the oil sample kit at a clean location as instructed by the laboratory and manufacturer of the oil
sample kit. If these instructions are not available refer to the next procedure which is meant as a guideline.
At least:
1. Prepare the oil sample kit at a clean location.
2. For cleaning purpose, only use white spirit or kerosine and let the parts dry on the air to prevent unnecessary contamination of the oil sample.
3. Fill in the laboratory forms and sample bottle labels as applicable. The oil sample details must include:
6-22
oil sample date (location, temperature and reason);
oil in use data (brand, type and time in use);
date of the previous sample;
equipment data (operating hours, oil volume);
vessel data (equipment identification, owner and vessel identification);
29 November 2012

required type of oil analysis.
4. Assemble the oil sample kit as applicable.

2. Make sure, free access is available.
3. Make sure, it is safe to work on the installation in operation. For your safety, do this procedure with two
persons, one person makes the oil samples and the other person, responsible for the safety, supervises
the work and installation.
4. When you take the oil samples during operation:
be careful, equipment that is in operation generates heat, hot surfaces/oil can cause (serious) burns
to the skin;
wear the applicable personal protective equipment to protect the eyes and skin;
the oil is hot and pressurized, do not get hot, pressurized oil onto your skin, hot and pressurized oil
can cause (serious) injury.
6.7.4 How to sample the lubrication system

CAUTION!
Work as clean as possible. If the sample becomes contaminated with external dirt or moisture, the oil
sample is no longer representative and not valid. Oil samples that are not valid can lead to wrong interpretations which can result in costly maintenance tasks or unnecessary downtime.
The propeller gearbox

NOTE!
This procedure assumes that the oil sample is taken from the drain valve which is located on
the top of the stem section.
29 November 2012
6-23

1. Clean the drain valve and the area around the drain
valve with white spirit or kerosine to prevent external
contamination of the oil sample.
2. Set the shut-off valve before the circulation pump in
the closed position.
3. Connect a drain hose to the drain valve.
4. Install an oil catch tank and drain approximately 4 dm
to flush the sample line.
5. Remove the drain hose.
6. Connect a new, clean sample hose to the drain valve.
7. Remove the cap from the oil sample bottle and keep
it in a clean location.
8. Fill the clean sample bottle for approximately 80% and
immediately close the sample bottle with the cap.
9. Make sure, the sample bottle is clearly and correctly
identified.
Set the shut-off valve before the circulation pump in
the open position.
10. Do an inspection of the oil level and add the specified
oil to get the correct level.
The upper gearbox

NOTE!
6-24
This procedure assumes that the oil sample is taken from the oil sample valve which is located
on the lubrication filter/bypass manifold.
29 November 2012

1. Clean the oil sample valve and the area around the oil
sample valve with white spirit or kerosine to prevent
external contamination of the oil sample.
2. On the filter/bypass manifold, set the shut-off valve in
the closed position.
Be aware, the oil is not filtered and cooled anymore.
3. On top of the stem section, set the shut-off valve before
the circulation pump in the closed position.
Be aware, the lubrication oil from the propeller gearbox
is not circulated anymore.
4. Connect a drain hose to the oil sample valve.
to flush the manifold and sample valve.
7. Connect a new, clean sample hose to the oil sample
valve.
identified.
11. Set the shut-off valve before the circulation pump in
the open position. Be aware, the lubrication oil from
the propeller gearbox is circulated again.
12. If necessary, Install a new filter element.
13. On the filter/bypass manifold, set the shut-off valve in
the open position. Be aware, the oil is filtered and
cooled again.
The header tank

NOTE!
This procedure assumes that the oil sample is taken with the use of a vacuum pump and that
the instructions that came with the vacuum pump are obeyed.
6.7.5 How to sample the steering system

The high pressure circuit
NOTE!
This procedure assumes that the oil sample is taken from the oil sample valve which is located
on one of the steering motor-units.
29 November 2012
6-25

1. Clean the oil sample valve and the area around the oil
sample valve with white spirit or kerosine to prevent
external contamination of the oil sample.
2. Connect a drain hose to the oil sample valve.
to flush the sample valve.
5. Connect a new, clean sample hose to the oil sample
valve.
identified.
The steering oil tank

1. Clean the area around the filler/breather valve with
white spirit or kerosine to prevent external contamination of the oil sample.
2. Let the cleaned area dry on the air.
3. Remove the filler/breather valve and keep it in a clean
location.
4. Cut the end of the new, clean sample hose at 45.
5. Lower the clean sample hose into the tank and make
sure, the sample hose ends approximately 10 cm
(4 inches) above the bottom of the tank.
6. Remove the cap from the sample bottle and keep it in
a clean location.
7. Use the vacuum pump to fill the clean sample bottle
for approximately 80% and immediately close the
sample bottle with the cap.
identified.
9. Remove the vacuum pump and sample hose from the
header tank.
11. Install the filler/breather valve onto the header tank, if
necessary install a new filler/breather valve.
6-26
29 November 2012

6.7.6 Job close up

CAUTION!
Do not use compressed air to clean or dry the oil sample tools. Compressed air is not sufficiently clean.
Oil sample tools that are contaminated by the residue of compressed air makes the oil sample not valid.
1. Sent the clearly identified oil sample-bottles and the related forms to an approved laboratory for analysis.
3. Clean all oil sample tools thoroughly with white spirit or kerosine.
4. At a clean location, let the clean oil sample tools dry on the air.
7. When the analysis report is received, insert a copy in the maintenance logbook and follow-up the recommendations or ask the Wrtsil service organisation for advise.
6.8
The functional test of the steering system

Refer to SOLAS Chapter 5, Regulation 26, Steering gear: Testing and drills.
WARNING!
When in dry-dock, do not turn the thruster without the permission (work permit) of the dock supervisor/health and safety coordinator. When you turn the thruster, the center point of gravity can change
which can disturb the balance of the vessel. Unsafe operation of the thruster can cause (serious) injury
to persons and (costly) damage to equipment.

Description
Specification
Quantity
Cleaning cloth
Lint-free
As required
Description
Specification
Quantity
Warning signs
Warning signs
"Do not operate - Test in progress"
Specification
Quantity
Description
Cleaning agent
As required
Steering oil

As required
Specification
Quantity
Description
Not applicable
29 November 2012
6-27

Description
Specification
Quantity
Not applicable
6-28
Description
Specification
Stop the thruster
29 November 2012

7. Troubleshooting
7.
Troubleshooting
This chapter is meant to give help with the fault isolation and recovery. The chapter includes safety instructions and troubleshooting charts.
7.1
Introduction
This section gives the troubleshoot procedures and data necessary to find and isolate the problems and
to solve them. You can start the procedure as a result of a system alarm, a preventive maintenance or inspection task or a function related problem reported by the crew.
The troubleshooting information gives also information about the required skill to assess and resolve the
problem. For some sub-systems, that are not in the scope of this manual, but are related to or have a direct
relation to the system, possible causes are mentioned with a reference to the related manuals that came
with these sub-systems.
7.2
Safety information
Inform persons who operate, troubleshoot or repair the equipment, and persons located close to the
equipment of possible dangerous situations. This advice is always overruled by any instruction issued from
a higher authority or contained in any (safety) standard.
Troubleshoot procedures can give dangerous situations if you do not obey the safety precautions. We have
done to the best of our abilities and knowledge at the time to tell and warn you, as accurately and as fully
as possible, about the possible dangerous situations when you use the thruster system, but the human
element can never be completely eliminated. You are responsible for the supervision and implementation
of the instructions as given in this manual.
In some cases the information may seem irrelevant, but it is to your advantage to know of all possible
dangerous situations. The possibility of (serious) injury depends, among other things, on the following
factors:
the professional skill of operating and maintenance persons;
the knowledge of these persons about the possible dangerous situations;
the degree of concentration of these persons during their work;
the type of work.
For detailed safety information, please refer to the section General information - Safety information.
7.3
Reference information
This chapter gives the general information to support the troubleshoot procedures.
7.3.1 Operational modes

Summary of the operational modes:
Follow-up:
the thruster is operated from the remote propulsion control panels with full functionality, through the
control cabinet (all controls and alarms are available);
Non follow-up (back-up):

the thruster is operated from the remote propulsion control panels with limited functionality, directly
(hard wired) through the solenoids on the valves;
Non follow-up:
the thruster is operated from the local control panels with limited functionality, directly (hard wired)
through the solenoids on the valves;
By hand:
If all electrical controls have failed, steering is possible with the manual operation of the solenoids on
the proportional control valve. Mechanical indication is available on the azimuth feedback unit.
29 November 2012
7-1

7. Troubleshooting
7.3.2 Hydraulic and lubrication systems

Problem
Result
Air in the oil, foam.
You will see foam in or on the oil if there is too much air in the oil. Too much air in the
oil means too much oxygen. Oxygen in the oil results in a chemical reaction, oxidation.
Oxidation causes acid compounds in the oil which will lead to contamination (e.g. sludge,
varnish deposits) and deterioration of the oil. Foam in the oil means less lubrication, loss
of hydraulic power (cavitation) and a shorter service life of the oil.
Degradation by foam is made worse by high oil temperatures, humid ambient conditions
and water in the oil.
Water in the oil, milky solution.
You will see a milky solution if there is too much water in the oil. Too much water (known
as hydrolysis) in the oil means too much oxygen and hydrogen soluble contamination.
Water in the oil causes acid compounds in the oil which will lead to contamination (e.g.
sludge, varnish deposits) and deterioration of the oil. water in the oil means less lubrication, loss of hydraulic power and a shorter service life of the oil.
Degradation by water is made worse by air in the oil, high oil temperatures and humid
ambient conditions.
Oil is too hot, beyond operat- When installed, you can see this on the temperature gauges or alarm system. High
ing temperature.
temperatures causes degradation of the oil and possibly contamination (e.g. varnish
deposits). High oil temperature results in a low oil viscosity which means less lubrication
and a shorter service life of the oil.
Degradation by high temperature is made worse by air/water in the oil and humid ambient
conditions.
Oil degradation.
Confirm oil degradation by an oil analysis. Oil degradation causes a shorter service life
of the oil by a loss of (corrosion prevention) additives, loss of lubrication (frequent valve
failures), reduction of flow, higher energy consumption (more heat) and an increased
rate of contaminated filter elements (clogging alarms).
Active hydraulic equipment You will find that active hydraulic equipment (e.g. valves, pumps) can suddenly generate,
suddenly generates excess- local, excessive heat for no reason. Such a sudden heat generation is often caused by
ive heat.
an excessive pressure drop over the hydraulic equipment. Such an excessive pressure
drop is an indication that the hydraulic equipment fails or shortly in time will fail as a
result of internal wear or damage.
7.3.3 Electrical systems

Summary of the IEC duty cycle ratings:
7.4
S1: Continuous operation, the motor operates long enough to get to the operational temperature (e.g.
the lubrication pump-unit);
S2 thru S5: not used in the thruster installation;
S6: Continuous operation with intermittent load, the motor operates in sequential, identical cycles
(constant load / no load) with no rest periods (e.g. the steering pump-unit);
S7 thru S8: not used in the thruster installation.
Follow up of alarms
This section helps you to follow up alarm indications and to solve the related problem. For detailed instructions, please refer to the related maintenance instructions that are part of this manual. For topics that are
beyond the scope of this operation and maintenance manual, you are advised to refer to the manufacturer's
documentation.
7-2
29 November 2012

7. Troubleshooting
Problem
Possible cause
Remedy
Skill
The clogging indicator on the NOTE!

filter unit shows red.
The oil now flows through the automatic by-pass and is not filtered anymore.
The filter element is clogged. Preventive maintenance
Mechanical
1. Remove the clogged filter element.

2. Install a new filter element.
3. After installation, set the shut-off
valve in the OPEN position.
Corrective maintenance
3. Take an oil sample and get an oil
analysis (type, contamination and
4. Add the correct type of oil, as specified in the section Technical data,
to get the correct level.
NOTE!
Steering and lubrication oil are different.
(Just after startup) cold oil
with a high viscosity.
This is normal operation, allow the oil to Mechanical

reach operational temperature. After the
oil is warm, the clogging indicator becomes green.
If not:
NOTE!
The clogging indicator has a 1. Do a functional test of the clogging Mechanical

failure.
indicator.
29 November 2012
7-3

7. Troubleshooting
Problem
Possible cause
Remedy
Skill
The oil level is too low.
The oil leaks from the

pipe/hose connections.
1. Repair the connection that failed.
Mechanical
2. Clean up the spilled oil.

NOTE!
The propeller shaft seal or

steering pipe seal is damaged.

Mechanical
1. If the level in the header tank has

Diver
significantly changed for no reason,
try to get a confirmation with an inspection by diver.
The sensor has an electrical 1. Do a visual inspection of the oil level. Mechanical
failure.
2. Make sure, the oil level is correct.
1. Do an inspection for wear, damage Electrical
and installation of the electrical wiring and connections.
2. Do a functional test of the sensor.
3. Remove the sensor that failed and
install a new sensor.
Problem
Possible cause
The oil pressure is too high. The oil side of the heat exchanger is blocked.
Remedy
Skill
1. Do an inspection of the heat exchanger.
Mechanical
The filter element is clogged. Refer to the problem: Follow up of alarms - The clogging
indicator on the filter unit shows red.
A valve has a problem (there 1. Do a functional test of the valve.
Mechanical
is a failure or the position is
2. Remove the valve that failed and innot correct).
stall a new valve.
3. Remove the used filter element and
install a new filter element.
If applicable:
Electrical
1. Do an inspection for wear, damage

2. Remove the solenoid that failed and
install a new solenoid.
A pipe or hose, is bent, indented or damaged.
1. Repair or remove the pipe or hose

that failed and install a new pipe or
hose.
Mechanical
2. Make sure, the required flow is

available.
The sensor has an electrical 1. Do an inspection for wear, damage Electrical
failure.
7-4
29 November 2012

7. Troubleshooting
Problem
Possible cause
Remedy
Skill
The oil temperature is too

high.
The cooling is not sufficient. 1. Do a functional test of the pump-unit. Mechanical

2. Make sure, the required flow is
available.
1. Do an inspection of the heat exchanger.
Mechanical
2. Make sure:
The gears or bearings give

too much friction.
the oil flow is through the heat

exchanger and not through the
high pressure by-pass valve;
the required water flow is available;
the cooling water temperature is

correct.
1. Do a functional test of the related

system.
Mechanical
2. Look and listen for deviations.

The lubrication system has
a failure.
1. Do a functional test of the lubrication Mechanical

pump-unit.
2. Make sure:
the level pump operates correctly;
the oil level in the upper gearbox

is correct;
the circulation pump operates

correctly;
the valves operate correctly.

failure.
Problem
Possible cause
Remedy
Skill
The water pressure is too

low (heat exchanger).
The water pump has a failure.
The vessel's water supply is beyond the scope of this

manual, for detailed instructions, refer to the documentation that came with the water supply system.
Water leak.
The vessel's water supply is beyond the scope of this

The sensor has an electrical The vessel's water supply is beyond the scope of this
failure.
7.5
Troubleshoot the gearbox related problems

This section helps you to solve the gearbox related problems. For detailed instructions, please refer to the
related maintenance instructions that are part of this manual. For topics that are beyond the scope of this
operation and maintenance manual, you are advised to refer to the manufacturer's documentation.
29 November 2012
7-5

7. Troubleshooting
7.5.1 The propeller gearbox

Problem
Possible cause
Remedy
Skill
Unusual, regular running

noise.
If a grinding noise is heard,

the bearings have a failure.

Mechanical
1. Do an inspection for wear and dam- Timely, ask the

age.
Wrtsil service
2. Remove the parts that failed and in- department for
assistance.
stall new parts.
Emergency solution
1. Let the commanding officer stop the
thruster to limit further possible
damage.
If a knocking noise is heard, 1. Take an oil sample and get an oil
the gear wheels or shafts
(connections) have a failure.
Commanding
officer
Mechanical

age.
Wrtsil service
assistance.
stall new parts.
Emergency solution
damage.
Unusual, irregular running
noise.
7-6
The oil is degraded or con- 1. Take an oil sample and get an oil
taminated.
Commanding
officer
Mechanical
29 November 2012

7. Troubleshooting
Problem
Possible cause
Remedy
Change in noise, vibrations. The propeller gearbox has a 1. Take an oil sample and get an oil
failure.
Skill
Mechanical

age.
Wrtsil service
assistance.
stall new parts.
Emergency solution
damage.
Commanding
officer
The propeller has an unbal- 1. Do an inspection of the propeller.

Diver
ance (caused by blade dam2. Make sure:
age, ropes, netting, etc.)
the propeller is not damaged and

the blades are not bent;
the propeller is free of foreign objects (e.g. rope, fishing nets, etc.);
the propeller has sufficient clearance from the ground.
1. Recondition or repair the propeller.
Timely, ask the

Wrtsil service
department for
assistance.
Emergency solution
Commanding
officer

damage.
There is an oil leak.
The oil leaks from pipe/hose 1. Repair the connection that failed.
connections.
Mechanical

NOTE!
The propeller shaft seal or
steering pipe seal is damaged.

Mechanical
1. If the level in the header tank has

Diver
significantly changed for no reason,
try to get a confirmation with an inspection by diver.
29 November 2012
7-7

7. Troubleshooting
7.5.2 The upper gearbox

Problem
Possible cause
Remedy
Skill
Unusual, regular running

noise.


Mechanical

age.
Wrtsil service
assistance.
stall new parts.
Emergency solution
damage.
If a knocking noise is heard, 1. Take an oil sample and get an oil
the gear wheels or shafts
(connections) have a failure.
Commanding
officer
Mechanical

age.
Wrtsil service
assistance.
stall new parts.
Emergency solution
damage.
Unusual, irregular running
noise.
The oil is degraded or con- 1. Take an oil sample and get an oil
taminated.
Change in noise, vibrations. The upper gearbox has a

failure.

Commanding
officer
Mechanical
Mechanical

and correct installation.
Timely, ask the

Wrtsil service
assistance.
stall new parts.
Emergency solution
damage.
Commanding
officer
The shaft has an unbalance 1. Do an inspection of the shaft and do Mechanical

(caused by damage or misany necessary work.
alignment).
Commanding
Emergency solution
officer
damage.
7-8
29 November 2012

7. Troubleshooting
Problem
Possible cause
Remedy
There is an oil leak.
The oil leaks from pipe/hose 1. Repair the connection that failed.
connections.
Skill
Mechanical

NOTE!
Oil leaks from the gearbox
seals / gaskets.

Mechanical

and correct installation.
Mechanical
2. Remove the gearbox seals / gaskets

that failed and install new gearbox
seals / gaskets.
Emergency solution
Mechanical
1. During operation, keep the oil level

in the header tank at the maximum
level.
2. If necessary, open the by-pass valve
(orifice) to adjust the oil flow into the
upper gearbox.
The upper gearbox is com- The lubrication system is
1. This is normal operation to prevent Mechanical
pletely filled with lubrication stopped.
internal corrosion and condensation.
oil.
The level pump has a failure. 1. Do a functional test of the level
Mechanical
pump.
2. Remove the level pump that failed
and install a new level pump.
Emergency solution
1. Operate the thruster at reduced
speed to limit heat generation.
Commanding
officer
The housing of the upper

The housing is made of cast 1. This is a normal situation because Mechanical
gearbox feels 'tacky' caused iron.
cast iron is a slightly porous material.
by an oil film.
2. Clean the outside of the housing
regularly to prevent further external
contamination.
7.5.3 The lubrication system

NOTE!
The vessel's electrical power supply is beyond the scope of this manual, for detailed instructions,
refer to the documentation that came with the electrical power system.
29 November 2012
7-9

7. Troubleshooting
Table 7.1 Lubrication - electrical driven
Problem
Possible cause
Remedy
Skill
The pump motor does not

start.
The pump motor has no

electrical power.
1. On the starter cabinet, make sure:
Electrical
the electrical power supply from

the vessel is available;
the MAIN switch is set to the Iposition.
1. Do an inspection for wear and dam- Electrical

age of the electrical wiring, main
contactor and connections.
2. Make sure, the (thermal) circuit
breaker is not tripped.
The pump is blocked.
1. Remove the blockage.
Mechanical
The (thermal) circuit breaker 1. Let the motor cool down.

has tripped.
2. Find and resolve the cause of the
mechanical overload or electrical
failure.
Mechanical,
Electrical
3. Remove the failed pump motor and

install a new pump motor.
4. When it is safe, reset the thermal
circuit breaker.
The pump motor has a high The pump motor has a
current consumption.
bearing failure.

age of the pump motor.
The oil is too thick (high vis- 1. Take an oil sample and get an oil
cosity).
Mechanical
1. Allow the oil to warm by friction heat Mechanical

of the gears. When this happens
more often, it is advised to install an
oil pre-heater.
1. If installed, the heat exchanger cools Mechanical
the oil too quickly (e.g. cooling water
is too cold, faulty thermostat).
The pump motor has a
power supply failure.
1. Do an inspection of the electrical

power supply.
Electrical
2. Make sure, the electrical power supply is correct (voltage and frequency).
The pump motor heats up
excessively.
The pump motor has an

overload condition (Oil too
thick, bearing failure).
Refer to the problem: The lubrication system - The pump

motor has a high current consumption.
The pump motor has a cool- 1. Let the motor cool down.
ing problem (blocked ventila- 2. Clean the pump motor, mind the
tion, ambient temperature
ventilation openings and heat sink.
too high).
Electrical

Electrical

power supply.
7-10
29 November 2012

7. Troubleshooting
Problem
Possible cause
Remedy
The pump does not give

sufficient flow.
The pump motor turns in the 1. Do an inspection of the wiring and

wrong direction.
connections.
Skill
Electrical
2. Mind the connections at the main

contactor and thermal circuit breaker.
There are voltage drops or
interruptions.
1. Make sure, the vessel's electrical

Electrical
power supply is available at a good
quality.
1. Do a functional test of the starter
cabinet.
Electrical
The pump does not get suffi- Refer to the problem: The lubrication system - The pump
cient oil.
has cavitation problems.
The pump has cavitation
problems.
The oil supply to the pump

is not correct.
1. Do an inspection of the oil supply to Mechanical

the pump.
2. Make sure:
the pipe or hose is not blocked or

shut off;
all connections are tight so that

air can not enter the pipe;
the oil is not too thick;
the static pressure is not too low.
Due to the weather, the ves- In heavy seas, this is normal operation. Mechanical
sel makes excessive yaw
and pitch movements which
makes the oil level in the upper gearbox vary significantly (waves).
Excessive noise is heard.

1. Let the pump unit cool down.
Mechanical,
2. Remove the failed pump unit and in- Electrical
stall a new pump unit.
CAUTION!
Do not re-tighten mounting parts that are installed with the use of a locking agent.
Mounting parts that are not installed with a lock washer are often locked with a locking
agent (Loctite). If you re-tighten mounting parts that are installed with the use of a locking
agent, (serious) damage or loss of equipment can occur.
Loose mounting materials.

and installation.
Mechanical
The pump does not get suffi- Refer to the problem: The lubrication system - The pump
cient oil.
has cavitation problems.
29 November 2012
7-11

7. Troubleshooting
Problem
Possible cause
Remedy
Skill

filler/breather valve.
There is too much oil in the 1. Make sure, the shut-off valve
Mechanical
header tank.
between the header tank and the
stem section is in the OPEN position.
Mechanical
2. Drain the oil from the header tank to

get the correct oil level.
3. Remove the contaminated
filler/breather valve and install a new
and clean filler/breather valve.
There is water in the oil.
Refer to the troubleshooting procedure: Follow up of alarms

- There is water in the oil.
There is foam in the oil.

Mechanical
2. Do an inspection for loose connections. Make sure, air can not enter
the system through a loose connection.
An active part (valves,
The part has an excessive 1. Let the part cool down.
pumps) suddenly generates pressure drop over the part
2. Do a functional test of the part.
excessive heat.
as a result of internal wear
3. Remove the part that failed and inor damage.
stall a new part.
Mechanical

Refer to the troubleshooting procedure: Follow up of alarms - There is water in the oil.
Offline filter/water separator

For the troubleshooting information of the (offline) filter/water separator unit, refer to the manufacturer's
operation and maintenance documentation that came with the (offline) filter/water separator unit.
7.6
Troubleshoot the propulsion related problems

This section helps you to solve the propulsion related problems. For detailed instructions, please refer to
the related maintenance instructions that are part of this manual. For topics that are beyond the scope of
this operation and maintenance manual, please refer to the manufacturer's documentation.
7-12
29 November 2012

7. Troubleshooting
7.6.1 The propulsion system

Problem
Possible cause
Remedy
Skill
The brake does not disengage.
The pneumatic air supply

does not relief.
1. Do not disengage the brake by hand. Commanding

officer
2. Only the commanding officer can
decide to disengage the brake even
if this means that the brake (disc)
gets damaged.
The actuation of the brake

has a failure.
1. Do an inspection of the brake actu- Mechanical

ation.
2. Make sure, the brake caliper can
move freely without bad moments.

failure.
7.7
Troubleshoot the steering related problems

This section helps you to solve the steering related problems. For detailed instructions, please refer to the
related maintenance instructions that are part of this manual. For topics that are beyond the scope of this
operation and maintenance manual, please refer to the manufacturer's documentation.
7.7.1 The steering system

Problem
Possible cause
Remedy
Skill
The pump motor does not

start.
There pump motor has no

electrical power.
1. On the starter cabinet, make sure:
Electrical
the electrical power supply from

the vessel is available;
the MAIN switch is set to the Iposition.

and installation of the electrical wiring, main contactor and connections.
2. Make sure, the (thermal) circuit
breaker is not tripped.
The pump is blocked
1. Remove the blockage.
The (thermal) circuit breaker 1. Let the motor cool down.

has tripped.
2. Find and resolve the cause of the
mechanical overload or electrical
failure.
Mechanical
Mechanical,
Electrical

4. When it is safe, reset the thermal
circuit breaker.
29 November 2012
7-13

7. Troubleshooting
Problem
Possible cause
The pump motor has a high The pump motor has a

current consumption.
bearing failure
Remedy
Skill

age of the pump motor.
The oil is too thick (high vis- 1. Take an oil sample and get an oil
cosity).
Mechanical
1. Allow the oil to warm by friction heat Mechanical

of the gears. When this happens
more often, it is advised to install an
oil pre-heater.
1. If installed, the heat exchanger cools Mechanical
the oil too quickly (cooling water too
cold).

power supply.
Electrical
The pump motor heats up
excessively.
The pump motor has an

overload condition (Oil too
thick, bearing failure).
Refer to the problem: The steering system - The pump

The pump motor has a cool- 1. Let the motor cool down.
ing problem (blocked ventila2. Clean the pump motor, mind the
tion, ambient temperature
ventilation openings and heat sink.
too high).
Electrical

Electrical

power supply.
The pump does not give

sufficient flow.
Motor turns in the wrong

direction.
1. Do an inspection of the wiring and

connections.
Electrical
2. Mind the connections at the main

contactor and thermal circuit breaker.
Voltage drops or interruptions.
1. Make sure, the vessel's electrical

Electrical
power supply is available at a good
quality.
1. Do an functional test of the starter
cabinet.
Electrical
The pump does not get suffi- Refer to the problem: Follow up of alarms - The clogging
cient oil.
indicator on the filter unit shows red.
Refer to the problem: The steering system - The pump has
cavitation problems.
7-14
29 November 2012

7. Troubleshooting
Problem
Possible cause
Remedy
Skill
The pump has cavitation

problems.
The oil supply to the pump

is not correct.
1. Do an inspection of the oil supply to Mechanical

the pump.
2. Make sure:

filler/breather valve.
the pipe or hose is not blocked or

shut off;
all connections are tight so that

air can not enter the pipe;
the oil is not too thick;
the boost pump (low pressure) is

operational.
There is too much oil in the 1. Take an oil sample and get an oil
tank.
Mechanical
2. Drain the oil from the tank to get the

correct oil level.
3. Remove the contaminated
filler/breather valve and install a new
and clean filler/breather valve.
Refer to the troubleshooting procedure: Follow up of alarms

- There is water in the oil.
There is foam in the oil.

Mechanical
2. Do an inspection for loose connections. Make sure, air can not enter
the system through a loose connection.
Excessive noise is heard.

1. Let the pump-unit cool down.

2. Remove the failed pump-unit and
install a new pump-unit.
Mechanical,
Electrical

1. Let the hydraulic motor-unit (planet- Mechanical
ary gear) cool down.
2. Remove the failed hydraulic motorunit (planetary gear) and install a new
hydraulic motor-unit (planetary gear).
CAUTION!
Do not re-tighten mounting parts that are installed with the use of a locking agent.
Mounting parts that are not installed with a lock washer are often locked with a locking
agent (Loctite). If you re-tighten mounting parts that are installed with the use of a locking
agent, (serious) damage or loss of equipment can occur.
Loose mounting materials.

and installation.
Mechanical
The pump does not get suffi- Refer to the problem: The steering system - The pump has
cient oil.
cavitation problems.
29 November 2012
7-15

7. Troubleshooting
Problem
Possible cause
Remedy
Skill
An active part (valves,

The part has an excessive 1. Let the part cool down.
pumps) suddenly generates pressure drop over the part
2. Do a functional test of the part.
excessive heat.
as a result of internal wear
3. Remove the part that failed and inor damage.
stall a new part.
Mechanical

Refer to the troubleshooting procedure: Follow up of alarms - There is water in the oil.
Steering movement too slow The steering pump-unit does Refer to the problem: The steering system - The pump
(lever control).
not operate correctly.
The steering (proportional)
control valve is blocked or
contaminated.
1. Let the part cool down.
Mechanical
2. Do a functional test of the steering

control valve.
3. Remove the valve that has failed and
install a new valve.
4. Remove the used filter elements and
install new filter elements.
A hydraulic motor-unit has a 1. Do a functional test of the hydraulic

failure.
motor-unit.
2. Make sure, the hydraulic motor-unit:
turns in the correct direction;
has no excessive quantity of leak

oil;
has no signs of cavitation problems.
3. Remove the hydraulic motor-unit that

failed and install a new hydraulic
motor-unit.
NOTE!
When a hydraulic motor-unit is disconnected from the
system, emergency steering is possible with a changed
steering behaviour!
Mechanical
Emergency solution
1. Disconnect the hydraulic steering
motor-unit that has failed.
2. Install blanking plugs on the disconnected pipes and hydraulic motorunit.
3. At the propulsion control panels, install a warning sign: "Warning Changed steering behaviour!".
Heavy azimuth fluctuation
when there is no steering
command given.
The feedback sensor is

worn.
1. Do a functional test of the azimuth

feedback system.
Electrical

No corresponding or remark- There are no deviations in the mechanical systems, high/low pressure/temperature, etc.
able change in azimuth
For detailed troubleshooting procedures and instructions of the propulsion control system,
compared with actual con- please refer to the applicable manual.
trol lever position.
7-16
29 November 2012

7. Troubleshooting
Problem
Possible cause
Remedy
Skill
The mechanical and electric- The azimuth feedback sys- 1. Do a functional test of the azimuth Electrical
al azimuth indication is not tem has a failure.
feedback system.
the same.
1. Do an inspection of the azimuth
feedback unit.
Mechanical
2. Make sure, the movement from the

slewing bearing is correctly transferred to the azimuth feedback unit.
Unable to change the aziThe control panel is not in
muth on the remote (propul- command.
sion) control panel.
The steering system is in
local control.
This is normal operation.
Commanding
1. Take over the control panel in com- officer
mand.
This is normal operation.
Commanding
When the system is in local control, it is officer
not possible to operate the system from
a remote control panel.
The control panel or related For detailed troubleshooting procedures and instructions
wiring has a failure.
of the propulsion control system, please refer to the applicable manual.
7.8
Drawings
DAAK100216 DAAK100217 A
DAAK101350 A
DAAK100253 DAAK100255 A
DAAK100254 A
DAAK015662 DAAK100265 DAAK101348 B
DAAK100246 DAAK100247 DAAK100266 A
DAAK100257 DAAK100310 A
DAAK103317 A
DAAK100645 A
DAAK100646 A
DAAK100647 A
DAAK100256 DAAK008012 A
W084843587 B
PAAI003138_D01 PAAI003138_D02 PAAI003138_D03 -
29 November 2012
Brake - Pneumatic control panel .......................................................................... 7-18

Pneumatic head pressure panel .......................................................................... 7-19
Coolers - diagram / specification .......................................................................... 7-20
Cooler - assembly ................................................................................................ 7-21
Steering system - hydraulic diagram .................................................................... 7-22
Steering system - power pack .............................................................................. 7-23
Steering system - Counter balance block ............................................................ 7-24
Steering system - Junction manifold ................................................................... 7-25
Lubrication system - Diagram .............................................................................. 7-26
Lubrication system - Oil pump upper gearbox ..................................................... 7-27
Lubrication system - Filter manifold upper gearbox ............................................. 7-28
Lubrication system - Header tank upper gearbox ................................................ 7-29
Lubrication system - Oil pump lower gearbox ...................................................... 7-30
Lubrication system - Header tank lower gearbox ................................................. 7-31
Hydraulic connections .......................................................................................... 7-32
Starter - Steering pump ....................................................................................... 7-35
Starter - Lubrication oil pump ............................................................................... 7-39
Starter - Lubrication oil pump(s) .......................................................................... 7-41
Electrical connections steering power pack ......................................................... 7-44
Wiring diagram terminal box JB12 ....................................................................... 7-45
Terminal box JB12 ............................................................................................... 7-46
Water separator 1/3 ............................................................................................. 7-47
Water separator 2/3 ............................................................................................. 7-48
Water separator 3/3 ............................................................................................. 7-49
7-17
200
180
654
AA1
p6 (4x)
45,5
120
601
113
130
7-18
44
AA4
622
DEPARTMENT
PSH
654
1/4"BSPP INTERNAL THREAD
601
SURFACE ROUGHNESS:
CENTRE LINE AVERAGE
( C.L.A. ) IN Nm
( EXAMPLES )
6,3
WEIGHT: 3 KG
1,6
ORDER NUMBER
DWG NUMBER
SHEET 1 OF
DAAK100216
N19-20163
REV
A3
REV.:
TYPE
ORIGINATES FROM
DRAWING
22-02-2012
DATE
CODE NR.
JLK
1:2
AA1
APPROVED
DESIGNED
SCALE:
BRAKE CONTROL PANEL

DIMENSIONS
IN MILIMETERS
TITLE
AIR SUPPLY
DRY AND CLEAN AIR ISO 8573-1 CLASS 3.4.3
MAX. 10 BAR
AA1, AA4
CONNECTIONS:
PC
ALL RIGHTS RESERVED. THIS DRAWING REMAINS THE PROPERTY OF

WARTSILA PROPULSION NETHERLANDS B.V. AND MAY WITHOUT PERMISSION OF THE OWNER, NOT
BE MULTIPLIED, BE USED FOR THIRD PARTIES OR BE GIVEN TO THIRD PARTIES FOR PERUSAL.
THIRD ANGLE PROJECTION
AA4
622

DAAK100216 - - Brake - Pneumatic control panel
29 November 2012
180
200
227
420.04
426.04
450
430
481
466.02
438
JB14
493
427.07
44
160
15
114
LA1
10 (6x)
210
LA2
430.09
LA2
430.09
D.E.
SIZE LA1 WAS 12L
26-09-2012
29 November 2012
A
1 +
Head pressure level detection
426.04
3 GND
blue
481
438
PC
10
466.02
PT
SURFACE ROUGHNESS:
CENTRE LINE AVERAGE
( C.L.A. ) IN Nm
( EXAMPLES )
6,3
DEPARTMENT
ORDER NUMBER
1,6
JLK
1:2
N19-20164
DWG NUMBER
SHEET 1 OF
16-03-2012
22-02-2012
DAAK100217
CODE NR.
UKPHC/DE00150
APPROVED
DESIGNED
SCALE:
DATE
493
JB14
LA1
427.07
PZ
PNEUMATIC HEAD
PRESSURE PANEL
DIMENSIONS
IN MILIMETERS
TITLE

WEIGHT: 5 KG
AIR SUPPLY
DRY AND CLEAN AIR ISO 8573-1 CLASS 3.4.3
MAX. 10 BAR
CONNECTIONS:
LA2 1/4"BSPP INTERNAL THREAD
LA1 10L
420.04
2 P
white
brown
4 n.c.
black
4-20 mA
0-4 bar
PT
466.02
REV
A A2
REV.:
ORIGINATES FROM
DRAWING
TYPE

DAAK100217 A - Pneumatic head pressure panel
7-19
340
380

DAAK101350 A - Coolers - diagram / specification
fkr001 Kroot
fkr001 Kroot
14.02.2012
14.02.2012
Approved
7-20
29 November 2012
29 November 2012
102
14
440.02
138
LL9
447
535
584
LL28
SURFACE ROUGHNESS:
CENTRE LINE AVERAGE
( C.L.A. ) IN Nm
( EXAMPLES )
6,3
1,6
DEPARTMENT
ORDER NUMBER
LL28
103
175
LW4
288
440.02
LW3
306
T. Saaltink
1:5
27-6-2012
29-3-2012
DATE
DWG NUMBER
SHEET 1 OF 1
DAAK100253
N07-90298
CODE NR.
UKPHC\JL00450
APPROVED
DESIGNED
SCALE:
LL9
REV
REV.:
A3
ORIGINATES FROM
DRAWING
TYPE
PIPE COOLER EKM1018TCN

Assembly Drawing
DIMENSIONS
IN MILIMETERS
TITLE
102
267

30
JIS-20K-DN32
JIS-20K-DN32
WEIGHT: 25KG
(APPROX)
LL9, LL28
LW3, LW4
CONNECTIONS:
LW4
LW3

DAAK100253 - - Cooler - assembly
7-21
11
165

DAAK100255 A - Steering system - hydraulic diagram
7-22
29 November 2012

DAAK100254 A - Steering system - power pack
29 November 2012
7-23
ME
262
220
M10 HOISTING HOLES (2X)
218.01
226.01
227.01
20
7-24
M16 MOUNTING HOLES (4X)

- 28 DEEP
180
20
67
SC2
165
263
MSC4
290
330
SL3
SL20
437
N08-02202
serial no.
prod. date
MSC3
SC1
217
218.02
226.02
227.02
243.01
MSC4
SC2
218.01
226.01
243.01
227.01
SC4
226.02
227.02
SC3
SC1
MSC3
SC3
SL3
215
SC4
6,3
1,6
DEPARTMENT
ORDER NUMBER
115
D. Eertink
1:2
27-6-2011
10-5-2011
DATE
DWG NUMBER
SHEET 1 OF 1
DAAK015662
N28-00454
CODE NR.
UKPHC\JL00450
APPROVED
DESIGNED
SCALE:
MANIFOLD CB ST NG16
DIMENSIONS
IN MILIMETERS

SURFACE ROUGHNESS:
CENTRE LINE AVERAGE
( C.L.A. ) IN Nm
( EXAMPLES )
TITLE
1.1/2"SAE-6000 PSI
1"SAE-3000 PSI
1/2"BSPP
ISO 15171-2 - M16X2
WEIGHT: 80 KG
SC1, SC2, SC3, SC4

SL3
SL20
MSC3, MSC4, ME
CONNECTIONS:
SL20
218.02
ME
TYPE
REV
REV.:
65
A1
ORIGINATES FROM
DRAWING

DAAK015662 - - Steering system - Counter balance block
29 November 2012
45
65
120
150
232
43
132
15
SC1.2
SC2.2
235
265
274
SC1.1
SC2.1
MOUNTING HOLES
M16x24 (4x)
30
SC1
132
SC2
43
SC1.1
45
26
SL20.1
SC2.1
MP1.1
78
228
15
29 November 2012
145
212.01
30
100
165
MP1.1
SURFACE ROUGHNESS:
CENTRE LINE AVERAGE
( C.L.A. ) IN Nm
( EXAMPLES )
6,3
1,6
DEPARTMENT
ORDER NUMBER
SC1
SC2
J. Leussink
1:2
27-6-2012
13-4-2012
DATE
DWG NUMBER
SHEET 1 OF 1
DAAK100265
N28-00599
CODE NR.
UKPHC\VV00150
APPROVED
DESIGNED
SCALE:
ST JUNCT MANIFOLD NG16

Assembly Drawing
DIMENSIONS
IN MILIMETERS
TITLE
212.03
MP1.2
MP1.2

SL20.2
SC2.2
1 1/4" BSPP
1" BSPP
1" BSPP
1/4" BSPP
1/4" BSPP
WEIGHT: APPROX 48 KG
SC1, SC2
SC1.1, SC1.2
SC2.1, SC2.2
MP1.1, MP1.2
SL20.1, SL20.2
205
212.01
SC1.2
CONNECTIONS:
60
SL20.1
SL20.2
212.03
TYPE
REV
REV.:
A1
ORIGINATES FROM
DRAWING

DAAK100265 - - Steering system - Junction manifold
7-25
175
45
222

DAAK101348 B - Lubrication system - Diagram
7-26
29 November 2012
12 (4x)
178
89
875
227
132
216
444
395
LL4
LL3
151
160
LL24
129
29 November 2012
267
226
434.01
28L
42L
42L
2" SAE - 3000 PSI
42L
MASS: APPROX. 70 KG
LL3
LL4
LL5
LL7
LL24
CONNECTIONS:
394
LL5
425.01
LL7
SURFACE ROUGHNESS:
CENTRE LINE AVERAGE
( C.L.A. ) IN Nm
( EXAMPLES )
12
10
6,3
1,6
DEPARTMENT
ORDER NUMBER
403.01
JLK
1:5
27-6-2012
22-3-2012
DATE
DWG NUMBER
SHEET 1 OF 1
DAAK100246
N19-11299
CODE NR.
UKPHC\VV00150
APPROVED
DESIGNED
SCALE:
REV
REV.:
A2
ORIGINATES FROM
DRAWING
TYPE
2-ST.PUMPSET G070+G010 IEC132

Assembly Drawing
DIMENSIONS
IN MILIMETERS
TITLE

422.01

DAAK100246 - - Lubrication system - Oil pump upper gearbox
7-27
134
403
136
LS4
Element removal
height = 65
426.01
430.01
740
464.01
160
419.01
233
85
20
15
200
190
LL33
546
LL4
250
7-28
59
420.01
25
SURFACE ROUGHNESS:
CENTRE LINE AVERAGE
( C.L.A. ) IN Nm
( EXAMPLES )
LL4
6,3
DEPARTMENT
ORDER NUMBER
420.01
1,6
J. Leussink
1:5
27-6-2012
26-3-2012
DATE
DWG NUMBER
SHEET 1 OF 1
DAAK100247
N19-20168
CODE NR.
UKPHC\VV00150
APPROVED
DESIGNED
SCALE:
LL33
REV
REV.:
A3
ORIGINATES FROM
DRAWING
TYPE
FILTER BY-PASS ASSY 80CN2

Assembly Drawing
WEIGHT: APPROX. 25 KG
LL4, LL33
LS4
(M16x2)
419.01
42L
MINIMESS
426.01
CONNECTIONS:
DIMENSIONS
IN MILIMETERS
TITLE
LS4
430.01

p14 (4x)
160
120
A(1:5)
464.01
PSAH

DAAK100247 - - Lubrication system - Filter manifold upper gearbox
29 November 2012
330
10
890
75
843
205
429.02
LL47
1510
=1350=
1780
480.02
REMOVAL DISTANCE 30 MM
415.00
429.01
450.02
205
431.02
LL3
LL11
843
90
LL15
100
MAX. OPERATING LEVEL = 667 (800L)
345
78
LL46
141
1879
121
40
14(4x)
305
810
=680=
TS
Made as build
INITIALS
30-07-2012
DESCRIPTION
DATE
A
29 November 2012
MODIFICATION
1590
1071
SURFACE ROUGHNESS:
CENTRE LINE AVERAGE
( C.L.A. ) IN Nm
( EXAMPLES )
6,3
1,6
DIMENSIONS
IN MILIMETERS
DEPARTMENT
ORDER NUMBER

1:5
T. Saaltink
9-5-2012
25-4-2012
DATE
DWG NUMBER
SHEET 1 OF 1
DAAK100266
N19-40180
CODE NR.
UKPHC\JL00450
APPROVED
DESIGNED
SCALE:
REV
REV.:
A1
ORIGINATES FROM
DRAWING
TYPE
800 L
273 L
Max. Operation level

Low level alarm
HEADERTANK 800L JIS

Assembly Drawing
APPROX. 410 KG
APPROX. 1090 KG
WEIGHT:
EXCLUDING OIL
INCLUDING OIL
TITLE
JIS 20K - DN20

JIS 20K - DN32
1.1/2''BSPP
1''BSPP
LL3
LL11, LL15
LL46
LL47
CONNECTIONS:

DAAK100266 A - Lubrication system - Header tank upper gearbox
7-29
LOW LEVEL =
228 mm (273L)
971
80
934
LL28
475.01
490
1169
= 950 =
ELEMENT REMOVAL SPACE 735MM
p14 (4x)
431.01
LL48
420.02
430.02
416.02
419.04
419.02
419.03
426.03
422.02
482.04
426.02
427.02
403.02
148
LL8.1
723
461.02
615
461.01
504
463.02
LL21
461.04
461.03
= 840 =
463.01
900
LL8.2
LS1
483
422.03
427.03
403.03
490
JB10
420.03
482.02
311
475.03
103
990
430.03
33
197
73
76
7-30
233
503
SURFACE ROUGHNESS:
CENTRE LINE AVERAGE
( C.L.A. ) IN Nm
( EXAMPLES )
6,3
1,6
DEPARTMENT
ORDER NUMBER
T. Saaltink
1:5
28-6-2012
6-4-2012
DATE
DWG NUMBER
SHEET 1 OF 1
DAAK100257
N25-02350
CODE NR.
UKPHC\JL00450
APPROVED
DESIGNED
SCALE:
REV
REV.:
A1
ORIGINATES FROM
DRAWING
TYPE
LUB OIL SET LGB 440V/60HZ JIS

Assembly Drawing
DIMENSIONS
IN MILIMETERS
TITLE

WEIGHT:
Approx. 220 kg
JIS 20K-DN32
JIS 20K-DN32
JIS 20K-DN32
JIS 20K-DN32
JIS 20K-DN15
CONNECTIONS:
LL8.1
LL8.2
LL28
LL48
LL21

DAAK100257 - - Lubrication system - Oil pump lower gearbox
29 November 2012
87
633
1090
836
429.01
LS3
429.01
LL14
427.05
151
415
14 (4x)
427.05
810
=600=
LL30
DRAIN
480.01
437.07
LA1A
435.06
REMOVAL HEIGHT = 16
LL11
LL14
426.05
202
300
LL3
431.02
LA1
LS3
LL12
426.05
LL12
431.02
LL29
151
435.05
1710
1751
1630
1510
LL30
LA1
437.07 415
MAX. TEST PRESSURE:

0.5 BAR
MAX. OPERATING PRESSURE:
0.3 BAR
ATTENTION!
435.05
Max operating
667 (800L)
50
LSAL
450.01
TS
Made as build
30-07-2012
29 November 2012
A
LL29
FILL
201
SURFACE ROUGHNESS:
CENTRE LINE AVERAGE
( C.L.A. ) IN Nm
( EXAMPLES )
435.06
6,3
1,6
DEPARTMENT
ORDER NUMBER
LL3
LL11
450.01
800 L
348 L
Low level
290 (348L)
J. Leussink
1:10
2-7-2012
2-7-2012
DATE
DWG NUMBER
SHEET 1 OF 1
DAAK100310
N19-40185
CODE NR.
UKPHC\VV00150
APPROVED
DESIGNED
SCALE:
836
REV
REV.:
A2
ORIGINATES FROM
DRAWING
TYPE
HEADERTANK 800L PRESS L-SW

Assembly Drawing
DIMENSIONS
IN MILIMETERS
TITLE
305
35

480.01
Max. Operation level

Low level alarm
450 kg
12L (Weldfitting 12x1.5)

42L (Plugged)
42L (Plugged)
JIS 20K-32
42L (Plugged)
MINIMESS (M16X2)
28L (Plugged)
1" BSPP (Plugged)
MASS:
TOTAL EXCL. OIL APPROX.
TOTAL INCL. OIL APPROX.
1130 kg
LA1
LL3
LL11
LL12
LL14
LS3
LL29 (FILL)
LL30 (DRAIN)
FUNCTIONAL CONNECTIONS

DAAK100310 A - Lubrication system - Header tank lower gearbox
7-31
1094
1122

DAAK103317 A - Hydraulic connections
fkr001 Kroot
fkr001 Kroot
10.08.2012
10.08.2012
Approved
7-32
29 November 2012

fkr001 Kroot
fkr001 Kroot
10.08.2012
10.08.2012
Approved
29 November 2012
7-33

fkr001 Kroot
fkr001 Kroot
10.08.2012
10.08.2012
Approved
7-34
29 November 2012

DAAK100645 A - Starter - Steering pump
29 November 2012
7-35

7-36
29 November 2012

29 November 2012
7-37

7-38
29 November 2012

DAAK100646 A - Starter - Lubrication oil pump
29 November 2012
7-39

DAAK100646 A - Starter - Lubrication oil pump
7-40
29 November 2012

DAAK100647 A - Starter - Lubrication oil pump(s)
29 November 2012
7-41

7-42
29 November 2012

29 November 2012
7-43

DAAK100256 - - Electrical connections steering power pack
7-44
29 November 2012

DAAK008012 A - Wiring diagram terminal box JB12
29 November 2012
7-45

W084843587 B - Terminal box JB12
7-46
29 November 2012

PAAI003138_D01 - - Water separator 1/3
29 November 2012
7-47

7-48
29 November 2012

29 November 2012
7-49

7-50
29 November 2012

29 November 2012
7-51

7-52
29 November 2012

29 November 2012
7-53

7-54
29 November 2012

29 November 2012
7-55

7-56
29 November 2012

29 November 2012
7-57

7-58
29 November 2012

29 November 2012
7-59

7-60
29 November 2012

29 November 2012
7-61

7-62
29 November 2012

29 November 2012
7-63

7-64
29 November 2012

29 November 2012
7-65

7-66
29 November 2012

29 November 2012
7-67

7-68
29 November 2012

29 November 2012
7-69

7-70
29 November 2012

29 November 2012
7-71
7-72
29 November 2012

8. Removal / Installation
8.
Removal / Installation
This chapter gives, in alphabetical order, the removal / installation procedures for the equipment which is
part of the system.
8.1
Remove the lubrication filter element

Description
Specification
Quantity
Cleaning cloth
Lint-free
As required
Description
Specification
Quantity
Oil catch tank
5 dm3
Warning signs
Filter wrench
Description
Specification
Cleaning oil
Quantity
As required
Description
Specification
Quantity
Not applicable
Description
Specification
Quantity
Not applicable
Description
Specification
Quantity
Not applicable
8.1.2 Preparation
Get access

WARNING!
Be careful and use the applicable Personal Protective Equipment (PPE). The lubrication oil system is
pressurized and hot. Pressurized and hot oil can cause (serious) injury to persons.
NOTE!
When the bypass valve is set to the bypass position, the oil does not flow through the filter
anymore. This means that the system uses unfiltered oil. The use of unfiltered oil for longer
periods can cause (serious) damage to the system.
29 November 2012
8-1

2. Set the manual bypass valve in the bypass position.
3. If necessary, let the filter unit cool down.
4. Make sure there is no flow through the oil filter unit.
8.1.3 Remove the filter element

CAUTION!
Do not try to clean the filter element. It is not possible to clean the disposable filter element. A cleaned
filter element, can cause (serious) damage to the equipment.
Refer to figure 8.1, Remove the lubrication filter element (typical).

WARNING!
Be careful when you use the consumable material(s). Obey the local and manufacturers health and
safety instructions. Use the applicable Personal Protective Equipment (PPE). Incorrect use can cause
(serious) injury to persons and damage to the environment.
1. Place the oil catch tank under the drain plug (5) of the filter bowl (4).
2. Use a clean lint-free cloth to clean the filter unit, to prevent contamination to enter the system.
3. Carefully open the drain plug (5) to release the residual pressure and remove the oil from the filter bowl (4).
4. Carefully remove the filter bowl (4) to avoid damage to the O-rings (3).
5. Pull the filter element (2) with a turn from the filter unit (1).
6. Use a clean lint-free cloth to clean:
1. the interior of the filter unit (1);
2. the interior and thread of the filter bowl (4);
3. the drain plug (5);
4. the O-rings (3).
7. Do an visual inspection of:
1. the automatic (internal) bypass valve for contamination,
2. the O-rings (3) for wear and damage.
8-2
29 November 2012

Figure 8.1 Remove the lubrication filter element (typical)
8.1.4 Job close up

1. Do an visual inspection of the oil. if the oil looks or smells suspicious, take an oil sample from the sample
location.
2. Install temporarily covers to prevent contamination and water to enter the system.
8.2
Remove the rope guard

Description
Specification
Quantity
Cleaning cloth
Lint-free
As required
Temporary cover
Plastic sheet, clean and transparent
As required
Description
Specification
Quantity
Work permits
Hot works
Warning signs
Access platform
Gas and oxygen cutting-torch
Protection blanket
29 November 2012
Fire resistant
8-3

Description
Specification
Quantity
Cleaning agent
As required
Description
Specification
Quantity
Not applicable
Description
Specification
Quantity
Not applicable
Description
Specification
Refer to the section Operational instructions
8.2.2 Preparation
WARNING!
Get access
2. Turn the thruster in the ahead direction. Refer to procedure Operate the thruster.

WARNING!
1. Make sure, the required work permits are available and valid.
2. At the control panels, install the warning signs: "Do not operate - Maintenance in progress".
3. Stop and lock-out the thruster.
4. Install the access platform(s) and make sure the access platform is validated and approved.
5. Put the protection blanket over the propeller shaft seal.
8.2.3 Remove the rope guard

Refer to figure 8.2, The rope guard - Removal (typical).
WARNING!
Obey the owners, manufacturers and shipyards safety instructions and work-permits. As a minimum
safety precaution: keep a valid fire-extinguisher nearby and protect the work area against sparks with
the help of a protection blanket. Incorrect use can result in (serious) injury to persons or damage to
equipment.
8-4
29 November 2012

WARNING!
1. On the rope guard (1), find the two welds (5).

2. Make sure the protection blanket is over the propeller shaft seal (3).
3. Use a gas and oxygen cutting-torch to separate the two halves of the rope guard (1).
4. If applicable, use a gas and oxygen cutting-torch to separate the rope guard (1) from the propeller
gearbox.
5. Make sure the rope guard (1) is only held by the bolts (2).
6. If installed, mind the net/rope cutters (6), they are sharp.
7. Hold the top halve of the rope guard (1) and remove the bolts (2).
8. Remove the top halve of the rope guard (1).
9. Hold the bottom halve of the rope guard (1) and remove the bolts (2).
10. Remove the bottom halve of the rope guard (1).
11. Remove the protection blanket.
8.2.4 Job close up

2. Install a temporarily cover to prevent contamination and water to enter the system.
29 November 2012
8-5

Figure 8.2 The rope guard - Removal (typical)
8.3
Remove the steering filter element

Description
Specification
Quantity
Cleaning cloth
Lint-free
As required
Description
Specification
Quantity
Oil catch tank
10 dm3
Warning signs
Filter wrench
Description
Specification
Cleaning oil
Quantity
As required
Description
Specification
Quantity
Not applicable
8-6
29 November 2012

Description
Specification
Quantity
Not applicable
Description
Specification
Stop the steering pump-unit
8.3.2 Preparation
Get access

4. Let the oil and the filter element cool down.
5. Release the oil pressure.
8.3.3 Remove the filter element

CAUTION!
Do not try to clean the filter element. It is not possible to clean the disposable filter element. A cleaned
filter element, can cause (serious) damage to the equipment.
For the return filter element

Refer to figure 8.3, Remove the return filter element (typical).
WARNING!
1. Place the oil catch tank under the filter unit.

2. Use a clean lint-free cloth to clean the filter unit (1) and filter element (3), to prevent contamination to
enter the system.
3. Remove and discard the filter element (3). Note that some oil will leak from the filter unit (1).
29 November 2012
8-7

4. Use a clean lint-free cloth to clean the interior of the filter unit (1).
5. Do an inspection of the automatic (internal) bypass valve.
Figure 8.3 Remove the return filter element (typical)
For the pump filter element

Refer to figure 8.4, Remove the pump filter element (typical).
WARNING!
1. Place the oil catch tank under the filter unit.

2. Use a clean lint-free cloth to clean the filter unit (1) and filter element (3), to prevent contamination to
enter the system.
3. Remove the filter element (3). Note that some oil will leak from the filter unit (1).
4. Use a clean lint-free cloth to clean the interior of the filter unit (1).
5. Do an inspection of the automatic (internal) bypass valve.
8-8
29 November 2012

Figure 8.4 Remove the pump filter element (typical)
8.3.4 Job close up

1. Do an visual inspection of the oil. if the oil looks or smells suspicious, take an oil sample from the sample
location.
2. Install temporarily covers to prevent contamination and water to enter the system.
8.4
Remove the steering motor-unit

NOTE!
You can do this procedure when the thruster is in port.

Alternatively you can do this procedure at sea, but only when the thruster is at rest.

Description
Specification
Quantity
Cleaning cloth
Lint-free
As required
Blanking plugs
For the oil ports of the steering motor and oil lines
12
Description
Specification
Quantity
Oil drain tank
5 dm3
Warning signs
29 November 2012
8-9

Description
Specification
Quantity
Lifting equipment
To lift the steering motor
Temporary cover
For the steering motor-unit
Description
Specification
Quantity
Cleaning agent
White spirit, kerosine
As required
Specification
Quantity
Description
Not applicable
Description
Specification
Quantity
Not applicable
Description
Specification
Stop the thruster.
Refer to the section Operation - Normal stop of the thruster
Drain the lubrication system.
Refer to the section Preventive maintenance - Drain the lubrication system
8.4.2 Preparation
Get access
Prepare the thruster

WARNING!
Only use approved and valid lifting equipment. Lifting equipment that is not approved or valid can be
unsafe. Unsafe lifting equipment can cause (serious) injury to persons or damage to equipment.
CAUTION!
If the steering system is set to off, in time, the steering system pressure will decrease. If the steering
system pressure minimizes, there is no actuation or power anymore to hold the thruster in position. Be
aware, as a result of external forces, a thruster which is not locked can turn freely with uncontrolled
movements.
1. Bring all tools, material and equipment to the failed steering motor-unit.
2. Make sure, the lifting equipment is correctly rated and valid.
3. Install the lifting equipment according the manufacturer's instructions.
4. If in open water:
1. Inform other vessels which are close by that you have limited steering and propulsion power.
2. Stop, or limit the movement of, the vessel.
5. Stop the thruster. Refer to the section Operation - Normal stop of the thruster.
8-10
29 November 2012


WARNING!

3. Lock-out the starter cabinet of the lubrication pump(s):
NOTE!
The pneumatic air supply is beyond the scope of this manual. For detailed instructions, refer
to the documentation that came with the pneumatic air-supply system.
4. Lock-out the pneumatic air supply to the header tank:

1. Close the air supply valve.
3. At the air service unit, open the condensate drain to release the air pressure.
4. Make sure the air pressure is 0 bar.
5. At the header tank, set the shut-off valve, to the stem section, into the closed position.
6. Let the steering motor-unit, the steering and lubrication oil cool down.
7. Release the hydraulic pressure:
Take an oil sample

the manufacturer for:
the steering oil;
the lubrication oil.
8.4.3 Disconnect the steering lines

Refer to figure 8.5: Steering motor-unit - Removal (Typical) .
29 November 2012
8-11

WARNING!
Do not get oil onto your skin or in your eyes. Oil can cause (serious) injury to persons.
CAUTION!
Keep the work area and tools clean! Do not let contamination enter the oil system. Contamination of the
oil system will cause (serious) damage to the equipment and costly downtime.
1. At the steering motor-unit, find the high pressure lines (2, 3), the vent line (5) and the leak line (1).
2. Install the oil drain tank to collect any leak oil.
3. Clean the connections and remove the paint as necessary.
4. Disconnect the leak line (1) and immediately install blanking caps on the open connections.
5. Disconnect the high pressure line (2) and immediately install blanking caps on the open connections.
6. Disconnect the high pressure line (3) and immediately install blanking caps on the open connections.
7. Clean the area (spilled oil).
8. Be aware, the failed steering motor-unit is now hydraulically disconnected from the steering system.
9. On the azimuth feedback unit, look at the azimuth indictor for a short period of time and make sure, the
thruster is at rest. If the thruster is not at rest, the thruster turns freely at the external forces, do not
proceed and wait until the thruster is at rest.
8.4.4 Drain the lubrication system

CAUTION!
If you drain the lubrication system, the static oil pressure on the seals gets too low. Static pressure which
gets too low, increases the risk of water ingress. Water ingress in the oil can cause (serious) damage to
equipment and costly downtime.
1. With respect to the attitude (roll/pitch) of the vessel, partially drain the lubrication system for approximately
20% of the lubrication oil volume. For detailed instructions, refer to the section Preventive maintenance
- Drain the lubrication system.
2. Make sure, the cover of the stem section is free of the lubrication oil.
3. Disconnect the vent line (5) and immediately install blanking caps on the open connections.
8.4.5 Remove the steering motor-unit

CAUTION!
Do not try to remove the steering motor-unit when the thruster is not at rest. A thruster, not at rest puts
mechanical forces onto the slewing bearing and the gearbox of the steering motor-unit. Mechanical
forces make the removal more difficult and can cause (minor) damage to the gear teeth. Damaged gear
teeth cause (serious) damage to equipment and costly downtime.
8-12
29 November 2012

NOTE!
There are differences in the installation of the steering motor-unit onto the stem section cover.
The differences are:
Gearbox size 2090 is installed with liquid gasket and attached with bolts and spring
washers or with nuts, threaded studs and spring washers;
Gearboxes with another (smaller) size are installed with an O-ring and attached with bolts
and spring washers.
For gearbox size 2090, attached with bolts and spring washers
Refer to figure 8.5: Steering motor-unit - Removal (Typical) .
1. Clean the area around the steering motor-unit (4).
2. Attach the lifting equipment to the steering motor-unit.
3. Keep the work area and tools clean. After you removed the steering motor-unit (4), any contamination
can fall into the stem section and cause, in time, damage to the bearings and gears.
5. If it is safe to remove the steering motor-unit (4), remove the bolts (6) and the spring washers (7).
6. Discard the spring washers (7).
NOTE!
The steering motor-unit is installed onto the stem section cover with liquid gasket. If you lift
the steering motor-unit, the liquid gasket will come loose in parts.
7. Make sure, it is safe to lift the steering motor-unit (4) from the stem section cover (8).
8. Carefully lift the steering motor-unit (4) from the stem section cover (8).
9. Remove the steering motor-unit (4) and make sure, no contamination can fall into the stem section.
10. Carefully, remove any loose particles from the stem section cover (8). Do not put your hands in the stem
section because external forces can move the steering gear unexpectedly.
11. Install a clean temporary cover over the opening in the stem section.
12. Do an inspection of the gear wheel at the bottom of the steering motor-unit (4) for signs of damage and
excessive wear. For future reference, make a note in the maintenance logbook.
29 November 2012
8-13

Figure 8.5 Steering motor-unit - Removal (Typical)
For gearbox size 2090, attached with nuts, threaded studs and spring washers
Refer to figure 8.6: Steering motor-unit - Removal (Typical).
5. If it is safe to remove the steering motor-unit (4), remove the nuts (6) and the spring washers (7).
NOTE!
The steering motor-unit is installed to the stem section cover with liquid gasket. If you lift
the steering motor-unit, the liquid gasket will come loose in parts.
7. Make sure, it is safe to lift the steering motor-unit (4) from the stem section.
8-14
29 November 2012

For gearbox with another size, attached with bolts, spring washers and an O-ring
Refer to figure 8.7: Steering motor-unit - Removal (Typical).
5. If it is safe to remove the steering motor-unit (4), remove the bolts (6) and the spring washers (7).
7. Make sure, it is safe to lift the steering motor-unit (4) from the stem section.
10. Remove and discard the O-ring (8).
29 November 2012
8-15

8.4.6 Job close up

CAUTION!
of) corrosion can cause serious damage to the gears and the bearings.
2. Keep the removed steering motor-unit in a clean location for further handling.
8.5
Install the lubrication filter element

Description
Specification
Quantity
Cleaning cloth
Lint-free
As required
Specification
Quantity
Description
8-16
dm3
Oil catch tank
Warning signs
1
2
29 November 2012

Description
Specification
Torque wrench
Quantity
1
Description
Specification
Cleaning oil
Lubrication oil
Quantity
As required
Refer to the section General maintenance - Table of lubric- As required

ants
Refer to the section General information - Technical data
Description
Specification
Quantity
Not applicable
Description
Specification
Quantity
Filter element
O-rings (Seal kit)
As required
Description
Specification
Remove the filter element
Refer to the section The lubrication system - Remove the filter element
8.5.2 Preparation
Get access

Make sure:
the warning signs: "Do not operate - Maintenance in progress" are in place;
the bypass valve is in the bypass position;
the system has cooled down;
the oil pressure is released.
8.5.3 Install the filter element

Refer to figure 8.8, Install the lubrication filter element (typical).
WARNING!
1. Place the oil catch tank under the filter unit (1).
2. If installed, remove the temporarily cover that prevents contamination to enter the system.
3. Make sure the interior of the filter bowl 4) is clean and free from signs of damage and corrosion.
29 November 2012
8-17

4. Apply a thin layer of lubrication oil to the thread of the drain plug (5) and install the drain plug (5) into
the filter bowl (4).
5. Do an inspection of the filter element (2). Make sure the filter element (2) is clean and free from signs of
damage.
6. Apply a thin layer of new, fresh and clean lubrication oil onto the seal of the filter element (2).
7. Install the filter element (2) in the filter unit (1). Make sure the filter element (2) is installed correctly.
8. Apply a thin layer of lubrication oil to the O-rings (3) and the thread of the filter bowl (4).
9. Fill the filter bowl (4) with new, fresh and clean lubrication oil.
10. Carefully attach, hand tight, the filter bowl (4) to the filter unit (1).
11. Use a clean lint-free cloth to clean the filter unit (1) and filter bowl (4).
12. Torque tighten the filter bowl (4).
Torque [Nm]
Torque [ft.lbs]
15CN
Type [size]
24
18
40CN
63
46
80CN
88
65
13. Set the bypass valve to the open position.

14. Monitor the operation of the lubrication system and make sure:
1. There are no oil leaks.
2. The clogging indicator stays green.
15. If necessary, fill the header tank to the correct level with new, fresh and clean lubrication oil.
8-18
29 November 2012

Figure 8.8 Install the lubrication filter element (typical)
8.5.4 Job close up

CAUTION!
Set the bypass valve in the correct position. If the oil flows through the bypass, the oil is not filtered.
Contaminated oil can cause (serious) damage and (costly) downtime to the equipment.
1. Make sure the bypass valve is set to the open position and the oil flow is through the filter unit.
4. If required, make a note of the anomalies in the maintenance logbook.
8.6
Install the rope guard

Description
Specification
Quantity
Cleaning cloth
Lint-free
As required
29 November 2012
8-19

Description
Specification
Quantity
Work permits
Hot works
Warning signs
Access platform
Welding equipment
1 set
Grinder
Protection blanket
Fire resistant
Inspection set
Inspection mirror and flash light
1 set
Specification
Quantity
Description
Cleaning agent
As required
Locking adhesive
T002005540, M20
W005903954, > M20
As required
Welding wire
Avesta P5
As required
Paint repair set
1 set
Description
Specification
Quantity
Not applicable
Description
Specification
Quantity
Not applicable
Description
Specification
Remove the rope guard
Refer to the section The gearbox arrangement
Metric torque tables
Refer to the section General maintenance.
Paint specification
Refer to the section General maintenance.
8.6.2 Preparation
Refer to figure 8.9, The rope guard - Installation (typical).
WARNING!
Get access
WARNING!

2. Make sure, the access platforms are in place and free access is available.
8-20
29 November 2012

3. Make sure, the thruster is turned to the direction ahead.

Make sure:
the warning signs are in place;
the work permits are valid;
the thruster is locked out.
Do a visual inspection
1. Remove the temporary cover.
3. Make sure, on the propeller shaft seal (3), static pressure is available.
4. Do a visual inspection of the area for signs of oil leaks, damage or corrosion.
6. In the maintenance logbook, make a note of the findings and work that is done.
Prepare the rope guard

1. If installed, mind the net/rope cutters, they are sharp.
2. Clean the rope guard.
3. Prepare the edges for welding.
If necessary you are allowed to attach a back-up welding strip to the bottom halve of the rope guard (1).
4. Make sure the edges are smooth and free of paint, corrosion and burrs.
8.6.3 Install the rope guard

Refer to figure 8.9, The rope guard - Installation (typical).
WARNING!
The parts can be heavy. The weight depends on the size. Use the appropriate and valid lifting equipment
to prevent (serious) injury to persons or damage to the equipment.
1. Put the protection blanket over the propeller shaft seal (3).
2. Clean the bolts and apply locking adhesive to the thread and keep them in a clean location.
3. Put and hold the bottom halve of the rope guard (1) in position.
4. Install the bolts (2) to the propeller gearbox (4) and tighten by hand.
5. Torque tighten the bolts (2). Refer to the Metric torque tables, reference K1.
6. Put and hold the top halve of the rope guard (1) in position.
7. Install the bolts (2) by hand.
8. Torque tighten the bolts (2). Refer to the Metric torque tables, reference K1.
9. If installed, make sure the net/rope cutters (6) are in the correct position.
10. Attach a ground clamp near the welding area.
11. Weld the bottom and top halve of the rope guard (1).
12. Use a grinder to make the weld (5) smooth.
13. Apply the paint scheme. Refer to the Paint specification.
14. Remove the protection blanket from the propeller shaft seal (3).
29 November 2012
8-21

8.6.4 Do the after installation test

WARNING!
Make sure it is safe to operate the system. Systems that are unsafe can cause (serious) injury or death
to persons.
1. Remove all tools, materials and equipment from the work area. Make sure, the propeller can turn freely.
2. Turn the propeller by hand and make sure, no unusual noises are heard.
3. Do a visual inspection for oil leaks at the propeller shaft seal. Make sure, no signs of oil leaks are visible.
8.6.5 Job close up

3. In the maintenance logbook, make a note of the findings and work that is done.
Figure 8.9 The rope guard - Installation (typical)
8-22
29 November 2012

8.7
Install the steering filter element

Description
Specification
Quantity
Cleaning cloth
Lint-free
As required
Specification
Quantity
Description
dm3
Oil catch tank
10
Warning signs
1
2
Description
Specification
Cleaning agent
Steering oil
Quantity
As required
Refer to the section General maintenance - Table of lubric- As required

ants
Description
Specification
Quantity
Not applicable
Description
Specification
Quantity
Filter element, return filter unit
Filter element, pump filter unit
Description
Specification
Remove the steering filter element Refer to the section Corrective maintenance - Remove the steering filter element
Start the steering pump-unit
8.7.2 Preparation
Get access

Make sure:
the starter cabinet of the steering pump is locked-out;
the pump-unit is off;
the oil pressure is released.
29 November 2012
8-23

8.7.3 Install the filter element

For the return filter element
Refer to figure 8.10, Install the return filter element (typical).
WARNING!
3. Make sure the interior of the filter unit (1) is clean and free from signs of damage and corrosion.
damage and corrosion.
5. Fill the filter element (3) with new, fresh and clean steering oil.
6. Apply a thin layer of new, fresh and clean steering oil onto the seal (2) of the filter element (3).
7. Attach, hand tight, the filter element (3) to the filter unit (1).
8. Tighten the filter element (3) by an extra 120 turn.
9. Use a clean lint-free cloth to clean the filter unit (1) and the filter element (3).
10. Do a test run of the steering system and make sure:
11. Fill the header tank to the correct level with new, fresh and clean steering oil.
8-24
29 November 2012

Figure 8.10 Install the return filter element (typical)
For the pump filter element

Refer to figure 8.11, Install the pump filter element (typical).
WARNING!
3. Make sure the interior of the filter unit (1) is clean and free from signs of damage and corrosion.
damage and corrosion.
5. Fill the filter element (3) with new, fresh and clean steering oil.
6. Apply a thin layer of new, fresh and clean steering oil onto the seal (2) of the filter element (3).
7. Attach, hand tight, the filter element (3) to the filter unit (1).
8. Tighten the filter element (3) by an extra 120 turn.
9. Use a clean lint-free cloth to clean the filter unit (1) and the filter element (3).
10. Do a test run of the steering system and make sure:
29 November 2012
8-25

11. Fill the header tank to the correct level with new, fresh and clean steering oil.
Figure 8.11 Install the pump filter element (typical)
8.7.4 Job close up

3. If required, make a note of the deviations in the maintenance logbook.
8.8
Install the steering motor-unit

NOTE!
You can do this procedure when the thruster is in port.

Alternatively you can do this procedure at sea, but only if the thruster is at rest.

Description
8-26
Specification
Quantity
Cleaning cloth
Lint-free
As required
Scraper
Non-metallic
29 November 2012

Description
Oil drain tank
Specification
5
dm3
Quantity
1
Warning signs
Hoisting equipment
To lift the steering motor-unit
Torque wrench
Description
Specification
Quantity
Cleaning agent
General purpose
As required
Cleaning agent
Super clean 7063
As required
Liquid gasket
Master Gasket 574 (gearbox model 2090 only)
As required
Lubrication oil
Refer to the section General maintenance As required

Table of lubricants
Steering oil
Refer to the section General maintenance As required

Table of lubricants
Description
Specification
Quantity
Spring washer
Refer to the Spare part catalogue
10
Description
Specification
Quantity
Steering motor-unit
O-ring

(For models other than gearbox model 2090)
Description
Specification
Start the thruster.
Refer to the section Operation - Start after maintenance
Metric torque tables
Refer to the section General maintenance - Metric torque tables
Fill the lubrication system
Refer to the section Preventive maintenance - Fill the lubrication system
Fill the steering system
Refer to the section Preventive maintenance - Fill the steering system
Do a test of the lubrication system Refer to the section Inspection, Test and Adjustment Do a functional test of the lubrication system
Do a test of the steering system
Refer to the section Inspection, Test and Adjustment Do a functional test of the steering system
8.8.2 Preparation
Get access

WARNING!
Only use approved and valid lifting equipment. Lifting equipment that is not approved or valid can be
unsafe. Unsafe lifting equipment can cause (serious) injury to persons or damage to equipment.
29 November 2012
8-27

NOTE!
The pneumatic air supply is beyond the scope of this manual. For detailed instructions, refer to
the documentation that came with the pneumatic air-supply system.
Make sure:
the lifting equipment is valid and installed according the manufacturer's instructions;
the starter cabinets of the pump-units are set to off and locked-out;
the pneumatic air supply to the header tank is shut-off and locked-out;
the pump-units are off;
the oil pressure is released;
the oil level in the stem section is below the slewing bearing.
Prepare the steering motor-unit

WARNING!
NOTE!
This procedure assumes that the steering motor and the gearbox are assembled together and
filled with lubrication oil.
1. Unpack the steering motor-unit and keep it in a safe place.

2. Make sure, there are no signs of an oil leak. Do any necessary work.
3. When clean, remove the blanking caps from the high pressure ports temporarily.
4. Rotate the gear wheel by hand. Make sure, there are no bad moments.
5. Install the blanking caps in the high pressure ports.
6. Thoroughly, remove the preservation fluid from the bare metal parts.
7. Make sure, there are no signs of corrosion. Do any necessary work.
8. Apply a thin layer of lubrication oil onto the gear wheel and leave the contact surface of the flange clean.
Prepare the stem section cover

WARNING!

2. Remove the temporary cover from the opening in the stem section.
3. Make sure, no contamination can fall into the stem section.
8-28
29 November 2012

4. Thoroughly but carefully, remove all contamination from the contact surface.
5. Make sure, there are no signs of corrosion. Do any necessary work.
8.8.3 Install the steering motor-unit

CAUTION!
Do not try to install the steering motor-unit if the thruster is not at rest. A thruster, not at rest puts
mechanical forces onto the slewing bearing and makes it turn. Mechanical forces make the installation
more difficult and can cause (minor) damage to the gear teeth. Damaged gear teeth cause (serious)
damage to equipment and costly downtime.
NOTE!
There are differences in the installation of the steering motor-unit onto the stem section cover.
The differences are:
Gearbox size 2090 is installed with liquid gasket and attached with bolts and spring
washers or with nuts, threaded studs and spring washers;
Gearboxes with another (smaller) size are installed with an O-ring and attached with bolts
and spring washers.
For gearbox size 2090, attached with bolts and spring washers
Refer to figure 8-31, Steering motor-unit - Installation (Typical).
2. Use a cleaning agent to remove all grease and oil from:
the contact surface of the flange of the steering motor-unit (4);
the contact surface of the stem section cover (8);
let the contact surfaces dry onto the air.
3. Attach the lifting equipment to the steering motor-unit (4).

4. On the azimuth feedback unit, look at the azimuth indicator for a short period of time and make sure,
the thruster is at rest. If the thruster is not at rest, the thruster turns freely at the external forces, do not
CAUTION!
Make sure, during and after installation, excessive liquid gasket can not flow or fall into the stem
section. Liquid gasket contaminates the lubrication oil. Contaminated lubrication oil can cause (serious)
5. If it is safe to continue, away from the gear opening and threaded holes, apply a continuous layer of liquid
gasket onto the contact surface of the stem section cover (8).
6. Put the steering motor-unit (4) in the correct position above the stem section cover (8). Make sure, the
oil lines and the holes match correctly.
7. Immediately, in one move, install the steering motor-unit (4) onto the stem section cover (8). Once the
steering motor-unit (4) contacts the liquid gasket, you can not move the steering motor-unit (4) without
damage to the liquid gasket.
8. Install the bolts (6) and the new spring washers (7) in a cross-wise sequence (e.g. 1-6-2-7-10-5-9-4-83).
9. Torque tighten the bolts (6), refer to the metric torque tables, letter (I), group (-), for the correct value.
10. Remove any excessive liquid gasket.
29 November 2012
8-29

11. Wait for approximately 30 minutes to let the liquid gasket cure.
12. Install the high pressure lines (2, 3) to the related oil ports of the steering motor-unit (4):
1. Clean the high pressure lines (2, 3) and the related oil ports of the steering motor-unit (4).
2. Remove the blanking caps, one at the time, from the high pressure lines (2, 3).
3. Do an inspection for internal cleanliness and signs of damage and corrosion.
4. Remove the blanking cap from the related oil port of the steering motor-unit (4).
5. Fill the steering motor, as much as possible, with steering oil.
6. Fill the line, as much as possible, with steering oil.
7. Connect the high pressure lines (2, 3) to the related oil ports of the steering motor-unit (4).
13. Install the leak line (1) to the related connection on the steering motor-unit (4):
1. Clean the leak line (1) and the related connection on the steering motor-unit (4).
2. Remove the blanking cap from the leak line (1).
4. Remove the blanking cap from the related connection on the steering motor-unit (4).
5. Connect the leak line (1) to the related connection on the steering motor-unit (4).
14. Install the vent line (5) to the related connection on the steering motor-unit (4)
1. Clean the vent line (5) and the related connection on the steering motor-unit (4).
2. Remove the blanking cap from the vent line (5).
5. Connect the vent line (5) to the related connection on the steering motor-unit (4).
15. Clean and remove all tools, materials and equipment from the work area.
16. Make sure, the area is safe and clean to fill the oil systems.
8-30
29 November 2012

Figure 8.12 Steering motor-unit - Installation (Typical)
For gearbox size 2090, attached with nuts, threaded studs and spring washers
Refer to figure 8.13, Steering motor-unit - Installation (Typical).
the threaded studs.

CAUTION!
Make sure, during and after installation, excessive liquid gasket can not flow or fall into the stem
section. Liquid gasket contaminates the lubrication oil. Contaminated lubrication oil can cause (serious)
5. If it is safe to continue, away from the gear opening and threaded studs, apply a continuous layer of liquid
gasket onto the contact surface of the stem section cover (8).
29 November 2012
8-31

oil lines and the threaded studs match correctly.
7. Immediately, in one move, install the steering motor-unit (4) onto the stem section cover (8). Once the
steering motor-unit (4) hits the liquid gasket, you can not move the steering motor-unit (4) without
damage to the liquid gasket.
8. Install the nuts (6) and the new spring washers (7) in a cross-wise sequence (e.g. 1-6-2-7-10-5-9-4-83).
9. Torque tighten the nuts (6), refer to the metric torque tables, letter (I), group (-), for the correct value.
10. Remove any excessive liquid gasket.
11. Wait for approximately 30 minutes to let the liquid gasket cure.
8-32
29 November 2012

For gearbox with another size, attached with bolts, spring washers and an O-ring
Refer to figure 8.14, Steering motor-unit - Installation (Typical).

5. If it is safe to continue, apply a thin layer of lubrication oil to the O-ring (8).
6. Install the O-ring (8) onto the stem section cover (9).
oil lines and the threaded studs match correctly.
8. Install the steering motor-unit (4) onto the stem section cover (9).
9. Install the bolts (6) and the new spring washers (7) in a cross-wise sequence (e.g. 1-6-2-7-10-5-9-4-83).
10. Torque tighten the bolts (6), refer to the metric torque tables, letter (I), group (-), for the correct value.
29 November 2012
8-33

8-34
29 November 2012

8.8.4 Fill the oil systems

CAUTION!
Keep the work area and tools clean! Do not let contamination enter the oil system. Contamination of the
oil system will cause (serious) damage to the equipment and costly downtime.
1. Fill the lubrication system with the specified oil to get to the correct oil level. Refer to the procedure: Fill
the lubrication system.
2. Fill the steering system with the specified oil to get to the correct oil level. Refer to the procedure: Fill
the steering system.
8.8.5 Do the after installation tests

1. Do a test of the lubrication system. Refer to the procedure: Do a functional test of the lubrication system.
2. Do a test of the steering system. Refer to the procedure: Do a functional test of the steering system.
8.8.6 Job close up

3. In the maintenance logbook, make a note of the work that is done.
4. Return the thruster into operation.
5. If applicable, send the failed steering motor-unit for repair to an approved service center.
8.8.7 After care

NOTE!
Oil systems which were open for maintenance or repair, do need after a period of operation
extra work. You must do this work to prevent early failure of the equipment caused by contamination that has accidentally entered the system.
Do the preventive maintenance task with interval MR. Refer to the section: Preventive maintenance.
1. Do an inspection of the steering motor-unit for oil leaks and correct installation. Do any necessary work.
2. Drain the lubrication oil from the gearbox of the steering motor-unit.
3. Fill the gearbox of the steering motor-unit with the specified lubrication oil to get to the correct oil level.
4. Do an inspection for oil leaks. Do any necessary work.
5. Remove the filter element from the lubrication system.
the manufacturer.
8. Remove the filter elements from the steering system.
the manufacturer.
10. Install the new filter elements.
8.9
Drawings
DAAK103528 B
DAAK103528 B
29 November 2012
Floating shaft arrangement .................................................................................. 8-37

Coupling - instruction sheet ................................................................................. 8-38
8-35

PAAI064158 T003001371 O
PAAI031938 B
PAAI031938 B
DAAK102321 C
DAAK011368 A
T002014339 P
T002010530_D01 M
T003005755 L
PAAI002732 A
DAAK004540 E
DAAK018911 B
DAAK103614 -
8-36
Brake assembly .................................................................................................... 8-39

Upper gearbox - Assembly ................................................................................... 8-40
Flange and speed pick-up assembly (starboard) ................................................. 8-41
Flange and speed pick-up assembly (port-side) .................................................. 8-42
Steering section arrangement .............................................................................. 8-43
Steering motor assembly ..................................................................................... 8-44
Azimuth feedback unit .......................................................................................... 8-45
Diagram azimuth feedback unit ............................................................................ 8-46
Intermediate shaft ................................................................................................ 8-47
Shank assembly ................................................................................................... 8-48
Propeller gearbox assembly ................................................................................. 8-49
Propeller assembly .............................................................................................. 8-50
Calculation sheet keyless propeller fit .................................................................. 8-51
29 November 2012

DAAK103528 B - Floating shaft arrangement
wja001 Janssen
wja001 Janssen
11.05.2012
11.05.2012
Approved
29 November 2012
8-37

DAAK103528 B - Coupling - instruction sheet
8-38
29 November 2012

PAAI064158 - - Brake assembly
29 November 2012
8-39

T003001371 O - Upper gearbox - Assembly
Approved
8-40
29 November 2012

PAAI031938 B - Flange and speed pick-up assembly (starboard)
Approved
29 November 2012
8-41

PAAI031938 B - Flange and speed pick-up assembly (port-side)
Approved
8-42
29 November 2012

DAAK102321 C - Steering section arrangement
aka015 Kam
aka015 Kam
02.03.2012
02.03.2012
Approved
29 November 2012
8-43

DAAK011368 A - Steering motor assembly
8-44
29 November 2012

T002014339 P - Azimuth feedback unit
29 November 2012
8-45

T002010530_D01 M - Diagram azimuth feedback unit
Approved
8-46
29 November 2012

T003005755 L - Intermediate shaft
Approved
29 November 2012
8-47

PAAI002732 A - Shank assembly
Approved
8-48
29 November 2012

DAAK004540 E - Propeller gearbox assembly
Approved
29 November 2012
8-49

DAAK018911 B - Propeller assembly
8-50
29 November 2012

DAAK103614 - - Calculation sheet keyless propeller fit
KEYLESS PROPELLER FIT

Job identification:
refer to drawing:
MP/01680.M1AT1x
T003004918 (Propeller shaft) & DAAK018679 (Propeller hub)
Class
DNV
DIMENSIONS
Diameter hub front
Diameter hub mid
Diameter hub rear
Shaft diameter front
Bore diameter
Length
Taper
815
666,5
518
300
0
643
25
MATERIALS
E-modulus hub
E-modulus shaft
Poissons ratio hub
Poissons ratio shaft
Yield point hub
Yield point shaft
Linear expansion coefficient hub
Linear expansion coefficient shaft
121
212
0,33
0,3
245
550
1,6
1,15
mm
mm
mm
mm
mm
mm
kN/mm 2
kN/mm 2
N/mm 2
N/mm 2
x 10-5
x 10-5
LOADS
Power
Input speed
Gear ratio
Torsionals
Total thrust
Propeller part
2000
790
4,680
10
220
1
FITTING
Service friction coefficient
Assisting mass
Hydraulic nut
SKF HMV
Press area nut
Dry / Oil mount 0 / 1
0,13
3238 kg
52 A
2
188 cm
1
REQUIRED PERFORMANCE
Torque safety
Stress safety
Maximum temperature
Minumum temperature
2,8
1,43
35
0
RESULTS
+/-
Contact pressure
Stress safety
Contact pressure
Torque safety
Safety values implicate pull-up tolerance.
Minimum start point load
Corresponding pressure
Final nut pressure at 20 C
Injection pressure at 20 C
Keyless 1.24.xlt
29 November 2012
kW
rpm
%
kN
( or FAG HYDNUT 260 )
(check with latest rules)

(check with latest rules)
o
C
o
C
DNV
Temperature
Minimum pull-up
Maximum pull-up
Design pull-up
Pull-up tolerance
Hub: Cunial
Shaft: free input
0,00
4,97
9,99
5,00
4,81
9,83
10,00
4,65
9,66
15,00
4,49
9,50
20,00
4,32
9,34
25,00
4,16
9,18
30,00
4,00
9,02
35,00
3,84
8,86
7,65
0,5
7,48
7,32
7,16
6,84
6,68
6,52
57,30
1,75
55,12
4,66
56,16
1,79
53,87
4,59
55,03
1,83
52,63
4,51
53,89
1,86
51,38
4,44
52,75
1,90
50,14
4,36
51,62
1,95
48,89
4,28
50,48
1,99
47,64
4,2
49,35
2,04
46,40
4,12
79,1 kN
25 bar
649 bar
795 + / - 45
bar

page 1
17:26 24.4.2012
8-51


PARTICULARS
Shaft thrust
Shaft torque
Shear force
Contact area
Required pressure at 0 C
Permitted pressure at 0 C
DIMENSIONS
Hub
Shaft
Bore
PRESSURES
Contact press at 6,5 mm at 20 C
Contact press at 7,5 mm at 20 C
FACTORS
B-factors
Ci-factors
Co-factors
220000
113145
788082
580151
N
Nm
N
mm 2
2
29,62 N/mm
2
70,25 N/mm
FRONT
815
300
0
MID
666,5
287,14
0
51,33
59,23
50,14
57,85
REAR
518 mm
274,28 mm
0 mm
2
45,72 N/mm
2
52,75 N/mm
2
1,688E-05 1,806E-05 2,073E-05 mm /N
0,000
0,000
0,000
0,368
0,431
0,529
M-matrix
Hub
Shaft
0,3603
0,1168
0,4208
0,1529
0,5294
0,2189
k-matrix
Hub at outer dia
Hub at inner dia
Shaft at outer dia
Shaft at inner dia
0,3151
2,0097
1,1788
1,0000
0,4598
2,1391
1,2374
1,0000
0,7931
2,4394
1,3567
1,0000
546,562
546
562
85,253
382,835
384,615
375,880
375
880
80,096
382,298
384,615
219,878
219
878
70,249
381,562
384,615
N/mm 2
N/mm 2
N/mm 2
N/mm 2
Achieved stresses at 20 C for pull-up of 7,5 mm

Hub at outer dia
18,660
26,598
Hub at inner dia
119,027
123,746
Shaft at outer dia
69,816
71,581
Shaft at inner dia
59,227
57,849
41,838
128,691
71,574
52,754
N/mm 2
N/mm 2
N/mm 2
N/mm 2
Permitted pressure at 0 C
Hub at outer dia
Hub at inner dia
Shaft at outer dia
Shaft at inner dia
NOTES:
B-factor:
Relative interference / achieved contact pressure

With: relative interference = interference / interference diameter and interference = pull-up distance / taper ratio
Ci-factors: Diameter proportions of the bore diameter / hub diameter
Co-factors: Diameter proportions of the shaft diameter / hub diameter
M-factors: Added stress due to transmitted torque
k-matrix: Equivalent uni-axial stress / contact pressure
Job identification:
refer to drawing:
Keyless 1.24.xlt
8-52
MP/01680.M1AT1x
T003004918 (Propeller shaft) & DAAK018679 (Propeller hub)

page 2
17:26 24.4.2012
29 November 2012


Pull-up diagram & Stamp data
pull-up [mm]
10,0
5,0
Maximum pull-up
Design pull-up
Minimum pull-up
0,0
0
10
15
20
Temperature [C]
25
30
35
Minimum (due to p.u. tolerance) contact pressure (at mid length) after mounting
60
MPa
55
50
45
0
Job identification:
Propeller drawing:
Start point load
Pull-up at 0 C
Pull-up at 35 C
Keyless 1.24.xlt
29 November 2012
10
15
20
Temperature [C]
25
30
35
MP/01680.M1AT1x
DAAK101297
79,1 kN
7,65 mm
6,52 mm

page 3
17:26 24.4.2012
8-53
8-54
29 November 2012

9. Storage and transport
9.
Storage and transport

This chapter gives the information about the storage and transport requirements, recommendations and
instructions.
9.1
Introduction
This section gives information about the receipt, storage and transport of the thruster and spare parts. The
information given is meant as a guideline. For detailed packaging, storage and transport instructions, please
refer to the manufacturer's documentation, or if applicable, the classification requirements.
The parts that are shipped by Wrtsil Netherlands B.V. are labeled and packed for indoor storage in a well
ventilated storage facility for a storage time up to 6 months with the exception for adverse climates. For
the detailed storage conditions, please refer to the chapter Technical data - Storage conditions.
Please be aware that the storage conditions are a factor for the degradation of the service life time. By the
nature of their chemical composition, some parts (rubber and plastics), oil and grease change in physical
properties during storage and ultimately they become unserviceable and need to be discarded. To obtain
the maximum shelf and service life time, make sure the storage time is as short as possible. When parts
are kept in on-board or long term storage (over 6 months), preventive maintenance or additional preservation
actions are required. For detailed instructions, please refer to the section Preventive maintenance.
If parts are shipped, the packaging must protect the parts against ambient conditions and physical damage
caused by transport.
For outdoor storage and storage in adverse ambient conditions, please ask Wrtsil Netherlands B.V. for
advice.
The general handling instructions are given by symbols which are shown on the packaging. They are
Symbol
Description
Instruction to prevent (serious) damage of the parts
Center of gravity
Risk of falling/tipping when handled
Fragile
Handle with care
Keep cool
Protect against direct sunlight (UV-Radiation)

Protect against heat
Keep dry
Protect against precipitation (Rain, snow, hail, etc.)

Store the parts inside
Use no hooks
Handle with care
This way up
Put the packaging with the arrows pointing upwards
29 November 2012
9-1

9.2
Receipt of parts
Inspect the shipment for missing parts and damage as soon as you receive the parts. If deviations are seen,
immediately report to the shipping company and Wrtsil Netherlands B.V. For future reference, make clear
photographs and include them with the damage report.
Leave the transport tools and the original packaging in place as long as possible to protect the parts against
ambient conditions and physical damage.
Upon receipt of the parts, make sure:
9.3
the packaging is clean and free of damage;
the shipment is complete in according with the supplied packing list;
the parts are free of damage;
the anti corrosion materials are valid for the intended storage period.
Lifting
DISCLAIMER
The next procedures are meant as guidelines because the weight and shape of the parts vary. The lifting
operation is always under the directions and responsibility of the appointed person who supervises the
lifting operation. Wrtsil Netherlands B.V declines any responsibility.
or error of whatever nature in consequence of any information as given in these guidelines.
WARNING!
The parts can be heavy. The weight depends on the size. Only use validated, sufficiently rated and approved lifting equipment and procedures that are supervised by a responsible person. Lifting equipment
and procedures that are not validated, approved and supervised can be unsafe. Lifting equipment and
procedures that are unsafe can cause (serious) injury or death to persons.
CAUTION!
Only use the applicable lifting facilities. Do not attach lifting tools to machined surfaces, shaft ends,
piping work or other externally mounted equipment other than the attached lifting facilities for handling
by crane or forklift truck.
1. Do a visual inspection of the lifting equipment.

Make sure the equipment is valid, free of any signs of wear and damage. Equipment that has signs of
serious wear or damage are regarded as unsafe.
2. Make sure free access and a free loading area are available.
3. Determine the weight of the part(s) which are lifted.
4. Determine the center of gravity and take notice of the lifting limitations.
5. Lift the parts by the instructions of the appointed person who supervises the lifting operation.
9.4
Long term storage of equipment

If you know that parts are stored for more then 6 months, contact Wrtsil Netherlands B.V. to make the
required arrangements.
Long term storage of parts requires preventive maintenance or additional preservation actions. Make sure
free access is available. For detailed instructions, please refer to the section Preventive maintenance.
9-2
29 November 2012

Rapid changes in temperature cause condensation. To avoid condensation, install climate control equipment
in storage areas where rapid temperature changes can occur.
For electric motors and equipment:
make sure the motor has not collected any moisture as a result of long term storage. Before use
measure the insulation resistance with the use of an insulation testing device (megger) set at a
measuring voltage of 500V;
note that the insulation resistance varies with the temperature. For detailed instructions, please refer
to the manufacturer's documentation.
For electronic parts:
open packaging of electrostatic sensitive devices (ESD marked) only in a static safe work area;
ESD parts must be handled according the manufacturer's instructions and in compliance with IEC
61340: Protection of electronic devices from electrostatic phenomena - General requirements.
For rubber and plastic parts:
make sure the parts are protected against direct sunlight, UV-light, contact with solvents and materials
that react with the rubber and plastic materials and excessive ventilation;
Seals and rubber parts (elastomers) must be stored according the manufacturer's instructions and in
compliance with ISO 2230: Rubber products. Guidelines for storage.
For bare (machined) surfaces:
make sure the layer of preservation fluid is closed and there are no signs of corrosion.
For painted surfaces:
make sure the layer of paint is closed and there are no signs of corrosion (also under the layer of
paint).
For oil filled parts:
make sure the parts are filled with the correct oil and preservation agents;
make sure the openings are sealed air-tight sealed.
For chemicals:
9.5
make sure that the chemicals (oil, grease, solvents) are stored and handled according the instructions
in the material safety data sheets.
Drawings
DAAK104633 DAAK018944 A
29 November 2012
Transport parts stem section with upper gearbox ................................................

Transport parts propeller gearbox ........................................................................
9-4
9-5
9-3

DAAK104633 - - Transport parts stem section with upper gearbox
nde004 Dekker
nde004 Dekker
20.07.2012
20.07.2012
Approved
9-4
29 November 2012

DAAK018944 A - Transport parts propeller gearbox
Approved
29 November 2012
9-5
9-6
29 November 2012

10. Spare parts catalogue
10. Spare parts catalogue

This chapter gives the spare part catalogue with detailed information about and the instructions how to
order the spare parts.
10.1 Drawings
DBAC426812 DBAC426812 -
29 November 2012
Spare parts catalogue - MP/01680.M1AT11P ..................................................... 10-2

Spare parts catalogue - MP/01680.M1AT12P ..................................................... 10-101
10-1

DBAC426812 - - Spare parts catalogue - MP/01680.M1AT11P
Title:
Page:
STT MP/01680.M1HT11P
Type:
Drawing:
BOM: PAAI066759/-
Product:
Seq. Item id
2 PAAI066777/3 PAAI066778/A
Item name
1 of 99
PAAI066759/-
Drawing
Inboard delivery
Outboard delivery
Quantity
1,0
1,0
Notes: - Sequence numbers not listed have not been used in this product.
- The quantities an item numbers shown on the parts list
are believed to be correct, the quantities shown on the
drawing are for illustration only.
END OF LIST
2012-11-20
10-2
29 November 2012

Title:
Inboard delivery
Type:
LMT2510-363/2500MO
BOM: PAAI066777/-
Page:
Drawing:
Product:
Seq. Item id
Item name
3 PAAI066762/A
4PS PAAI066769/A
5 PAAI066763/C
Shafting arrangement
Upper gearbox arrangement
Hydraulic/pneumatic system
7PS.
90
95
99
Stemsection arrangement
Miscellaneous components
Newbuild tools
Newbuild spares
PAAI066768/C
PAAI066764/B
PAAI066765/C
PAAI066766/A
2 of 99
PAAI066759/-
Drawing
DAAK101813-Piping
DAAK101429-Block diagram
DAAK101812-Instruction
DAAK018233-Electric diagram
DAAK101810-Specification
Quantity
1,0
1,0
1,0
1,0
1,0
1,0
1,0
END OF LIST
2012-11-20
29 November 2012
10-3

Title:
Type:
FS2510-363/2500WO
BOM: PAAI066762/A
Page:
Drawing:
Product:
PAAI066759/-
Item name
Drawing
361 PAAI105826/-
Flexible coupling
362 PAAI064158/-
Brake assembly
DAAK103528-Floating intermediate
shaft
PAAI064158_D01--/Brake assembly
Seq. Item id
3 of 99
Quantity
1,0
1,0
END OF LIST
2012-11-20
10-4
29 November 2012

Title:
Page:
Flexible coupling
4 of 99
Type:
Drawing: DAAK103528-Floating intermediate shaft
BOM: PAAI105826/-
Product:
PAAI066759/-
Item name
Drawing
1 PAAI105831/A
Flexible coupling piece
2 PAAI105832/-
Flange type coupling
3 PAAI105833/-
Flange type coupling
shaft
shaft
shaft
Seq. Item id
Quantity
1,0
1,0
1,0
END OF LIST
2012-11-20
29 November 2012
10-5

Title:
Brake assembly
Type:
GMR-P
5 of 99
Drawing: PAAI064158_D01--/Brake assembly
BOM: PAAI064158/-
Seq. Item id
Page:
Product:
PAAI066759/-
Item name
Drawing
PAAI040402_D01-A/Brake assembly
T003002099_D01-B/Brake assembly
1L
1R
2
2A
3
PAAI040402/A
T003002099/B
M710190137/W006350223/A
T003000616/3
Brake assembly
Brake assembly
Reducing socket nipple
Male stud connector
Hydraulic hose
4A
4B
5
6
7
9
W006350223/A
W006350209/W007375016/A
M712040383/W007281065/PAAI064115/C
Male stud connector

Male stud connector
Plain washer
Hexagon socket head cap screw
Support
PAAI064115_D01-C/Support
Quantity
T003000616_D02-3/Hydraulic
hoseT003000616_D01-3/Hydraulic
hose
1,0
1,0
2,0
2,0
2,0
2,0
2,0
4,0
6,0
4,0
1,0
END OF LIST
2012-11-20
10-6
29 November 2012

Title:
Type:
FS2510-363/2500WO
BOM: PAAI066763/C
Page:
Drawing: DAAK101813-Piping
Product:
PAAI066759/-
Item name
Drawing
550 PAAI107806/554 PAAI108839/-
Lubrication system
Lube oil and hydr. connections
570 PAAI107807/585 PAAI107808/599 PAAI108600/-
Hydraulic system
Starter
Water separator
DAAK101348-Lubrication diagram
DAAK103317-Lube oil and hydr.
connections
DAAK100255-Hydraulic diagram
Seq. Item id
6 of 99
Quantity
1,0
1,0
1,0
1,0
1,0
END OF LIST
2012-11-20
29 November 2012
10-7

Title:
Page:
Lubrication system
Type:
Drawing: DAAK101348-Lubrication diagram
BOM: PAAI107806/-
Product:
PAAI066759/-
Item name
Drawing
1 PAAI107846/-
Filter arrangement
2 PAAI107848/-
Oil cooler
3 PAAI108307/-
Oil tank
4 PAAI104140/-
Pneumatic control panel
5 PAAI107849/-
Pump unit
6 PAAI108310/-
Filter arrangement
7 PAAI107847/-
Oil cooler
7 PAAI108308/-
Oil tank
9 PAAI104070/-
Brake control panel
DAAK100257-Filter arrangement
DAAK100258-Diagram
DAAK100253-Oil cooler
DAAK104550-Oil tank
DAAK100310-Oil tank
DAAK100217-Pneumatic control
panel
DAAK102953-Pneumatic control
panel
DAAK100246-Pump unit
DAAK104551-Oil tank
DAAK100266-Oil tank
DAAK100216-Brake control panel
Seq. Item id
7 of 99
Quantity
1,0
1,0
1,0
1,0
1,0
1,0
1,0
1,0
1,0
END OF LIST
2012-11-20
10-8
29 November 2012

Title:
Type:
Seq. Item id
Item name
10 PAAI030459/Bell housing
10_1 PAAI062882/Bell housing
12 W084836911/B Flexible coupling
PAAI025498/B
PAAI109031/PAAI109033/PAAI034529/A
T018374400/PAAI031883/-
8 of 99
Drawing: DAAK100257-Filter arrangement
BOM: PAAI107846/-
12_1
403.02
403.03
416.02
419.02
419.03
Page:
Filter arrangement
Flexible coupling
E-motor
E-motor
Orifice
Non-return valve
Non-return valve
419.04 PAAI029115/420.02 PAAI037351/420.03 PAAI029989/-
Non-return valve
Non-return valve
Non-return valve
422.02
422.03
426.02
426.03
427.02
427.03
430.02
430.03
431.01
461.01
461.02
461.03
461.04
461A
461B
PAAI109034/PAAI063527/PAAI034591/PAAI108783/PAAI037327/PAAI039285/PAAI030494/PAAI032019/PAAI032499/PAAI013861/A
PAAI013861/A
PAAI013861/A
PAAI013861/A
PAAI026619/A
PAAI028975/A
Screw pump
Screw pump
Pressure filter
Filter
Safety valve
Safety valve
Ball valve
Ball valve
Ball valve
Pressure switch
Pressure switch
Pressure switch
Pressure switch
Measuring coupling
Measuring coupling
463.01
463.02
463A
463B
PAAI013861/A
PAAI013861/A
PAAI026619/A
PAAI028975/A
Pressure switch
Pressure switch
Measuring coupling
Measuring coupling
475.01
475.51
482.02
482.04
482.02A
482.04A
483
490
490A
PAAI008723/C
PAAI013605/B
PAAI039264/A
PAAI006728/B
PAAI022999/A
PAAI022999/A
PAAI005608/C
PAAI102689/PAAI015247/-
Temperature switch
Tube
Pressure gauge
Pressure gauge
Measuring coupling
Measuring coupling
Thermometer
Junction box
Connector
Product:
DAAK100258-Diagram
PAAI066759/-
Drawing
PAAI030459_D01--/Bell housing
W084836911_D01-B/Flexible
coupling
PAAI025498_D01-B/Flexible coupling
DAAK011732-E-motor
DAAK011732-E-motor
DAAK006983-Non-return valve
DAAK007013-Coupling arrangement
DAAK007013-Coupling arrangement
DAAK105145-Screw pump
DAAK006240-Screw pump
DAAK007309-Pressure filter
DAAK101899-Filter
PAAI037327_D01--/Safety valve
DAAK006837-Ball valve
DAAK006898-Pressure switch
DAAK007002-Measuring coupling
PAAI028975_D01-A/Measuring
coupling
coupling
DAAK006842-Thermostat
DAAK006878-Pressure gauge
DAAK002570-Measuring tool
DAAK009068-Thermometer
PAAI015247_D01--/Connector
Quantity
1,0
1,0
1,0
1,0
1,0
1,0
1,0
1,0
1,0
1,0
1,0
1,0
1,0
1,0
1,0
1,0
1,0
1,0
1,0
1,0
1,0
1,0
1,0
1,0
1,0
8,0
8,0
1,0
1,0
4,0
4,0
1,0
1,0
1,0
1,0
1,0
1,0
1,0
1,0
8,0
2012-11-20
29 November 2012
10-9

Title:
Page:
Filter arrangement
Type:
BOM: PAAI107846/-
Seq. Item id
9 of 99
Item name
Product:
DAAK100258-Diagram
PAAI066759/-
Drawing
Quantity
END OF LIST
2012-11-20
10-10
29 November 2012

Title:
Flexible coupling
Type:
R24.28-19
Drawing: W084836911_D01-B/Flexible coupling
BOM: W084836911/B
Seq. Item id
12A PAAI035617/12B PAAI030460/A
12C PAAI030457/-
Page: 10 of 99
Product:
PAAI066759/-
Item name
Drawing
Coupling hub
Gear ring
Coupling hub
PAAI035617_D01--/Coupling hub
PAAI030460_D01-A/Gear ring
Quantity
1,0
1,0
1,0
END OF LIST
2012-11-20
29 November 2012
10-11

Title:
Flexible coupling
Type:
R19.24-14
Drawing: PAAI025498_D01-B/Flexible coupling
BOM: PAAI025498/B
Seq. Item id
12_1A PAAI032080/12_1B PAAI032078/A
12_1C PAAI032079/-
Page: 11 of 99
Product:
PAAI066759/-
Item name
Drawing
Coupling hub
Gear ring
Coupling hub
PAAI032078_D01-A/Gear ring
Quantity
1,0
1,0
1,0
END OF LIST
2012-11-20
10-12
29 November 2012

Title:
Pressure filter
Type:
80CN210QM250E2E21
BOM: PAAI034591/-
Seq. Item id
426.02A PAAI006928/B
426.02B PAAI044504/A
Page: 12 of 99
Drawing: DAAK007309-Pressure filter
Product:
PAAI066759/-
Item name
Drawing
Filter element
Seal kit
Quantity
1,0
1,0
END OF LIST
2012-11-20
29 November 2012
10-13

Page: 13 of 99
Title:
Filter
Type:
BGLS1505QLBE8ER48F1
BOM: PAAI108783/-
Seq. Item id
426.03A PAAI006391/D
426.03C PAAI040698/426.3B PAAI104326/463.02 PAAI015836/C
Drawing: DAAK101899-Filter
Product:
PAAI066759/-
Item name
Drawing
Filter cartridge
Seal kit
Sleeve
DAAK006527-Filter
PAAI040698_D01--/Seal kit
DAAK006527-Filter
DAAK014533-Filling filter
DAAK102148-Dirt indicator
Dirt indicator
Quantity
1,0
1,0
1,0
1,0
END OF LIST
2012-11-20
10-14
29 November 2012

Title:
Page: 14 of 99
Oil cooler
Type:
Drawing: DAAK100253-Oil cooler
BOM: PAAI107848/-
Seq. Item id
440.02 PAAI027378/-
Product:
PAAI066759/-
Item name
Drawing
Oil cooler
Quantity
1,0
END OF LIST
2012-11-20
29 November 2012
10-15

Title:
Page: 15 of 99
Oil tank
Type:
Drawing: DAAK104550-Oil tank
BOM: PAAI108307/-
Seq. Item id
3
415
426.05
427.05
431.02
435.05
435.06
435.07
450.01
480.01
480.51
PAAI030396/PAAI011836/PAAI109038/PAAI030614/A
PAAI040132/PAAI044139/PAAI047458/PAAI101513/PAAI052114/PAAI066496/PAAI058530/-
Product:
DAAK100310-Oil tank
PAAI066759/-
Item name
Drawing
Gasket
Filler-breather
Filter
Non-return valve
Valve
Ball valve
Valve
Needle valve
Level switch
Level gauge
Float
DAAK002296-Filler-breather
DAAK101884-Filter
DAAK010547-Valve
PAAI047458_D01--/Valve
DAAK101664-Needle valve
DAAK002602-Level switch
DAAK018124-Level gauge
PAAI058530_D01--/Float
Quantity
1,0
1,0
1,0
1,0
1,0
1,0
1,0
1,0
1,0
1,0
1,0
END OF LIST
2012-11-20
10-16
29 November 2012

Title:
Type:
Drawing: DAAK100217-Pneumatic control panel
BOM: PAAI104140/-
Seq. Item id
420.04
426.04
426.51
427.07
427.52
430.52
438
466.02
466.02A
481
493
Page: 16 of 99
PAAI005881/A
PAAI032511/PAAI045120/PAAI033795/PAAI032530/PAAI041683/PAAI022140/-
Product:
DAAK102953-Pneumatic control panel

PAAI066759/-
Item name
Drawing
Non-return valve
Air filter
Bracket
Relief valve
Fastening bracket
Ball valve
Regulator
Pressure sensor
Cable
Pressure gauge
Junction box
DAAK019096-Air filter
DAAK006737-Relief valve
DAAK011647-Regulator
DAAK009233-Pressure sensor
DAAK007114-Regulator
Quantity
1,0
1,0
2,0
1,0
1,0
1,0
1,0
1,0
1,0
1,0
1,0
END OF LIST
2012-11-20
29 November 2012
10-17

Page: 17 of 99
Title:
Air filter
Type:
P31FA12EMBN
BOM: PAAI105514/-
Seq. Item id
426.04A PAAI064740/-
Drawing: DAAK019096-Air filter

Product:
PAAI066759/-
Item name
Drawing
Filter element
Quantity
1,0
END OF LIST
2012-11-20
10-18
29 November 2012

Title:
Page: 18 of 99
Pump unit
Type:
Drawing: DAAK100246-Pump unit
BOM: PAAI107849/-
Seq. Item id
10
12
403.1
422.01
434
PAAI031014/PAAI015006/B
PAAI109044/PAAI013350/B
PAAI033625/-
Product:
PAAI066759/-
Item name
Drawing
Bell housing
Flexible coupling
E-motor
Gear pump, double
Safety valve
PAAI015006_D01-B/Flexible coupling
DAAK014062-E-motor
DAAK007263-Gear pump
Quantity
1,0
1,0
1,0
1,0
1,0
END OF LIST
2012-11-20
29 November 2012
10-19

Title:
Flexible coupling
Type:
R28.38-N/3
BOM: PAAI015006/B
Seq. Item id
12A PAAI028033/A
12B PAAI033304/12C PAAI028032/A
Page: 19 of 99
Product:
PAAI066759/-
Item name
Drawing
Coupling hub
Gear ring
Coupling hub
PAAI028033_D01-A/Coupling hub
PAAI033304_D01--/Gear ring
Quantity
1,0
1,0
1,0
END OF LIST
2012-11-20
10-20
29 November 2012

Title:
Type:
BOM: PAAI108310/-
Seq. Item id
419.01
420.01
426.01
430.01
464.01
Page: 20 of 99
Filter arrangement
T018374400/PAAI037351/PAAI035768/A
PAAI030494/PAAI013861/A
Product:
PAAI066759/-
Item name
Drawing
Non-return valve
Non-return valve
Pressure filter
Ball valve
Pressure switch
Quantity
1,0
1,0
1,0
1,0
1,0
END OF LIST
2012-11-20
29 November 2012
10-21

Title:
Pressure filter
Type:
80CN220QEVM3KG244
BOM: PAAI035768/A
Seq. Item id
426.01A PAAI026752/426.01B PAAI044504/A
Page: 21 of 99
Product:
PAAI066759/-
Item name
Drawing
Filter element
Seal kit
Quantity
1,0
1,0
END OF LIST
2012-11-20
10-22
29 November 2012

Title:
Page: 22 of 99
Oil cooler
Type:
BOM: PAAI107847/-
Seq. Item id
437.01 PAAI032012/A
440.01 PAAI027378/-
Product:
PAAI066759/-
Item name
Drawing
Non-return valve
Oil cooler
Quantity
1,0
1,0
END OF LIST
2012-11-20
29 November 2012
10-23

Title:
Page: 23 of 99
Oil tank
Type:
BOM: PAAI108308/-
Seq. Item id
2
415
431.02
450.01
480.02
480.51
PAAI040843/PAAI011836/PAAI040132/PAAI017473/B
PAAI066496/PAAI058530/-
Product:
DAAK100266-Oil tank
PAAI066759/-
Item name
Drawing
Gasket
Filler-breather
Valve
Level switch
Level gauge
Float
DAAK010547-Valve
PAAI017473_D01-A/Level switch
DAAK018124-Level gauge
PAAI058530_D01--/Float
Quantity
1,0
1,0
1,0
1,0
1,0
1,0
END OF LIST
2012-11-20
10-24
29 November 2012

Title:
Type:
Drawing: DAAK100216-Brake control panel
BOM: PAAI104070/-
Seq. Item id
601
601.51
601.52
622
622A
622.51
654
Page: 24 of 99
Brake control panel
PAAI037297/PAAI101954/PAAI005887/A
PAAI108899/PAAI065117/PAAI108900/PAAI005895/C
Product:

PAAI066759/-
Item name
Drawing
Directional valve
Connector
Silencer
Air filter
Pressure gauge
Bracket
Pressure switch
DAAK007934-Directional valve
DAAK006937-Silencer
Quantity
1,0
1,0
2,0
1,0
1,0
1,0
1,0
END OF LIST
2012-11-20
29 November 2012
10-25

Page: 25 of 99
Title:
Air filter
Type:
P31EA12EMBBNTP
BOM: PAAI108899/-

Product:
PAAI066759/-
Seq. Item id
Item name
Drawing
622A PAAI064740/-
Filter element
Quantity
1,0
END OF LIST
2012-11-20
10-26
29 November 2012

Title:
Type:
Drawing: DAAK103317-Lube oil and hydr.
BOM: PAAI108839/-
Seq. Item id
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
22
23
24
25
26
27
30
31
32
Page: 26 of 99
W084842947/A
PAAI105045/PAAI105047/M710714527/A
M710801232/A
PAAI104699/PAAI104885/PAAI104708/PAAI108501/PAAI108502/M710712232/A
PAAI105024/A
PAAI108590/PAAI108593/PAAI106917/PAAI108636/W006410057/PAAI108659/PAAI108658/PAAI109053/PAAI108639/PAAI108643/PAAI108645/PAAI108664/PAAI108633/PAAI037390/B
PAAI109059/T002017030/A
W006350148/B
PAAI064240/-
Item name
Male stud connector
Precision steel pipe
Tube end reducer
Union tee
Male stud connector
SAE flange
Male stud connector
Male stud connector
Union elbow
Swivel nut elbow
SWIVEL UNION
Flange assembly
Male stud connector
Male stud connector
SAE flange
Blind flange
Threaded flange
Male stud connector
33 W084815517/-
Male stud connector
34
35
36
37
38
39
40
41
42
43
44
45
46

Flange assembly
Union
Reducer
Swivel nut run tee
Tube end reducer
Union tee
Male stud connector
Male stud connector
Union elbow
Union elbow
PAAI108604/PAAI108602/PAAI109073/W006380004/PAAI107877/W084819419/W006370015/W006430013/A
W084821014/PAAI104888/W005904004/W006410046/B
W006410010/-
Product:
connections
PAAI066759/-
Drawing
Quantity
DAAK104570--/Precision steel pipe

DAAK104613--/Precision steel
pipe
pipe
pipe
pipe
pipe
DAAK103433-SAE flange

DAAK103433-SAE flange
DAAK100959-Threaded flange
PAAI064240_D01--/Precision steel
pipe
DAAK101616--/Lower gearbox
assembly
6,0
1,0
1,0
6,0
4,0
2,0
2,0
2,0
1,0
1,0
4,0
4,0
1,0
1,0
2,0
4,0
1,0
1,0
1,0
6,0
4,0
1,0
1,0
1,0
2,0
4,0
4,0
1,0
4,0
1,0
2,0
1,0
1,0
3,0
2,0
2,0
1,0
4,0
2,0
1,0
2,0
6,0
1,0
1,0
2012-11-20
29 November 2012
10-27

Title:
Page: 27 of 99
Type:
BOM: PAAI108839/-
Seq. Item id
Product:
connections
PAAI066759/-
Item name
Drawing
47
48
49
50
51
52
53
54
55
56
57
58
59
60
61
62
63
64
65
66
PAAI104698/PAAI104903/PAAI104915/W006430061/PAAI108431/W006430081/A
PAAI103484/M710190393/A
W006440007/PAAI103492/PAAI064743/M710801122/A
PAAI104912/W006370030/A
W006430069/A
W002000363/A
M710100126/A
W084837133/U000000556/M710100229/B

Swivel nut run tee
Swivel nut run tee
Union cross
Pipe
Union tee
Tube end reducer
Union tee
Tube end reducer
Straight female pipe nipple
Safety valve
Filler-breather
67
68
69
70
71
72
80
81
82
83
84
85
86
90
91
92
93
94
95
96
100
101
102
103
104
T002012383/1
T001020770/W006590057/A
T002016820/1
T002016818/1
PAAI103471/PAAI108485/PAAI108491/PAAI108450/W006350221/B
PAAI108492/PAAI108487/PAAI108394/M710100333/A
PAAI045168/A
W006410048/A
T002012384/B
M710801134/A
PAAI100412/PAAI040252/A
PAAI015504/T003000527/W084851293/W084825835/PAAI108407/-
Ball valve
Reducing nipple
Adapter
Sight glass
Vent
Male stud connector
Pipe assembly
Male stud connector
Union elbow
Ball valve
Union tee
Restrictor
Pipe clamp
Pipe clamp
Pipe clamp
Pipe clamp
Strip
Quantity


PAAI064743_D01--/Pipe
T001015248_D01-T001015248
W084838296_D01-Safety valve
U000000561-Description
M710100229_D01-A/Straight female
pipe nipple
T002012383_D01-1/Ball valve
T001020769_D01-Reducing nipple
DAAK010369-Adapter
T002016820_D01-1/Sight glass
T002016818_D01-1/Vent
DAAK104699--/Pipe assembly
T002012383_D01-Ball valve
T002005068_D01-Restrictor
W084851293_D01--/Pipe clamp
DAAK104693--/Strip
1,0
1,0
1,0
1,0
1,0
2,0
1,0
1,0
1,0
1,0
1,0
1,0
1,0
1,0
1,0
1,0
1,0
1,0
2,0
1,0
1,0
1,0
2,0
1,0
1,0
1,0
1,0
1,0
1,0
5,0
1,0
1,0
1,0
11,0
5,0
5,0
3,0
2,0
1,0
1,0
2,0
2,0
1,0
1,0
2,0
2012-11-20
10-28
29 November 2012

Title:
Page: 28 of 99
Type:
BOM: PAAI108839/-
Seq. Item id
Product:
connections
PAAI066759/-
Item name
Drawing
DAAK104698--/Frame
DAAK104696--/Spacer piece
DAAK104700--/Frame
105
106
107
108
109
110
111
112
113
PAAI108413/PAAI108498/PAAI108583/PAAI104877/PAAI108818/M713000424/M713000431/M713000480/M713000530/-
Frame
Spacer piece
Frame
Strip
Strip
Hexagon head screw
Hexagon head screw
Hexagon head screw
Hexagon head screw
114
115
116
117
M714040033/M716100031/M716100033/M716100036/A
Hexagon nut
Square washer
Square washer
Square washer
W084849264_D01-B/Flange cover
W084849264_D01-A/Flange cover
W084849264_D01--/Stroomlijnkap
Quantity
1,0
2,0
1,0
2,0
2,0
4,0
4,0
4,0
8,0
4,0
8,0
4,0
8,0
END OF LIST
2012-11-20
29 November 2012
10-29

Title:
Flange assembly
Type:
Jis DN32-20k
Drawing:
BOM: PAAI109053/-
Seq. Item id
1
2
3
5
W007110160/A
M714040036/M716100036/A
PAAI109060/-
6 PAAI109058/7 PAAI109057/-
Page: 29 of 99
Item name
Hexagon bolt
Hexagon nut
Square washer
Packing ring
Threaded flange
Blind flange
Product:
PAAI066759/-
Drawing
Quantity
W084833926_D01-Packing
T002006324_D01-Packing
DAAK104855--/Threaded flange
4,0
4,0
4,0
1,0
1,0
1,0
END OF LIST
2012-11-20
10-30
29 November 2012

Title:
Flange assembly
Type:
Jis DN20-20k
Page: 30 of 99
Drawing:
BOM: PAAI109073/-
Product:
PAAI066759/-
Item name
Drawing
1 M710100229/B
2
3
4
5
6
7
Threaded flange
Hexagon bolt
Hexagon nut
Square washer
Blind flange
Packing ring
M710100229_D01-A/Straight female
pipe nipple
DAAK104857--/Threaded flange
Seq. Item id
PAAI109075/M713005486/M714040033/M716100033/PAAI109074/PAAI109076/-
W084833926_D01-Packing
T002006324_D01-Packing
Quantity
1,0
1,0
4,0
4,0
4,0
1,0
1,0
END OF LIST
2012-11-20
29 November 2012
10-31

Title:
Page: 31 of 99
Hydraulic system
Type:
Drawing: DAAK100255-Hydraulic diagram
BOM: PAAI107807/-
Product:
PAAI066759/-
Item name
Drawing
1 PAAI107845/-
Hydraulic power pack
2 PAAI065029/B
Safety valve
3 PAAI108309/-
Manifold
DAAK104427-Hydraulic power pack

PAAI065029_D01-Safety valve
DAAK015662-Safety valve
DAAK104428-Manifold
DAAK100265-Manifold
Seq. Item id
Quantity
1,0
1,0
1,0
END OF LIST
2012-11-20
10-32
29 November 2012

Title:
Type:
Drawing: DAAK104427-Hydraulic power pack
BOM: PAAI107845/-
Seq. Item id
2
6
10
11
12
31
32.01
32.04
33
35
38.01
39
40
201
206
208.01
216
230
234
240.01
241.01
243.02
243.51
243.52
243.53
250.01
261
261.51
261.52
264.01
265
271
273.01
273.03
273.05
273.06
273.03A
Page: 32 of 99
PAAI030624/PAAI030552/PAAI032961/PAAI032955/PAAI034278/A
PAAI011332/PAAI044257/PAAI011381/B
PAAI044132/PAAI008745/B
PAAI044259/PAAI026619/A
PAAI022999/A
PAAI059642/W084824198/A
PAAI109049/PAAI011836/PAAI033184/A
PAAI109047/PAAI044608/A
PAAI044535/PAAI033907/PAAI033906/PAAI045794/PAAI045793/PAAI109048/PAAI045792/PAAI011385/B
PAAI012812/PAAI033184/A
PAAI109051/PAAI013087/A
PAAI008060/B
PAAI012437/A
PAAI005820/C
PAAI012437/A
PAAI052326/-
Item name
Gasket
Gasket
Bell housing
Gasket
Flexible coupling
Seal
Shuttle valve
Shuttle valve
Orifice
Orifice
Non-return valve
Measuring coupling
Measuring coupling
Directional valve
4/3-way valve
E-motor
Filler-breather
Non-return valve
Non-return valve
Vane pump
Non-return valve
Relief valve
Compensator
Cartridge valve
Cover
Return filter
Valve inner part
Handle
Plug
Non-return valve
Oil cooler
Level switch
Dirt indicator
Pressure switch
Pressure switch
Pressure switch
Measuring coupling
273.05A PAAI028975/A
Measuring coupling
273.06A PAAI052326/-
Measuring coupling
298 PAAI008723/C
298.51 PAAI013605/B
Temperature switch
Tube
Product:

PAAI066759/-
Drawing
PAAI034278_D01-A/Flexible coupling
DAAK011446-Shuttle valve
PAAI011381_D01-B/Shuttle valve
DAAK014062-E-motor
DAAK009058-Cartridge valve
DAAK007355-Vane pump
DAAK006229-Valve
DAAK006229-Valve
DAAK006229-Valve
DAAK006229-Valve
DAAK018735-Filter
DAAK007850-Handle
PAAI013087_D01--/Level switch
DAAK006880-Dirt indicator
PAAI052326_D01--/Measuring
coupling
coupling
PAAI052326_D01--/Measuring
coupling
Quantity
1,0
1,0
1,0
1,0
2,0
1,0
1,0
1,0
2,0
4,0
1,0
10,0
1,0
1,0
1,0
1,0
1,0
1,0
1,0
1,0
1,0
1,0
1,0
1,0
1,0
1,0
1,0
1,0
1,0
1,0
1,0
1,0
1,0
1,0
1,0
1,0
1,0
1,0
1,0
1,0
1,0
2012-11-20
29 November 2012
10-33

Title:
Type:
BOM: PAAI107845/-
Seq. Item id
310
312.01
314
315.01
326
326A
Page: 33 of 99
PAAI012969/B
PAAI012990/B
PAAI005608/C
PAAI012962/B
PAAI102689/PAAI015247/-
Product:

PAAI066759/-
Item name
Drawing
Dip stick
Pressure gauge
Thermometer
Dirt indicator
Junction box
Connector
DAAK007237-Dip stick
DAAK009068-Thermometer
PAAI015247_D01--/Connector
Quantity
1,0
1,0
1,0
1,0
1,0
2,0
END OF LIST
2012-11-20
10-34
29 November 2012

Title:
Flexible coupling
Type:
R48.60X080-31,75K
BOM: PAAI034278/A
Seq. Item id
12A PAAI034277/12B PAAI011704/B
12C PAAI034276/A
Page: 34 of 99
Drawing: PAAI034278_D01-A/Flexible coupling
Product:
PAAI066759/-
Item name
Drawing
Coupling hub
Gear ring
Coupling hub
PAAI011704_D01-B/Gear ring
Quantity
1,0
1,0
1,0
END OF LIST
2012-11-20
29 November 2012
10-35

Page: 35 of 99
Title:
Return filter
Type:
STF1010QBP2ELC243
BOM: PAAI109048/-
Seq. Item id
250.01A PAAI010177/B
Product:
PAAI066759/-
Item name
Drawing
Filter cartridge
DAAK007805-Return filter
Quantity
1,0
END OF LIST
2012-11-20
10-36
29 November 2012

Title:
Safety valve
Type:
NG16
Page: 36 of 99
Drawing: PAAI065029_D01-Safety valve
BOM: PAAI065029/B
Seq. Item id
39
218.01
218.02
226.01
226.02
227.01
227.02
243.01
PAAI026619/A
PAAI047888/A
PAAI047888/A
Product:
PAAI066759/-
Item name
Drawing
Measuring coupling
Counter balance valve
Non-return valve
Non-return valve
Non-return valve
Non-return valve
Relief valve
DAAK102784-Counter balance valve
DAAK102784-Counter balance valve
DAAK009198-Relief valve
Quantity
2,0
1,0
1,0
1,0
1,0
1,0
1,0
1,0
END OF LIST
2012-11-20
29 November 2012
10-37

Title:
Page: 37 of 99
Manifold
Type:
Drawing: DAAK104428-Manifold
BOM: PAAI108309/-
Seq. Item id
212.01 PAAI108962/212.03 PAAI108962/-
Product:
DAAK100265-Manifold
PAAI066759/-
Item name
Drawing
Directional valve
Directional valve
Quantity
1,0
1,0
END OF LIST
2012-11-20
10-38
29 November 2012

Title:
Page: 38 of 99
Starter
Type:
Drawing: DAAK019608-Specification
BOM: PAAI107808/-
Product:
Seq. Item id
1 PAAI107839/A
2 PAAI107840/A
3 PAAI107841/A
PAAI066759/-
Item name
Drawing
Starter
Starter
Starter
DAAK100647-Starter
DAAK100646-Starter
DAAK100645-Starter
Quantity
1,0
1,0
2,0
END OF LIST
2012-11-20
29 November 2012
10-39

Title:
Page: 39 of 99
Water separator
Type:
Drawing:
BOM: PAAI108600/-
Product:
Seq. Item id
1 PAAI003138/-
PAAI066759/-
Item name
Drawing
Water separator
PAAI003138_D03--/Water separator
Quantity
1,0
END OF LIST
2012-11-20
10-40
29 November 2012

Title:
Miscellaneous components
Type:
FS2510-363/2500WO
BOM: PAAI066764/B
Page: 40 of 99
Drawing:
Product:
PAAI066759/-
Seq. Item id
Item name
Drawing
9017 PAAI105850/9092 PAAI111470/-
Anodes plan
Name plate
DAAK018296_D01-Anodes plan
Quantity
1,0
1,0
END OF LIST
2012-11-20
29 November 2012
10-41

Title:
Anodes plan
Type:
LMT 3510
Page: 41 of 99
Drawing: DAAK018296_D01-Anodes plan
BOM: PAAI105850/-
Seq. Item id
1 W008997015/-
Product:
PAAI066759/-
Item name
Drawing
Zinc anode
T002002416_D07-Anode
T002002416_D02-Anode
T002002416_D01-Anode
T002002416_D06-Anode
T002002416_D03-Anode
T002002416_D04-Anode
T002002416_D05-Anode
Quantity
15,0
END OF LIST
2012-11-20
10-42
29 November 2012

Page: 42 of 99
Title:
Name plate
Type:
FS2510-363/2500WO
BOM: PAAI111470/-
Seq. Item id
1
2
5
6
10
PAAI111471/W007580262/PAAI111473/W008997036/PAAI111472/-
Drawing:
Product:
PAAI066759/-
Item name
Drawing
Type shield
Grooved pin
Label
Tie wrap
Name plate
DAAK105768-Type shield
DAAK105770-Label
DAAK105769-Name plate
Quantity
14,0
56,0
50,0
50,0
17,0
END OF LIST
2012-11-20
29 November 2012
10-43

Page: 43 of 99
Title:
Type shield
Type:
FS2510-363/2500WO
BOM: PAAI111471/-
Seq. Item id
1 T003000513/7
Drawing: DAAK105768-Type shield

Product:
PAAI066759/-
Item name
Drawing
Type shield (rm)
T003000513_D01-7/Type shield (rm)
Quantity
1,0
END OF LIST
2012-11-20
10-44
29 November 2012

Page: 44 of 99
Title:
Label
Type:
FS2510-363/2500WO
BOM: PAAI111473/-
Seq. Item id
10 T001007434/-
Drawing: DAAK105770-Label
Product:
PAAI066759/-
Item name
Drawing
Label (rm)
T001007434_D01--/Label (rm)
Quantity
1,0
END OF LIST
2012-11-20
29 November 2012
10-45

Title:
Newbuild tools
Type:
FS2510-363/2500WO
BOM: PAAI066765/C
Page: 45 of 99
Drawing:
Product:
PAAI066759/-
Seq. Item id
Item name
Drawing
9518 T003004907/3
9521 PAAI064599/A
Mounting tool
Transport tool
T003004907_D01-3/Mounting tool
DAAK018944_D01-Lower gearbox
assembly
9591 T003004290/1
9594 PAAI108609/-
Toolbox
Hoisting and transport parts
9596 T002050610/5
Pump unit assembly
9597 PAAI003102/-
Blocking device
Quantity
DAAK104633-Hoisting and transport

parts
T002050610_D01-5/Pump unit
assembly
T002050610_D02-5/Pump unit
assembly
W084844509_D01-Blocking device
1,0
2,0
1,0
2,0
1,0
2,0
END OF LIST
2012-11-20
10-46
29 November 2012

Title:
Mounting tool
Type:
2500
Page: 46 of 99
Drawing: T003004907_D01-3/Mounting tool
BOM: T003004907/3
Seq. Item id
Item name
1 W007250045/B Hydraulic nut

2 T003004852/Pressure ring
3 T003000538/Threaded rod
5 W007375031/-
Product:
PAAI066759/-
Drawing
T003004852_D01--/Pressure ring
T002017357_D01-Threaded rod
T002017357_D02-Threaded rod
Plain washer
Quantity
1,0
1,0
8,0
8,0
END OF LIST
2012-11-20
29 November 2012
10-47

Title:
Transport tool
Type:
FS 2510
Drawing: DAAK018944_D01-Lower gearbox
BOM: PAAI064599/A
Seq. Item id
1 PAAI062785/A
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
M712040436/PAAI062789/W007000249/T002051872/B
T002005882/1
M712040487/W084827782/M714040046/M713005689/W084836206/PAAI056502/W007000943/W084851561/M735000028/M713000632/-
Page: 47 of 99
Product:
assembly
PAAI066759/-
Item name
Drawing
Auxiliary tool
PAAI062785_D04-A/Auxiliary tool
PAAI062785_D02-A/
!!See TC for complete info!!

Adapter
Seamless O-ring
Cap
Distance bush
Threaded rod
Hexagon nut
Hexagon bolt
Bow shackle
Protection bush
Seamless O-ring
Hexagon bolt
Bonded seal
Hexagon head screw
Quantity
PAAI062789_D01--/Adapter
T002051872_D01-C/Cap
T002005882_D01-1/Distance bush
PAAI056502_D01--/Protection bush
1,0
12,0
1,0
1,0
1,0
12,0
10,0
2,0
5,0
1,0
4,0
1,0
1,0
12,0
2,0
2,0
END OF LIST
2012-11-20
10-48
29 November 2012

Title:
Page: 48 of 99
Toolbox
Type:
Drawing:
BOM: T003004290/1
Product:
Seq. Item id
1
2
3
4
5
T001024794/1
T002002000/1
T002008068/1
T002016670/1
T003001482/2
PAAI066759/-
Item name
Drawing
Grease gun
Hose
Grease
Box
Nipple
T001024794_D01-1/Grease gun
T002008068_D01-1/Grease
DAAK018428-Box
T003001482_D01-2/Nipple
Quantity
1,0
1,0
4,0
1,0
2,0
END OF LIST
2012-11-20
29 November 2012
10-49

Title:
Hoisting and transport parts
Type:
CS2510
Drawing: DAAK104633-Hoisting and transport parts
BOM: PAAI108609/-
Seq. Item id
1
2
3
4
5
6
7
8
9
10
PAAI064425/W084842761/B
W084842758/A
PAAI011369/A
PAAI011374/B
T003004037/A
M714040050/M716000050/M301106020/A
W084828532/A
Page: 49 of 99
Product:
PAAI066759/-
Item name
Drawing
Closing plate
Packing
Lifting plate
Transport tool
Transport tool
Threaded rod
Hexagon nut
Plain washer
Hot rolled U-bar (rm)
Precision pipe (rm)
PAAI064425_D01--/Closing plate
W084842761_D01-B/Packing
W084842758_D01-A/Lifting plate
PAAI011369_D01-A/Transport tool
PAAI011374_D01-B/Transport tool
Quantity
1,0
1,0
2,0
1,0
2,0
18,0
36,0
36,0
3000,0
800,0
END OF LIST
2012-11-20
10-50
29 November 2012

Title:
Pump unit assembly
Type:
2500 bar
Drawing: T002050610_D01-5/Pump unit assembly
BOM: T002050610/5
Seq. Item id
Item name
A W006040130/A Hand pump

B T003002588/1 Hand pump
12
13
14
15
16
T001014487/3
M713000534/M716100036/A
T002009672/1
T001014976/1
Page: 50 of 99
Support
Hexagon head screw
Square washer
Sealing ring
Foundation
Product:
T002050610_D02-5/Pump unit assembly

PAAI066759/-
Drawing
W006040130_D01-A/Hand pump
T003002588_D01-1/Hand pump
T003002588_D02-1/Hand pump
T003002588_D03-1/Hand pump
T003002588_D04-1/Hand pump
T003002588_D05-1/Hand pump
T003002588_D06-1/Hand pump
T002050610_D02-Pump unit
assembly
T002050610_D
T001014487_D01-3/Support
T002009672_D01-1/Sealing ring
T001014976_D01-1/Foundation
Quantity
1,0
1,0
1,0
2,0
2,0
2,0
2,0
END OF LIST
2012-11-20
29 November 2012
10-51

Title:
Blocking device
Type:
BLOCKING BREVINI
BOM: PAAI003102/-
Seq. Item id
Item name
1 W084844509/A Blocking device
Page: 51 of 99
Drawing: W084844509_D01-Blocking device
Product:
PAAI066759/-
Drawing
Quantity
W084844509_D01-A/Blocking device
1,0
END OF LIST
2012-11-20
10-52
29 November 2012

Title:
Blocking device
Type:
CALZONI MR125-190
BOM: W084844509/A
Seq. Item id
1 PAAI100092/2 M718500481/3 T003002952/-
Page: 52 of 99
Drawing: W084844509_D01-A/Blocking device
Product:
PAAI066759/-
Item name
Drawing
Flange
Heavy cylindrical spring dowel
Coupling
DAAK100060--/Flange
T003002952_D01--/Coupling
Quantity
1,0
2,0
1,0
END OF LIST
2012-11-20
29 November 2012
10-53

Title:
Newbuild spares
Type:
FS2510-363/2500WO
BOM: PAAI066766/A
Seq. Item id
Item name
9990 PAAI109591/-
Commissioning parts
Page: 53 of 99
Drawing:
Product:
PAAI066759/-
Drawing
Quantity
1,0
END OF LIST
2012-11-20
10-54
29 November 2012

Title:
Commissioning parts
Type:
FS2510/2500 WO
BOM: PAAI109591/-
Page: 54 of 99
Drawing:
Product:
PAAI066759/-
Item name
Drawing
1 T001048197/-
Liquid locking adhesive
T002011639_D04-T002011639
T002011639_D05-T002011639
T002011639_D08-T002011639
T002011639_D09-T002011639
T002011639_D12-T002011639
T002011639_D11-T002011639
T002011639_D10-T002011639
T002011639_D06-T002011639,
2
3
4
5
6
7
8
9

Degreaser fluid
Liquid gasket
Filter cartridge
Filter element
Filter element
Filter cartridge
Seq. Item id
T002005540/A
T003000506/A
T002014948/W005903954/PAAI010177/B
PAAI026752/PAAI006928/B
PAAI006391/D
DAAK007805-Return filter
DAAK006527-Filter
Quantity
1,0
1,0
1,0
1,0
1,0
2,0
2,0
2,0
2,0
END OF LIST
2012-11-20
29 November 2012
10-55

Title:
Type:
FS2510-363/2500WO
BOM: PAAI066769/A
Page: 55 of 99
Drawing:
Product:
PAAI066759/-
Item name
Drawing
741 PAAI060107/D
Upper gearbox assembly
771 PAAI031938/B
Speed pick-up arrangement
T003001371_D03-Upper gearbox
assembly
assembly
assembly
PAAI031938_D01-B/Speed pick-up
arrangement
Seq. Item id
Quantity
1,0
2,0
END OF LIST
2012-11-20
10-56
29 November 2012

Title:
Type:
2500-1.8 CW
Page: 56 of 99
Drawing: T003001371_D03-Upper gearbox
BOM: PAAI060107/D
Product:
assembly
assembly
assembly
PAAI066759/-
Item name
Drawing
T003001362/4
T001017994/4
T003001359/5
T001019050/7
T001019046/5
T002013521/2
T001019764/2
Upper gearbox
Lantern piece
Bearing housing
Bearing housing
Cover
Cover
Housing for rotary seal
8 T001019762/2
9V T003003208/7
Curved tooth coupling
10 T003001360/B
Fit ring
T003001362_D01-4/Upper gearbox
T001017994_D01-4/Lantern piece
T003001359_D01-5/Bearing housing
T001019046_D01-5/Cover
T002013521_D01-2/Cover
T001019764_D01-2/Housing for
rotary seal
T001019762_D01-2/Housing for
rotary seal
T003000217_D04-Curved tooth
coupling
coupling
coupling
coupling
T003001990_D01-Adjusting ring
DAAK101801-Adjusting ring
T003001348_D01-Bevel gear wheel
T001019860_D01-Bush
T003001347_D01-Pinion shaft
T0030013
T003005721_D01-2/Output shaft
T001080659_D01-Locking nut
T001019772_D01-2/Locking nut
T001019943_D01-2/Split ring
T003001508_D01-1/Distributing piece
T001019946_D01-5/Manifold block
T001019947_D01-D/Cover
T001019941_D01-6/Bearing race
T001019942_D01-3/Liner
Seq. Item id
1
2
3
4
5
6
7
11R PAAI060133/-
17
19
20
22
23
24
25
26
27
28
29
30
31
32
33
T003005721/2
T003000542/2
T001019772/2
T003001349/1
T001019943/2
T003001508/1
T001019946/5
T001019947/D
T001019941/6
T001019942/3
T001034133/5
T001019950/4
T001019857/4
T003001372/1
T001019853/1
Gear set for upper gearbox
Output shaft
Locking nut
Locking nut
Bearing housing
Split ring
Distributing piece
Manifold block
Cover
Bearing race
Liner
Red cap
Distance bush
Distance bush
Ring
Fit ring
T003001372_D01-1/Ring
T001019853_D01-1/Fit ring
Quantity
1,0
1,0
1,0
1,0
1,0
1,0
1,0
1,0
1,0
1,0
1,0
1,0
1,0
1,0
1,0
1,0
1,0
1,0
1,0
1,0
1,0
2,0
1,0
1,0
1,0
1,0
2012-11-20
29 November 2012
10-57

Title:
Type:
2500-1.8 CW
Page: 57 of 99
BOM: PAAI060107/D
Product:
assembly
assembly
assembly
PAAI066759/-
Item name
Drawing
34 T003001361/B
Fit ring
35 T001019851/B
Fit ring
37
38
40
43
T001019948/6
T001019949/3
T001010581/2
T001020886/-
Suction line
Cover
Key
Hardened cylindrical pin
44
45
46
47
48
T001003859/D
M301035275/M301035275/M301035275/T002050761/1
T001019948_D01-6/Suction line
T001019949_D01-3/Cover
T001010581_D01-2/Key
T003000231_D01-Pin
T003000231_D03-Pin
T003000231_D02-Pin
T003000231_D05-Pin
T003000231_D04-Pin
T001003859_D01-D/Spring
Seq. Item id
Quantity
Spring
Precision pipe (rm)
Precision pipe (rm)
Precision pipe (rm)
Hex.socket set screw cone point T002050761_D01-1/Hex.socket set
screw cone point
49 T002050762/1 Hex.socket set screw cone point T002050762_D01-1/Hex.socket set
screw cone point
51 W006210906/A Double row spheric.roll.bearing
52 W006210001/- Double row spheric.roll.bearing
53 W006200201/- Double row spheric.roll.bearing
54 W006260033/- Spherical roller thrust bearing
55 W006200174/A Spherical roller thrust bearing
56 W006220030/A Cylindrical roller bearing
57 W007001277/- O-ring
58 W007035511/- O-ring
59 W007001069/- O-ring
60 W007001062/- O-ring
61 W007000977/- O-ring
62 W007000653/- O-ring
63 W007035270/- O-ring
64 W007000712/- O-ring
65 W007000641/- O-ring
66 W084813333/- Seamless O-ring
67 W007001423/- O-ring with vulcanized joint
68 T001010605/Oil seal
69 W007065070/- Oil seal
70 T001019945/C Support ring
T001019945_D01-C/Support ring
71 M718700420/- Retaining ring for shaft
72 M718700422/- Retaining ring for shaft
73 PAAI016544/D Distance bush
DAAK105607-Dimension table
W084831549_D01-Distance bush
1,0
1,0
1,0
1,0
1,0
1,0
4,0
900,0
1130,0
1400,0
2,0
1,0
1,0
1,0
1,0
1,0
1,0
1,0
2,0
2,0
1,0
1,0
1,0
1,0
2,0
1,0
1,0
1,0
1,0
1,0
2,0
1,0
1,0
1,0
16,0
2012-11-20
10-58
29 November 2012

Title:
Type:
2500-1.8 CW
BOM: PAAI060107/D
Seq. Item id
74
75
76
77
78
79
80
81
82
83
84
85
86
87
89
90
91
92
94
95
96
97
98
99
100
101
102
103
104
105
106
107
108
109
110
111
112
113
121
131
132
134
M712040590/M713000532/M712045389/M713005489/M713000480/M712040383/T002007789/1
M711050488/W007000647/M711050387/W006350221/B
M714040041/M714040036/W007355084/M716100033/M716100036/A
M716100041/T003000445/2
M710380243/M710380248/M710380256/M713090039/M731000290/M731000302/M731000340/A
M731000261/T001067975/4
T001020196/W006356700/B
T003005728/W006410044/A
W084821025/W006800185/A
T002009672/1
T003000749/1
T003000604/M710380239/M710380256/M713005536/T003000578/A
T002007667/W084824439/A
Page: 58 of 99
Product:
Item name
Hexagon head screw
Hexagon bolt
Hexagon head screw
Screw
Stud 1,25d
O-ring with vulcanized joint
Stud 1,25d
Male stud connector
Hexagon nut
Hexagon nut
Screw
Square washer
Square washer
Square washer
Locking plate
Hexagon head screw plug
Lifting eye bolt
Copper sealing ring
Copper sealing ring
Copper sealing ring
Copper sealing ring
Disc spring
Sight glass
Male stud connector
Measuring coupling
Union elbow
Hexagon socket pipe plug
Valve
Sealing ring
Pressure gauge
Measuring coupling
Hexagon bolt
Packing ring
Blind flange
Oil pipe
assembly
assembly
assembly
PAAI066759/-
Drawing
T002007789_D01-1/Screw
T003000445_D01-2/Locking plate
T001068794_D01-Disc spring
T001020196_D01--/Sight glass
T001021507_D01-T001021507
T002000727_D01-Valve
T002009672_D01-1/Sealing ring
T001021507_D01-T001021507
T002007667_D01--/Blind flange
W084824438_D01-Oil pipe
Quantity
16,0
22,0
24,0
4,0
28,0
6,0
1,0
20,0
1,0
6,0
2,0
20,0
10,0
1,0
32,0
56,0
20,0
1,0
3,0
4,0
6,0
1,0
12,0
4,0
12,0
2,0
3,0
1,0
9,0
1,0
3,0
1,0
1,0
1,0
1,0
1,0
2,0
1,0
4,0
1,0
1,0
1,0
2012-11-20
29 November 2012
10-59

Title:
Type:
2500-1.8 CW
BOM: PAAI060107/D
Seq. Item id
135 W004630028/-
Page: 59 of 99
Item name
Product:
assembly
assembly
assembly
PAAI066759/-
Drawing
Red cap
Quantity
1,0
END OF LIST
2012-11-20
10-60
29 November 2012

Title:
Upper gearbox
Type:
2500
Drawing: T003001362_D01-4/Upper gearbox
BOM: T003001362/4
Seq. Item id
10 T002050741/2
Page: 60 of 99
Product:
PAAI066759/-
Item name
Drawing
Upper gearbox (rm)
Quantity
1,0
END OF LIST
2012-11-20
29 November 2012
10-61

Title:
Lantern piece
Type:
2500 BWH
Page: 61 of 99
Drawing: T001017994_D01-4/Lantern piece
BOM: T001017994/4
Seq. Item id
10 T001017995/2
Product:
PAAI066759/-
Item name
Drawing
Lantarn piece (rm)
T001017994_D01-Lantern piece
Quantity
1,0
END OF LIST
2012-11-20
10-62
29 November 2012

Title:
Bearing housing
Type:
2500 BWH
Drawing: T003001359_D01-5/Bearing housing
BOM: T003001359/5
Seq. Item id
10 T003001506/4
Page: 62 of 99
Product:
PAAI066759/-
Item name
Drawing
Bearing housing (rm)
T003001359_D01-Bearing housing
Quantity
1,0
END OF LIST
2012-11-20
29 November 2012
10-63

Title:
Bearing housing
Type:
2500 BWH
BOM: T001019050/7
Seq. Item id
10 T001019761/5
Page: 63 of 99
Product:
PAAI066759/-
Item name
Drawing
Quantity
1,0
END OF LIST
2012-11-20
10-64
29 November 2012

Title:
Type:
2500
Drawing: T001019764_D01-2/Housing for rotary
BOM: T001019764/2
Seq. Item id
10 T001019765/1
Page: 64 of 99
Product:
seal
PAAI066759/-
Item name
Drawing
Housing for rotary seal (rm)
T001019764_D01-Housing for rotary

seal
Quantity
1,0
END OF LIST
2012-11-20
29 November 2012
10-65

Title:
Type:
2500 BWH
BOM: T001019762/2
Seq. Item id
10 T001019763/1
Page: 65 of 99
Product:
seal
PAAI066759/-
Item name
Drawing
Housing for rotary seal (rm)
T001019762_D01-Housing for rotary

seal
Quantity
1,0
END OF LIST
2012-11-20
10-66
29 November 2012

Title:
Output shaft
Type:
2500
Page: 66 of 99
Drawing: T003005721_D01-2/Output shaft
BOM: T003005721/2
Seq. Item id
10 T003004962/2
Product:
PAAI066759/-
Item name
Drawing
Output shaft (rm)
T003004962_D01-2/Output shaft (rm)
Quantity
1,0
END OF LIST
2012-11-20
29 November 2012
10-67

Title:
Type:
2500
Drawing: PAAI031938_D01-B/Speed pick-up
BOM: PAAI031938/B
Seq. Item id
2 M712045390/3 PAAI031712/10 E000003372/A
Page: 67 of 99
Item name
Product:
arrangement
PAAI066759/-
Drawing
Quantity

Mounting bracket
PAAI031712_D01--/Mounting bracket
Switch
E000007991-Electric Diagram
2,0
1,0
2,0
END OF LIST
2012-11-20
10-68
29 November 2012

Title:
Type:
FS2510-363/2500WO
BOM: PAAI066768/C
Page: 68 of 99
Drawing:
Product:
PAAI066759/-
Item name
Drawing
421 PAAI102501/D
422 PAAI102912/-
Stem section assembly

Intermediate shaft assembly
423 PAAI044001/-
Steering motor assembly
424 PAAI004521/B
Azimuth feedback unit
DAAK102321-Stem section assembly

T003005755_D01-Intermediate shaft
assembly
DAAK011368_D01-Steering motor
assembly
DAAK014251_D01-Version table
T002014339_D01-Azimuth feedback
unit
DAAK000920_D01-Azimuth feedback
unit
W084843587_D01-B/Terminal box
T002010530_D01-Azimuth feedback
drive
Seq. Item id
430 W084843587/B Terminal box

435 PAAI003849/Azimuth feedback drive
Quantity
1,0
1,0
3,0
1,0
1,0
1,0
END OF LIST
2012-11-20
29 November 2012
10-69

Title:
Type:
LMT2510
Drawing: DAAK102321-Stem section assembly
BOM: PAAI102501/D
Seq. Item id
1
2
3
4
5
6
PAAI101210/A
PAAI004282/M730000474/M712082433/M730030050/6
PAAI004230/B
7 T002010288/-
Page: 69 of 99
Product:
PAAI066759/-
Item name
Drawing
Steering pipe
Liner
Seamless O-ring
Hex.socket set screw cone point
V-ring
DAAK101509-Steering pipe
PAAI004282_D01--/Liner
Oil seal
8
9
10
11
12
13
14
15
16
17
18
19
20
22
23
24
25
PAAI004283/M712040276/W007000250/PAAI004291/W007050001/W007100549/W006210920/A
W084838523/A
W005903590/A
T003001088/4
M712045597/PAAI100882/B
W006350148/B
PAAI108870/PAAI108892/PAAI004322/C
PAAI002818/E
Pressure ring
Seamless O-ring
Retaining ring
Seamless O-ring
Hexagon head screw
Double row spheric.roll.bearing
Locking washer
Hexagon head screw
Fitted sleeve
Stem box
Male stud connector
Oil pipe
Oil pipe
Steering hub
Slewing bearing
26
31
32
35
53
54
55
56
57
58
59
60
61
62
64
65
69
75
M712045489/PAAI004384/M712040382/PAAI004385/A
W084814773/A
M716600033/PAAI004363/W007375031/M713005689/M731000302/PAAI062106/PAAI004559/M735000030/W007000417/M712045490/M713005689/M716100046/PAAI002501/-

Ring
Split ring
Hexagon head screw
Dubo retaining ring
Centring ring
Plain washer
Hexagon bolt
Copper sealing ring
Closing plate
Bonded seal
O-ring
Hexagon bolt
Square washer
Lifting eye
Quantity
M730030050_D01-6/V-ring
PAAI004230_D01-B/Housing for
rotary seal
T002008717_D01-Oil seal
T002008717_D02-Oil seal
PAAI004283_D01--/Pressure ring
PAAI004291_D01--/Retaining ring
DAAK104023-Locking washer
T003001088_D01-4/Fitted sleeve
DAAK101360-B/Stem box
DAAK104781--/Oil pipe
DAAK104785--/Oil pipe
PAAI004322_D01-C/Steering hub
PAAI002818_D02-E/Slewing
bearingPAAI002818_D01-E/Slewing
bearing
PAAI004384_D01--/Ring
PAAI004385_D01-A/Split ring
PAAI004363_D01--/Centring ring
PAAI062106_D01--/Closing plate
PAAI002501_D01--/Lifting eye
1,0
1,0
1,0
1,0
1,0
1,0
4,0
1,0
24,0
1,0
1,0
1,0
24,0
1,0
20,0
24,0
20,0
20,0
1,0
6,0
2,0
2,0
1,0
1,0
60,0
1,0
12,0
1,0
4,0
4,0
1,0
108,0
16,0
6,0
1,0
1,0
16,0
6,0
48,0
48,0
48,0
4,0
2012-11-20
10-70
29 November 2012

Title:
Type:
LMT2510
BOM: PAAI102501/D
Seq. Item id
82 PAAI002782/F
95
97
98
99
100
105
106
107
108
109
111
112
115
116
117
118
127
128
148
215
325
326
M718500584/A
PAAI004290/M711050383/M714040036/M716100036/A
PAAI004289/W005904548/PAAI002837/PAAI003759/M710380248/M710380256/M731000340/A
M713000532/M716000036/W084851791/A
M730000277/W084842925/B
M730000877/PAAI004387/PAAI004388/M712040487/M716000041/-
327 W007000448/900 W084816812/F
Page: 70 of 99
Product:
PAAI066759/-
Item name
Drawing
Steering angle indicator
PAAI002760_D01-Steering angle
indicator

Distance ring
Stud 1,25d
Hexagon nut
Square washer
Distance ring
O-ring
Copper sealing ring
Hexagon head screw
Plain washer
Cover
Seamless O-ring
Cover
Seamless O-ring
Locking washer
Guiding ring
Plain washer
O-ring
Type shield
PAAI004290_D01--/Distance ring
PAAI004289_D01--/Distance ring
W084851791_D01-A/Cover
W084842925_D01-B/Cover
PAAI004387_D01--/Locking washer
PAAI004388_D01--/Guiding ring
W084833876_D99-C/Shaft assembly
W084833876_D99B/Aft_propulsion_assy
W084840581_D99--/Shaft assembly
W084816812_D01-F/Type shield
Quantity
1,0
10,0
1,0
30,0
30,0
30,0
1,0
2,0
1,0
1,0
5,0
5,0
1,0
26,0
26,0
1,0
1,0
1,0
1,0
1,0
1,0
20,0
20,0
1,0
1,0
END OF LIST
2012-11-20
29 November 2012
10-71

Title:
Steering pipe
Type:
FS2510
Page: 71 of 99
Drawing: DAAK101509-Steering pipe
BOM: PAAI101210/A
Seq. Item id
1 PAAI101238/-
Product:
PAAI066759/-
Item name
Drawing
Steering pipe (rm)
DAAK101524--/Steering pipe (rm)
Quantity
1,0
END OF LIST
2012-11-20
10-72
29 November 2012

Title:
Page: 72 of 99
Type:
Drawing: PAAI002760_D01-Steering angle indicator
BOM: PAAI002782/F
Product:
Seq. Item id
1
2
3
4
5
6
7
W007250516/PAAI015572/A
M730000017/PAAI014340/A
PAAI015595/A
PAAI015623/A
M730000011/-
Item name
Lifting eye nut
Bush
Seamless O-ring
Compression spring
Plug
Pin
Seamless O-ring
PAAI066759/-
Drawing
PAAI015572_D01-A/Bush
PAAI015595_D01-A/Plug
PAAI015592_D01-Pin
Quantity
1,0
1,0
2,0
1,0
1,0
1,0
1,0
END OF LIST
2012-11-20
29 November 2012
10-73

Title:
Type:
2510-2500
Page: 73 of 99
Drawing: T003005755_D01-Intermediate shaft
BOM: PAAI102912/-
Product:
assembly
PAAI066759/-
Item name
Drawing
1 PAAI102913/2 T003003209/H
Vertical intermediate shaft

Coupling
3
4
5
6
7
T003005756_D01-Intermediate shaft
coupling
coupling
DAAK017041_D01-Documentation
T003001667_D01--/Bush
T003001668_D01-A/Centring pin
T003001669_D01--/Retaining plate
Bush
Centring pin
Retaining plate
Ring
W084822498_D01--/Ring
Seq. Item id
T003001667/T003001668/A
T003001669/M712040330/W084822498/-
Quantity
1,0
2,0
1,0
1,0
1,0
12,0
1,0
END OF LIST
2012-11-20
10-74
29 November 2012

Title:
Type:
ED2090MR/21,09/160cc
BOM: PAAI044001/-
Seq. Item id
Page: 74 of 99
Drawing: DAAK011368_D01-Steering motor
Product:
assembly
PAAI066759/-
Item name
Drawing
1 PAAI042498/A
Hydraulic motor
2 PAAI016942/B
Planetary gearing
DAAK011143-Documentation
PAAI042498_D01--/Hydraulic motor
W084842225_D01-Reduction
gearbox
3 M712045284/4 M714040031/-

Hexagon nut
W084833876_D99-C/Shaft assembly
W084833876_D99B/Aft_propulsion_assy
W084840581_D99--/Shaft assembly
5 M716100031/- Square washer
7 PAAI047510/Centring bush
PAAI047510_D01--/Centring bush
8 W084842086/C Gear wheel
W084842086_D01-C/Gear wheel
9 PAAI047512/Retaining plate
PAAI047512_D01--/Retaining plate
10 M712045282/- Hexagon socket head cap screw
Quantity
1,0
1,0
5,0
5,0
5,0
1,0
1,0
1,0
3,0
END OF LIST
2012-11-20
29 November 2012
10-75

Title:
Planetary gearing
Type:
ED 2090 MR i=21,09
BOM: PAAI016942/B
Seq. Item id
Item name
2 W084842226/B Reduction gearbox

2a W084843894/A Connection
Page: 75 of 99
Drawing: W084842225_D01-Reduction gearbox
Product:
PAAI066759/-
Drawing
Quantity
W084843894_D01-A/Connection
1,0
1,0
END OF LIST
2012-11-20
10-76
29 November 2012

Title:
Type:
Sam 5x potm
Drawing: T002014339_D01-Azimuth feedback unit
BOM: PAAI004521/B
Seq. Item id
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
T002010151/5
T003002120/2
T003002118/A
T002014174/3
T002014175/T002010145/2
T002010144/2
T002010651/5
T002010652/5
T002010142/9
T002006116/5
T002014176/3
T003002982/2
T002010140/3
T002010148/A
T002010146/1
W007032004/-
18 W007001412/20V T003002807/A
Page: 76 of 99
Product:
DAAK000920_D01-Azimuth feedback unit

PAAI066759/-
Item name
Drawing
Foundation plate
Ring
Base plate
Bush
Shaft
Shaft
Shaft
Gear wheel
Gear wheel
Gear wheel
Gear wheel
Dial
Pointer
Bush
Sight glass
Packing
Quadring
T002010151_D01-5/Foundation plate
T003002120_D01-2/Ring
T003002118_D01-A/Base plate
T002014174_D01-3/Bush
T002014175_D01--/Shaft
T002010145_D01-2/Shaft
T002010144_D01-2/Shaft
T002010142_D01-Gear wheel
T002010142_D01-Gear wheel
T002010142_D01-9/Gear wheel
T002014176_D01-3/Dial
T003002982_D01-2/Pointer
T002010140_D01-3/Bush
T002010148_D01-A/Sight glass
T002010146_D01-1/Packing
T001010529_D01-T001010529
T001010529_D02-T001010529
O-ring
Potentiometer
21
22
23
24
M712030372/T001032500/B
T002013019/B
T002013020/C
Slotted cheese head screw

Rail
Terminal
Square washer plate
25
26
27
28
29
30
31
32
33
34
35
36
37
38
T001032499/M713001326/B
M712045136/T001036516/W007355085/M712030372/M712031424/T001036516/M712084066/T002010154/7
T001044147/1
T001033878/3
M718500124/T003002807/A
End bracket
Hexagon head screw
Clamp
Screw
Clamp
Hex.socket set screw cup point
Transmitter box
Nut
Cable gland
Potentiometer
39 T002013036/-
Potentiometer
40 M718500128/-
T003002807_D02-A/Potentiometer
T001032500_D01-Rail
T002013019_D01-Terminal
T002013020_D01-Square washer
plate
T001032500_D01-Rail
T001036516_D01--/Clamp
T001036516_D01--/Clamp
T002010154_D01-7/Transmitter box
T002013033_D05-Potentiometer
Quantity
1,0
1,0
1,0
1,0
1,0
1,0
1,0
1,0
1,0
1,0
1,0
1,0
1,0
1,0
1,0
1,0
1,0
1,0
1,0
2,0
180,0
28,0
1,0
2,0
4,0
4,0
3,0
3,0
1,0
4,0
12,0
8,0
1,0
2,0
2,0
1,0
1,0
1,0
1,0
2012-11-20
29 November 2012
10-77

Title:
Type:
Sam 5x potm
BOM: PAAI004521/B
Seq. Item id
41
42
43
44
45
46
49
50
59V
60
61
62
63
64
65
66
68
70
71
80
M718500124/M718700160/T001033878/3
T001044147/1
M716000023/W008997038/C
T001071968/T003002119/2
T002006116/5
T002006116/5
T002006116/5
T002013255/B
T002013256/C
T002013257/B
T002014177/A
W001960005/T002010156/2
W084809412/A
M716601023/T003002900/A
Page: 77 of 99
Product:
Item name
Retaining ring for shaft
Cable gland
Nut
Plain washer
Blind plug
Bearing bush
Bracket
Gear wheel
Gear wheel
Gear wheel
Number marking
Number marking
Number marking
Clamping ring
Plain washer
Plain bearing
Dubo retaining ring
Electric cable

PAAI066759/-
Drawing
Quantity
T001038024_D01-Bearing bush
T003002119_D01-2/Bracket
T002013255_D01-B/Number marking
T002013256_D01-C/Number marking
T002013257_D01-B/Number marking
T002014177_D01-A/Clamping ring
T002010156_D01-2/Plain bearing
T003002900_D01-A/Electric cable
1,0
1,0
2,0
2,0
1,0
4,0
2,0
2,0
1,0
1,0
1,0
1,0
1,0
1,0
1,0
1,0
1,0
4,0
4,0
3,0
END OF LIST
2012-11-20
10-78
29 November 2012

Title:
Page: 78 of 99
Terminal box
Type:
Drawing: W084843587_D01-B/Terminal box
BOM: W084843587/B
Product:
Seq. Item id
1
4
5
6
7
8A
W006903060/F
W006920210/B
W006920208/W006920119/W006920343/W084841700/A
Item name
Drawing
Terminal box
End bracket
Terminal clamp
Rail
Terminal
Number card clamp
W006903060_D01-F/Terminal box
W006920210_D01-B/End bracket
8B W084841701/A Number card clamp

8C W084841702/A Number card clamp
8D W084841703/A Number card clamp
9
10
11
12
13
14
15
16
20
21
22
W084816521/W084842647/T003000672/A
M712040174/M716101027/A
W084832891/C
W001960005/T003002900/A
T001033878/3
T001044147/1
T003003281/A
PAAI066759/-
Nut
Cable gland
Sealing ring
Square spring lock washer
Strip
Plain washer
Electric cable
Cable gland
Nut
Sealing ring
W084841700_D01-A/Number card
clamp
clamp
clamp
clamp
T003000672_D01-A/Sealing ring
W084832891_D01-C/Strip
T003002900_D01-A/Electric cable
T003000672_D01-Sealing ring
Quantity
1,0
1,0
2,0
0,3
36,0
1,0
1,0
1,0
1,0
32,0
16,0
16,0
4,0
4,0
2,0
4,0
50,0
10,0
20,0
10,0
END OF LIST
2012-11-20
29 November 2012
10-79

Title:
Azimuth feedback drive
Type:
3500, Z=19 M=12
BOM: PAAI003849/-
Seq. Item id
Page: 79 of 99
Drawing: T002010530_D01-Azimuth feedback drive
Product:
PAAI066759/-
Item name
Drawing
PAAI003842_D01--/Pinion
T002010204_D01-2/Bearing bush
T002010203_D01-2/Shaft
W084850375_D01--/Cover
T002010214_D02-B/Clamping ring
T002010215_D02-3/Spacer pin
T002010561_D02-3/Flexible
couplingT002010561_D01-3/Flexible
coupling
1
2
3
4
5
6
7
PAAI003842/T002010204/2
T002010203/2
W084850375/T002010214/B
T002010215/3
T002010561/3
Pinion
Bearing bush
Shaft
Cover
Clamping ring
Spacer pin
Flexible coupling
10
11
12
13
14
15
16
18
19
W007375037/M714050036/A
M718500376/A
M730000277/T001001109/A
M713000374/M730030020/B
M718500232/M712045180/-
Plain washer
Hex. nut w. nylon locking ring
Seamless O-ring
Oil seal
Hexagon head screw
V-ring
M730030020_D01-B/V-ring
Quantity
1,0
1,0
1,0
1,0
1,0
4,0
1,0
1,0
1,0
1,0
1,0
1,0
6,0
1,0
2,0
4,0
END OF LIST
2012-11-20
10-80
29 November 2012

Title:
Outboard delivery
Type:
LMT 2510-363/2500 WO
BOM: PAAI066778/A
Seq. Item id
Item name
1PS PAAI066767/D
17PS PAAI066770/B
Propeller arrangement
Pod arrangement
Page: 80 of 99
Drawing:
Product:
PAAI066759/-
Drawing
Quantity
1,0
1,0
END OF LIST
2012-11-20
29 November 2012
10-81

Title:
Type:
FS2510-363/2500WO
BOM: PAAI066767/D
Page: 81 of 99
Drawing:
Product:
PAAI066759/-
Item name
Drawing
109 PAAI105855/-
111 PAAI111344/114 PAAI064978/B
Propeller cap assembly

Propeller assembly
DAAK018679_D01-Propeller hub
DAAK103614-Fixed pitch propeller
DAAK105678-Propeller cap assembly
DAAK018911_D01-Propeller
assembly
Seq. Item id
Quantity
1,0
1,0
1,0
END OF LIST
2012-11-20
10-82
29 November 2012

Title:
Type:
FS2500
Drawing: DAAK018679_D01-Propeller hub
BOM: PAAI105855/-
Seq. Item id
1 W006564007/-
Page: 82 of 99
Product:
Item name

PAAI066759/-
Drawing
Hexagon socket collar plug
Quantity
1,0
END OF LIST
2012-11-20
29 November 2012
10-83

Title:
Page: 83 of 99
Type:
Drawing: DAAK105678-Propeller cap assembly
BOM: PAAI111344/-
Product:
Seq. Item id
50
51
52
53
54
55
56
57
58
PAAI110840/A
M730000460/W007100391/W007375025/W007550008/W006552120/M731000200/W084839228/W007385030/-
PAAI066759/-
Item name
Drawing
Propeller cap
Seamless O-ring
Hexagon head screw
Plain washer
Locking wire
Copper sealing ring
Hexagon head screw
Copper sealing ring
DAAK105427-A/Propeller cap
Quantity
1,0
1,0
8,0
8,0
2,0
2,0
2,0
1,0
1,0
END OF LIST
2012-11-20
10-84
29 November 2012

Title:
Propeller assembly
Type:
2500/2510FP
Drawing: DAAK018911_D01-Propeller assembly
BOM: PAAI064978/B
Seq. Item id
Page: 84 of 99
Product:
PAAI066759/-
Item name
Drawing
T001011294_D01-4/Cap
DAAK104663--/Spacer ring
T001016055_D01-2/Pressure ring
1
2
3
4
5
6
T001011294/4
PAAI108672/T001016055/2
M731000290/T001016069/5
T001016094/5
Cap
Spacer ring
Pressure ring
Copper sealing ring
Labyrinth seal
Fairing cover split version
9
10
11
12
13
14
15
16
17
18
19
99
W007000575/W007100391/W007110143/W007100387/W084809330/A
W006564007/W007375026/W007000909/M716000436/W006580044/W007035243/PAAI045184/B

Hexagon head screw
Hexagon bolt
Hexagon head screw
Plain washer
O-ring
Plain washer
Bonded seal
O-ring
Sealing compound
PAAI045184_D01-A/Sealing
compound
T001016069_D01-5/Labyrinth seal
T001016094_D01-5/Fairing cover
split version
Quantity
1,0
1,0
1,0
3,0
1,0
1,0
1,0
8,0
12,0
12,0
8,0
3,0
12,0
1,0
8,0
8,0
1,0
6,0
END OF LIST
2012-11-20
29 November 2012
10-85

Title:
Page: 85 of 99
Cap
Type:
Drawing: T001011294_D01-4/Cap
BOM: T001011294/4
Product:
Seq. Item id
10 T001011295/3
PAAI066759/-
Item name
Drawing
Cap (rm)
T001011294_D01-Cap
Quantity
1,0
END OF LIST
2012-11-20
10-86
29 November 2012

Title:
Labyrinth seal
Type:
2500FP
Drawing: T001016069_D01-5/Labyrinth seal
BOM: T001016069/5
Seq. Item id
10 T001010714/3
Page: 86 of 99
Product:
PAAI066759/-
Item name
Drawing
Labyrinth seal (rm)
T001016069_D01-Labyrinth seal
Quantity
1,0
END OF LIST
2012-11-20
29 November 2012
10-87

Title:
Type:
2500FP
Page: 87 of 99
Drawing: T001016094_D01-5/Fairing cover split
BOM: T001016094/5
Seq. Item id
10 T001016095/5
Product:
Item name
Split fairing cover
version
PAAI066759/-
Drawing
(rm)
Quantity
T001016094_D01-Fairing cover split

version
1,0
END OF LIST
2012-11-20
10-88
29 November 2012

Title:
Pod arrangement
Type:
FS2510-363/2500WO
BOM: PAAI066770/B
Page: 88 of 99
Drawing:
Product:
PAAI066759/-
Seq. Item id
Item name
Drawing
1712 PAAI105056/-
Lower gearbox assembly
1714 PAAI060060/A
Shank assembly
assembly
assembly
PAAI002732_D01-Shank assembly
Quantity
1,0
1,0
END OF LIST
2012-11-20
29 November 2012
10-89

Title:
Type:
F2510
BOM: PAAI105056/-
Seq. Item id
1K
2K
3
4
5
8A
9A
PAAI059142/T003006019/4
T003001521/4
PAAI059154/T003001529/2
T002051320/7
T003003208/7
10A T003000445/2
11A PAAI059868/-
13 PAAI101843/B
Page: 89 of 99
Product:
assembly
assembly
PAAI066759/-
Item name
Drawing
Pod
Bearing cover
Bearing housing
Cover
Fairing cover
Bearing housing
DAAK017519_D01-Pod
DAAK004531_D01-Bearing cover
PAAI059154_D01--/Cover
T003001529_D01-2/Fairing cover
coupling
coupling
coupling
coupling
T003000445_D01-2/Locking plate
T002051271_D01-Bush
DAAK102798-Stern tube
sealDAAK101827-B/Stern tube seal
T003004918_D01-2/Propeller shaft
T001080659_D01-Locking nut
T003004900_D01-2/Retaining plate
T003000444_D01-2/Ring
T003004898_D01-2/Bearing cover
T003004866_D01-2/Cap
T003001512_D01-1/Distance ring
T002051352_D01-3/Bush
Locking plate
Gear set for lower gearbox
Stern tube seal
16A
19A
20
21A
23
24
26
27A
29
30
T003004918/2
T003000542/2
T003004900/2
T003000444/2
T003004898/2
T003004866/2
T003001512/1
T002051352/3
M713000482/T003001513/B
Propeller shaft
Locking nut
Retaining plate
Ring
Bearing cover
Cap
Distance ring
Bush
Hexagon head screw
Distance ring
31
36
37
41
43
44
45
46
T002051355/1
T001016068/3
T002051632/4
T002012950/1
T001017984/1
T002051018/1
T001003859/D
T002004954/-
Split ring
Dowel
Oil pipe
Spring
Compression spring
48 W006564104/A Hexagon socket collar plug

60 PAAI053081/C Double row spheric.roll.bearing
Quantity
T002051355_D01-1/Split ring
T001016068_D01-3/Dowel
T002051632_D01-4/Oil pipe
T003000231_D01-Pin
T003000231_D01-Pin
T003000231_D01-Pin
T001003859_D01-D/Spring
T002004954_D01--/Compression
spring
T002004954_D02--/Compression
spring
1,0
1,0
1,0
1,0
1,0
1,0
1,0
1,0
1,0
1,0
1,0
1,0
1,0
1,0
1,0
1,0
1,0
1,0
8,0
1,0
1,0
1,0
1,0
1,0
1,0
2,0
6,0
11,0
4,0
1,0
2012-11-20
10-90
29 November 2012

Title:
Type:
F2510
BOM: PAAI105056/-
Seq. Item id
61
62
63A
64
65A
66
67
68
69
70
71
72
73
74
75
76
77
78
79
80
81
82
83
84
86
87
88
89
90
91
92
93
94
96
97
98
100
101
102
120
127
132
133
134
W006210906/A
PAAI053081/C
W006260026/W006260041/A
W006200174/A
W006210908/A
W006200174/A
W007001384/W007001259/W007001218/W007031011/W006580044/W007031001/W007052900/W007031000/W007001398/W007029900/W007550008/W007053100/M710712228/A
M718700442/A
W007000011/M710761228/A
W007110148/B
M713005590/W006564110/B
M731000302/M712040383/W007265046/W007100386/W007110150/A
W007100413/A
M713005642/W006552115/A
M712045489/W007210124/B
M712045592/A
T001034133/5
M301035286/A
W007375034/A
W005102801/A
M713001580/A
M716600039/T003004901/1
Page: 90 of 99
Item name
Product:
assembly
assembly
PAAI066759/-
Drawing

Spherical roller thrust bearing
O-ring
O-ring
O-ring
Seamless O-ring
Bonded seal
Seamless O-ring
Seamless O-ring
Seamless O-ring
Seamless O-ring
Locking wire
Male stud connector
O-ring
Union elbow
T001015244_D01-T001015244
Hexagon bolt
DAAK018892_D99--/Shaft assembly
Hexagon bolt
Copper sealing ring
Stud 1,25d
Hexagon head screw
Hexagon bolt
Hexagon head screw
Hexagon bolt
Hexagon nut
Red cap
Precision pipe (rm)
Plain washer
Pipe clamp
Hexagon head screw
Dubo retaining ring
Plug
T003004901_D01-1/Plug
Quantity
1,0
1,0
1,0
1,0
1,0
1,0
1,0
1,0
1,0
1,0
1,0
1,0
1,0
1,0
1,0
1,0
1,0
6,2
1,0
4,0
1,0
1,0
2,0
1,0
8,0
1,0
9,0
6,0
12,0
8,0
23,0
12,0
12,0
1,0
16,0
12,0
20,0
1,0
1000,0
20,0
1,0
1,0
1,0
4,0
2012-11-20
29 November 2012
10-91

Title:
Type:
F2510
Page: 91 of 99
BOM: PAAI105056/-
Product:
assembly
assembly
PAAI066759/-
Seq. Item id
Item name
Drawing
140A
151
152
153
Ring
Hexagon bolt
T002051351_D01-1/Ring
T002051351/1
W007580265/M712085274/A
M713005438/A
Quantity
1,0
6,0
6,0
2,0
END OF LIST
2012-11-20
10-92
29 November 2012

Title:
Bearing housing
Type:
FS2510
BOM: T003001521/4
Seq. Item id
10 T003001537/3
Page: 92 of 99
Product:
PAAI066759/-
Item name
Drawing
Quantity
1,0
END OF LIST
2012-11-20
29 November 2012
10-93

Title:
Fairing cover
Type:
FS2510
Page: 93 of 99
Drawing: T003001529_D01-2/Fairing cover
BOM: T003001529/2
Seq. Item id
10 T003001530/2
Product:
PAAI066759/-
Item name
Drawing
Fairing cover (rm)
T003001529_D01-Fairing cover
Quantity
1,0
END OF LIST
2012-11-20
10-94
29 November 2012

Title:
Oil pipe
Type:
2510
Page: 94 of 99
Drawing: T002051632_D01-4/Oil pipe
BOM: T002051632/4
Seq. Item id
1
2
3
4
5
T002051633/1
PAAI065681/W006410038/A
PAAI065706/B
PAAI065682/B
Product:
PAAI066759/-
Item name
Drawing
Welding nipple
Oil pipe
Union elbow
Oil pipe
Oil pipe
T002051633_D01-1/Welding nipple
PAAI065681_D01--/Oil pipe
PAAI065706_D01-B/Oil pipe
PAAI065682_D01-B/Oil pipe
Quantity
1,0
1,0
2,0
1,0
1,0
END OF LIST
2012-11-20
29 November 2012
10-95

Title:
Pod
Type:
FS2510
Page: 95 of 99
Drawing: DAAK017519_D01-Pod
BOM: PAAI059142/-
Seq. Item id
10 PAAI059143/-
Product:
PAAI066759/-
Item name
Drawing
Pod (rm)
DAAK017518_D01-Pod (rm)
Quantity
1,0
END OF LIST
2012-11-20
10-96
29 November 2012

Title:
Bearing cover
Type:
FS2510
Drawing: DAAK004531_D01-Bearing cover
BOM: T003006019/4
Seq. Item id
10 T003006018/4
Page: 96 of 99
Product:
PAAI066759/-
Item name
Drawing
Bearing cover (rm)
DAAK004531_D01-Bearing cover
Quantity
1,0
END OF LIST
2012-11-20
29 November 2012
10-97

Title:
Propeller shaft
Type:
FS2510
Drawing: T003004918_D01-2/Propeller shaft
BOM: T003004918/2
Seq. Item id
10 T003001510/4
Page: 97 of 99
Product:
PAAI066759/-
Item name
Drawing
Propeller shaft (rm)
T003001510_D03-4/Propeller shaft
(rm)
Quantity
1,0
END OF LIST
2012-11-20
10-98
29 November 2012

Title:
Shank assembly
Type:
2510
Drawing: PAAI002732_D01-Shank assembly
BOM: PAAI060060/A
Seq. Item id
1
2
3
4
5
6
7
8
9
10
11
12
PAAI059110/T003001490/B
T001016091/4
W007210132/B
W007265034/W007550008/W007035092/W007000249/PAAI102951/W007100395/B
M716600041/W007031007/-
Page: 98 of 99
Product:
PAAI066759/-
Item name
Drawing
Shank
Oil line
Shoulder bolt
Hexagon nut
Stud 1,25d
Locking wire
O-ring
Seamless O-ring
Centring ring
Hexagon head screw
Dubo retaining ring
Seamless O-ring
DAAK017541_D01-Shank
PAAI006777_D01-Oil line
DAAK002984_D01-Shoulder bolt
DAAK102373--/Centring ring
Quantity
1,0
1,0
22,0
30,0
30,0
3,2
2,0
1,0
1,0
6,0
4,0
2,0
END OF LIST
2012-11-20
29 November 2012
10-99

Title:
Shank
Type:
FS2510
Page: 99 of 99
Drawing: DAAK017541_D01-Shank
BOM: PAAI059110/-
Seq. Item id
10 PAAI059111/-
Product:
PAAI066759/-
Item name
Drawing
Shank (rm)
DAAK017542_D01-Shank (rm)
Quantity
1,0
END OF LIST
2012-11-20
10-100
29 November 2012

Title:
STT MP/01680.M1AT12P
Type:
BOM:
Page: 1 of 83
Drawing:
PAAI066761/-
Seq. Item name

2 Inboard delivery
3 Outboard delivery
Product:
PAAI066761/-
Item id
PAAI066779/A
PAAI066780/-
Quantity
1,0
1,0
END OF LIST
2012-11-20
29 November 2012
10-101

Inboard delivery
Title:
Page: 2 of 83
Type:
LMT2510-363/2500MO
Drawing:
BOM:
PAAI066779/A
Product:
Seq. Item name

3
4S
5
7S
PAAI066761/-
Item id
PAAI066762/A
PAAI066773/C
PAAI108589/B
PAAI066774/A
Quantity
1,0
1,0
1,0
1,0
END OF LIST
2012-11-20
10-102
29 November 2012

Title:
Page: 3 of 83
Type:
FS2510-363/2500WO
Drawing:
BOM:
PAAI066762/A
Product:
PAAI066761/-
Seq. Item name
Item id
361 Flexible coupling

362 Brake assembly
PAAI105826/PAAI064158/-
Quantity
1,0
1,0
END OF LIST
2012-11-20
29 November 2012
10-103

Title:
Flexible coupling
Drawing: DAAK103528-Floating intermediate shaft
Type:
BOM:
Page: 4 of 83
PAAI105826/-
Seq. Item name

1 Flexible coupling piece
2 Flange type coupling
3 Flange type coupling
Product:
PAAI066761/-
Item id
PAAI105831/A
PAAI105832/PAAI105833/-
Quantity
1,0
1,0
1,0
END OF LIST
2012-11-20
10-104
29 November 2012

Brake assembly
Title:
Page: 5 of 83
Type:
GMR-P
Drawing: PAAI064158_D01--/Brake assembly
BOM:
PAAI064158/-
Product:
Seq. Item name

1L
1R
2
2A
3
4A
4B
5
6
7
9
Brake assembly
Brake assembly
Male stud connector
Hydraulic hose
Male stud connector
Male stud connector
Plain washer
Support
PAAI066761/-
Item id
PAAI040402/A
T003002099/B
M710190137/W006350223/A
T003000616/3
W006350223/A
W006350209/W007375016/A
M712040383/W007281065/PAAI064115/C
Quantity
1,0
1,0
2,0
2,0
2,0
2,0
2,0
4,0
6,0
4,0
1,0
END OF LIST
2012-11-20
29 November 2012
10-105

Title:
Type:
FS2510-363/2500WO
BOM: PAAI108589/B
Page: 6 of 83
Drawing: DAAK101813-Piping
Product:
PAAI066761/-
Seq. Item name
Item id
550
554
570
585
599
PAAI107806/PAAI108919/PAAI107807/PAAI107808/PAAI108600/-
Lubrication system
Hydraulic system
Starter
Water separator
Quantity
1,0
1,0
1,0
1,0
1,0
END OF LIST
2012-11-20
10-106
29 November 2012

Lubrication system
Title:
Page: 7 of 83
Drawing: DAAK101348-Lubrication diagram
Type:
PAAI107806/-
BOM:
Seq. Item name

1
2
3
4
5
6
7
7
9
Filter arrangement
Oil cooler
Oil tank
Pump unit
Filter arrangement
Oil cooler
Oil tank
Brake control panel
Product:
PAAI066761/-
Item id
PAAI107846/PAAI107848/PAAI108307/PAAI104140/PAAI107849/PAAI108310/PAAI107847/PAAI108308/PAAI104070/-
Quantity
1,0
1,0
1,0
1,0
1,0
1,0
1,0
1,0
1,0
END OF LIST
2012-11-20
29 November 2012
10-107

Title:
Filter arrangement
Type:
BOM: PAAI107846/-
Seq. Item name

10
10_1
12
12_1
403.02
403.03
416.02
419.02
419.03
419.04
420.02
420.03
422.02
422.03
426.02
426.03
427.02
427.03
430.02
430.03
431.01
461.01
461.02
461.03
461.04
461A
461B
463.01
463.02
463A
463B
475.01
475.51
482.02
482.04
482.02A
482.04A
483
490
490A
Page: 8 of 83
Bell housing
Bell housing
Flexible coupling
Flexible coupling
E-motor
E-motor
Orifice
Non-return valve
Non-return valve
Non-return valve
Non-return valve
Non-return valve
Screw pump
Screw pump
Pressure filter
Filter
Safety valve
Safety valve
Ball valve
Ball valve
Ball valve
Pressure switch
Pressure switch
Pressure switch
Pressure switch
Measuring coupling
Measuring coupling
Pressure switch
Pressure switch
Measuring coupling
Measuring coupling
Temperature switch
Tube
Pressure gauge
Pressure gauge
Measuring coupling
Measuring coupling
Thermometer
Junction box
Connector
Product:
DAAK100258-Diagram
PAAI066761/-
Item id
PAAI030459/PAAI062882/W084836911/B
PAAI025498/B
PAAI109031/PAAI109033/PAAI034529/A
T018374400/PAAI031883/PAAI029115/PAAI037351/PAAI029989/PAAI109034/PAAI063527/PAAI034591/PAAI108783/PAAI037327/PAAI039285/PAAI030494/PAAI032019/PAAI032499/PAAI013861/A
PAAI013861/A
PAAI013861/A
PAAI013861/A
PAAI026619/A
PAAI028975/A
PAAI013861/A
PAAI013861/A
PAAI026619/A
PAAI028975/A
PAAI008723/C
PAAI013605/B
PAAI039264/A
PAAI006728/B
PAAI022999/A
PAAI022999/A
PAAI005608/C
PAAI102689/PAAI015247/-
Quantity
1,0
1,0
1,0
1,0
1,0
1,0
1,0
1,0
1,0
1,0
1,0
1,0
1,0
1,0
1,0
1,0
1,0
1,0
1,0
1,0
1,0
1,0
1,0
1,0
1,0
8,0
8,0
1,0
1,0
4,0
4,0
1,0
1,0
1,0
1,0
1,0
1,0
1,0
1,0
8,0
2012-11-20
10-108
29 November 2012

Title:
Filter arrangement
Type:
BOM: PAAI107846/-
Seq. Item name
Page: 9 of 83
Product:
DAAK100258-Diagram
PAAI066761/-
Item id
Quantity
END OF LIST
2012-11-20
29 November 2012
10-109

Title:
Flexible coupling
Page: 10 of 83
Type:
R24.28-19
Drawing: W084836911_D01-B/Flexible coupling
BOM:
W084836911/B
Product:
PAAI066761/-
Seq. Item name
Item id
12A Coupling hub

12B Gear ring
12C Coupling hub
PAAI035617/PAAI030460/A
PAAI030457/-
Quantity
1,0
1,0
1,0
END OF LIST
2012-11-20
10-110
29 November 2012

Title:
Flexible coupling
Page: 11 of 83
Type:
R19.24-14
BOM:
PAAI025498/B
Product:
Seq. Item name

12_1A Coupling hub
12_1B Gear ring
12_1C Coupling hub
PAAI066761/-
Item id
PAAI032080/PAAI032078/A
PAAI032079/-
Quantity
1,0
1,0
1,0
END OF LIST
2012-11-20
29 November 2012
10-111

Title:
Pressure filter
Page: 12 of 83
Type:
80CN210QM250E2E21
BOM:
PAAI034591/-
Product:
Seq. Item name

426.02A Filter element
426.02B Seal kit
PAAI066761/-
Item id
PAAI006928/B
PAAI044504/A
Quantity
1,0
1,0
END OF LIST
2012-11-20
10-112
29 November 2012

Title:
Filter
Page: 13 of 83
Type:
BGLS1505QLBE8ER48F1
BOM:
PAAI108783/-
Product:
Seq. Item name

426.03A
426.03C
426.3B
463.02
Filter cartridge
Seal kit
Sleeve
Dirt indicator
PAAI066761/-
Item id
PAAI006391/D
PAAI040698/PAAI104326/PAAI015836/C
Quantity
1,0
1,0
1,0
1,0
END OF LIST
2012-11-20
29 November 2012
10-113

Title:
Oil cooler
Page: 14 of 83
Type:
BOM: PAAI107848/-
Product:
Seq. Item name

440.02 Oil cooler
PAAI066761/-
Item id
PAAI027378/-
Quantity
1,0
END OF LIST
2012-11-20
10-114
29 November 2012

Title:
Oil tank
Page: 15 of 83
Type:
BOM: PAAI108307/-
Product:
Seq. Item name

3
415
426.05
427.05
431.02
435.05
435.06
435.07
450.01
480.01
480.51
Gasket
Filler-breather
Filter
Non-return valve
Valve
Ball valve
Valve
Needle valve
Level switch
Level gauge
Float
DAAK100310-Oil tank
PAAI066761/-
Item id
PAAI040132/PAAI044139/PAAI047458/PAAI101513/PAAI052114/PAAI066496/PAAI058530/-
Quantity
1,0
1,0
1,0
1,0
1,0
1,0
1,0
1,0
1,0
1,0
1,0
END OF LIST
2012-11-20
29 November 2012
10-115

Title:
Page: 16 of 83
Type:
Drawing: DAAK100217-Pneumatic control panel
BOM: PAAI104140/-
Product:
Seq. Item name

420.04
426.04
426.51
427.07
427.52
430.52
438
466.02
466.02A
481
493
Non-return valve
Air filter
Bracket
Relief valve
Fastening bracket
Ball valve
Regulator
Pressure sensor
Cable
Pressure gauge
Junction box
DAAK102953-Pneumatic control panel

PAAI066761/-
Item id
PAAI005881/A
PAAI032511/PAAI045120/PAAI033795/PAAI032530/PAAI041683/PAAI022140/-
Quantity
1,0
1,0
2,0
1,0
1,0
1,0
1,0
1,0
1,0
1,0
1,0
END OF LIST
2012-11-20
10-116
29 November 2012

Title:
Air filter
Page: 17 of 83
Type:
P31FA12EMBN
BOM:
PAAI105514/-
Product:
Seq. Item name

PAAI066761/-
Item id
PAAI064740/-
Quantity
1,0
END OF LIST
2012-11-20
29 November 2012
10-117

Title:
Pump unit
Page: 18 of 83
Type:
Drawing: DAAK100246-Pump unit
BOM: PAAI107849/-
Product:
Seq. Item name

10
12
403.1
422.01
434
Bell housing
Flexible coupling
E-motor
Gear pump, double
Safety valve
PAAI066761/-
Item id
PAAI031014/PAAI015006/B
PAAI109044/PAAI013350/B
PAAI033625/-
Quantity
1,0
1,0
1,0
1,0
1,0
END OF LIST
2012-11-20
10-118
29 November 2012

Title:
Flexible coupling
Page: 19 of 83
Type:
R28.38-N/3
BOM:
PAAI015006/B
Product:
PAAI066761/-
Seq. Item name
Item id
12A Coupling hub

12B Gear ring
12C Coupling hub
PAAI028033/A
PAAI033304/PAAI028032/A
Quantity
1,0
1,0
1,0
END OF LIST
2012-11-20
29 November 2012
10-119

Title:
Filter arrangement
Page: 20 of 83
Type:
BOM: PAAI108310/-
Product:
Seq. Item name

419.01
420.01
426.01
430.01
464.01
Non-return valve
Non-return valve
Pressure filter
Ball valve
Pressure switch
PAAI066761/-
Item id
T018374400/PAAI037351/PAAI035768/A
PAAI030494/PAAI013861/A
Quantity
1,0
1,0
1,0
1,0
1,0
END OF LIST
2012-11-20
10-120
29 November 2012

Title:
Pressure filter
Page: 21 of 83
Type:
80CN220QEVM3KG244
BOM:
PAAI035768/A
Product:
Seq. Item name

426.01B Seal kit
PAAI066761/-
Item id
PAAI026752/PAAI044504/A
Quantity
1,0
1,0
END OF LIST
2012-11-20
29 November 2012
10-121

Title:
Oil cooler
Page: 22 of 83
Type:
BOM: PAAI107847/-
Product:
Seq. Item name

437.01 Non-return valve
440.01 Oil cooler
PAAI066761/-
Item id
PAAI032012/A
PAAI027378/-
Quantity
1,0
1,0
END OF LIST
2012-11-20
10-122
29 November 2012

Title:
Oil tank
Page: 23 of 83
Type:
BOM: PAAI108308/-
Product:
Seq. Item name

2
415
431.02
450.01
480.02
480.51
Gasket
Filler-breather
Valve
Level switch
Level gauge
Float
DAAK100266-Oil tank
PAAI066761/-
Item id
PAAI040843/PAAI011836/PAAI040132/PAAI017473/B
PAAI066496/PAAI058530/-
Quantity
1,0
1,0
1,0
1,0
1,0
1,0
END OF LIST
2012-11-20
29 November 2012
10-123

Title:
Brake control panel
Page: 24 of 83
Type:
Drawing: DAAK100216-Brake control panel
BOM: PAAI104070/-
Product:
Seq. Item name

601
601.51
601.52
622
622A
622.51
654
Directional valve
Connector
Silencer
Air filter
Pressure gauge
Bracket
Pressure switch

PAAI066761/-
Item id
PAAI037297/PAAI101954/PAAI005887/A
PAAI108899/PAAI065117/PAAI108900/PAAI005895/C
Quantity
1,0
1,0
2,0
1,0
1,0
1,0
1,0
END OF LIST
2012-11-20
10-124
29 November 2012

Title:
Air filter
Page: 25 of 83
Type:
P31EA12EMBBNTP
BOM:
PAAI108899/-
Product:
Seq. Item name

622A Filter element
PAAI066761/-
Item id
PAAI064740/-
Quantity
1,0
END OF LIST
2012-11-20
29 November 2012
10-125

Title:
Page: 26 of 83
Type:
BOM: PAAI108919/-
Product:
Seq. Item name

1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
22
23
24
25
26
27
30
31
32
33
34
35
36
37
38
39
40
41
42
43
44
Male stud connector

Tube end reducer
Union tee
Male stud connector
SAE flange
Male stud connector
Male stud connector
Union elbow
Swivel nut elbow
SWIVEL UNION
Flange assembly
Male stud connector
Male stud connector
SAE flange
Blind flange
Threaded flange
Male stud connector
Male stud connector
Flange assembly
Union
Reducer
Swivel nut run tee
Tube end reducer
Union tee
Male stud connector
Male stud connector
connections
PAAI066761/-
Item id
W084842947/A
PAAI105045/PAAI105047/M710714527/A
M710801232/A
PAAI104699/PAAI104885/PAAI104708/PAAI108501/PAAI108502/M710712232/A
PAAI105024/A
PAAI108590/PAAI108593/PAAI106917/PAAI108636/W006410057/PAAI108659/PAAI108658/PAAI109053/PAAI108639/PAAI108643/PAAI108645/PAAI108664/PAAI108633/PAAI037390/B
PAAI109059/T002017030/A
W006350148/B
PAAI064240/W084815517/PAAI108604/PAAI108602/PAAI109073/W006380004/PAAI107877/W084819419/W006370015/W006430013/A
W084821014/PAAI104888/W005904004/-
Quantity
6,0
1,0
1,0
6,0
4,0
2,0
2,0
2,0
1,0
1,0
4,0
4,0
1,0
1,0
2,0
4,0
1,0
1,0
1,0
6,0
4,0
1,0
1,0
1,0
2,0
4,0
4,0
1,0
4,0
1,0
2,0
1,0
1,0
3,0
2,0
2,0
1,0
4,0
2,0
1,0
2,0
6,0
2012-11-20
10-126
29 November 2012

Title:
Page: 27 of 83
Type:
BOM: PAAI108919/-
Product:
Seq. Item name

45
46
47
48
49
50
51
52
53
54
55
56
57
58
59
60
61
62
63
64
65
66
67
68
69
70
71
72
80
81
82
83
84
85
86
90
91
92
93
94
95
96
Union elbow
Union elbow
Swivel nut run tee
Swivel nut run tee
Union cross
Pipe
Union tee
Tube end reducer
Union tee
Tube end reducer
Safety valve
Filler-breather
Ball valve
Reducing nipple
Adapter
Sight glass
Vent
Male stud connector
Pipe assembly
Male stud connector
Union elbow
Ball valve
Union tee
Restrictor
connections
PAAI066761/-
Item id
W006410046/B
W006410010/PAAI104698/PAAI104903/PAAI104915/W006430061/PAAI108431/W006430081/A
PAAI103484/M710190393/A
W006440007/PAAI103492/PAAI064743/M710801122/A
PAAI104912/W006370030/A
W006430069/A
W002000363/A
M710100126/A
W084837133/U000000556/M710100229/B
T002012383/1
T001020770/W006590057/A
T002016820/1
T002016818/1
PAAI103471/PAAI108485/PAAI108491/PAAI108450/W006350221/B
PAAI108922/PAAI108925/PAAI108394/M710100333/A
PAAI045168/A
W006410048/A
T002012384/B
M710801134/A
PAAI100412/PAAI040252/A
Quantity
1,0
1,0
1,0
1,0
1,0
1,0
1,0
2,0
1,0
1,0
1,0
1,0
1,0
1,0
1,0
1,0
1,0
1,0
1,0
1,0
2,0
1,0
1,0
1,0
2,0
1,0
1,0
1,0
1,0
1,0
1,0
5,0
1,0
1,0
1,0
11,0
5,0
5,0
3,0
2,0
1,0
1,0
2012-11-20
29 November 2012
10-127

Title:
Page: 28 of 83
Type:
BOM: PAAI108919/-
Product:
connections
PAAI066761/-
Seq. Item name
Item id
100
101
102
103
104
105
106
107
108
109
110
111
112
113
114
115
116
117
PAAI015504/T003000527/W084851293/W084825835/PAAI108407/PAAI108413/PAAI108498/PAAI108583/PAAI104877/PAAI108818/M713000424/M713000431/M713000480/M713000530/M714040033/M716100031/M716100033/M716100036/A
Pipe clamp
Pipe clamp
Pipe clamp
Pipe clamp
Strip
Frame
Spacer piece
Frame
Strip
Strip
Hexagon head screw
Hexagon head screw
Hexagon head screw
Hexagon head screw
Hexagon nut
Square washer
Square washer
Square washer
Quantity
2,0
2,0
1,0
1,0
2,0
1,0
2,0
1,0
2,0
2,0
4,0
4,0
4,0
8,0
4,0
8,0
4,0
8,0
END OF LIST
2012-11-20
10-128
29 November 2012

Flange assembly
Title:
Page: 29 of 83
Type:
Jis DN32-20k
Drawing:
BOM:
PAAI109053/-
Product:
Seq. Item name

1
2
3
5
6
7
Hexagon bolt
Hexagon nut
Square washer
Packing ring
Threaded flange
Blind flange
PAAI066761/-
Item id
W007110160/A
M714040036/M716100036/A
PAAI109060/PAAI109058/PAAI109057/-
Quantity
4,0
4,0
4,0
1,0
1,0
1,0
END OF LIST
2012-11-20
29 November 2012
10-129

Flange assembly
Title:
Page: 30 of 83
Type:
Jis DN20-20k
Drawing:
BOM:
PAAI109073/-
Product:
Seq. Item name

1
2
3
4
5
6
7

Threaded flange
Hexagon bolt
Hexagon nut
Square washer
Blind flange
Packing ring
PAAI066761/-
Item id
M710100229/B
PAAI109075/M713005486/M714040033/M716100033/PAAI109074/PAAI109076/-
Quantity
1,0
1,0
4,0
4,0
4,0
1,0
1,0
END OF LIST
2012-11-20
10-130
29 November 2012

Title:
Hydraulic system
Drawing: DAAK100255-Hydraulic diagram
Type:
BOM:
Page: 31 of 83
PAAI107807/-
Seq. Item name

1 Hydraulic power pack
2 Safety valve
3 Manifold
Product:
PAAI066761/-
Item id
PAAI107845/PAAI065029/B
PAAI108309/-
Quantity
1,0
1,0
1,0
END OF LIST
2012-11-20
29 November 2012
10-131

Title:
Type:
BOM: PAAI107845/-
Seq. Item name

2
6
10
11
12
31
32.01
32.04
33
35
38.01
39
40
201
206
208.01
216
230
234
240.01
241.01
243.02
243.51
243.52
243.53
250.01
261
261.51
261.52
264.01
265
271
273.01
273.03
273.05
273.06
273.03A
273.05A
273.06A
298
Page: 32 of 83
Gasket
Gasket
Bell housing
Gasket
Flexible coupling
Seal
Shuttle valve
Shuttle valve
Orifice
Orifice
Non-return valve
Measuring coupling
Measuring coupling
Directional valve
4/3-way valve
E-motor
Filler-breather
Non-return valve
Non-return valve
Vane pump
Non-return valve
Relief valve
Compensator
Cartridge valve
Cover
Return filter
Valve inner part
Handle
Plug
Non-return valve
Oil cooler
Level switch
Dirt indicator
Pressure switch
Pressure switch
Pressure switch
Measuring coupling
Measuring coupling
Measuring coupling
Temperature switch
Product:

PAAI066761/-
Item id
PAAI011332/PAAI044257/PAAI011381/B
PAAI044132/PAAI008745/B
PAAI044259/PAAI026619/A
PAAI022999/A
PAAI059642/W084824198/A
PAAI109049/PAAI011836/PAAI033184/A
PAAI109047/PAAI044608/A
PAAI044535/PAAI033907/PAAI033906/PAAI045794/PAAI045793/PAAI109048/PAAI045792/PAAI011385/B
PAAI012812/PAAI033184/A
PAAI109051/PAAI013087/A
PAAI008060/B
PAAI012437/A
PAAI005820/C
PAAI012437/A
PAAI052326/PAAI028975/A
PAAI052326/PAAI008723/C
Quantity
1,0
1,0
1,0
1,0
2,0
1,0
1,0
1,0
2,0
4,0
1,0
10,0
1,0
1,0
1,0
1,0
1,0
1,0
1,0
1,0
1,0
1,0
1,0
1,0
1,0
1,0
1,0
1,0
1,0
1,0
1,0
1,0
1,0
1,0
1,0
1,0
1,0
1,0
1,0
1,0
2012-11-20
10-132
29 November 2012

Title:
Type:
BOM: PAAI107845/-
Seq. Item name

298.51
310
312.01
314
315.01
326
326A
Page: 33 of 83
Tube
Dip stick
Pressure gauge
Thermometer
Dirt indicator
Junction box
Connector
Product:

PAAI066761/-
Item id
PAAI013605/B
PAAI012969/B
PAAI012990/B
PAAI005608/C
PAAI012962/B
PAAI102689/PAAI015247/-
Quantity
1,0
1,0
1,0
1,0
1,0
1,0
2,0
END OF LIST
2012-11-20
29 November 2012
10-133

Title:
Flexible coupling
Page: 34 of 83
Type:
R48.60X080-31,75K
Drawing: PAAI034278_D01-A/Flexible coupling
BOM:
PAAI034278/A
Product:
PAAI066761/-
Seq. Item name
Item id
12A Coupling hub

12B Gear ring
12C Coupling hub
PAAI034277/PAAI011704/B
PAAI034276/A
Quantity
1,0
1,0
1,0
END OF LIST
2012-11-20
10-134
29 November 2012

Title:
Return filter
Page: 35 of 83
Type:
STF1010QBP2ELC243
BOM:
PAAI109048/-
Product:
Seq. Item name

250.01A Filter cartridge
PAAI066761/-
Item id
PAAI010177/B
Quantity
1,0
END OF LIST
2012-11-20
29 November 2012
10-135

Title:
Safety valve
Type:
NG16
BOM: PAAI065029/B
Seq. Item name

39
218.01
218.02
226.01
226.02
227.01
227.02
243.01
Measuring coupling
Non-return valve
Non-return valve
Non-return valve
Non-return valve
Relief valve
Page: 36 of 83
Drawing: PAAI065029_D01-Safety valve
Product:
PAAI066761/-
Item id
PAAI026619/A
PAAI047888/A
PAAI047888/A
Quantity
2,0
1,0
1,0
1,0
1,0
1,0
1,0
1,0
END OF LIST
2012-11-20
10-136
29 November 2012

Title:
Manifold
Page: 37 of 83
Type:
Drawing: DAAK104428-Manifold
BOM: PAAI108309/-
Product:
Seq. Item name

212.01 Directional valve
212.03 Directional valve
DAAK100265-Manifold
PAAI066761/-
Item id
PAAI108962/PAAI108962/-
Quantity
1,0
1,0
END OF LIST
2012-11-20
29 November 2012
10-137

Title:
Starter
Drawing: DAAK019608-Specification
Type:
BOM:
Page: 38 of 83
PAAI107808/-
Seq. Item name

1 Starter
2 Starter
3 Starter
Product:
PAAI066761/-
Item id
PAAI107839/A
PAAI107840/A
PAAI107841/A
Quantity
1,0
1,0
2,0
END OF LIST
2012-11-20
10-138
29 November 2012

Title:
Water separator
Type:
BOM:
Page: 39 of 83
Drawing:
PAAI108600/-
Seq. Item name

1 Water separator
Product:
PAAI066761/-
Item id
PAAI003138/-
Quantity
1,0
END OF LIST
2012-11-20
29 November 2012
10-139

Title:
Page: 40 of 83
Type:
FS2510-363/2500WO
Drawing:
BOM:
PAAI066773/C
Product:
PAAI066761/-
Seq. Item name
Item id
421
422
423
424
430
435
PAAI102501/D
PAAI102912/PAAI044001/PAAI004521/B
W084843587/B
PAAI003849/-

Terminal box
Quantity
1,0
1,0
3,0
1,0
1,0
1,0
END OF LIST
2012-11-20
10-140
29 November 2012

Title:
Page: 41 of 83
Type:
LMT2510
BOM:
PAAI102501/D
Product:
Seq. Item name

1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
22
23
24
25
26
31
32
35
53
54
55
56
57
58
59
60
61
62
64
65
69
75
Steering pipe
Liner
Seamless O-ring
V-ring
Oil seal
Pressure ring
Seamless O-ring
Retaining ring
Seamless O-ring
Hexagon head screw
Locking washer
Hexagon head screw
Fitted sleeve
Stem box
Male stud connector
Oil pipe
Oil pipe
Steering hub
Slewing bearing
Ring
Split ring
Hexagon head screw
Dubo retaining ring
Centring ring
Plain washer
Hexagon bolt
Copper sealing ring
Closing plate
Bonded seal
O-ring
Hexagon bolt
Square washer
Lifting eye
PAAI066761/-
Item id
PAAI101210/A
PAAI004282/M730000474/M712082433/M730030050/6
PAAI004230/B
T002010288/PAAI004283/M712040276/W007000250/PAAI004291/W007050001/W007100549/W006210920/A
W084838523/A
W005903590/A
T003001088/4
M712045597/PAAI100882/B
W006350148/B
PAAI108870/PAAI108892/PAAI004322/C
PAAI002818/E
M712045489/PAAI004384/M712040382/PAAI004385/A
W084814773/A
M716600033/PAAI004363/W007375031/M713005689/M731000302/PAAI062106/PAAI004559/M735000030/W007000417/M712045490/M713005689/M716100046/PAAI002501/-
Quantity
1,0
1,0
1,0
1,0
1,0
1,0
4,0
1,0
24,0
1,0
1,0
1,0
24,0
1,0
20,0
24,0
20,0
20,0
1,0
6,0
2,0
2,0
1,0
1,0
60,0
1,0
12,0
1,0
4,0
4,0
1,0
108,0
16,0
6,0
1,0
1,0
16,0
6,0
48,0
48,0
48,0
4,0
2012-11-20
29 November 2012
10-141

Title:
Page: 42 of 83
Type:
LMT2510
BOM:
PAAI102501/D
Product:
PAAI066761/-
Seq. Item name
Item id
82
95
97
98
99
100
105
106
107
108
109
111
112
115
116
117
118
127
128
148
215
325
326
327
900
PAAI002782/F
M718500584/A
PAAI004290/M711050383/M714040036/M716100036/A
PAAI004289/W005904548/PAAI002837/PAAI003759/M710380248/M710380256/M731000340/A
M713000532/M716000036/W084851791/A
M730000277/W084842925/B
M730000877/PAAI004387/PAAI004388/M712040487/M716000041/W007000448/W084816812/F

Distance ring
Stud 1,25d
Hexagon nut
Square washer
Distance ring
O-ring
Copper sealing ring
Hexagon head screw
Plain washer
Cover
Seamless O-ring
Cover
Seamless O-ring
Locking washer
Guiding ring
Plain washer
O-ring
Type shield
Quantity
1,0
10,0
1,0
30,0
30,0
30,0
1,0
2,0
1,0
1,0
5,0
5,0
1,0
26,0
26,0
1,0
1,0
1,0
1,0
1,0
1,0
20,0
20,0
1,0
1,0
END OF LIST
2012-11-20
10-142
29 November 2012

Title:
Steering pipe
Page: 43 of 83
Type:
FS2510
Drawing: DAAK101509-Steering pipe
BOM:
PAAI101210/A
Product:
Seq. Item name

1 Steering pipe (rm)
PAAI066761/-
Item id
PAAI101238/-
Quantity
1,0
END OF LIST
2012-11-20
29 November 2012
10-143

Title:
Page: 44 of 83
Drawing: PAAI002760_D01-Steering angle indicator
Type:
PAAI002782/F
BOM:
Seq. Item name

1
2
3
4
5
6
7
Lifting eye nut

Bush
Seamless O-ring
Compression spring
Plug
Pin
Seamless O-ring
Product:
PAAI066761/-
Item id
W007250516/PAAI015572/A
M730000017/PAAI014340/A
PAAI015595/A
PAAI015623/A
M730000011/-
Quantity
1,0
1,0
2,0
1,0
1,0
1,0
1,0
END OF LIST
2012-11-20
10-144
29 November 2012

Title:
Type:
2510-2500
BOM: PAAI102912/-
Seq. Item name

1
2
3
4
5
6
7
Vertical intermediate shaft

Coupling
Bush
Centring pin
Retaining plate
Ring
Page: 45 of 83
Drawing: T003005755_D01-Intermediate shaft
Product:
assembly
PAAI066761/-
Item id
PAAI102913/T003003209/H
T003001667/T003001668/A
T003001669/M712040330/W084822498/-
Quantity
1,0
2,0
1,0
1,0
1,0
12,0
1,0
END OF LIST
2012-11-20
29 November 2012
10-145

Title:
Type:
ED2090MR/21,09/160cc
BOM: PAAI044001/-
Seq. Item name

1
2
3
4
5
7
8
9
10
Hydraulic motor
Planetary gearing
Hexagon nut
Square washer
Centring bush
Gear wheel
Retaining plate
Page: 46 of 83
Drawing: DAAK011368_D01-Steering motor
Product:
assembly
PAAI066761/-
Item id
PAAI042498/A
PAAI016942/B
M712045284/M714040031/M716100031/PAAI047510/W084842086/C
PAAI047512/M712045282/-
Quantity
1,0
1,0
5,0
5,0
5,0
1,0
1,0
1,0
3,0
END OF LIST
2012-11-20
10-146
29 November 2012

Title:
Planetary gearing
Type:
ED 2090 MR i=21,09
BOM: PAAI016942/B
Seq. Item name

2 Reduction gearbox
2a Connection
Page: 47 of 83
Drawing: W084842225_D01-Reduction gearbox
Product:
PAAI066761/-
Item id
W084842226/B
W084843894/A
Quantity
1,0
1,0
END OF LIST
2012-11-20
29 November 2012
10-147

Title:
Type:
Sam 5x potm
BOM: PAAI004521/B
Page: 48 of 83
Product:

PAAI066761/-
Seq. Item name
Item id
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
20V
21
22
23
24
25
26
27
28
29
30
31
32
33
34
35
36
37
38
39
40
41
42
43
T002010151/5
T003002120/2
T003002118/A
T002014174/3
T002014175/T002010145/2
T002010144/2
T002010651/5
T002010652/5
T002010142/9
T002006116/5
T002014176/3
T003002982/2
T002010140/3
T002010148/A
T002010146/1
W007032004/W007001412/T003002807/A
M712030372/T001032500/B
T002013019/B
T002013020/C
T001032499/M713001326/B
M712045136/T001036516/W007355085/M712030372/M712031424/T001036516/M712084066/T002010154/7
T001044147/1
T001033878/3
M718500124/T003002807/A
T002013036/M718500128/M718500124/M718700160/T001033878/3
Foundation plate
Ring
Base plate
Bush
Shaft
Shaft
Shaft
Gear wheel
Gear wheel
Gear wheel
Gear wheel
Dial
Pointer
Bush
Sight glass
Packing
Quadring
O-ring
Potentiometer
Rail
Terminal
Square washer plate
End bracket
Hexagon head screw
Clamp
Screw
Clamp
Transmitter box
Nut
Cable gland
Potentiometer
Potentiometer
Cable gland
Quantity
1,0
1,0
1,0
1,0
1,0
1,0
1,0
1,0
1,0
1,0
1,0
1,0
1,0
1,0
1,0
1,0
1,0
1,0
1,0
2,0
180,0
28,0
1,0
2,0
4,0
4,0
3,0
3,0
1,0
4,0
12,0
8,0
1,0
2,0
2,0
1,0
1,0
1,0
1,0
1,0
1,0
2,0
2012-11-20
10-148
29 November 2012

Title:
Type:
Sam 5x potm
BOM: PAAI004521/B
Page: 49 of 83
Product:

PAAI066761/-
Seq. Item name
Item id
44
45
46
49
50
59V
60
61
62
63
64
65
66
68
70
71
80
T001044147/1
M716000023/W008997038/C
T001071968/T003002119/2
T002006116/5
T002006116/5
T002006116/5
T002013255/B
T002013256/C
T002013257/B
T002014177/A
W001960005/T002010156/2
W084809412/A
M716601023/T003002900/A
Nut
Plain washer
Blind plug
Bearing bush
Bracket
Gear wheel
Gear wheel
Gear wheel
Number marking
Number marking
Number marking
Clamping ring
Plain washer
Plain bearing
Dubo retaining ring
Electric cable
Quantity
2,0
1,0
4,0
2,0
2,0
1,0
1,0
1,0
1,0
1,0
1,0
1,0
1,0
1,0
4,0
4,0
3,0
END OF LIST
2012-11-20
29 November 2012
10-149

Terminal box
Title:
Drawing: W084843587_D01-B/Terminal box
Type:
BOM:
W084843587/B
Seq. Item name

1
4
5
6
7
8A
8B
8C
8D
9
10
11
12
13
14
15
16
20
21
22
Page: 50 of 83
Terminal box
End bracket
Terminal clamp
Rail
Terminal
Number card clamp
Number card clamp
Number card clamp
Number card clamp
Nut
Cable gland
Sealing ring
Square spring lock washer
Strip
Plain washer
Electric cable
Cable gland
Nut
Sealing ring
Product:
PAAI066761/-
Item id
W006903060/F
W006920210/B
W006920208/W006920119/W006920343/W084841700/A
W084841701/A
W084841702/A
W084841703/A
W084816521/W084842647/T003000672/A
M712040174/M716101027/A
W084832891/C
W001960005/T003002900/A
T001033878/3
T001044147/1
T003003281/A
Quantity
1,0
1,0
2,0
0,3
36,0
1,0
1,0
1,0
1,0
32,0
16,0
16,0
4,0
4,0
2,0
4,0
50,0
10,0
20,0
10,0
END OF LIST
2012-11-20
10-150
29 November 2012

Title:
Page: 51 of 83
Type:
3500, Z=19 M=12
Drawing: T002010530_D01-Azimuth feedback drive
BOM:
PAAI003849/-
Product:
Seq. Item name

1
2
3
4
5
6
7
10
11
12
13
14
15
16
18
19
Pinion
Bearing bush
Shaft
Cover
Clamping ring
Spacer pin
Flexible coupling
Plain washer
Hex. nut w. nylon locking ring
Seamless O-ring
Oil seal
Hexagon head screw
V-ring
PAAI066761/-
Item id
PAAI003842/T002010204/2
T002010203/2
W084850375/T002010214/B
T002010215/3
T002010561/3
W007375037/M714050036/A
M718500376/A
M730000277/T001001109/A
M713000374/M730030020/B
M718500232/M712045180/-
Quantity
1,0
1,0
1,0
1,0
1,0
4,0
1,0
1,0
1,0
1,0
1,0
1,0
6,0
1,0
2,0
4,0
END OF LIST
2012-11-20
29 November 2012
10-151

Title:
Page: 52 of 83
Type:
FS2510-363/2500WO
Drawing:
BOM:
PAAI066774/A
Product:
PAAI066761/-
Seq. Item name
Item id
741 Upper gearbox assembly

771 Speed pick-up arrangement
PAAI060106/D
PAAI031938/B
Quantity
1,0
2,0
END OF LIST
2012-11-20
10-152
29 November 2012

Title:
Page: 53 of 83
Type:
2500-1.8 CCW
BOM: PAAI060106/D
assembly
assembly
assembly
PAAI066761/-
Product:
Seq. Item name
Item id
1
2
3
4
5
6
7
8
9V
10
11L
17
19
20
22
23
24
25
26
27
28
29
30
31
32
33
34
35
37
38
40
43
44
45
46
47
48
49
T003001362/4
T001017994/4
T003001359/5
T001019050/7
T001019046/5
T002013521/2
T001019764/2
T001019762/2
T003003208/7
T003001360/B
PAAI060134/T003005721/2
T003000542/2
T001019772/2
T003001349/1
T001019943/2
T003001508/1
T001019946/5
T001019947/D
T001019941/6
T001019942/3
T001034133/5
T001019950/4
T001019857/4
T003001372/1
T001019853/1
T003001361/B
T001019851/B
T001019948/6
T001019949/3
T001010581/2
T001020886/T001003859/D
M301035275/M301035275/M301035275/T002050761/1
T002050762/1
Upper gearbox
Lantern piece
Bearing housing
Bearing housing
Cover
Cover
Fit ring
Gear set for upper gearbox
Output shaft
Locking nut
Locking nut
Bearing housing
Split ring
Distributing piece
Manifold block
Cover
Bearing race
Liner
Red cap
Distance bush
Distance bush
Ring
Fit ring
Fit ring
Fit ring
Suction line
Cover
Key
Spring
Precision pipe (rm)
Precision pipe (rm)
Precision pipe (rm)
Quantity
1,0
1,0
1,0
1,0
1,0
1,0
1,0
1,0
1,0
1,0
1,0
1,0
1,0
1,0
1,0
1,0
1,0
1,0
1,0
1,0
1,0
2,0
1,0
1,0
1,0
1,0
1,0
1,0
1,0
1,0
1,0
1,0
4,0
900,0
1130,0
1400,0
2,0
1,0
2012-11-20
29 November 2012
10-153

Title:
Type:
2500-1.8 CCW
BOM: PAAI060106/D
assembly
assembly
assembly
PAAI066761/-
Seq. Item name

51
52
53
54
55
56
57
58
59
60
61
62
63
64
65
66
67
68
69
70
71
72
73
74
75
76
77
78
79
80
81
82
83
84
85
86
87
89

Cylindrical roller bearing
O-ring
O-ring
O-ring
O-ring
O-ring
O-ring
O-ring
O-ring
O-ring
Seamless O-ring
Oil seal
Oil seal
Support ring
Distance bush
Hexagon head screw
Hexagon bolt
Hexagon head screw
Screw
Stud 1,25d
Stud 1,25d
Male stud connector
Hexagon nut
Hexagon nut
Screw
Square washer
Page: 54 of 83
Product:
Item id
W006210906/A
W006210001/W006200201/W006260033/W006200174/A
W006220030/A
W007001277/W007035511/W007001069/W007001062/W007000977/W007000653/W007035270/W007000712/W007000641/W084813333/W007001423/T001010605/W007065070/T001019945/C
M718700420/M718700422/PAAI016544/D
M712040590/M713000532/M712045389/M713005489/M713000480/M712040383/T002007789/1
M711050488/W007000647/M711050387/W006350221/B
M714040041/M714040036/W007355084/M716100033/-
Quantity
1,0
1,0
1,0
1,0
1,0
1,0
2,0
2,0
1,0
1,0
1,0
1,0
2,0
1,0
1,0
1,0
1,0
1,0
2,0
1,0
1,0
1,0
16,0
16,0
22,0
24,0
4,0
28,0
6,0
1,0
20,0
1,0
6,0
2,0
20,0
10,0
1,0
32,0
2012-11-20
10-154
29 November 2012

Title:
Page: 55 of 83
Type:
2500-1.8 CCW
BOM: PAAI060106/D
assembly
assembly
assembly
PAAI066761/-
Product:
Seq. Item name
Item id
90
91
92
94
95
96
97
98
99
100
101
102
103
104
105
106
107
108
109
110
111
112
113
121
131
132
134
135
M716100036/A
M716100041/T003000445/2
M710380243/M710380248/M710380256/M713090039/M731000290/M731000302/M731000340/A
M731000261/T001067975/4
T001020196/W006356700/B
T003005728/W006410044/A
W084821025/W006800185/A
T002009672/1
T003000749/1
T003000604/M710380239/M710380256/M713005536/T003000578/A
T002007667/W084824439/A
W004630028/-
Square washer
Square washer
Locking plate
Lifting eye bolt
Copper sealing ring
Copper sealing ring
Copper sealing ring
Copper sealing ring
Disc spring
Sight glass
Male stud connector
Measuring coupling
Union elbow
Hexagon socket pipe plug
Valve
Sealing ring
Pressure gauge
Measuring coupling
Hexagon bolt
Packing ring
Blind flange
Oil pipe
Red cap
Quantity
56,0
20,0
1,0
3,0
4,0
6,0
1,0
12,0
4,0
12,0
2,0
3,0
1,0
9,0
1,0
3,0
1,0
1,0
1,0
1,0
1,0
2,0
1,0
4,0
1,0
1,0
1,0
1,0
END OF LIST
2012-11-20
29 November 2012
10-155

Upper gearbox
Title:
Page: 56 of 83
Type:
2500
Drawing: T003001362_D01-4/Upper gearbox
BOM:
T003001362/4
Product:
Seq. Item name

10 Upper gearbox (rm)
PAAI066761/-
Item id
T002050741/2
Quantity
1,0
END OF LIST
2012-11-20
10-156
29 November 2012

Lantern piece
Title:
Page: 57 of 83
Type:
2500 BWH
Drawing: T001017994_D01-4/Lantern piece
BOM:
T001017994/4
Product:
Seq. Item name

10 Lantarn piece (rm)
PAAI066761/-
Item id
T001017995/2
Quantity
1,0
END OF LIST
2012-11-20
29 November 2012
10-157

Bearing housing
Title:
Page: 58 of 83
Type:
2500 BWH
BOM:
T003001359/5
Product:
Seq. Item name

10 Bearing housing (rm)
PAAI066761/-
Item id
T003001506/4
Quantity
1,0
END OF LIST
2012-11-20
10-158
29 November 2012

Bearing housing
Title:
Page: 59 of 83
Type:
2500 BWH
BOM:
T001019050/7
Product:
Seq. Item name

PAAI066761/-
Item id
T001019761/5
Quantity
1,0
END OF LIST
2012-11-20
29 November 2012
10-159

Title:
Type:
2500
BOM: T001019764/2
Seq. Item name

10 Housing for rotary seal (rm)
Page: 60 of 83
Product:
seal
PAAI066761/-
Item id
T001019765/1
Quantity
1,0
END OF LIST
2012-11-20
10-160
29 November 2012

Title:
Type:
2500 BWH
BOM: T001019762/2
Seq. Item name

10 Housing for rotary seal (rm)
Page: 61 of 83
Product:
seal
PAAI066761/-
Item id
T001019763/1
Quantity
1,0
END OF LIST
2012-11-20
29 November 2012
10-161

Output shaft
Title:
Page: 62 of 83
Type:
2500
Drawing: T003005721_D01-2/Output shaft
BOM:
T003005721/2
Product:
Seq. Item name

10 Output shaft (rm)
PAAI066761/-
Item id
T003004962/2
Quantity
1,0
END OF LIST
2012-11-20
10-162
29 November 2012

Title:
Type:
2500
BOM: PAAI031938/B
Seq. Item name

2 Hexagon socket head cap screw
3 Mounting bracket
10 Switch
Page: 63 of 83
Drawing: PAAI031938_D01-B/Speed pick-up
Product:
arrangement
PAAI066761/-
Item id
M712045390/PAAI031712/E000003372/A
Quantity
2,0
1,0
2,0
END OF LIST
2012-11-20
29 November 2012
10-163

Title:
Outboard delivery
Page: 64 of 83
Type:
LMT2510-363/2500WO
Drawing:
BOM:
PAAI066780/-
Product:
PAAI066761/-
Seq. Item name
Item id
1S Propeller arrangement
17S Pod arrangement
PAAI066772/D
PAAI066776/B
Quantity
1,0
1,0
END OF LIST
2012-11-20
10-164
29 November 2012

Title:
Page: 65 of 83
Type:
FS2510-363/2500WO
Drawing:
BOM:
PAAI066772/D
Product:
PAAI066761/-
Seq. Item name
Item id
109 Fixed pitch propeller

111 Propeller cap assembly
114 Propeller assembly
PAAI105853/PAAI111347/PAAI064978/B
Quantity
1,0
1,0
1,0
END OF LIST
2012-11-20
29 November 2012
10-165

Title:
Type:
FS2500
BOM: PAAI105853/-
Seq. Item name

3 Hexagon socket collar plug
Page: 66 of 83
Drawing: DAAK018679_D01-Propeller hub
Product:

PAAI066761/-
Item id
W006564007/-
Quantity
1,0
END OF LIST
2012-11-20
10-166
29 November 2012

Title:
Page: 67 of 83
Drawing: DAAK105678-Propeller cap assembly
Type:
BOM:
PAAI111347/-
Seq. Item name

50
51
52
53
54
55
56
57
58
Propeller cap
Seamless O-ring
Hexagon head screw
Plain washer
Locking wire
Copper sealing ring
Hexagon head screw
Copper sealing ring
Product:
PAAI066761/-
Item id
PAAI111161/M730000460/W007100391/W007375025/W007550008/W006552120/M731000200/W084839228/W007385030/-
Quantity
1,0
1,0
8,0
8,0
2,0
2,0
2,0
1,0
1,0
END OF LIST
2012-11-20
29 November 2012
10-167

Propeller assembly
Title:
Page: 68 of 83
Type:
2500/2510FP
Drawing: DAAK018911_D01-Propeller assembly
BOM:
PAAI064978/B
Product:
Seq. Item name

1
2
3
4
5
6
9
10
11
12
13
14
15
16
17
18
19
99
Cap
Spacer ring
Pressure ring
Copper sealing ring
Labyrinth seal
Hexagon head screw
Hexagon bolt
Hexagon head screw
Plain washer
O-ring
Plain washer
Bonded seal
O-ring
Sealing compound
PAAI066761/-
Item id
T001011294/4
PAAI108672/T001016055/2
M731000290/T001016069/5
T001016094/5
W007000575/W007100391/W007110143/W007100387/W084809330/A
W006564007/W007375026/W007000909/M716000436/W006580044/W007035243/PAAI045184/B
Quantity
1,0
1,0
1,0
3,0
1,0
1,0
1,0
8,0
12,0
12,0
8,0
3,0
12,0
1,0
8,0
8,0
1,0
6,0
END OF LIST
2012-11-20
10-168
29 November 2012

Cap
Title:
Page: 69 of 83
Drawing: T001011294_D01-4/Cap
Type:
BOM:
T001011294/4
Seq. Item name

10 Cap (rm)
Product:
PAAI066761/-
Item id
T001011295/3
Quantity
1,0
END OF LIST
2012-11-20
29 November 2012
10-169

Labyrinth seal
Title:
Page: 70 of 83
Type:
2500FP
Drawing: T001016069_D01-5/Labyrinth seal
BOM:
T001016069/5
Product:
Seq. Item name

10 Labyrinth seal (rm)
PAAI066761/-
Item id
T001010714/3
Quantity
1,0
END OF LIST
2012-11-20
10-170
29 November 2012

Title:
Type:
2500FP
Drawing: T001016094_D01-5/Fairing cover split
BOM: T001016094/5
Product:
Seq. Item name

10 Split fairing cover
Page: 71 of 83
version
PAAI066761/-
Item id
(rm)
T001016095/5
Quantity
1,0
END OF LIST
2012-11-20
29 November 2012
10-171

Title:
Pod arrangement
Page: 72 of 83
Type:
FS2510-363/2500WO
Drawing:
BOM:
PAAI066776/B
Product:
PAAI066761/-
Seq. Item name
Item id
1712 Lower gearbox assembly

1714 Shank assembly
PAAI105057/PAAI060060/A
Quantity
1,0
1,0
END OF LIST
2012-11-20
10-172
29 November 2012

Title:
Type:
F2510
BOM: PAAI105057/-
Page: 73 of 83
Product:
assembly
assembly
PAAI066761/-
Seq. Item name
Item id
1K
2K
3
4
5
8A
9A
10A
11A
13
16A
19A
20
21A
23
24
26
27A
29
30
31
36
37
41
43
44
45
46
48
60
61
62
63A
64
65A
66
67
68
69
70
PAAI059142/T003006019/4
T003001521/4
PAAI059154/T003001529/2
T002051320/7
T003003208/7
T003000445/2
PAAI059885/PAAI101843/B
T003004918/2
T003000542/2
T003004900/2
T003000444/2
T003004898/2
T003004866/2
T003001512/1
T002051352/3
M713000482/T003001513/B
T002051355/1
T001016068/3
T002051632/4
T002012950/1
T001017984/1
T002051018/1
T001003859/D
T002004954/W006564104/A
PAAI053081/C
W006210906/A
PAAI053081/C
W006260026/W006260041/A
W006200174/A
W006210908/A
W006200174/A
W007001384/W007001259/W007001218/-
Pod
Bearing cover
Bearing housing
Cover
Fairing cover
Bearing housing
Locking plate
Gear set for lower gearbox
Stern tube seal
Propeller shaft
Locking nut
Retaining plate
Ring
Bearing cover
Cap
Distance ring
Bush
Hexagon head screw
Distance ring
Split ring
Dowel
Oil pipe
Spring
Compression spring
O-ring
O-ring
O-ring
Quantity
1,0
1,0
1,0
1,0
1,0
1,0
1,0
1,0
1,0
1,0
1,0
1,0
1,0
1,0
1,0
1,0
1,0
1,0
8,0
1,0
1,0
1,0
1,0
1,0
1,0
2,0
6,0
11,0
4,0
1,0
1,0
1,0
1,0
1,0
1,0
1,0
1,0
1,0
1,0
1,0
2012-11-20
29 November 2012
10-173

Title:
Type:
F2510
BOM: PAAI105057/-
Seq. Item name

71
72
73
74
75
76
77
78
79
80
81
82
83
84
86
87
88
89
90
91
92
93
94
96
97
98
100
101
102
120
127
132
133
134
140A
151
152
153
Seamless O-ring
Bonded seal
Seamless O-ring
Seamless O-ring
Seamless O-ring
Seamless O-ring
Locking wire
Male stud connector
O-ring
Union elbow
Hexagon bolt
Hexagon bolt
Copper sealing ring
Stud 1,25d
Hexagon head screw
Hexagon bolt
Hexagon head screw
Hexagon bolt
Hexagon nut
Red cap
Precision pipe (rm)
Plain washer
Pipe clamp
Hexagon head screw
Dubo retaining ring
Plug
Ring
Hexagon bolt
Page: 74 of 83
Product:
assembly
assembly
PAAI066761/-
Item id
W007031011/W006580044/W007031001/W007052900/W007031000/W007001398/W007029900/W007550008/W007053100/M710712228/A
M718700442/A
W007000011/M710761228/A
W007110148/B
M713005590/W006564110/B
M731000302/M712040383/W007265046/W007100386/W007110150/A
W007100413/A
M713005642/W006552115/A
M712045489/W007210124/B
M712045592/A
T001034133/5
M301035286/A
W007375034/A
W005102801/A
M713001580/A
M716600039/T003004901/1
T002051351/1
W007580265/M712085274/A
M713005438/A
Quantity
1,0
1,0
1,0
1,0
1,0
1,0
1,0
6,2
1,0
4,0
1,0
1,0
2,0
1,0
8,0
1,0
9,0
6,0
12,0
8,0
23,0
12,0
12,0
1,0
16,0
12,0
20,0
1,0
1000,0
20,0
1,0
1,0
1,0
4,0
1,0
6,0
6,0
2,0
2012-11-20
10-174
29 November 2012

Title:
Type:
F2510
BOM: PAAI105057/-
Seq. Item name
Page: 75 of 83
Product:
assembly
assembly
PAAI066761/-
Item id
Quantity
END OF LIST
2012-11-20
29 November 2012
10-175

Bearing housing
Title:
Page: 76 of 83
Type:
FS2510
BOM:
T003001521/4
Product:
Seq. Item name

PAAI066761/-
Item id
T003001537/3
Quantity
1,0
END OF LIST
2012-11-20
10-176
29 November 2012

Fairing cover
Title:
Page: 77 of 83
Type:
FS2510
Drawing: T003001529_D01-2/Fairing cover
BOM:
T003001529/2
Product:
Seq. Item name

10 Fairing cover (rm)
PAAI066761/-
Item id
T003001530/2
Quantity
1,0
END OF LIST
2012-11-20
29 November 2012
10-177

Oil pipe
Title:
Page: 78 of 83
Type:
2510
Drawing: T002051632_D01-4/Oil pipe
BOM:
T002051632/4
Product:
Seq. Item name

1
2
3
4
5
Welding nipple
Oil pipe
Union elbow
Oil pipe
Oil pipe
PAAI066761/-
Item id
T002051633/1
PAAI065681/W006410038/A
PAAI065706/B
PAAI065682/B
Quantity
1,0
1,0
2,0
1,0
1,0
END OF LIST
2012-11-20
10-178
29 November 2012

Pod
Title:
Page: 79 of 83
Type:
FS2510
Drawing: DAAK017519_D01-Pod
BOM:
PAAI059142/-
Product:
Seq. Item name

10 Pod (rm)
PAAI066761/-
Item id
PAAI059143/-
Quantity
1,0
END OF LIST
2012-11-20
29 November 2012
10-179

Bearing cover
Title:
Page: 80 of 83
Type:
FS2510
Drawing: DAAK004531_D01-Bearing cover
BOM:
T003006019/4
Product:
Seq. Item name

10 Bearing cover (rm)
PAAI066761/-
Item id
T003006018/4
Quantity
1,0
END OF LIST
2012-11-20
10-180
29 November 2012

Propeller shaft
Title:
Page: 81 of 83
Type:
FS2510
Drawing: T003004918_D01-2/Propeller shaft
BOM:
T003004918/2
Product:
Seq. Item name

10 Propeller shaft (rm)
PAAI066761/-
Item id
T003001510/4
Quantity
1,0
END OF LIST
2012-11-20
29 November 2012
10-181

Shank assembly
Title:
Page: 82 of 83
Type:
2510
Drawing: PAAI002732_D01-Shank assembly
BOM:
PAAI060060/A
Product:
Seq. Item name

1
2
3
4
5
6
7
8
9
10
11
12
Shank
Oil line
Shoulder bolt
Hexagon nut
Stud 1,25d
Locking wire
O-ring
Seamless O-ring
Centring ring
Hexagon head screw
Dubo retaining ring
Seamless O-ring
PAAI066761/-
Item id
PAAI059110/T003001490/B
T001016091/4
W007210132/B
W007265034/W007550008/W007035092/W007000249/PAAI102951/W007100395/B
M716600041/W007031007/-
Quantity
1,0
1,0
22,0
30,0
30,0
3,2
2,0
1,0
1,0
6,0
4,0
2,0
END OF LIST
2012-11-20
10-182
29 November 2012

Shank
Title:
Page: 83 of 83
Type:
FS2510
Drawing: DAAK017541_D01-Shank
BOM:
PAAI059110/-
Product:
Seq. Item name

10 Shank (rm)
PAAI066761/-
Item id
PAAI059111/-
Quantity
1,0
END OF LIST
2012-11-20
29 November 2012
10-183
10-184
29 November 2012

P.O. Box 6
5150 BB, Drunen
The Netherlands
T: +31 (0)416 388115

F: +31 (0)416 373162
www.wartsila.com

009 Propulsion Azimuth Thruster - S

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Operation & Maintenance Manual

Operation & Maintenance Manual

Operation & Maintenance Manual

General information ..................................................................................................................................

Operation & Maintenance Manual

General maintenance ................................................................................................................................

Operation & Maintenance Manual

Assembly instructions for piping .......................................................................................................

Preventive maintenance ...........................................................................................................................

Operation & Maintenance Manual

Inspection, Test and Adjustment .............................................................................................................

Operation & Maintenance Manual

Removal / Installation ...............................................................................................................................

Operation & Maintenance Manual

Storage and transport ..............................................................................................................................

10. Spare parts catalogue ..............................................................................................................................

Operation & Maintenance Manual

Operation & Maintenance Manual

This chapter gives an introduction, safety information, classification and technical

STORAGE AND TRANSPORT

SPARE PARTS CATALOGUE

Operation & Maintenance Manual

Liability and warranty

Modification(s) to the equipment without prior consent of Wrtsil Netherlands B.V..

Operation & Maintenance Manual

1.4.1 Intended use

1.4.2 General safety

the professional skill of operating and maintenance persons;

the knowledge of these persons about the possible dangerous situations;

the degree of concentration of these persons during their work;

the type of work.

Lock-out - Tag-out procedure

Make the system safe

Return the system into operation

Operation & Maintenance Manual

Access and escape routes

Material and equipment

Operation & Maintenance Manual

A diving operation, to work under water, is always dangerous.

the diving equipment is valid, ready and safe for use;

the safe diving measurements are taken;

a standby diver is available and ready for immediate deployment.

2. Lock out the applicable systems and equipment.

1.4.3 Notational convention

A note gives additional information for clarification.

Operation & Maintenance Manual

Forward side, front

Right hand side, right

Aft side, rear, back

Left hand side, left

Operation & Maintenance Manual

CW, turning right

as looking at the clock

CCW, turning left

as looking at the clock

Inward over the top

as looking at the hub

Outward over the top port side = CCW

as looking at the hub

as looking at the fan

CW, turning right

Operation & Maintenance Manual