III-2 Rolls-Royce Boegschroef Timca Manual + Scedules T9255-56 Rev A PDF

1.
INTRODUCTION
USER MANUAL 2. SAFETY
Kamewa Ulstein
Tunnel Thruster 3. SCOPE OF SUPPLY
TT1650 ICE CP
4. SYSTEM DESCRIPTION
Mechanical, Hydraulic and Electric system
5. TECHNICAL DATA
Unit identification
Shipyard : Stochnia Szczecinska Nowa
Yard no. : B201/II/1 6. OPERATION INSTRUCTIONS
Unit: : T9255-56
Date : 18 Jan 2006
7. MAINTENANCE
INSTRUCTIONS
Application engineer for this project:
Kjell Kristian Gustavsen
kjell.gustavsen@rolls-royce.com 8. SPARE PARTS
Direct phone : +47 700 14 662
Direct fax : +47 700 14 014
9. TOOLS
Contract manager for this project:

Kim Varhaug
kim.varhaug@rolls-royce.com 10. DESIGN DRAWINGS
Direct phone : +47 700 14 456
Direct fax : +47 700 14 017
User Manual
Table of contents
1 INTRODUCTION.............................................................................................................. 6
1.1 Purpose ....................................................................................................................... 6
1.2 Abbreviations ............................................................................................................. 8
2 Safety.................................................................................................................................. 9
2.1 General statement ....................................................................................................... 9
2.2 Warnings .................................................................................................................... 9
2.3 Safety instructions .................................................................................................... 10
2.4 Operation restrictions ............................................................................................... 11
3 Scope of supply ................................................................................................................ 12
3.1 General ..................................................................................................................... 12
3.2 Delivery specification .............................................................................................. 12
3.3 General information ................................................................................................. 12
3.4 Tunnel and gear housing .......................................................................................... 12
3.5 Propeller hub ............................................................................................................ 12
3.6 Servo system ............................................................................................................ 12
3.7 Plan for testing and documentation.......................................................................... 14
4 System description ........................................................................................................... 15
4.1 System overview ...................................................................................................... 15
4.2 Design....................................................................................................................... 16
4.3 Drive system............................................................................................................. 17
4.4 Marking .................................................................................................................... 17
5 Technical data .................................................................................................................. 18
5.1 Application info........................................................................................................ 18
5.2 Motor........................................................................................................................ 18
5.3 Thruster/Tunnel........................................................................................................ 18
5.4 Hydraulic System ..................................................................................................... 18
5.5 Remote Control ........................................................................................................ 18
5.6 Weights..................................................................................................................... 18
5.7 Documentation ......................................................................................................... 18
5.8 Torsional vibration data ........................................................................................... 19
5.9 Startup torque at zero pitch (Preliminary)................................................................ 20
6 Operation instructions ...................................................................................................... 21
6.1 Precautions before start up ....................................................................................... 21
6.2 Start-up instruction................................................................................................... 21
6.3 Operation instructions .............................................................................................. 22
6.4 Installation instructions ............................................................................................ 23
7 Maintenance instructions.................................................................................................. 45
7.1 Routine maintenance ................................................................................................ 45
7.2 Inspection during normal docking and guarantee docking ...................................... 46
7.3 Trouble shooting ...................................................................................................... 49
8 Spare Parts........................................................................................................................ 50
8.1 Standard spare parts ................................................................................................. 50
8.2 Additional spares...................................................................................................... 50
8.3 Preservation of spares............................................................................................... 50
8.4 Ordering spare parts ................................................................................................. 51
9 Tools................................................................................................................................. 55
9.1 Tools......................................................................................................................... 55
10 Design drawings and documents...................................................................................... 56
This document is the property of Rolls-Royce and may not be redistributed or reproduced in any way, without the written permission of Rolls-Royce. Failure to
do so is a violation of copyright laws.
User Manual 18 Jan 2006 Page 2

User Manual
10.1 Dimension drawings................................................................................................. 56
10.2 Assembly drawings .................................................................................................. 56
10.3 Hydraulics ................................................................................................................ 56
10.4 Hydraulic units ......................................................................................................... 56
10.5 Oil Tanks .................................................................................................................. 56
10.6 Electrics.................................................................................................................... 56
10.7 Painting spesification ............................................................................................... 56
10.8 Hydraulic system...................................................................................................... 59
10.9 Flushing of hydraulic system ................................................................................... 59
10.10 Hydraulic system description ............................................................................... 60
10.11 Gravity tank (ENG-0124)..................................................................................... 61

User Manual
Table of figures
Figure 1 - Block diagram of mechanic hydraulic and electric system ..................................... 15
Figure 2 - How the movement of the piston rod is transmitted to the turning of blades ........ 16
Figure 3 - Coupling components............................................................................................. 25
Figure 4 - Alignment ............................................................................................................... 26
Figure 5 - Coupling orientation during maintenance. ............................................................. 27
Figure 6 - Viscosity limits....................................................................................................... 29
Figure 7 - Trouble shooting diagram....................................................................................... 49

User Manual
Appendix
Appendix 1 - Drawing: 312149, Control form alignment motor foundation ....................... 62
Appendix 2 - Drawing: 312322, Instruction for flushing ..................................................... 63
Appendix 3 - Drawing: 311130, Instruction for oil filling ................................................... 64
Appendix 4 - Drawing: K586431, Tightening of screws, propeller hub .............................. 65
Appendix 5 - Drawing: 416934, Spare parts, filter inserts ................................................... 66
Appendix 6 - Drawing: 416766, Injector, coupling TT ....................................................... 67
Appendix 7 - Drawing: K141156, Mounting tool drive shaft coupling TT ......................... 68
Appendix 8 - Drawing: 313084, Dimension drawing tunnel thruster T9255-56 ................. 69
Appendix 9 - Drawing: 217653, Main assembly ................................................................. 70
Appendix 10 - Drawing: 108410, Main assembly ............................................................... 71
Appendix 11 - Drawing: 108980, Tunnel assembly ............................................................ 72
Appendix 12 - Drawing: 108981, Propeller unit assembly ...................................................... 74
Appendix 13 - Drawing: 108981, Propeller unit assembly ...................................................... 75
Appendix 14 - Drawing: 108981, Propeller unit assembly .................................................. 76
Appendix 15 - Drawing: 108500, Propeller hub assembly ...................................................... 80
Appendix 16 - Drawing: 108500, Propeller hub assembly .................................................. 81
Appendix 17 - Drawing: K141353, Gear coupling assembly .............................................. 83
Appendix 18 - Drawing: K141995.3, Feed back assembly .................................................. 84
Appendix 19 - Drawing: 109401, Hydraulic diagram .......................................................... 86
Appendix 20 - Drawing: 416906, Alarm list ........................................................................ 87
Appendix 21 - Drawing: 217353, Hydraulic connections thruster top ................................ 88
Appendix 22 - Drawing: 217213, Hydraulic module ........................................................... 90
Appendix 23 - Drawing: 312502, Arrangement pump unit ................................................. 92
Appendix 24 - Drawing: 312475, Filter arrangement .......................................................... 94
Appendix 25 - Drawing: 311290, Hand pump ..................................................................... 96
Appendix 26 - Drawing: 217255, Gravity tank .................................................................... 98
Appendix 27 - Drawing: 17-355-870, Drive motor ............................................................... 100
Appendix 28 - Drawing: K141514, Painting instruction drawing ......................................... 101
Appendix 29 - Drawing: K141514, Painting instruction drawing ..................................... 102

User Manual
1 INTRODUCTION
This User Manual has been compiled to assist personnel responsible for the operation and maintenance of the
KAMEWA ULSTEIN TUNNEL THRUSTER by Rolls-Royce Marine AS, and should therefore always be
available for the technical staff.
Our service department will provide any technical information required after start up of the installation.
1.1 Purpose
The Kamewa Ulstein tunnel thruster is mounted in a transverse tunnel in the bow of a vessel and in some cases,
also the stern. There are four blades and the blade pitch is controllable within an angle of ±30º. The clearance
between the tunnel wall and the blade tips is about 0.5% of the propeller diameter. The tunnel thruster can also
be regarded as an axial pump with a high flow rate at a low head.
The controllable pitch tunnel thruster runs at a constant shaft speed and the power and thrust are controlled by
changing the pitch of the blades. The propeller always rotates in the same direction. As starboard and port thrust
must be equal, the blades are designed with zero initial pitch and symmetrical blade section – the blades are
entirely plane. Two types of blade shapes exist – the Kaplan shapes and the high-skew shape. The latter type has
a lower noise level and is standard since 1994.
The tunnel thruster has two purposes:
• To keep the vessel in position in a crosswind
• To turn the vessel at zero or low ahead speed.
In the first case, it is the lateral plane (side projection) of the vessel above the waterline that decides the thrust
and tunnel thruster size. In the latter case, it is the underwater lateral plane.
The tunnel thruster develops a thrust of 0.13 – 0.16 kN/kW (10-12 kp/hp). A simple rule of thumb for the thrust
is:
T = k(PD x D)2/3 [kN]
PD [kW] = propeller power

D [m] = propeller diameter
k = constant
Providing the shaft speed is optimal and the thruster is run at near or full power, k » 0.97
The blade area of the propeller is chosen with the purpose of avoiding thrust breakdown due to cavitation. The
cause and effect of cavitation needs a more detailed explanation:
On a working propeller, high water velocities will occur locally on the blades. According to the laws of physics,
an increase in velocity is accompanied by a decrease of pressure and also a decrease of the boiling point. If the
boiling point drops right down to the temperature of the water, “cold boiling” occurs. This is cavitation. The
cavitation bubbles contain water vapour and no air. The bubbles are carried by the flow and when they reach a
zone of increasing pressure, they collapse rapidly. This can be heard as hard metallic bangs. All propellers
running at full power have more or less cavitation. However, excessive cavitation may lead to vibration and
eventually erosion of the blade surface.
Cavitation erosion seldom occurs on tunnel thrusters. In order to avoid damage to the tunnel wall, a strip of
stainless steel is located in the way of the propeller tip. In order to minimize the flow resistance, the edges of the
tunnel openings should have a chamfer of about 0.1D
The center of the tunnel opening should be located at least one diameter below the lowest waterline in order to
avoid air drawing and 0.75 – 1.0 D above the keel, in order to avoid recirculation of the water. Both phenomena
may cause loss of thrust.
If possible, the distance from the tunnel opening to the propeller should be at least 0.3 D; otherwise the
turbulence of the flow caused by the edge of the opening may result in noisy cavitation.
The above recommendations are shown in “Tunnel installation requirement”.
The presence of the tunnel openings in the hull plating will cause a small increase of the propulsive resistance of
a vessel. Arranging a fairing at the downside stream of the opening can reduce this increase.

User Manual
In some cases, the tunnel openings are equipped with grids in order to prevent foreign matter to enter the tunnel.
In case the grid consists of flat and round bars, the flat bars should be fitted at right angles to the flow past the
opening, in order to prevent a resistance-increasing vortex in the tunnel. However, the use of grids is not
recommended as foreign matter can still enter through the grid, but be prevented from getting out at the
discharge side thus causing blockage.
When a stationary vessel is turned with a tunnel thruster, the vessel is also given a sideways motion. The
simultaneous turning and crabbing results in a slow longitudinal motion of the vessel, ahead when the tunnel
thruster is located in the bow, astern when it is located at the stern. This should be kept in mind when
manoeuvring in narrow harbours.
When the vessel makes headway, the effect of the tunnel thruster decreases on most vessels. The reason for this
is the development of a low-pressure zone behind the thruster discharge jet, the low-pressure acting on the hull
and opposing the thrust of the tunnel thruster.
At increasing ship speed, the jet is deflected along the side of the hull. The entire hull side is then affected by
low pressure, developing a transverse force but no turning moment opposing the tunnel thruster moment. At
speed astern, the loss of moment is less noticeable with a tunnel thruster located at the bow.
The drop in steering moment varies with the type of vessel. On certain vessels, the effect of the tunnel thruster
disappears entirely above 4-5 knots, on others the effect is retained over the entire speed range.
At ahead speed, a vessel often has a certain small drift angle. The oblique inflow to the bow develops a pressure
field at one side of the bow, causing a force that may exceed the thrust of the tunnel thruster. Experience from a
trial with a product tanker can be summarized as follows:
At ahead speeds, it is possible to:
• Prevent a turn form developing
• Initiate a turn
• Once a turn has developed, it cannot be stopped and the rudder must be used.
Stern tunnel thrusters are located close to the main propellers and may be disturbed by these, especially at
running astern, as the propeller race sweeps by the tunnel openings. At low speed manoeuvring, it may,
therefore, be advantageous to operate either the main propellers or the steering propeller(s)
At zero ship speed, the turning rate is proportional to the cube root of the power; thus a 10% power increase
causes about 3% turning rate increase. For a given vessel and tunnel thruster size, the turning rate can be
calculated. The time stated for a 90° turn is valid for deep water, i.e. 4-5 times the vessel’s draught. In shallow
water, the resistance to the turning increases – for a distance of one meter between the keel and the sea bottom,
the turning rate may be halved.
At full power, the discharge velocity is about 6 m/s. For a tunnel thruster with a diameter of 2m, the discharge
volume will be about 19 m³/s, which is a considerable flow of water and may affect smaller vessels in the
vicinity.
The manual should be used as guide for ordering spare parts. It is recommended to use only original spare parts
from our spare part stock. The guarantee is only valid on condition that original parts are used within the
guarantee period. The drawings with part lists will be found after the description. The parts on each drawing are
given an item number. Description of each part is given in the parts list for each specific drawing.
When ordering spare parts, following information must be given:
• Installation No. (T- followed by a number), vessel’s and owner’s name.
• Shipping address and invoicing address.
• Drawing No., Pos. No., Art. No. and Quantity.
Please inform immediately any change in name and ownership to enable us to record the new information.

User Manual
1.2 Abbreviations
The following abbreviations are used in the manual:
• ºC Centigrade (temperature)
• CP Controlable pitch (propeller)
• cSt Centistoke (oil viscosity)
• FP Fixed pitch (propeller
• Hz Hertz (frequency)
• kg Kilogram (weight)
• kW Kilowatt (power)
• l/min Liters per minute (flow)
• MCR Maximum continous rating (power rating)
• mm Millimeters (lengths and diameters)
• RPM Revolutions per minute (rotation speed)
• V Volt (voltage)"

User Manual
2 SAFETY
Read this chapter very carefully. It concerns your safety. Chapter 2.2 is a description how the safety information
is presented in the manual. It also gives a general account of basic safety precautions to be taken when installing
and testing the propeller system.
2.1 General statement

"UNDERTAKING ANY WORK ENVISAGED BY THIS DOCUMENT MAY EITHER DIRECTLY OR
INDIRECTLY CREATE RISKS TO (1) THE SAFETY AND HEALTH OF THE PERSON UNDERTAKING
THE WORK OR (2) THE PRODUCT AND/OR ITS COMPONENTS WHILST THE WORK IS BEING
UNDERTAKEN.
IT IS THE RESPONSIBILITY OF THE USER TO ENSURE THAT APPROPRIATE CONTROLS AND
PRECAUTIONS ARE IDENTIFIED AND APPLIED IN RELATION TO THE WORK ENVISAGED BY
THIS DOCUMENT IN ACCORDANCE WITH RELEVANT STATUTORY, LEGAL AND INDUSTRY
REQUIREMENTS TO PROTECT THE HEALTH AND SAFETY OF THE PERSONS UNDERTAKING THE
WORK.
IT IS ALSO THE USER’S RESPONSIBILITY TO ENSURE THAT APPROPRIATE CONTROLS AND
PRECAUTIONS ARE IDENTIFIED AND APPLIED IN RELATION TO WORK ENVISAGED BY THIS
DOCUMENT TO PROTECT AGAINST RISKS TO THE TUNNEL THRUSTER AND/OR ITS
COMPONENTS WHILST THE WORK IS BEING UNDERTAKEN.
NEITHER THIS DOCUMENT, NOR ITS USE, IN ANY WAY ABSOLVES THE USER FROM THEIR
RESPONSIBILITY TO ENSURE THAT THE CONTROLS AND PRECAUTION REFERRED TO ABOVE
ARE IMPLEMENTED.
IF, WHILST UNDERTAKING ANY WORK ENVISAGED BY THIS DOCUMENT, YOU BECOME
AWARE OF ANY ROLLS-ROYCE PRODUCT DESIGN RELATED FEATURE WHICH COULD CREATE
RISK TO A PERSON UNDERTAKING WORK OR TO THE PRODUCT AND/OR ITS COMPONENTS
PLEASE CONTACT THE RESPECTIVE TECNICAL PRODUCT MANAGER AT ROLLS-ROYCE
MARINE AS IMMEDIATELY."
It is the user’s responsibility to make all relevant hazard identifications and risk assessments of all the activities
associated with the use of this document.
It is the user’s responsibility to design and implement safe systems of work and to supply safe equipment
(including, without limitation, safety equipment) and training (including, without limitation, health and safety
training) to anyone using this document to work on products to which it relates.
A user without the relevant experience of working in accordance with this document or with products, or similar
products, to which it relates should seek appropriate advice to enable them to identify the appropriate health and
safety controls and precautions and controls and precautions to protect against risks to the product and/or its
components whilst work is being undertaken. Technical assistance can be sought from Rolls-Royce and will be
subject to Rolls-Royce’s terms and conditions.
2.2 Warnings
Warning!
If these instructions are not followed, there is a risk of personal injury, serious damage to the product or
property, or major operating faults.
Caution!
Draws attentions to factors that may cause damage or operational faults of the product or to property.
Note!
Draws attention to important information that facilitates maintenance or operation.

User Manual
2.3 Safety instructions
2.3.1 Starting up
Warning!
If any malfunction is detected when performing function control before using the tunnel thruster, the
malfunction must be investigated and remedied. Operating a tunnel thruster with a malfunction in the control
system or hydraulic system may cause personal injury or equipment damage. Of the same reasons, any
malfunction that might occur in the systems when the tunnel thruster is in operation, must be remedied or the
thruster taken out of service.
Warning!
Be aware of the fact that the tunnel thruster is a pump with a large inlet duct. People or material close to the
tunnel can be sucked in. Always keep a safety area on both sides of the ship. Also be aware of the risk for
erosion caused by the water flow in harbours with quays built up by erodible material.
2.3.2 Maintenance and repair

Warning!
Never work alone when installing heavy components, even when using secure lifting equipment such as
lockable block and tackle. Most lifting devices require two people, one to see to the lifting device and one to
ensure that the components do not get caught and damaged.
Caution!
Prior to welding, check that the electric system of the boat is disconnected.
Caution!
When welding closer than 10 m from the Rolls-Royce control system equipment, all power supplies must be
disconnected before welding work starts. Supply filters might be damaged and control system function can be
jeopardised.
Warning!
Always wear protective goggles if there is a risk of splinters, grinding sparks and splashes from acid or other
chemicals. Your eyes are extremely sensitive and an injury to them can result in you losing your sight.
Caution!
Most chemicals intended for the product (engine and gearbox oils, glycol, gasoline and diesel), or chemicals
intended for the workshop (degreasing agent, paints and solvents) are harmful to your health. Read the
instructions on packaging carefully! Always follow protective measures (using a protective mask, goggles,
gloves etc.). Make sure that other personnel are not unknowingly exposed to harmful substances in the air that
they breathe for example. Ensure that ventilation is good. Deal with used and excess chemicals as directed.
Caution!
Ensure that the warning or information decals on the product are always visible. Replace decals which are
damaged or painted over.
Warning!
Using other hydraulic oil than the specified in this manual may cause malfunctions when manouvering the
boat. This may cause personal injury and equipment damage.
Caution!
At replacement of parts in the hydraulic system, take care of the hydraulic oil. Any oil spillage, even a small one,
will cause environmental damage. Have recycling or destruction stations to take care of used filter elements and
worn out hydraulic oil.
Caution!
If hydraulic oil disappears from the system and there is a risk that this oil is polluting the seawater, the system
must immediately be remedied.
Note!
Use spare parts produced by Rolls-Royce or a manufactorer approved or licenced by them. Even if a small part
has identical measures it can have been manufactured from wrong material with a risk for break down or a
shorter lifetime.

User Manual
2.4 Operation restrictions
Caution!
Do not use the tunnel thruster if local rules are not admitting this.
Warning!
If any malfunction is detected when performing function control before using the tunnel thruster, the
malfunction must be investigated and remedied. Operating a tunnel thruster with a malfunction in the control
system or hydraulic system may cause personal injury or equipment damage. Of the same reasons, any
malfunction that might occur in the systems when the tunnel thruster is in operation, must be remedied or the
thruster taken out of service.

User Manual
3 SCOPE OF SUPPLY
3.1 General
(Per shipset)
3.1.1 Mechanics
One complete KaMeWa Ulstein Tunnel Thruster unit with electric drive motor.
3.1.2 Hydraulics
Hydraulic unit for control of propeller pitch, lubrication and cooling of the thruster unit.
3.1.3 Electrics
Electric driven AC-motor
3.2 Delivery specification
3.3 General information

KAMEWA ULSTEIN TUNNEL THRUSTER, is a transverse thruster with controllable pitch, designed for
vessels where high degree of manoeuverability is required. Type and size of tunnel thruster depends of type and
application of the vessel. Number of thrusters installed may vary depending on type of vessel, required thrust and
back-up requirements. The prime mover is normally an electric motor running at constant speed. Separate diesel
engine or hydraulic drive are common alternatives having insufficient generator capacity or using existing
hydraulic power pack for cargo handling. The controllable pitch is electric - hydraulic operated. An electric
driven oil pump supplies oil to the servo system.
3.4 Tunnel and gear housing

The thruster unit as shown on the “Dimension dwg.” has a tunnel which is made of steel and welded into the
hull. The gear housing is made of nodular cast iron and connected to the tunnel with a flange connection. It is
supported by a stay, which is welded to the inside of the tunnel after the gear housing is installed in correct
position. On top of the tunnel, the motor foundation is installed, on which the electric motor is mounted. The
power from the electric motor is transmitted via a toothed coupling to the pinion shaft and the bevel gear to the
shaft and propeller. The pinion shaft in propeller unit is in upper position, supported by two axial roller bearings.
In lower position it is supported by a spherical roller bearing. The bearings absorbs the forces in axial direction,
caused by the helical teeth. The roller bearing absorbs the radial force. To facilitate installation a bearing, and
guide ring is fitted. The gearwheels have helical teeth which are hardened and grinded. The propeller shaft is
tapered in the aft end to which the propeller hub flage coupling is oil shrink fitted. The propeller shaft is in aft
end supported by two axial roller bearings. These absorb the axial load from the propeller thrust. In front end the
shaft assembly is supported by a spherical roller bearing which absorbs the radial force. The shaft sealing box is
of the lip seal type.
3.5 Propeller hub

The propeller hub is cast in one piece of Ni-Al-bronze. The hub acts as bearing surfaces for the propeller blades.
The propeller blades are cast in Ni-Al-bronze, machined and balanced according to the requirement of ISO R484
class II. The propeller blades can be removed in situ, i.e. without removal of the unit from the vessel. Each blade
is bolted to a crank pin ring, which again is supported by the hub. The crank pin ring is equipped with an
eccentric located tap. A sliding shoe is fitted to this tap, and the sliding shoe is again running in grooves on the
piston rod. By moving the actuating piston rod in axial direction, and thereby moving the sliding shoes, the
propeller blades will be rotated simultaneously and give forward or aft pitch.
3.6 Servo system

The servo system is an open circuit where the gear box act like oil reservoir. A combined header and expansion
tank allow the oil to expand as the temperature rise and to create positive pressure inside the thruster in relation

User Manual
to the water pressure outside. A level switch in the tank monitor the level. The system may have one or two
servo pumps depending on owners requirement. In case of 2 pumps only one is running at the time. The other
pump is in standby mode. Either pump can be selected as main pump to get equal running hours. The standby
pump starts automatically if the pressure drop under a certain limit set on a pressure switch. The servo pump
supply oil through the pressure filter to the pitch control proportional valve. The valve has built in sequence and
relief valve in addition to the control function. The complete servo pump oil capacity flow through the valve.
When the pitch does not change, all oil flows back into the system except for internal leaks. When changing the
pitch needed oil flows to either the port or starboard gate. Return oil from the servo cylinder flows back through
the valve into the system. At all times required oil pressure and flow to compensate for internal leaks to hold the
blades in position is directed to the correct gate by the remote control operating the proportional valve.
The oil is cooled by the sea water flowing by the submerged gearbox. The gear housing is continuously vented
from the input shaft seal housing to the header tank. The system is monitored by pressure switches giving alarm
and shut down in case of failure in the system. Differential pressure sensor to monitor the filter conditions is
supplied. In case of two pumps a pressure switch is installed to control the auto start of the stand by pump.
Technical spesification ................................................................... See spec.

User Manual
3.7 Plan for testing and documentation
ITEM DESCRIPTION TYPE DOCUMENT

1 Plan for testing and documentation Instruction KK00962
2 Quality level standard Instruction KK00887
STANDARD ITEMS:
3 Propeller unit:
3.1 Gear housing, visual and dimensional inspection Dimension report KK00891
3.2 Gearwheel Dimension report Subcontractor
3.3 Shrink fit, gearwheel Measuring report KK00964
3.4 Mesh contact for bevel gears Measuring report KK00965
3.5 Drive shaft Dimension report Subcontractor
3.6 Propeller shaft, penetrant examinated Procedure KK00893
3.7 Hub coupling, penetrant examinated Procedure KK00960
3.8 Hub coupling, pull - up Measuring report KK00964
3.9 Oil distribution sleeve / box, visual and dimensional insp. Dimension report KK00959
3.10 Oil distribution pipe Procedure KK00961
3.11 Flexible coupling - drive shaft, pull - up Test report KK00964
3.12 Axial play Measuring report KK00964
4 Assembly propeller hub:
4.1 Propeller blade, static balancing Measuring report KK00052
4.2 Propeller blade, penetrant examinated Procedure KK00888
4.3 Hub body, penetrant examinated Procedure KK00895
4.4 Crank disc, penetrant examinated Procedure KK00892
4.5 Blade bolts, penetrant examinated Procedure KK00890
5 Hydraulic system:
5.1 Electric motor, pump aggregate Test report Subcontractor
5.2 Pressure testing, hydraulic module Test report KK00901
6 Thruster unit assembled:
6.1 Leakage detection Test report KK00966
6.2 Function testing of servomechanism by air Test report KK00966
6.3 Flushing Test report KK00967
6.4 Pitch test Test report KK00967
6.5 Pressure testing Test report KK00967
6.6 Spin test Test report KK00967
7 As built data Measuring report KK00964
ORDER RELATED ITEMS:

8 Remote control, shop test Test report Subcontractor
9 Tunnel unit:
9.1 Tunnel, final inspection Dimension report KK00907
9.2 Motor foundation, final inspection Dimension report KK00916
9.3 Clearance blade / tunnel Measuring report KK00980
10 Painting inspection Report KK00414
11 Top bevel gear Test report Subcontractor
12 List of certificate List KK00968
13 Registration of nonconformity report numbers List KK00910
14 Procedure for FAT Procedure KK00981
15 Quality confirmation Certificate KK00982
16 Checklist List KK00986
17 Works certificate Certificate

User Manual
4 SYSTEM DESCRIPTION
The tunnel thruster system consists of three main parts:
• Mechanical parts for power transformation of propeller rotation.
• Hydraulic parts for lubrication and hydraulic control of the equipment.
• Electric parts for control and drive of motors and pumps.
4.1 System overview
Figure 1 - Block diagram of mechanic hydraulic and electric system

User Manual
4.2 Design
4.2.1 General
The propeller unit comprises a propeller tunnel in which a 1 – stay gear housing is bolted (including a welded
support plate). A 4 – bladed propeller and shaft assembly are mounted in bearings in the gear housing.
4.2.2 Tunnel
The tunnel is welded onto the ship’s hull. For this reason only the gear housing can be dismantled off the ship,
not the propeller tunnel.
4.2.3 Propeller
The main part of the tunnel thruster is the propeller hub with blades and the propeller shaft. One spherical roller
bearing and two axial roller bearings support the shaft. The shaft seal prevents water from penetrating and oil
leakage.
4.2.4 How the propeller operates

In the propeller hub, there is a servomotor, which turns the propeller blades. The servomotor consists of an
integrated piston and an axially moving piston rod. The movement is obtained by leading pressure oil to one side
or the other side of the piston. The piston rod has a crosshead with four transverse slots for sliding shoes, one for
each of the blades. The eccentric crank pin fits into the hole of the sliding shoe. The crank pin ring is supported
in a bearing lining, which is integrated with the hub body. When the piston rod moves, the crank pin rotates with
the circular movement transmitted via the piston rod slot – sliding shoe and crank pin. Then the propeller blade,
which is fixed on the crank pin ring by screws, will turn. Each blade is provided with a sealing ring to prevent
water penetration to the hub or oil leakage.
Figure 2 - How the movement of the piston rod is transmitted to the turning of blades

User Manual
4.2.5 Pressure oil from the servomotor piston

The pressure oil is led to the required side of the piston in the hub servo through the hole-bored propeller shaft
and the oil inlet pipe. The oil distribution box in the gear casing has two pressure chambers. One pressure
chamber is connected to its side of the servomotor piston via the channel formed by the hole bored into the
propeller shaft and the outside of the oil pipe. The second pressure chamber is connected to its side of the
servomotor piston via the oil inlet pipe. The oil distribution box is not provided with low pressure seal and
therefore there will always be a certain amount of leakage into the gear casing. In this way, the oil is
automatically refilled in the tank. The four-way valve at the hydraulic unit (see under 'Hydraulic system') guides
the pressure oil via pipes and hoses to the required chamber. At the same time, the return oil from the other
chamber is draining. The oil inlet pipe is bolted to the piston rod and follows its movement. The oil inlet pipe is
connected to the feedback device via linkage.
4.3 Drive system

The propeller is driven via a bevel gear in the gear casing. The pinion shaft is mounted in the stay supporting the
gear casing. The gear wheel is shrunk on the propeller shaft. One spherical roller bearing and two taper roller
bearings support the pinion shaft.
4.4 Marking
For easy identification of the goods, all units are marked with ID No, drawing and item reference. Each package
is normally marked as specified in the order documents.

User Manual
5 TECHNICAL DATA
5.1 Application info
Type................................................................................................ TT1650 ICE CP
Application ..................................................................................... Ice class 1A S
Classification society...................................................................... LRS Ice
Vessel type ..................................................................................... Cargo carrier
Vessel class notation ...................................................................... LRS
5.2 Motor
Drive Motor type ............................................................................ Electric AC motor.
Drive Motor Requirements............................................................. 4 Poled motor, IP23 Protection, S2-60 Operation
Drive Motor power......................................................................... 850 kW
Drive Motor shaft speed ................................................................. 1770 rpm
Direction of Drive Motor seen towards motor shaft end ................ Counter-clockwise
Drive motor starter ......................................................................... Not supplied
Power supply for Drive Motor ...................................................... 3 x 440V 60Hz
5.3 Thruster/Tunnel
Propeller speed ............................................................................... 374 rpm
Calculated thrust............................................................................. 120 kN
Propeller tip speed .......................................................................... 32.3 m/s
Direction of propeller rotation ....................................................... Clockwise
Propeller blade diameter ................................................................ 1650 mm
Propeller blade design .................................................................... Kaplan design
Propeller type ................................................................................. Controllable pitch
Number of propeller blades ........................................................... 4
Propeller material, hub / blades ...................................................... Ni.Al Bronze / Stainless steel
Tunnel diameter, inner ................................................................... 1680 mm
Tunnel length.................................................................................. 1850 mm
5.4 Hydraulic System

Pitching time full - starboard / port ................................................ 15 Seconds (Approx
Oil pump flow ................................................................................ 17.5 l/min
Power supply for oil pump unit. ..................................................... 4.6 kW / 3 x 440V 60Hz
Oil volume in thruster unit ............................................................. 198 Litres
Oil volume in gravity tank.............................................................. 110 Litres
Required oil volume for total installation....................................... 308 Litres
5.5 Remote Control

Type of electronic remote control ................................................. Helicon X
Required main power supply to remote control ............................ 220 VAC
Reqired Back-up power supply ...................................................... 24 VDC (from battery)
5.6 Weights
Weight of thruster and tunnel (dry) ............................................... 3700 kg
Weight of electric Drive Motor and starter .................................... Installation info
The thruster system is dimensioned according to above classification society rules valid on the date of this
datasheet.
User Manual 16 May 2006 Page 18

User Manual
5.8 Torsional vibration data
Rolls Royce Marine AS

Dep. Propulsion Ulstein
N-6065 ULSTEINVIK
NORWAY
Phone : +47 70014000
Telefax: +47 70014028
Page : 1
Date : 18 Jan 2006 11:16
Rev. :
Order no.: T9255-56
================================================================
---< TORO version 1.0 >---
NATURAL TORSIONAL VIBRATIONS FOR STRAIGHT SYSTEMS
================================================================
INPUT DATA
----------------------------------------------------------------
MASS No. IDENTIFIER INERTIA(kg*m2) STIFFNESS(Nm/rad) RPM
----------------------------------------------------------------
1 Propeller 111.093 11.336E6 374.0
2 Gearwheel 14.463 1000.000E6 374.0
3 Pinion 0.102 0.967E6 1770.0
4 Coupling 0.484 0.000E6 1770.0
5 Motor 0.000 0.000E6 1770.0

User Manual
5.9 Startup torque at zero pitch (Preliminary)

Speed Speed Propeller Total
% Rpm Nm Nm
0 0 0 0
10 177 0 21
20 354 3 38
30 531 11 58
40 708 26 86
50 885 51 123
60 1062 89 174
70 1239 141 239
80 1416 211 323
90 1593 301 426
100 1770 413 553
Propeller resistance curve at zero pitch

ISO VG 68 at 0 °C = ISO VG 100 at 20 °C
600
500
400
Nm
300
200
100
0
0 200 400 600 800 1000 1200 1400 1600 1800 2000
RPM

User Manual
6 OPERATION INSTRUCTIONS
6.1 Precautions before start up
• Ensure that all mechanic and hydraulic components are mounted as specified (in case of any
alterations since the installation period) and that nothing is missing.
• Ensure that all electrical connections are completed.
• Check that all cabinet earthings are made properly.
• Make sure to have all electric power available (but do not power up!).
• Make sure that the work will not be disturbed by testing of other machinery or painting.
• Keep oil (of correct type) available for topping up.
If depending on service from other company to run the prime mover, make needed arrangement to organise this.
6.2 Start-up instruction

Valid for new units and units after reconditioning.
Warning!
The pitch setting system must be final air vented according to following procedure below before starting up
the drive motor.
• Adjust zero-pitch on the feedback device. Set the remote control system to local control mode.
• Start the hydraulic pump and set the pitch in end position by means of local manual control of the
control valve on the pump unit.
• Relief valve setting value (V64) to be adjusted to 6 M Pa.
• The pitch is to be manoeuvred 10 times to each end position. The relief valve pressure is to be kept for
5 seconds at each end position.
• The relief valve pressure to be set to value stated on hydraulic diagram. Pitch to be set to zero-pitch.
• When the air venting procedure is finished, the oil tank is to be filled up to max oil level.
• Close shut-off valve (V56) and disconnect the filling pump. (Connection ZZ can alternatively be
permanently connected to an oil filling system)
• Valve V54 to be secured in fully open position. Set the control in remote control position
• The hydraulic system is now ready for operation.

User Manual
6.3 Operation instructions

6.3.1 Before starting the tunnel thruster
• Check that power is available.
• Start the electric driven hydraulic pump.
• Check that there is no alarm.
• The pitch will automatically go to zero.
6.3.2 Starting drive motor

• Start the drive motor.
• Check that drive motor has started. Lamp indicates drive motor running.
• The tunnel thruster is now ready for use.
6.3.3 Operation
• Select control panel by pushing the “COMMAND REQUEST” push button. When “IN COMMAND”
lamp lights, the control panel is in command.
• The propeller thrust can now be manoeuvred in desired direction by means of the control lever.
• The propeller thrust is approximately proportional to the position of the control lever, via the pitch
curve.
6.3.4 Stopping the tunnel thruster

• Set the control lever to 0-position.
• Stop the drive motor.
• Stop the electric driven hydraulic pump.

User Manual
6.4 Installation instructions

Control form alignment motor foundation ..................................... 312149
Instruction for flushing................................................................... 312322
Instruction for oil filling ................................................................. 311130

User Manual
6.4.1 Gear coupling mounting instruction

The drive shaft is tapered at the upper end to fit the taper on the shaft coupling.
The coupling can be mounted and dismounted without removing the electric motor.
Drive up the coupling with jacking screw.

• By using hydraulic injector, the locking plate and a special wrench to drive up the coupling on the
drive shaft:
• Coupling outer part and coupling boss to be lowered down onto the drive shaft.
• Connect the oil injector to the connection point on the coupling boss.
• Arrange the locking plate with cylindrical pins and the centre bolt on the drive shaft.
• Tighten the centre bolt until there is "metallic contact" between all parts.
• Connect the oil injector to the connection point on the coupling boss.
• Take a reference measurement towards coupling boss for using when "pull-up" the coupling.
• Pump up the injector pressure and pull-up the coupling to correct "pull-up length" by using the centre
bolt.
• Reduce the injector pressure to 0.0 MPa, before the "pull-up" tool can be removed.
• Remove the oil injector.
Note!
Never connect and use the oil injector without having the coupling secured by the locking plate or a hydraulic
jack. The coupling can be dismounted by using the above procedure in the opposite direction.

User Manual
6.4.2 Installation and maintenance instructions for MT gear couplings for Rolls Royce Marine
AS
The different coupling components are shown below:
Figure 3 - Coupling components
Preparation
• Make sure that all the parts are on hand and clean.
• Apply a light coat of grease to the o-rings (6) and install them in the sleeves (2) grooves. Place the
sleeve over the shafts prior to install the hubs.
Assembly
• Heat the hubs for most interference fit, to 150ºC, never exceed +300ºC. Do not use an open flame
burner, heat the hub in oil, oven or through induction.
• Check the appropriate drawings how to install the hubs on the shaft. Verify how to turn the hubs on
the shafts as a mistake could lead to an improper installation procedure.
Alignment
• Allow the hubs to cool down.
• Use dial indicators to check the alignment (see Fig 2). For radial alignment (offset) set the indicator to
zero and rotate the hub on which the indicator is mounted.

User Manual
Figure 4 - Alignment
For angular alignment:
• Check either through a gage or clock that GAP is within permissible value.
• Maximum GAP = 0.2 mm
For radial alignment:
• Check either through a gage or clock that SAG is within permissible value.
• Maximum SAG = 0.15 mm
For axial alignment:
• Check appropriate distance between shaft ends as per the approved drawings.
• Maximum Space = 8 ± 2 mm
Lubrication
Couplings are supplied with protective grease but not with working grease. The teeth mesh has to be cleaned
from any protective oil or grease prior to lubrication. Before the outer sleeves are placed on the hubs, 70% of
grease quantity should be hand packed into hubs and sleeves teeth and surrounding areas.
(Remaining 30% should be pumped into the outer sleeve lubrication holes, after completed mounted)
Grease Quantity per half couplings should be 0.25 kg.
Recommended lubricants:
The following greases are optimal for the below conditions:
• Angular misalignment less than 35’.
• Coupling surface temperature lower than 70ºC.
• Speed not too high. (< 3000 r.p.m.)
• Speed not too low. (> 200 r.p.m.)
• No shocks, no big reversing loads.
• Good sealing conditions, and
• No severe environment, the following greases can be used:
First priority grease types

• TEXACO Coupling Grease KP 0/1 K-30
• SHELL Albida GC-1
• MOBIL Mobil Grease XTC
• KLUBER Klüberplex GE 11-680

User Manual
Second priority grease types

If non of the first priority greases are available.
• Base oil Viscosity: Higher than 500 CST at 40ºC and higher than 40 CST at 100ºC.
• Consistency following NLGI: between 0 and 1.
• Thickener content (Metallic soap): Less than 8%.
• Drop point: Higher than 120ºC
• Heavy additive (Molybdenum disulphide): The less the better. The best is nothing.
• EP additive: Allowable and good.
• Oxidation inhibitors: Required.
If working conditions are different from the ones above mentioned, please contact our technical department. For
speeds below 200 r.p.m., NLGI-O is recommended, and at very low speed. NLGI-OO.
Bolt up the sleeve

Bolt up the sleeve with the recommended tightening torque, after installing the o-ring in place. Using grease on
the o-ring is recommended. Make sure that flange lubrication holes, after mounting, are 90º angle to each other.
Flange Bolt tightening torque =230 Nm
Maintenance
• Relubrication every 6 months or 3000 working hours.¹
• Turn the coupling so that flange lubrication holes are in position according to Figure below.
Figure 5 - Coupling orientation during maintenance.

• Remove the A-in and A-out plugs and pump grease into the A-in hole until grease leak out from A-
out.
• Put in plugs and repeat with the remaining two holes (B-in and B-out).
• Inspection every 24 months or 8000 working hours.¹
• Before moving the sleeves, clean the hub surfaces near the o-rings of rust or dirt.
• Remove flange bolts and flange o-ring.
• Control the gears and seals.
• Get rid of the old grease and add new grease.
1) This is valid, only if conditions are normal as stated in lubrication. At higher temperature, low speed and
reversing drive, more frequent lubrication and inspection are needed.
For additional information, please contact RRM.

User Manual
6.4.3 Installation of feedback
Pitch Feedback Device

The feedback device is to be bolted to the propeller unit during installation at yard. The mechanical movement is
transmitted by means of a link and lever to the potentiometer. The potentiometer is electrically connected to the
central unit of the bridge.
The device shall be placed on the top flange of the tunnel. See enclosed drawing "Feedback device".
• You shall provide the device with protection covers if necessary. It shall be accessible for adjustment
and maintenance.
• In general the indicating rod (to tunnel) should be protected from paint and dirt in order to avoid
problem with the feedback movement.
• Before starting up, the installation of the feedback device should be inspected as per our checklist.
• The installation is made after that the tunnel is finally painted and welded to the hull structure and/or
that the motor foundational (optional) is installed.
• The device must not be painted.
Turning Direction of Pitch Indicator Pin / Water Flow Direction
Anti-clockwise
Water flow direction from the propeller towards the gear house (gear house down-streams the propeller) The
ship moves towards the propeller side.
Clockwise
Water flow direction from the gear house towards the propeller (gear house up-streams the propeller) The ship
moves towards the pinion shaft side.

User Manual
6.4.4 Requirements for hydraulic oil

A solvent refined mineral oil of good quality, containing additives against foaming shall be used. The viscosity
shall be within the limits in the diagram below. For work in tropical waters only, choose viscosity on the upper
limit and for arctic conditions, on the lower limit. The viscosity of the oil shall be within the limits also after a
long time in service.
Figure 6 - Viscosity limits

Shearing stability (for oils containing VI improvers)
decrease of viscosity at 98.9°C after shearing 250 cycles .............. max. 20% DIN 51382
Density (20°C)................................................................................ max 910 kg/m3
Flash point (COC) .......................................................................... min 180°C ASTM D 92
Emulsion test .................................................................................. 30 min / 3 ml ASTM D 1401
Air release (50°C)........................................................................... 10 min DIN 51381
Corrosion test on copper (3 h 100°C)............................................. degree 2 DIN 51759
Rust test (24 h) ............................................................................... 0 ASTM D 665 B
Oxidation stability increase of neutralising number after
1000 h max ..................................................................................... 2.0 mg KOH/g oil ASTM D 943
Influence on packing material (mat 70 NBR/769 Messrs Carl Freudenberg GmbH) after 100 h And 80°C
Change in volume........................................................................... -1 to +4 % DIN 53521
Change in hardness......................................................................... 6 4 shore DIN 53505
For steering propellers and thrusters, the oil must also fulfil the following requirement:
Load carrying property (FZG gear test) ......................................... Load step 12 DIN 51354
Do not mix motor oil with other types of oil, even if they fulfil the requirements in this specification. Very small
amounts of motor oil in e.g. turbine or hydraulic oils mean that the quality of these oils is considerably lowered.
The oil is changed when laboratory tests show that something of the following has happened:
• Too high neutralising number
• Too low remaining amount of EP-additives
• Too high amounts of insoluble particles in the oil
• The viscosity is not within the limits in the diagram above.

User Manual
Example of Suitable Lubrication Oils

Oil Maker ....................................................................................... Oil Designation
BP................................................................................................... ENERGOL GR-XP 68
CALTEX ........................................................................................ REGAL MARINE 500
CASTROL...................................................................................... ALPHA SP 68
CHEVRON .................................................................................... NL GEAR COMPOUND 68
ELF................................................................................................. EPONA-Z 68
ELF................................................................................................. VISGA 68
ESSO .............................................................................................. SPARTAN EP 68
FRANCE PETROLEUM ............................................................... TOTAL CARTER EP 100
MOBIL........................................................................................... MOBIL GEAR 626
SHELL ........................................................................................... OMALA OIL 68
TEXACO ....................................................................................... MEROPA 68
Remark: If other brands would be used, please contact us for consulting.
Warning!
Using other oil than according the specifications given by Rolls-Royce may cause malfunctions when
manouvering the boat. This may cause personal injury and equipment damage.

User Manual
6.4.5 Oil filling instructions for tunnel thrusters with CP-hub
Oil filling
• Immediately upon arrival, the propeller unit shall be filled with oil and air vented according to the
following instructions:
• The oil type and viscosity to be used has to be according to Rolls Royce Marine AS instruction ENG-
0100, load step FZG12 shall be passed (FZG 12+)
• The cleanliness of the oil should be according to ISO 4406, Grade 16/13 or better
• For filling up, use a pump with a filter, 10 micron or better, in the discharge line
Hub, high pressure chamber

• Turn the propeller so that the hub venting holes are in upward direction.
− Loosen the two plugs.
− Note! Plugs located in hub cylinder and coupling flange.
• The oil to be filled slowly through connections AA and BB at the top of the propeller unit. Air is
vented via the two holes.
• The high pressure chambers are filled and vented when air free oil appears at the holes. The plugs to
be mounted and secured by welding as per separate instruction.
• If the piping is installed at this stage, the filling must be carried out through connections A and B at
the pump unit.
• During fitting of pipes at a later stage, oil has to be filled into these pipes and air has to be vented at
the connections AA and BB respectively, before final tightening of these pipe connections to the
propeller unit.
Propeller unit and hub low pressure sphere

• The oil is filled through connection FF and air vented through connection VV. One of the plugs for
the hub low pressure sphere to be in upward position. Loosen the plug for air venting.
− Note! These plugs are diametrically positioned in the spherical part of the hub body.
The hub is air - vented when air free oil appears at the hole.
If the hydraulic system is installed, instructions below must be followed.
• Connect the filling device to connection ZZ
• Close the shut off valve (V54), open the valve (V56) and connect a test hose to VT/VVT on the
hydraulic pump unit. Loosen the air-venting plug in the hub low pressure sphere.
• Start to fill oil into the propeller unit.
• When air free oil appears in VT/VVT and in the hole in the hub low pressure sphere, close the air
venting hole in the hub and disconnect the test hose at VT and open the shut off valve V54.
• Continue to fill oil into the system until the oil tank is filled up. The above given instruction is valid
for new installations and for installations after reconditioning.
• When topping up the oil tank from a low level (not empty), the oil can be filled via connection Z/PT2
at the pump unit.

User Manual
6.4.6 Instruction for piping

Note!
For dimension and type of pipes, refer to "Hydraulic System Drawing".
• Preferable should no welded pipes, welded bends or fittings be used in the hydraulic system. If welded
pipes have to be used, the welds must be thoroughly cleaned and pickled in 20% sulperic acid for at
least four - 4 - hours, next flushed thoroughly with water and then filled with hot solution of sodium
carbonate, which is to be left in for one - 1 - hour. Thereafter the pipes are to be flushed once more
with hot water and then dried and inside pipe surface covered with oil.
• Pipe ends must be cleaned well after pipe has been cut. Remove all sharp edges on fittings, flanges
and tubes. Do not apply thread sealant or soft joint packing. For flanged pipes use oil resistance
rubber packing. The following type of liquid seal can be used if manufacturer's recommendation is
followed strictly: Loctite or Permatex.
• All pipes must be well shaped and installed with only the minimum of bends. Do not use filler
material and heat when bending pipes, but bend in cold condition using suitable tube bending
equipment.
• During all time make sure that all pipes (and other openings) are sealed off. Plastic plugs and rags in
pipe ends are not to be regarded as adequate precaution for preventing dirt and moisture to enter the
system.
• Do not connect permanently before system has been flushed or manually cleaned. Refer to cleaning
procedure.
• Care should be taken to fit all pipes free from stress.
Note!
Our equipment has been delivered in cleaned condition and has been test run in our workshop. The utmost care
must therefore be taken to avoid introduction of impurities into the system by careless pipe laying or handling.

User Manual
6.4.7 Inspections of tunnel thruster installation (Installation checklist)
Date ................................................................................................ 18 Jan 2006

Order No......................................................................................... T9255-56
TT size / type.................................................................................. TT1650 ICE CP
Issuer / signature.............................................................................
Shipyard ......................................................................................... Stochnia Szczecinska Nowa
Yard / Newb No ............................................................................. B201/II/1
CHECKS TO BE CARRIED OUT BEFORE LAUNCHING
• Corrosion protection, painting, anodes, etc ------------------------------------------------------- F

• Blade tip clearance recorded ------------------------------------------------------------------------ F
• Thruster unit connected to gravity tank ----------------------------------------------------------- F
• Tanks and pipes cleaned----------------------------------------------------------------------------- F
• Thruster system filled with suitable oil. See our specification oil
requirements.------------------------------------------------------------------------------------------ F
• All screws and plugs tightened and locked with Loctite See drawing
tunnel with thruster unit ----------------------------------------------------------------------------- F
• Check of all sealings and plugs for leakage------------------------------------------------------- F
• If drive motor is included, see separate instruction ---------------------------------------------- F
REMARKS:

User Manual
CHECKS PRIOR TO STARTING UP / SEA TRIAL
• Gear coupling / shaftline recorded (See separate installation description

from supplier) ---------------------------------------------------------------------------------------- F
• Gear coupling filled with suitable grease --------------------------------------------------------- F
• Mechanical installation of feedback device See separate instruction
‘Installation procedure ------------------------------------------------------------------------------- F
Hydraulic system:
• Cable / piping installation --------------------------------------------------------------------------- F

• Before filling the system, check that pipes and tanks are thoroughly
cleaned------------------------------------------------------------------------------------------------- F
• Check that the system is filled with suitable oil (see above) ----------------------------------- F
• Check oil level ---------------------------------------------------------------------------------------- F
• Check pump motor, direction of rotation (clockwise) ------------------------------------------- F
• The pitch setting system air-vented in accordance with starting up
instruction of pitch setting system’ ---------------------------------------------------------------- F
• Run the pump for 4 hours --------------------------------------------------------------------------- F
• Check filter-------------------------------------------------------------------------------------------- F
• Check / adjust all alarm switches / transmitters -------------------------------------------------- F
Drive motor equipment (optional)
The start up has to be performed by an authorised el engineer.
• Mechanical installation ------------------------------------------------------------------------------ F

• Direction of rotation (clockwise seen from above) ---------------------------------------------- F
• Cable check ------------------------------------------------------------------------------------------- F
• Insulation test of electric motor recorded (see separate instruction) -------------------------- F
• Starter equipment properly installed --------------------------------------------------------------- F
Remote control system
Before start up of the remote control system, check that the directions given in the ‘installation description’ for
the control system are followed.
• Power supply------------------------------------------------------------------------------------------ F
• Cubicles ----------------------------------------------------------------------------------------------- F
• Controls------------------------------------------------------------------------------------------------ F
• Cables-------------------------------------------------------------------------------------------------- F
• Connection of cables--------------------------------------------------------------------------------- F
Paragraphs 7 to 9 below require use of a hand terminal and to be performed by a specialist educated to use the
Rolls Royce Marine AS digital control system.

User Manual
Commissioning prior to sea trial
• Test for earth faults against ship’s hull ------------------------------------------------------------ F

• Supply voltages: correct polarity ------------------------------------------------------------------- F
• Cable check: supply and solenoids correctly connected ---------------------------------------- F
• Switch on ‘Supply’: check lamp tests. Check computer start ---------------------------------- F
• Eliminate all alarm indications on the ANA PC boards----------------------------------------- F
• Run the pitch locally. Measure the total stroke of the movement to find
out the middle position. Set pitch feedback to 20.0 mA at mechanical
end position Starboard and check that mechanical end position Port is
not below 4.0 mA. Port and Starboard direction to be determined. For
thrust direction, see ‘Main Data’ sheet included in chapter 2 (‘Main
Data’) in the installation diagram. ----------------------------------------------------------------- F
• Calibrate pitch feedback to 105% at mechanical end positions -------------------------------- F
• Calibrate drive motor current feedback at ‘zero’ with stopped motor------------------------- F
• Calibrate DM voltage or RPM feedback at ‘zero’ with stopped motor
(cabling is the Yard’s responsibility) ------------------------------------------------------------- F
• Simulate drive motor running----------------------------------------------------------------------- F
• Check functions from Engine Control Room panel (Option)----------------------------------- F
• Check functions from Bridge panels--------------------------------------------------------------- F
• Calibrations and parameter settings according to Rolls Royce--------------------------------- F
• Marine AS specification / calibration list --------------------------------------------------------- F
Pitch mode ON
• Set the Parameter *PITCHMODE in Process LOGICAL to ‘ON’ ---------------------------- F

• Start the drive motor and check the correct direction of the water flow
from the thruster when slowly operating the lever ----------------------------------------------- F
• Slowly move the lever towards STBD until 100 % drive motor current
is obtained. At that position, calibrate the Pitch feedback ‘High’ to 0.95.
(Pitch curve ‘Pitch mode’ stops at 95%) ---------------------------------------------------------- F
• Slowly move the lever towards PORT until 100% drive current is
reached in that direction and calibrate the Pitch feedback ‘Low’ to 0.95.
Do not change the zero pitch calibration. --------------------------------------------------------- F
• Now check that 100% drive motor current is obtained with the lever to
max STBD and max PORT position. With the lever in one of these end
positions (and the drive motor current at 100%), calibrate the drive
motor current input ‘High’ to 1.00 ----------------------------------------------------------------- F
• Calibrate the DM voltage or RPM feedback input ‘High’ to 1.00 with
the DM voltage or RPM at 100% (option) ------------------------------------------------------- F

User Manual
Pitch mode OFF
• Set the parameter *PITCHMODE in Process LOGICAL to ‘OFF’ --------------------------- F

• Now check that 100% drive motor current still is obtained with the
lever position at max STBD and max PORT ----------------------------------------------------- F
• If the system is hunting, increase the parameter PULSEBAND or
decrease the parameter PULSETIME in the process CONTROL.
Observe that if the PULSETIME is too short, there can be problems to
get the zero pitch within the dead band------------------------------------------------------------ F
• After the sea trial is finished, make notes of all parameters and
calibration values that have been changed during the commissioning.
One copy is to be left on board and one copy to be brought to Rolls
Royce Marine AS for filing. ------------------------------------------------------------------------ F
REMARKS:

User Manual
6.4.8 Trials program

We suggest the following tests are carried out on the equipment delivered by us (times are estimated and for each
propeller).
Note!
Propeller centre immersion at least 1 times propeller diameter during tests.
At quay before trials

• Start-up and check of the control system through pitch re-setting, the propeller stopped (time approx.
4 hours).
• Rotation tests of the propeller at zero pitch (approx. 1 hour).
• If possible, operation with part and full loads starboard and port (time approx. 1 hour.
Warning!
During the sea trial it is in the responsibility of the captain/ship operator that the waters around the ship is
free from people and objects.
Warning!
Before a sea trial can be carried out, be absolutely sure that the function of the system is according to the
specifications. The adjustments of propeller pitch positions must have been made and the control system fully
tested.
Test during technical trial

• Setting and limiting of output (time approx. 1 hour).
• Turning tests with the vessel stationary. Start with the vessel having the fore directed against the wind
and then turn the ship to starboard by manoeuvring to 90°. Return the ship with full effect in the port
direction until the ship returns to the original starting position.
Repeat above test for port. (time approx. 0.5 hours).
During the test, read the compass continuously every ten seconds and the Amp-meter at equal intervals.
• Steering test (Zig-Zagging tests) in ahead direction.
Initial position with the fore of the vessel against the wind. Rudder position is to be amidships and the vessel
should have a speed of about 3-6 knots. Using the steering propeller, take the vessel Zig-Zag with 20° course
difference to both sides. Reverse the steering propeller when the course difference is 20°. Read the compass
every 10 seconds (time approx 1 hour for each speed).
Further tests are to be carried out if required by the classification society.

User Manual
6.4.9 General terms for commissioning

Service assistance included in the contract:
ACTIVITIES TO BE PERFORMED BY THE SHIPYARD PRIOR TO ARRIVAL OF ROLLS-ROYCE

MARINE (RRM) SERVICE ENGINEER(S):
Before launching:
• Welding of tunnel into hull
• Measurement of roundness of tunnel and blade tip clearances after welding. Data to be sent to RRM
for approval.
• Filling of oil in gear housing and propeller hub. Hub to be airbled. Note type of oil and quantity.
• If sea level reaches bottom of tunnel after launching, the gear housing has to be pressurized before
launching. Gravity tank and pipes must be cleaned before oil filling. Cleanness to be accepted by
owners representative.
After launching:
• Installation of hydraulic components and gravity tank (before sea level reaches tunnel, see above).
• Installation of piping according to diagram.
• Mounting of drive motor, drive shaft coupling etc.
• Lining up of shafting (motor, intermediate shaft, if any). Recorded data to be sent UPR.
• Mounting of actuator and/or feedback arrangement for remote control system.
• Arrangement of electric components and installation of electric cables according to diagram.
• Flushing of the hydraulic pipes installed by the shipyard, according to RRM's flushing diagram.
Critical components to be by-passed.
• Checking/cleaning of gravity tank before oil filling (approval by shipowner's representative).
Reconnecting pipes according to diagram (after flushing).
• Refilling oil according to oil filling instruction. Tooth couplings (and bearings and bulkhead glands, if
any) to be grease filled.
Commissioning/checking to be carried out by shipyard before rolls-royce marine (RRM) service

engineer is called for to carry out starting up:
• That all equipment is mounted and piping completed.
• That flushing of the hydraulic pipes are completed.
• That all external cabling are completed.
• That all connections are checked according to cable lists and that all terminal blocks are properly
tightened.
• That electric power is available (Do not switch on).
• That system is ready for testing.
• That there is undisturbed access to all equipment.
• The draft of ship is sufficient for testing of thruster. (Top of tunnel is min. 0,75 m under sea level)

User Manual
ACTIVITIES PERFORMED UNDER SUPERVISION OF ROLLS-ROYCE MARINE (RRM) SERVICE

ENGINEER(S):
Before starting up:

• Checking of installation work made by the shipyard (as far as practically possible without doing
demounting).
• Checking of hydraulic system installed by shipyard (positions of components, piping according to
diagram, cleanness of pipes (take samples if not oil filled), filter, coupling, tanks, pump etc.)
• Starting up servo pump(s). Check for leakages, bleeding air.
• Checking and adjustment of pressure setting for relief-, sequence-, reduction-valve etc.
• Local test of pitch manoeuvre with necessary adjustments.
• Checking of electric cabling for remote control system, control transfer etc.
• Switch on electric power and starting up the remote control system. Preliminary adjustments.
• Checking of set-point for pressure- and temperature switches.
• Checking of functions for pressure- and temperature alarms, interlock functions and possible auto-
start of servo pump(s). (Together with shipyard/classification society.)
Running alongside quay:

• Start of drive motor and checking direction of rotation.
• Checking of pressures, temperatures, filters, oil level and possible leakages.
• Gradually increase of pitch and motorload (according to running-in procedure).
• Checking and adjusting of zero-pitch, max. pitch port and starboard, indicators and of automatic pitch
reduction (if any).
• Adjustment of mechanical end stops for pitch actuator.
• Function test of systems for shipyard/classification society (or at sea trial).
• Completion of RRM "Sea Trial Report" (or at sea trial)
• Preparation for sea trial (filters, oil level etc.)
• Acceptance of installation(s). (Sea Trial Report) If service engineer present at sea trial, acceptance to
be made after final testing there.
At sea trial:
• Testing of tunnel thrusters can normally be completed at quayside. If RRM service engineer(s) are
present at sea trial in connection with other propulsion system(s), the following activities should be
performed:
• Observation of temperatures, pressures, filters, oil level and leakages, if any. Necessary adjustments
and corrections to be made.
• Correction of remote control adjustments, if necessary.
• Manoeuvre tests for classification society.
• Manoeuvre tests for completion of RRM "Sea Trial Report". (if not carried out before)
• Adjustment of remote control.
• Acceptance of installations. (Sea Trial Report)

User Manual
6.4.10 Sea trial report

The sea trial report is placed at the next four pages.
It should be sent back to Rolls Royce Marine AS when accomplished.

User Manual
Date: Issuer: Sea trial date: File No:
TT size/type: Hubsize/type: Unit No: Yard/yard No:

TT1650
Motor: Material, hub: Class society: Owner:

LRS
Motor power / rev.: Propeller rev.: Type of vessel: Name of vessel:

Container
Sea trial report, page 1/4
SEA TRIAL REPORT - DELIVERY

PORT STARBOARD
Power: __________ __________ [kW]
Revolutions: __________ __________ [rpm]
Pitch (if applicable): __________ __________ [P/D]
Thrust: __________ __________ [kN]
FWD AFT
Draught: __________ __________ [meter]
Propeller noise: _______________________

Propeller vibrations: _______________________
REMARKS:

User Manual
Propeller unit's position in hull: Bow
Direction of rotation, propeller: Clockwise seen from propeller hub side
Direction of rotation, input shaft: Clockwise seen towards shaft end
OBSERVATIONS NOMINAL ACTUAL
Observation of max servo pressures

Pitch 0, max RPM: Observation __________ [bar]
Full pitch starboard: Observation __________ [bar]
Full pitch port: Observation __________ [bar]
max obs. pressure when making manoeuvres: Observation __________ [bar]
Observations and adjustments of valves

Relief valve pitch oil (V64): 120 bar __________ [bar]
Sequence valve pitch oil (V51): 20 bar __________ [bar]
Relief valve lubrication oil (V67): 1,2 bar __________ [bar]
Relief valve return oil gear housing: 0,8 bar __________ [bar]
Gravity tank pressure, gear housing: Observation __________ [bar]
Shaft seal pressure: Observation __________ [bar]
Temperatures
Oil temperature: max_______ __________ [°C]
Oil cooler, lub. oil in/out: max_______ _____/_____ [°C]
Oil cooler, water in/out: max_______ _____/_____ [°C]
Sealing housing input shaft: Observation __________ [°C]
Alarms
Alarms low pitch pressure: 7 bar __________ [bar]
Interlock start drive motor: 3 bar __________ [bar]
Alarms high pressure: 160 bar __________ [bar]
Autostart stand-by pump I: 5 bar __________ [bar]
Autostart stand-by pump II: 5 bar __________ [bar]

User Manual
OBSERVATIONS NOMINAL ACTUAL
Drive motor
Load at full pitch: To be noted __________
Load at zero pitch: To be noted __________
Pitch
100% pitch starboard: Measured __________ [mm]
Zero pitch: Measured __________ [mm]
100% pitch port: Measured __________ [mm]
End position starboard: Measured __________ [mm]
End postion port: Measured __________ [mm]
Make a sketch at this report's last page, and mark where measurements are made.
Pitch manouvering speed

Full pitch starboard to port: 15-20 sec __________ [sec]
Full pitch port to starboard: 15-20 sec __________ [sec]
Data for vessel (one thruster) (if applicable)

Turning time 360° to starboard, 0 knots: Observation __________ [sec]
Turning time 360° to port, 0 knots: Observation __________ [sec]
Turning time 360° to starboard, 3 knots: Observation __________ [sec]
Turning time 360° to port, 3 knots: Observation __________ [sec]
When two or more thrusters are used together, also make records of turning
time for combination of these at separate page.
OBSERVATIONS TYPE VOLUME
Oil/grease filled
Gear housing: __________ __________ [litres]
Tooth coupling: __________ __________ [litres]

User Manual
REMARKS / SKETCH:
This installation is tested and adjusted according to this "Sea trial report" and "General terms"
For Rolls Royce Marine AS

dep. Propulsion Ulstein: For customer:
Date:____________________ Date:____________________
Sign:____________________ Sign:____________________

User Manual
7 MAINTENANCE INSTRUCTIONS
The tunnel thruster equipment needs regular inspection and maintenance.
The inspection range depends on the following: If you suspect a fault, which requires dismantling of the
propeller unit, the inspection work will be comprehensive. In other cases, the propeller unit can remain in the
ship during inspection and checking.
An inspection which requires dismantling of the propeller unit should be carried out in the presence of a
representative from Rolls Royce Marine AS.
After inspection, all loosened plugs and screws are to be locked in accordance with the instructions.
7.1 Routine maintenance

7.1.1 Weekly inspection
When the equipment is used, the following details are to be checked every week:
• Inspection for noise and abnormal vibrations of the drive motor.
− Check that the bearings, gaskets, electric apparatus and motors are not abnormally heated.
− Observe also other abnormal phenomena.
• Check that the oil level is normal and that there is no leakage in the hydraulic system.
7.1.2 Monthly inspection

• Check the intermediate shaft, couplings and bearings.
• If el driving motor, check and follow the lubrication instructions given on the lubrication schedule of
the motor. Check brushes and slip rings on wound-rotor AC motors in order to discover any wearing
down. The brushes are also to be cleaned in order to remove coal dust etc.
• If hydraulically driven, follow the valid instruction for service and maintenance.
7.1.3 Yearly inspection

• Take oil samples and have them analyzed by the supplier.
• Change oil if needed, according to the results of the analysis.
• Check the gear backlash.
• Check and refill grease in the intermediate shaft bearing and gear couplings.

User Manual
7.2 Inspection during normal docking and guarantee docking

Before docking, the propeller is to be carefully controlled with regard to noises, etc. If there are any remarks of
observations, the propeller should be entirely dismantled. If no abnormal phenomena are discovered, the
following control routines are to be carried out:
• Turn the propeller by hand in order to check that bearings and gear do not jam.
• Carry out a pressure testing of the propeller.
• Take oil samples from the hydraulic oil system. If the oil contains water or other impurities, then it is
to be changed.
• Check the hull tunnel in order to find any corrosion damages. Check the condition of the anodes; see
“Installation drawing”. Replace any attacked anodes. Check the condition of the painting and renew
when required.
• Lubricate the driving motor in accordance with the instructions on the lubrication chart of the motor.
• Lubricate the intermediate shaft and the bearing for the intermediate shaft (if exists) with grease.
• Start the driving motor and pay attention to noise, overheating, vibration and so on. This is to be done,
if possible, before docking is finished.
Warning!
Before you are allowed to start the drive motor in dock; Remove all working tools and foreign material in the
tunnel and inform the shipyard foreman that the propeller will be run so he can inform the personnel in the
area around the propeller.
If any abnormal phenomena have been discovered during inspection, the propeller is to be dismantled so that a
careful examination can be carried out.
Note!
An inspection which requires dismantling of the propeller unit should be carried out in the presence of a
representative from Rolls Royce Marine AS.

User Manual
7.2.1 Pressure testing of the propeller

A pressure test of the propeller is to be carried out during the inspection work, in order to enable a discovery of
any sealing damages. The pressure testing and control is carried out as follow:
• Carry out the pressure testing of the propeller when the upper tank is connected and during repeated
operations in the port and starboard directions. Check especially that there is no leakage of oil around
the propeller shaft seal and the blade sealing rings.
• Control the hydraulic equipment, including tubings.
7.2.2 Adjustment of oil pressure

The pressure relief valve, as well as the pressure switches are adjusted on delivery and in normal cases, no
additional adjustment is needed. If the pressure is to be checked or adjusted, do as follows:
• Actuate the control valve manually, so that the propeller gets into a limit position (starboard or port).
• Check the oil pressure. If necessary, the pressure can be adjusted by means of the control screw on the
relief valve.
• Check that the operation is smooth and safe. An increased pressure does not mean a shorter operating
time.
• Set the pressure switches at values given in hydraulic diagram.
7.2.3 Gear backlash

When checking the gear backlash, do the following:
Lock the propeller blades by knocking in wooden wedges between the propeller blades and the tunnel.
Warning!
Do not forget to remove the wedges after the measurement!
Secure a lever on the upper end of the drive shaft (see drawing) or other suitable arrangement. The length of the
lever should be more than the measure Radius below.
Measure by means of an indictor gauge, the movement which can be obtained on the drive shaft. Check that the
backlash is within the limits given below:
Backlash ......................................................................................... 0.30 + 0.05 mm
Radius............................................................................................. 56.6 mm
Figures are valid at +20°C
When the backlash is increased to 1.5 times the maximum value given above, we recommend an overhaul of the
unit, or contact Rolls-Royce Marine AS for a recommendation.

User Manual
7.2.4 Dismantling of the propeller blades

When replacing the O-ring, the propeller blade (the blade sealing ring), or when replacing a damaged propeller
blade, it is not necessary to dismantle the whole propeller unit from the tunnel. The distance between the blade
tip and the tunnel allows the blade to be lifted from its seat and taken away. A blade of a smaller propeller can be
lifted away manually by two men; larger propellers may sometimes require a special lifting arrangement,
depending on tunnel length and the yard’s facilities. Such special tools are not included with the Rolls Royce
Marine AS delivery.
Dismantling of propeller blades:
• Drain the oil from the gear housing and the upper tank by removal of the plugs in the gear housing.
• Cut away the locking plates for the blade bolts by means of a chisel and remove the bolts.
• Lift the blade from its position. If it is necessary to use lifting points, lifting eyes can be welded in the
tunnel. If the tunnel is equipped with a stainless strip (optional), do not weld in that area.
• Pull out the blade from the tunnel.
• The open blade pocket should be covered as soon as the blade is taken away.
• Clean under the blade foot and the blade pocket before the blade is remounted. Lubricate the O-ring
and the bearing surface. Do not lubricate the surface of the crank pin ring.
Caution!
You are not allowed to use a wrench (pneumatic, hydraulic or electric).
Tightening of screws, propeller hub ............................................... K586431
7.2.5 Drive shaft seal

During operation, some oil drops from the sealing may be seen. This is normal and not considered to be leakage.
If a leakage occurs from the seal ring, the drive shaft coupling can easily be removed without removing the
electric motor, and the seal ring can be replaced.
7.2.6 Change and refilling of oil

The hydraulic / lubrication oil is to be changed if an oil analysis indicates that the oil is impure or in bad
condition.
Take oil samples at least once a year and have them analysed by the oil supplier.
Oil used must fulfil our “Requirements for hydraulic oil” (11867-E).
For required oil volume, see chapter 6.
Drain of oil
The installed pump (P53) is to be used for drainage.
• Close valve V54 and open valve V53
• Drain the oil
Refilling of oil
• Close valve V53 and open valve V54
• Refill the system via the filling connection, Z, on the valve manifold. (See drawing “Hydraulic pump
unit”)
• Check the oil level in the oil tank.
Note!
The valve V54 is to be locked in open position.
Note!
Cleanliness is essential.

User Manual
7.3 Trouble shooting
Figure 7 - Trouble shooting diagram

User Manual
8 SPARE PARTS
8.1 Standard spare parts
Spare parts, filter inserts................................................................. 416934
8.2 Additional spares

1 Seal kit for pump per ship
1 Spare complete pump per ship series
8.3 Preservation of spares

Spareparts have to be stored in proper conditions:
O-rings and sealings: Dark, cold dustfree.
Bearings: Dry, cold without strong vibrations.
Filters, bolts, nuts, anodes and couplings: Dry.

User Manual
8.4 Ordering spare parts

SERVICE AND SPARES FOR ULSTEIN KAMEWA EQUIPMENT
ADDRESS TELEPHONE FAX MOBILE
AMERICA
USA
Rolls-Royce Marine Inc +1 504 464 4561 +1 504 464 4565
200 James Drive West
St. Rose, LA 70087 USA
Rolls-Royce Commercial Marine +1 954 745 5400 +1 954 745 5401

4350 Oakes Road, Suite 528
Fort Lauderdale, FL 33314 USA
Rolls-Royce Marine Inc +1 508 660 6328 +1 508 660 6210

110 Norfolk Street
Walpole, MA 02081 USA
Rolls-Royce Marine Seattle +1 206 782 9190 +1 206 782 0176

4451 – 14th Avenue NW
Seattle, WA 98107-4696
SOUTH AMERICA
Rolls-Royce Marine Ltda. +55 21 2277 0100 +55 21 2262 1952
Av. Almirante Barroso 52, 9th floor
20031-000 RIO DE JANEIRO – RJ
Brazil
CANADA
Rolls-Royce Canada Ltd +1 902 468 2883 +1 905 468 2759
(GSN Commercial Marine)
196 Joseph Zatzman Drive, Unit 9
Dartmouth, Nova Scotia
Canada B3B 1N4
*= off hours no.

User Manual
ASIA
CHINA
Rolls-Royce Marine Shanghai +86 21 638 78808 +86 21 538 25793 +86 21 628 14228
RM 911-915 Lippo Plaza
No. 222, Huaihai Road (M)
200021 SHANGHAI China
HONG KONG
Rolls-Royce Maine Hong Kong Ltd +852 2526 6937 +852 2868 5344
3303-3305 Shui On Centre
6-8 Harbour Road, Wanchai
HONG KONG SAR
INDIA
Rolls-Royce +91 22 820 45 41 +91 22 820 45 42
Mumbai, India
JAPAN
Rolls-Royce Marine Japan K.K. +81 3 3237 6861 +81 3 3237 6846
Tobunsha Bldg. 4F
2-5-1, Kudan-Minami
Chiyoda-ku
TOKYO 102-0074 JAPAN
KOREA
Rolls-Royce Marine Korea Ltd +82 51 831 4100 +82 51 831 4101
Noksan State Industrial Complex 18B-2L
1578-1, Songjeong-dong, Gangseo-gu
BUSAN 618-270 Korea
RUSSIA
Rolls Royce Marine +7 4232 495484 +7 4232 495484
Vladivostok Rep Office
5F, 3-B, Streinikova Str.
690065 Vladivostok, Russia
SINGAPORE
Rolls Royce Marine Singapore Pte Ltd Service:
No 6 Tuas Drive 1, Jurong +65 9632 1347 +65 862 8390 +65 98466277*
SINGAPORE 638673 Spares:
+65 960 39198 +65 862 5386
*= off hours no.

User Manual
EUROPE
BENELUX
Rolls-Royce Marine Benelux B.V. +31 10 409 0920 +31 10 409 0921 +31 0651 531 528*
P.O. Box 666 (Werfdijk 2)
3195 HV Pernis Netherlands
DENMARK
Rolls-Royce Marine AS – Denmark +45 98 11 49 55 +45 98 11 49 45 +45 40 19 49 55
Værftsvej 23
DK-9000 AALBORG Denmark
FINLAND
Rolls-Royce Marine Oy Ab +358 2 83791 +358 2 8379 4874 +358 49 666 678
PO Box 220 (Suojantie 5)
FIN-26101 RAUMA Finland
FRANCE
Rolls-Royce Marine France +33 1 468 62811 +33 1 468 79398
Immeuble de Monaco
4 Place des Etas-Unis
F-94150 RUNGIS France
GERMANY
Rolls-Royce Marine Deutschland Gmbh
+49 40 780 9190 +49 40 780 91919 +49 40 780 9190*
Kamerunweg 7
D-20457 Hamburg Germany
GREECE
Kaminco Overseas Inc +30 1 45 28 240 +30 1 42 94 887
Presented by KAMINIS Co Ltd +30 1 42 93 355
‘KAMINKO PROPULSION SERVICES’
57 Akti Miaouil PO Box 80115
GR-PIRAEUS 18510 Greece Telex: 212424 kam gr
E-mail: Kamewz.service@kaminco.com
ITALY
Rolls-Royce Marine Italia s.r.l. +39 010 572 1922 +39 010 572 1950 +39 348 7121506*
Piazza delia Vittoria 14/19
I-16121 GENOVA Italy
NORWAY
Rolls-Royce Marine AS +47 70 01 40 00 Spares: +47 900 10 997*
dept. Propulsion - Ulstein +47 70 01 40 18
Sjøgata 98 Tech. support:
N-6065 ULSTEINVIK, NORWAY +47 70 01 40 12
E-mail:
ulstein@rolls-royce.com
*= off hours no.

User Manual
POLAND
Rolls-Royce Marine Poland +48 587 820 655 +48 587 820 656
Alfa Plaza Building
Batorego 28-32 str.
81336 GDYNIA Poland
SPAIN
Rolls-Royce Espana SA +34 977 296 444 +34 977 296 450
PO Box 894
E-43080 TARRAGONA Spain
SWEDEN
Rolls-Royce AB +46 550 84000 +46 70 528 6566*
Box 1010 Spares:+46 550 84776
S-681 29 Kristinehamn Sweden Service:+46 550 84671
E-mail: Tech support:+46 550 84771
sweden.techsup@rolls-royce.com
spares.sweden@rolls-royce.com
UK
Rolls-Royce Commercial Marine Ltd (UK)
Green Street, Green Road +44 1322 394 300 +44 1322 394 302 +44 790 151 7070*
Dartford Kent DA1 1QG UK
AUSTRALIA
Rolls-Royce Marine Australia Pty Ltd
Perth Office +61 8 9336 7910 +61 8 9336 7920 +61 418 567 523*
1 Mouat Street
Fremantle, WA 6160 AUSTRALIA
Melbourne Office +61 3 9873 0988 +61 3 9873 0866 +61 417 323 077*
Office 4, 5 Redland Drive
Mitcham, VIC 3132 AUSTRALIA
*= off hours no.

User Manual
9 TOOLS
9.1 Tools
Injector, coupling TT...................................................................... 416766
Mounting tool drive shaft coupling TT .......................................... K141156

User Manual
10 DESIGN DRAWINGS AND DOCUMENTS

10.1 Dimension drawings
Dimension drawing tunnel thruster T9255-56................................ 313084
10.2 Assembly drawings

Main assembly................................................................................ 217653
Main assembly................................................................................ 108410
Tunnel assembly............................................................................. 108980
Propeller unit assembly .................................................................. 108981
Propeller hub assembly .................................................................. 108500
Gear coupling assembly ................................................................. K141353
Feed back assembly........................................................................ K141995
10.3 Hydraulics
Hydraulic diagram.......................................................................... 109401
Alarm list........................................................................................ 416906
Hydraulic connections thruster top................................................. 217654
10.4 Hydraulic units

Hydraulic module ........................................................................... 217213
Arrangement pump unit.................................................................. 312502
Filter arrangement .......................................................................... 312475
Hand pump ..................................................................................... 311290
10.5 Oil Tanks

Gravity tank.................................................................................... 217255
10.6 Electrics
Drive motor ................................................................................... 17-355-870
10.7 Painting spesification

Painting instruction drawing........................................................... K141514

User Manual
10.7.1 Standard painting specification

The equipment are to be painted according to specification below. Coated areas are to give corrosion protection
under normal transportation, storage and outfitting period. The final treatment is carried out by the yard
according to the total painting system for the ship.
Preparation before coating acc. to:

ISO 8501-1: .................................................................................... Surface preparation.
ISO 8503-1: .................................................................................... Steel roughness. (Medium (G) Ry 50-80 micron.)
ISO 8502-3: .................................................................................... Dust-free testing before painting.
ISO 8502-4: .................................................................................... Climatic conditions when painting. (Air
temperature and steel temperature to be minimum +10 °C or 3 °C above dew point.)
Tunnel General:
Sandblasting to SA 2,5 Strip coating before one layer of
Epoxy Primer Interguard 269 EGA 088/089. ................................. 40 - 80 micron.
Aditional on not accessible area after mounting(Dwg.
K141514) TT:
One layer Intershield 300 (Bronze) ................................................ min.150 micron.
One layer Intershield 300 (Alu.)..................................................... min.150 micron.
Additional Sealed area between inner and outer tunnel
(Dwg. 416720) TT-SS :
One layer Intershield 300 (Alu)...................................................... min.150 micron.
Sealring between inner and outer tunnel SS:
Sealring motorfoundation:
Stainless steel:
Surface prep. acc. To Fabrication guide item 5.5 Epoxy
Primer Interguard 269 EGA 088/089 ............................................. 40 - 80 micron.
Motor foundation General:

Additional Outside area below sealing ring, and inside
TT-SS :
Support brackets General:

Hull module General:

Epoxy Primer Interguard 269 EGA 088/089 .................................. 40 - 80 micron.
Thruster unit General:

Epoxy Primer Interguard 269 EGA 088/089 .................................. 40 - 80 micron.
Additional Not accessible area after mounting TT-SS /
TT (Dwg. K141514) (Dwg. 416720)
Ropeguard

User Manual
Epoxy Primer Interguard 269 EGA 088/089 ................................. 40 - 80 micron.
Gear box
Inside:
Interguard 276 EGA 080/089 white ............................................... 40 - 80 micron.
Outside:
Epoxy Primer Interguard 269 EGA 088/089 ................................. 40 - 80 micron.
Executed by RRM:
Interprime 198 grey. ....................................................................... 40 - 80 micron
One layer Interlack DQE322 Green color RAL 6019. ................... 40 - 80 micron.
Oil tank
Inside:
Sandblasting to SA 2,5 One layer Epoxy Primer, Interguard
269 EGA 088/089 .......................................................................... 40 - 80 micron.
Outside:
Sandblasting to SA 2,5 One layer Epoxy Primer, Interguard
269 EGA 088/089 .......................................................................... 40 - 80 micron.
Executed by RRM:
Interprime 198 grey. ....................................................................... 40 - 80 micron.
One layer Interlack DQE322, green colour, RAL 6019 ................. 40 - 80 micron.
Hydraulic module general:

One layer Epoxy Primer, Interguard 269 EGA 088/089 ................ 40 - 80 micron.
Executed by RRM:
Interprime 198 grey. ....................................................................... 40 - 80 micron.
One layer Interlack DQE322 green colour, RAL 6019 .................. 40 - 80 micron.
Drive motor/starter general

Delivered according to sub supplier's standard painting
specification.
Electronic equipment
Control panel ................................................................................. RAL 9011, black.
Electronic cabinet ........................................................................... RAL 7032, grey
Starter cabinet ................................................................................ RAL 7032, grey

User Manual
10.8 Hydraulic system

Installation of Equipment
The components have to be located according to "Hydraulic System Diagram", enclosed in manual.
The hydraulic module shall be located close to the TT unit (max. 8 m) as straight as possible with a minimum of
bends. The pump unit consists of pump, shaft coupling, el motor, necessary valves, pressure switches, gauge and
terminal box.
The piping to be manufactured of steel, with a minimum diameter as stated on the ‘Hydraulic System Diagram’
and dimensioned to meet the requirements of the classification society. The piping to be assembled as short and
straight as possible, with a minimum of bends. The maximum pipe length is 15m.
Completed piping to be pressure tested to 1.5 x max working pressure or according to requirements of the
classification society.
10.9 Flushing of hydraulic system

The piping between the main components to be flushed according to drawing: 312322, "Flushing of Hydraulic
System".
Oil filling and venting of Thrusters and Hydraulic System.

The thruster and the hydraulic system to be filled with oil (according to oil list) and vented according to oil
filling procedure, "Oil filling instructions for tunnel thrusters with CP-hub"
Make sure that all piping is flushed according to flushing procedure on drawing: 312322, "Flushing of
Hydraulic System" before oil filling.
Oil quality to be according to oil list, "Requirements for hydraulic oil".
Start up of Hydraulic System:

The hydraulic system to be started up according to start up procedure for the hydraulic system: Eng-017
Oil Pressure
The system is designed for a maximum working pressure of 100 bar (10 MPa)
Necessary pressure for manoeuvring the pitch is to be checked during the sea trial (See sea trial report in
manual).
The pump pressure is approx. 20 bar (2 MPa) when the control valve is in its middle position. The pressure can
be higher at starting up, if the oil is cold

User Manual
10.10 Hydraulic system description

The pitch setting of the propeller is carried out by means of hydraulic oil pressure. For this purpose, a hydraulic
pump unit and a gravity tank belongs to the propeller equipment. Regarding the hydraulic system, see ‘Hydraulic
System Diagram’. The system is to be maintained in such a way that it is always in the best condition. The oil
recommendations are to be followed, as well as the instructions given in the maintenance chapter.
Hydraulic module
Pump (P51)
The pump is vertically mounted on the module and is driven by an electric motor. The actual pump and motor
data is listed in the technical information in the manual.
Pressure filter (F51)

The oil filter is mounted on the module.
The filter is equipped with:
• A 10 micron element with visual/electrical indicator that provides a visual warning/electrical signal
when the element needs to be replaced with a new element; normally included in the standard spare
part set.
• A by-pass valve (V55), which prevents element damage in cases of extreme clogging or at cold start.
Note!
The indicator can show "red" at operation with cold oil. This does not necessarily mean that the filter element is
clogged.
Pitch control valve (V60)

The control valve is of proportional type and has devices for flow control, independent of load. The valve keeps
the propeller pitch in set position.
The pressure relief valve (V64) is fixed at start-up at a value of 100 bar (10 Mpa)
Pressure switches (PS52, PS53, PS54)

The hydraulic module is equipped with one pressure switch for "alarm, low pressure" (PS52), one pressure
switch for "interlock, stop drive motor" (PS53) and one pressure switch for "alarm, high pressure" (PS54).
The switches are normally pre-set before delivery. See "Hydraulic System Diagram".

User Manual
10.11 Gravity tank (ENG-0124)

The oil tank will work both as a main oil tank and as a gravity tank. Because of this, it must be installed above
the highest waterline.
The tank is equipped with a level switch (LS51) for "low level alarm" on the top. The switch can be easily
dismantled at testing. Alarm point is approx. 80% of maximum oil volume.
A temperature switch (TS51) for "alarm, high oil temperature" is installed in the oil tank. Normal alarm point is
65°C.
Location of gravity Tank:

The piping between thruster top, hydraulic module and the tank, is to be as short and straight as possible with a
minimum of 15° slope on the piping.
The gravity tank has to be located according to the formula:
Height_Gravity_tank = Max_draught x 1,15 + 3,3 (meter)
Height_Gravity_tank: Height from Tunnel Thruster centre to bottom of gravity tank. Tolerance
from 0 to +1 meter.
Max_draught: Height from Tunnel Thruster centre to maximum water line (level).
Note!
When variation between "maximum water line" and "minimum water line" is above 6 meter an arrangement with
pressurised gravity tank with controllable air pressure has to be considered. Depending on operation duty and
operation time in different draughts.
Drain Pump
For draining of oil, and also for oil test, a hand pump is delivered. This pump to be located max 3 meter above
the propeller centre.

Appendix 1 - Drawing: 312149, Control form alignment motor foundation Page 62
Appendix 2 - Drawing: 312322, Instruction for flushing Page 63
Appendix 3 - Drawing: 311130, Instruction for oil filling Page 64
Appendix 4 - Drawing: K586431, Tightening of screws, propeller hub Page 65
Appendix 5 - Drawing: 416934, Spare parts, filter inserts Page 66
Appendix 6 - Drawing: 416766, Injector, coupling TT Page 67
Appendix 7 - Drawing: K141156, Mounting tool drive shaft coupling TT Page 68
Appendix 8 - Drawing: 313084, Dimension drawing tunnel thruster T9255-56 Page 69
Appendix 9 - Drawing: 217653, Main assembly Page 70
Appendix 10 - Drawing: 108410, Main assembly Page 71
Appendix 11 - Drawing: 108980, Tunnel assembly Page 72
Art.no.: 108980 TUN.PROP.ENH. TT1650 ICE CP Rev: -
TUN. PROP.UNIT TT1650 ICE CP
Pos. no. Art. no. Name No. of. Unit Pos. no. Art. no. Name No. of. Unit
1 K986658 STAG 1 PC. |
STAY |
2 . * SE ORDRE 1 PC. |
* SEE ORDER |
3 108981 PROP.ENHET 1 PC. |
PROP. UNIT |
4 108987 PROPELLHODE 1 PC. |
PROP.HUB |
5 551604 PROPELLBLAD 4 PCS. |
PROP.BLADE |
6 K141127 PINJONG 1 PC. |
PINION SHAFT |
7 K141126 TANNHJUL 1 PC. |
GEARWHEEL |
8 108562 ARR.TUNNELMONTERING 1 PC. |
ARR.TUNNEL MOUNTING |
9 K141995.3 ARR.FEEDBACK 1 PC. |
ASS.FEEDBACK DEVICE |
Part list for article no. 108980 Page 73

Appendix 12 - Drawing: 108981, Propeller unit assembly
Appendix 13 - Drawing: 108981, Propeller unit assembly
Appendix 14 - Drawing: 108981, Propeller unit assembly Page 76
Art.no.: 108981 PROP.ENHET TT1650 ICE CP Rev: A
PROP. UNIT TT1650 ICE CP
1 108547 GEARHUS 1 PC. | 22 K983927 SKIVE 1 PC.
GEAR HOUSE AUX/ICE | WASHER
2 K141124 THR.LAGERHUS 1 PC. | 23 K983617 BUNNDEKSEL 1 PC.
END COVER | COVER
3 K983493 ENDE DEKSEL 1 PC. | 24 K141169 FORING 1 PC.
END COVER | LINER
4 . * SE ORDRE 1 PC. | 25 K141177 DEKSEL DRIVE SHAFT SEAL 1 PC.
* SEE ORDER | COVER DRIVE SHAFT SEAL
5 .. * SE ORDRE 1 PC. | 26 ... *SE ARR.TUNNEL 4 PCS.
* SEE ORDER | SEE ARR.TUNNEL
6 107829 PROPELLAKSEL 1 PC. | 27 K983587 STYREHYLSE 1 PC.
PROP.SHAFT | GUIDE SLEEVE
7 K141130 LAGERHUS 1 PC. | 28 83179 EO-PLUGG VSTI 1 PC.
BEARING HOUSING | EO-PLUG VSTI
8 K141131 LAGERDEKSEL 1 PC. | 29 K983678 STRØMN.DEKSEL 1 PC.
BEARING COVER | FAIRING COVER TT
9 107821 FLENSKOPLING 1 PC. | 30 K983679 INNFØRINGSPLUGG TT 2 PCS.
HUB COUPLING | INLET PLUG TT
10 216509 OLJERØR 1 PC. | 31 K112177 ADAPTER 1 PC.
OIL PIPE | ADAPTER
11 K983673 FORING 1 PC. | 32 K983625 DISTANSESKIVE 6 PCS.
BUSHING | SPACING WASHER TT
12 216647 ARR.TILBAKEFØRING 1 PC. | 33 991387 PLASTELEM.RØRKLEMME 4 PCS.
ARR.FEEDBACK | PLAST.ELEM.PIPE CLAMP
13 K983663 OD-BOKS DIA. 1 PC. | 34 K954022 PLUGG 1 PC.
OD-BOX DIA. | PLUG
14 K983666 PLATE TT 1 PC. | 35 991397 TOPPLATE RØRKLEMME 2 PCS.
PLATE TT | TOP PLATE PIPE CLAMP
15 K141174 ARM FEEDBACK 1 PC. | 37 93538 4 PCS.
LEVER FEEDBACK | HEX.SCREW M
16 K141147 ARM 1 PC. | 38 991391 PLASTELEM.RØRKLEMME 6 PCS.
LEVER | PLAST.ELEM.PIPE CLAMP
17 K983875 CARRIER PIN TT 1 PC. | 39 991398 TOPPLATE RØRKLEMME 3 PCS.
CARRIER PIN TT | TOP PLATE PIPE CLAMP
18 109324 STRØMN.DEKSEL 1 PC. | 40 312003 HYLSEBOKS 1 PC.
FAIRING | STERNTUBE BOX
19 K983838 SKIVE TT 1 PC. | 41 84762 6 PCS.
DISC TT | HEX.SCREW M
21 K141143 GJENNOMF. 1 PC. | 42 86003 LAGER SKF 1 PC.
COVER | BEARING SKF
Pos. no. Art. no. Name No. of. Unit | Pos. no. Art. no. Name No. of. Unit
43 99373 LAGER SKF 1 PC. | 69 92625 O-RING NBR 199.3X 5.70 1 PC.
BEARING SKF | O-RING NBR
44 992251 LAGER SKF 1 PC. | 70 90029 O-RING NBR 2 PCS.
45 992252 LAGER SKF 1 PC. | 71 992258 O-RING NBR 1 PC.
46 91295 LAGER SKF 1 PC. | 72 992259 O-RING NBR 1 PC.
47 96610 LAGER SKF 1 PC. | 75 93751 SEEGERRING I 1 PC.
BEARING SKF | CIRCLIP
48 992253 AKSELMUTTER KMT 1 PC. | 76 90036 SEEGERRING A 1 PC.
COLLAR NUT KMT | CIRCLIP
49 992254 AKSELMUTTER KMT 1 PC. | 79 84988 GJ.STIFT M 3 PCS.
COLLAR NUT KMT | GRUB SCREW M
50 992035 LAGER SKF GE 1 PC. | 80 92346 GJ.STIFT M 2 PCS.
BEARING SKF GE | GRUB SCREW M
53 992038 STEMPELRING 1 PC. | 81 94195 GJ.STIFT 6 PCS.
PISTON RING | GRUB SCREW
54 992039 STEMPELRING 1 PC. | 84 992053 2 PCS.
PISTON RING | HEX.SCREW M
55 992255 TETN.RING BABSL 1 PC. | 85 90440 8 PCS.
SEALING RING | HEX.SCREW
56 992041 SKRAPERING 1 PC. | 86 91886 3 PCS.
STRIPPER | HEX.SCREW
58 82444 V-RING NITRIL 1 PC. | 88 90957 SYL.SKRU M 11 PCS.
V-RING NITRIL | SOCKET SCREW M
59 93045 PAKNINGSSK. 2 PCS. | 89 95237 SYL.SKRU 2 PCS.
BONDED SEAL | SOCKET SCREW
60 94562 PAKN.SK. 2 PCS. | 91 91905 SYL.SKRU M 2 PCS.
BONDED SEAL | SOCKET SCREW M
63 992042 O-RING FPM 1 PC. | 92 84607 SYL.SKRU M 6 PCS.
O-RING FPM | SOCKET SCREW M
64 82233 O-RING NBR 1 PC. | 93 91059 SYL.SKRU M 2 PCS.
O-RING NBR | SOCKET SCREW M
65 992043 O-RING NBR 2 PCS. | 94 93020 SYL.SKRU M 4 PCS.
O-RING NBR | SOCKET SCREW M
66 992044 O-RING NBR 1 PC. | 95 91208 SYL.SKRU 5 PCS.
O-RING NBR | SOCKET SCREW
67 93628 O-RING NBR 2 PCS. | 96 90340 SYL.SKRU 12 PCS.
O-RING NBR | SOCKET SCREW

Pos. no. Art. no. Name No. of. Unit | Pos. no. Art. no. Name No. of. Unit
97 90411 SYL.SKRU 6 PCS. | 126 992006 LOCTITE NO.243 50 ML 0 PC.
SOCKET SCREW | LOCTITE
98 84632 SYL.SKRU 12 PCS. | 127 992051 LOCTITE 0 PC.
SOCKET SCREW | LOCTITE
99 92684 SYL.SKRU 10 PCS. | 131 93415 PAKN FLYTENDE RAUD NON 0 PC.
SOCKET SCREW | JOINTING COMPOUND NON
103 85179 MONEL-SKIVE Ø 3 PCS. |
WASHER MONEL Ø |
104 93920 1 PC. |
HEX.NUT |
105 90067 LÅSETRÅD Ø 0 M |
LOCK WIRE |
106 95347 GJ. STANG .135 M |
THREADED ROD |
108 992048 LENKEHODE AS 2 PCS. |
LINK HEAD |
110 93822 EO-KROPP GE 2 PCS. |
EO-BODY GE |
111 83374 EO-KROPP EW 2 PCS. |
EO-BODY EW |
112 992127 SLANGE RS 2 PCS. |
HOSE |
113 992128 SLANGE 1 PC. |
HOSE |
117 83181 EO-PLUGG VSTI 3 PCS. |
EO-PLUG VSTI |
118 90509 PLUGG 3 PCS. |
PLUG TAPER |
119 90189 EO-PLUGG VSTI R 1 PC. |
EO-PLUG VSTI R |
120 992049 PLUGG VSTI 2 PCS. |
PLUG VSTI |
121 992132 SLANGEBESKYTTELSE 10 M |
HOSE |
122 992131 SLANGEBESKYTTELSE HG - 1 M |
HOSE |
124 992440 PLUGG 1 PC. |
PLUG |
125 992235 PLUGG 1 PC. |
PLUG |

Appendix 15 - Drawing: 108500, Propeller hub assembly
Appendix 16 - Drawing: 108500, Propeller hub assembly Page 81
Art.no.: 108500 PROPELLHODE 46XF8/4 Rev: C
ASS.PROP.HUB 46XF8/4
1 108501 PROPELLBOSS 1 PC. | 23 90601 SYL.SKRU M 4 PCS.
HUB BODY | SOCKET SCREW M
2 108778 KULISSE 1 PC. | 24 992003 FJÆR 3 PCS.
GUIDE | SPRING
3 216911 TAPPSKIVE 4 PCS. | 25 992004 LÅSEPLATE 16 PCS.
CRANK PIN RING | LOCKING PLATE
4 85203 MONEL-SKIVE Ø 24 PCS. | 26 992005 LÅSEPLATE 8 PCS.
WASHER MONEL Ø | LOCKING PLATE
5 312126 GLIDESKO 4 PCS. | 28 992006 LOCTITE 0 PC.
SLIDING SHOE | LOCTITE
6 312127 BLADBOLT 24 PCS. | 29 992007 LOCTITE 0 PC.
BLADE BOLT | LOCTITE
7 K915818 STYREPINNE 4 PCS. | 30 93415 PAKN FLYTENDE RAUD NON 0 PC.
GUIDE PIN | JOINTING COMPOUND NON
8 416555 STYREPINNE Ø 4 PCS. | 31 992009 GREASE TEFLON PTFE 0 PC.
GUIDE PIN Ø | GREASE TEFLON PTFE
9 312128 SERVORØRHOLDER 1 PC. | 32 992010 MOLYCOTE G-RAPID PLUS 0 PC.
PITCH PIPE CLAMP | MOLYCOTE G-RAPID PLUS
10 K954022 PLUGG 3 PCS. |
PLUG |
11 312129 GLIDEKLOSS 1 PC. |
SLIDING BAR |
12 312130 FJÆRHOLDER 1 PC. |
SPRING RETAINER |
13 416810 DYSE 2 PCS. |
NOZZLE |
14 85199 MONEL-SKIVE Ø 12 PCS. |
WASHER MONEL Ø |
17 992024 STYRERING RWR 1 PC. |
GUIDE RING RWR |
18 992000 STEMPELRING GHH/C 2 PCS. |
PISTON RING GHH/C |
19 992042 O-RING FPM 3 PCS. |
O-RING FPM |
20 416473 BLADTETNING 4 PCS. |
SEAL RING PROP.BL. |
21 992002 O-RING NBR 1 PC. |
O-RING NBR |
22 90918 12 PCS. |
HEX.SCREW |
Appendix 17 - Drawing: K141353, Gear coupling assembly Page 83
Appendix 18 - Drawing: K141995.3, Feed back assembly Page 84
Art.no.: K141995.3 ARR.FEEDBACK TT1650 CP Rev: -
ASS.FEEDBACK DEVICE TT1650 CP
1 K993764 BRAKETT TT 1 PC. |
BRACKET TT |
2 K993766 ARM TT 1 PC. |
LEVER TT |
3 K993765 ARM TT 1 PC. |
LEVER TT |
4 900458 GJ. STANG 1 PC. |
THREADED ROD |
5 90174 2 PCS. |
HEX.SCREW |
6 90455 SYL.SKRU M 2 PCS. |
SOCKET SCREW M |
7 90957 SYL.SKRU M 3 PCS. |
SOCKET SCREW M |
8 93462 2 PCS. |
HEX.NUT |
9 992048 LENKEHODE AS 2 PCS. |
LINK HEAD |
10 K984664 ARR.TRANSM. 1 PC. |
ASS.TRANSM. |
11 992006 LOCTITE 1 PC. |
LOCTITE |
Part list for article no. K141995.3 Page 85

Appendix 19 - Drawing: 109401, Hydraulic diagram Page 86
Appendix 20 - Drawing: 416906, Alarm list Page 87
Appendix 21 - Drawing: 217353, Hydraulic connections thruster top Page 88
Art.no.: 217353 HYDR.THR.TOP TT1650/1850 AUX+ Rev: -
HYDR.THR.TOP TT1650/1850 AUX+
1 312662 MONT.PL.HYDR.RØR 1 PC. | 22 94245 EO-KROPP G 1 PC.
MOUN.PL.HYDR.PIPE | EO-BODY G
2 312663 MONT.PL.HYDR.RØR 1 PC. |
MOUN.PL.HYDR.PIPE |
4 87499 EO-KROPP SV 2 PCS. |
EO-BODY SV |
5 95140 EO-KROPP SV 2 PCS. |
EO-BODY SV |
6 901381 EO-MÅLEPUNKT VKA 2 PCS. |
EO-TEST POINT VKA |
7 83422 EO-KROPP EL 2 PCS. |
EO-BODY EL |
8 990784 EO-KROPP GZ 1 PC. |
EO-BODY GZ |
9 92998 EO-KROPP EL 3 PCS. |
EO-BODY EL |
10 901382 EO-MÅLEPUNKT VKA 2 PCS. |
EO-TEST POINT VKA |
11 94366 NR.VENTIL RHD 1 PC. |
NR.VALVE RHD |
12 90006 EO-KROPP GE 1 PC. |
EO-BODY GE |
EO-BODY GE |
14 93784 EO-RED UT/IN BSP RI 1 PC. |
EO-RED O/I BSP RI |
15 90599 EO-KROPP GE 1 PC. |
EO-BODY GE |
16 991107 2 PCS. |
|
17 991109 6 PCS. |
|
18 991123 7 PCS. |
|
19 91904 HYDR.RØR 1 M |
HYDR.PIPE ST |
20 990936 HYDR.RØR 2 M |
HYDR.PIPE |
21 80311 HYDR.RØR 2 M |
HYDR.PIPE ST |
Appendix 22 - Drawing: 217213, Hydraulic module Page 90
Art.no.: 217213 HYDR.MODUL TT1650 CP 1.PUMPE Rev: A
HYDR.MODULE TT1650 CP 1.PUMP
1 312024 FUND. HYDR.MOD 1 PC. |
|
4 312481 ARR.PROP.VENTIL 1 PC. |
ARR.PROP.VALVE |
5 312480 ARR.PRESS.PANEL 1 PC. |
ARR.PR.SWITCH PANEL |
6 901321 MANOMETER 1 PC. |
PRESS.GAU |
7 98718 EO-TESTPUNKT MAV 2 PCS. |
EO-TEST POINT MAV |
8 901344 SLANGE 1 PC. |
HOSE F.MEASURING POINT |
9 312575 SLANGE 1 PC. |
HOSE |
10 98967 HYDR.RØR 1 M |
HYDR.PIPE |
11 80311 HYDR.RØR .5 M |
HYDR.PIPE ST |
12 901349 MASK.SKR MF 3 PCS. |
MASK.SKR MF |
13 312599 ARR.KOPL.BOKS TT 1 PC. |
ARR.JUNCTION BOX TT |
14 413247TT SKILT 1 PC. |
SIGN |
15 409438 SKILT "PUMP 1 PC. |
SIGN PUMP |
16 83179 EO-PLUGG VSTI 1 PC. |
EO-PLUG VSTI |

Appendix 23 - Drawing: 312502, Arrangement pump unit Page 92
Art.no.: 312502 ARR.P.AGG. TT1650-1850 CP COMM Rev: A
ARR.P.UNIT.COMM.TT1650-1850 CP
1 901341 EL.MOTOR 1 PC. | 21 83421 EO-KROPP EL 1 PC.
EL.MOTOR | EO-BODY EL
2 901342 PUMPE COM 1 PC. | 22 990463 EO-MÅLEPUNKT VKA 2 PCS.
PUMP COM | EO-TEST POINT VKA
3 901343 KOPL.HUS 1 PC. | 23 991428 EO-PLUGG VKA 1 PC.
PUMP ADAPTER | EO-PLUG VKA
4 900633 EL.KOPL.ROTEX 1 PC. | 24 991099 1 PC.
EL.COUPL. ROTEX |
5 900632 TANNKRANS ROTEX 1 PC. | 25 991123 5 PCS.
SPIDER ROTEX |
6 900634 EL.KOPL.ROTEX 1 PC. | 26 84627 SYL.SKRU 4 PCS.
EL.COUPL. ROTEX | SOCKET SCREW
7 416715 ADAPTERPLATE 1 PC. | 27 90869 FJÆRSKIVE 4 PCS.
ADAPTORPLATE | SPRING WASHER
8 80311 HYDR.RØR .5 M |
HYDR.PIPE ST |
9 312473 SLANGE 1 PC. |
HOSE |
10 84135 KULEVENTIL 1 PC. |
BALL VALVE |
11 901121 NR.VENTIL RHD 1 PC. |
NR.VALVE RHD |
12 95140 EO-KROPP SV 1 PC. |
EO-BODY SV |
13 95134 EO-KROPP GE 1 PC. |
EO-BODY GE |
14 90599 EO-KROPP GE 1 PC. |
EO-BODY GE |
15 94698 EO-KROPP EGE 1 PC. |
EO-BODY EGE |
EO-BODY EGE |
17 91479 EO-KROPP W 1 PC. |
EO-BODY W |
18 90286 EO-KROPP ET 2 PCS. |
EO-BODY ET |
19 83554 EO-RED RED 2 PCS. |
EO-RED RED |
20 83374 EO-KROPP EW 1 PC. |
EO-BODY EW |
Appendix 24 - Drawing: 312475, Filter arrangement Page 94
Art.no.: 312475 ARR.FILTER ENKELT 26P2 Rev: A
ARR.FILTER SINGLE 26P2
1 901307 FILTER 1 PC. |
OIL FILTER |
2 901308 SMUSSIND. 1 PC. |
DIRT |
3 992200 FILTERINNSATS 1 PC. |
FILTER INSERT |
EO-BODY GE |
5 83423 EO-KROPP EL 1 PC. |
EO-BODY EL |
6 83554 EO-RED RED 1 PC. |
EO-RED RED |
7 990463 EO-MÅLEPUNKT VKA 1 PC. |
EO-TEST POINT VKA |
8 991113 1 PC. |
|
9 94169 4 PCS. |
HEX.SCREW |
10 91341 FJÆRSKIVE 4 PCS. |
SPRING WASHER |

Appendix 25 - Drawing: 311290, Hand pump Page 96
Art.no.: 311290 ARR.HANDP. TT2650-3300 Rev: A
ARR.HANDP.DRAIN TT2650-3300
1 84311 HANDPUMPE DESIGN A SIZE 1 PC. |
HAND PUMP DESIGN A SIZE |
2 84135 KULEVENTIL 3 PCS. |
BALL VALVE |
3 94061 EO-RED UT/IN BSP RI 2 PCS. |
EO-RED O/I BSP RI |
EO-BODY GE |
5 991123 8 PCS. |
|

Appendix 26 - Drawing: 217255, Gravity tank Page 98
Art.no.: 217255 OLJETANK 110L M/T.ALARM+2.NIVÅ Rev: A
OIL TANK 110L M/T.ALARM+2.LEVE
1 992389 OLJETANK 1 PC. |
OIL TANK |
2 992392 LUFTE FILTER 1 PC. |
AIR BREATHER |
3 900701 NIVÅBRYTER 1 PC. |
LEVEL SWITCH |
4 992387 TEMP.FØLER ISN 1 PC. |
TEMP.SENSOR TRAFAG |
5 83181 EO-PLUGG VSTI 4 PCS. |
EO-PLUG VSTI |
6 991310 EO-PLUGG VSTI 1 PC. |
EO-PLUG VSTI |
7 413247TT SKILT 1 PC. |
SIGN |
8 90006 EO-KROPP GE 1 PC. |
EO-BODY GE |
EO-BODY EGE |
10 84144 KULEVENTIL 1 PC. |
BALL VALVE R |
EO-BODY GE |
12 991123 3 PCS. |
|

Appendix 28 - Drawing: K141514, Painting instruction drawing
Appendix 29 - Drawing: K141514, Painting instruction drawing Page 102

III-2 Rolls-Royce Boegschroef Timca Manual + Scedules T9255-56 Rev A PDF

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1.

USER MANUAL 2. SAFETY

Contract manager for this project:

User Manual 18 Jan 2006 Page 2

User Manual 18 Jan 2006 Page 3

User Manual 18 Jan 2006 Page 4

User Manual 18 Jan 2006 Page 5

PD [kW] = propeller power

User Manual 18 Jan 2006 Page 6

User Manual 18 Jan 2006 Page 7

User Manual 18 Jan 2006 Page 8

2.1 General statement

User Manual 18 Jan 2006 Page 9

2.3.2 Maintenance and repair

User Manual 18 Jan 2006 Page 10

User Manual 18 Jan 2006 Page 11

3.2 Delivery specification

3.3 General information

3.4 Tunnel and gear housing

3.5 Propeller hub

3.6 Servo system

User Manual 18 Jan 2006 Page 12

User Manual 18 Jan 2006 Page 13

3.7 Plan for testing and documentation

ITEM DESCRIPTION TYPE DOCUMENT

ORDER RELATED ITEMS:

User Manual 18 Jan 2006 Page 14

4.1 System overview

Figure 1 - Block diagram of mechanic hydraulic and electric system

User Manual 18 Jan 2006 Page 15

4.2.4 How the propeller operates

User Manual 18 Jan 2006 Page 16

4.2.5 Pressure oil from the servomotor piston

4.3 Drive system

User Manual 18 Jan 2006 Page 17

5.4 Hydraulic System

5.5 Remote Control

User Manual 16 May 2006 Page 18

5.8 Torsional vibration data

Rolls Royce Marine AS

User Manual 18 Jan 2006 Page 19

5.9 Startup torque at zero pitch (Preliminary)

70 1239 141 239

80 1416 211 323

90 1593 301 426

100 1770 413 553

Propeller resistance curve at zero pitch

User Manual 18 Jan 2006 Page 20

6.2 Start-up instruction

User Manual 18 Jan 2006 Page 21

6.3 Operation instructions

6.3.2 Starting drive motor

6.3.4 Stopping the tunnel thruster

User Manual 18 Jan 2006 Page 22

6.4 Installation instructions

User Manual 18 Jan 2006 Page 23

6.4.1 Gear coupling mounting instruction

Drive up the coupling with jacking screw.

User Manual 18 Jan 2006 Page 24

Figure 3 - Coupling components

User Manual 18 Jan 2006 Page 25

First priority grease types

User Manual 18 Jan 2006 Page 26