Volume I

MAN Diesel
Updates
1.01 General data
1.02 Propeller equipment, VBS1080
1.03 Servo system

MAN Diesel A/S
13 December 2010
Zhenhua Heavy Industry, Shanghai
Guangzhou Wenchong Shipyard, Huangpu
6500 cbm Trailing Suction Hopper Dredger
MAN Diesel, Ref. No.: P-21145 & P-21146 2 x VBS1080 ODF and AT2000 PCS
Updates
Section Description Drawing no. Remarks Init. Date of update

Link
---oooOOOooo---
End of Section - Updates

MAN Diesel A/S
13 December 2010
1.01 General data
Drawing ident no Description Part ident no Item Date of

no update
Addendum 1.01.1 Addendum for General data
2 01 57 16-6.6 List of symbols
2 14 80 85-8.2 Propeller lub. oil spec. - common system
2 14 80 88-3.3 Propeller servo oil specification
1699910-8.1 Storage of propeller equipment
1699912-1.1 Storage of electronic equipment
2 14 50 19-7.2 Commissioning check list, VBS-ODF
---oooOOOooo---
End of Section 1.01 - General data
 MAN Supply
 Yard Supply Edition 1
MAN Diesel A/S
13 December 2010
Addendum 1.01.1 General data
The Installation Manual on the MAN Diesel extranet contains relevant information, instructions and
drawings that notoriously have proven to be necessary to carry out the installation of the
equipment supplied by MAN Diesel. The Installation Manual is made specifically for each project
and to be used for the installation. After commissioning the Installation Manual will not be updated
and the Instruction Manuals are to be used instead.
We kindly draw your attention to the fact that the Installation Manual is the only relevant place you
may find information for customizing the installation of your plant. All previous information sent to
you must not be used for design of the installation. Documentation such as the Project Guides
may only be used for guidance. However, the Installation Manual may contain sections of the
Project Guides.
---oooOOOooo---
End of General data
 MAN B&W Supply

MAN Diesel
Info. No.: Item Name: Item Id.:

Copyright
3P0106 Propeller lub oil spec - common system 2148085-8

Scale: Size: Product Type: Page No.: Projection:
MAN Diesel
VB & VBS 1 (2)
2009 MAN Diesel
A4
Date Des. Chk. A.C. Revision Change Chg. Not. Rev.
20090820 KEB KEB 00
20100921 KEB KEB Z4 Various changes re additional oil properties 01
20100924 KEB KEB Z4 Oxidation test result: ≤ 6% added 02
03
General
This specification is valid for type VB & VBS propeller systems, designed with a common
lubricating oil system, i.e. both the internal pitch mechanism in the hub and the shaft
bearings in the stern tube are lubricated by the same oil/-system.
System pressure is normally set by a gravity tank placed above the loaded water line of
Diesel and is not to be disclosed to any third party without the specific prior written permission of MAN Diesel
This drawing is the property of MAN Diesel and is to be treated as confidential by the party to whom it has been submitted by MAN
the vessel.
Oil types & Viscosity grades

Both normal mineral based marine engine/motor- and gear oils as well a biodegradable
oil can be selected as lubricating oil for the propeller.
NOTE !
It is strongly recommended to use the biodegradable HYDROX BIO as lubricating oil for
the propeller hub and stern tube, in case the biodegradable ECOSURE HSE is used for
the VBS propeller servo system.
Approved oil types/viscosity grades according to the following tables:
Mineral oil:
All Continuous Continuous

Operation profile  purpose arctic tropical
<5°C >25°C
ISO VG 
*100 68 150
Single grade Gear oil *
SAE 
30 30 40
Single grade Engine/Motor oil
Biodegradable oil: (emulsifying)
All Continuous Continuous

Operation profile  purpose arctic tropical
<5°C >25°C
ISO VG 
*100 68 100
Vickers Oils, HYDROX BIO **
* Recommended
** For some stern tube/shaft seal types, special Viton (fluoro elastomer) rings must be used
for operation with this oil (check with actual seal manufacturer)
MAN Diesel

Copyright
3P0106 Propeller lub oil spec - common system 2148085-8

MAN Diesel
VB & VBS 2 (2)
2009 MAN Diesel
A4
20100924 KEB KEB Z4 Oxidation test result: ≤ 6% added 02
Additional important oil properties

The following additional oil properties have to be fulfilled:
 Rust protection acc. to ASTM D665 A&B or similar  Pass

 Copper strip corrosion acc. to ASTM D130 or similar  Pass 1B
 Oxidation stability acc. to ASTM D2893 (312h at 95°C)  ≤ 6%
 FZG scuffing test acc. to DIN 51354-2, A/8.3/90, fail stage  LS 10
Compatibility, used materials:

 Mineral oils: NBR (Nitrile/Perbunan) 168h at 100°C - DIN 51524-2  Pass

 Biodegr. oils: NBR (Nitrile/Perbunan) 1000h at 80°C - ISO 15380 HEES  Pass
 Biodegr. oils: FPM / FKM (Viton®) 1000h at 100°C - ISO 15380 HEES  Pass
 Glued NBR (Loctite 406®/Ethylcyanoacrylate)  Pass
 PTFE / PFA / FEP (Teflon®)  Pass
 Q / SiR (Silicone compound)  Pass
 Thread locking agent (Loctite 243®/Dimethacrylateester)  Pass
 Alkyd and Epoxy based paint/coating  Pass
Compatibility, stern tube/shaft seals:
 Oil (stern tube) approved by stern tube/shaft seal manufacturer/supplier  Pass
Warranty
In the contractual warranty period for the propeller equipment, the oil used must fulfil the
above specifications. Any deviation will only be allowed provided a written acceptance is
given by MAN.
Further MAN take no responsibility for difficulties that might be caused by the oil itself.
MAN Diesel

Copyright
3P0106
Info. No.:
Propeller servo oil specification 2148088-3
MAN Diesel
VBS – ODF/ODS 1 (2)
2010 MAN Diesel
A4
20100311 KEB KEB 00
20100915 KEB KEB Z4 Various changes re additional oil properties 01
20100924 KEB KEB Z4 FZG fail stage changed to LS12 02
20101001 KEB KEB Z4 Compatibility Sn & Pb based white metal added 03
General
This specification is valid for VBS propeller systems type ODF and ODS. Both types
includes an Hydraulic Power Unit (HPU). The HPU includes servo oil tank, pump units,
control valves, cooler, filters etc.
Oil types & Viscosity grades

Both normal mineral based hydraulic oils as well a biodegradable* oil can be selected as
pressure fluid for the servo system.
NOTE !
It is strongly recommended to use the biodegradable HYDROX BIO as lubricating oil for
the propeller hub and stern tube, in case the biodegradable ECOSURE HSE is selected
for the VBS propeller servo system.
Approved oil types/viscosity grades according to the following table:
Viscosity Manufacturers
Oil types Classification Grade &
(DIN 51519/ISO3448) Designation
Various
HLP (DIN)
Mineral oils ISO VG 100 oil producing
HM (ISO)
companies
Vickers Oils
Biodegradable oils * HEES (ISO) ISO VG 100
ECOSURE HSE 100 *
* IMPORTANT NOTE for selecting biodegradable oil
Before selecting biodegradable oil, HPU compatibility MUST be verified by MAN.

MAN Diesel

Copyright
3P0106 Propeller servo oil specification 2148088-3

MAN Diesel
VBS – ODF/ODS 2 (2)
2010 MAN Diesel
A4
20101001 KEB KEB Z4 Compatibility Sn & Pb based white metal added 03
Additional important oil properties

The following additional oil properties have to be fulfilled:
Minimum requirements for

 - mineral based hydraulic oils acc. to DIN 51524-2  Pass
 - biodegradable hydraulic oils acc. to ISO 15380 HEES  Pass
 Cleanliness acc. to ISO 4406 for new oil added to the system  Pass 21/19/16
 Filterability acc. to DIN 51524-2  Pass
 Viscosity Index VI acc. to ISO 2909  Pass ≥ 95

 FZG scuffing test acc. to DIN 51354-2, A/8.3/90, fail stage  LS 12
 Pump test acc. to DIN 51389/2 Vickers V104C (≈ oil type VG 68)  Pass
Compatibility, used materials:
 Mineral oils: NBR (Nitrile/Perbunan) 168h at 100°C - DIN 51524-2  Pass

 Biodegr. oils: NBR (Nitrile/Perbunan) 1000h at 80°C - ISO 15380 HEES  Pass
 Biodegr. oils: FPM / FKM (Viton®) 1000h at 100°C - ISO 15380 HEES  Pass
 Glued NBR (Loctite 406®/Ethylcyanoacrylate)  Pass
 PTFE / PFA / FEP (Teflon®)  Pass
 Q / SiR (Silicone compound)  Pass
 Thread locking agent (Loctite 243®/Dimethacrylateester)  Pass
 Alkyd and Epoxy based paint/coating  Pass
 Cast Tin (Sn) & Lead (Pb) based white metal (Sb, Cu, Cd, Zn, Ni, Bi)  Pass
Warranty
In the contractual warranty period for the propeller equipment, the oil used must fulfil the
above specifications. Any deviation will only be allowed provided a written acceptance is
given by MAN.
Further MAN take no responsibility for difficulties that might be caused by the oil itself.
MAN Diesel
1699910-8.1
Page 1 (1) Storage of propeller equipment 912000
General
Dispatch conditions of propeller equipment Maintenance intervals

from MAN Diesel
Protection maintenance must be carried out at the
The propeller equipment is treated by MAN Diesel following intervals prior to installation:
with conservation grease. Furthermore the propel-
ler equipment is covered with foil, shock absorbing Good storage conditions
material and a wooden layer. The propeller hub is (dry and indoor)................... every 12 months
furthermore sealed by a tarpaulin. Poor storage conditions
(outdoor)................................ every 3 months
Storage of propeller equipment at cus- Immediately after installation in the ship, the propeller
tomer shaft must be treated with preservation oil/grease in
order to avoid corrosion and damages to the shaft.
Upon arrival of equipment it is yard responsibility to
visually inspect that there are no damages to the
protection cover.
Minimum protection during storage must be by

covering with tarpaulins to keep dry. The propeller
equipment should be keept in the wooden founda-
tion as delivered.
MAN Diesel do however recommend indoor storage

and maintaining min 5˚C above outdoor temperature
to avoid condensation and sweating.
09.17
MAN Diesel
1699912-1.1
Page 1 (1) Storage of electronic equipment 912000
General
Dispatch conditions of electronic equipment Installation works

from MAN Diesel
During the installation period the yard has to protect
Panels and control unit are packed in well-sealed the cabinets and electrical equipments against water,
boxes and to protect the components from corrosion dust and fire.
they are supplied with a Cor-trol VCI Vapour It is not allowed to do any welding works near the
Corrosion Inhibitor giving an invisible protective cabinets. The cabinets have to be fixed to the floor
ionic layer. or to the walls by means of screws.
Small electronic components are packed in poly If it is inevitable to do wielding works near the cabinet
bags supplied with Cor-trol VCI tablets. the cabinets and panels have to be protected against
heat, electric current and electromagnetic influences.
For protection against current, all cabling has to be
Storage of electronic equipment at custom- disconnected from affected components.
ers
Installation of additional components inside the
The equipment should always be stored in a dry en- cabinets is allowed upon approval by the responsible
vironment. Under normal warehouse conditions the project manager of MAN Diesel only.
Cor-trol VCI will give long term protection provided
they remain sealed and maintained in such a condi-
tion that prevents any air circulation within.
Protection maintenance
Provided the sealing has been properly maintained

no additional measures are needed for the entire
period of protection.
The electronic equipment can be put into operation

without degreasing, coating removal or cleaning.
09.17
MAN Diesel

Copyright
6P0221 Check list 2145019-7

MAN Diesel
A4 VBS - ODF 1 (11)
2009 MAN Diesel

20090218 KEB PAA 00
20090407 KEB PAA Z4 New template & responsibility marking changed to * 01
20090629 KEB PAA Z4 Pres. level low 10 to 15 bar + Check for st.tube pipe 02
03
Check list for commissioning of propeller type

VBS – ODF
Project number
Propeller number
Propeller type
Lloyds number
Vessel name
Handling of this checklist:
All items/ works in this checklist, which are marked as sole “Yard” responsibility, have to
be carried out by the costumer (shipyard) before arrival of MAN commissioning
personnel.
Please return this undersigned and completed list 7 days before the requested arrival of
the commissioning personnel to the project manager in Order Management Department
at MAN Diesel.
If at that time any works, which are marked as sole “Yard” responsibility, are not yet
settled, then please note in the column “Remarks” the actual status of these works with
expected date of settlement.
Request of commissioning personnel:
Please inform the project manager at MAN Diesel about your preliminary request of the
commissioning personnel approximately 14 days before starting the works, which have
to be done by the yard and MAN together.
The final confirmation of the commissioning personnel request should be sent to the
project manager at MAN Diesel 3 working days before the requested arrival date of the
commissioning personnel.
Contacts at MAN Diesel:
Order Management Department

Niels Juels Vej 15
9900 Frederikshavn
Denmark
Phone: +45 96 20 41 00
Fax: +45 96 20 40 28
Web: www.mandiesel.com
MAN Diesel

Copyright
6P0221 Check list 2145019-7

MAN Diesel
VBS - ODF 2 (11)
2009 MAN Diesel
A4
Marked field (*) shows the responsibility Yard MAN Diesel Remarks
1. General Requirements
All tools incl. special tools for propeller are available for the MAN *
Diesel commissioning engineer(s)
Engine room is accessible with fire fighting equipment available and *
dangerous areas marked. Safety precautions are taken on
electrically equipment
2. Components: extent of delivery,

preservation and inspection for damages
Hub complete *
Propeller blades *
Aft shaft seal *
Stern tube *
Stern tube liners *
Propeller shaft *
Oil box *
Fore shaft seal *
Coupling flange *
ODF (OD-unit) *
Interm. shaft 1 *
Interm. shaft 2 *
Interm. shaft 3 *
Hydraulic power unit (HPU) *
Accessories *
Others *
Additional remarks/sketches:
MAN Diesel

Copyright
6P0221 Check list 2145019-7

MAN Diesel
VBS - ODF 3 (11)
2009 MAN Diesel
A4
3. Installation
Before installation of propeller shaft, all pipe work in the stern tube to * *
be pressure tested with air at approx 3 bar.
(It's recommended to test also after installation of shaft, before
mounting of coupling flanges, bolts etc.)
Installation according to propeller equipment drawing: * *
ident no: _________________________
Alignment of aft stern tube seal within seal specification

* *
Installation dimension for stern tube seals according to propeller * *

equipment drawing measured:
AFT___________[mm] FORE____________[mm]
Direction of rotation seen from aft: (mark with X ): * *
Single screw ship:
Anticlockwise____ or Clockwise____
Twin screw ship: (2 check list's must be used):
Stb propeller ......: Anticlockwise____ or Clockwise____
Port propeller......: Anticlockwise____ or Clockwise____
All propeller blades mounted with sealing and slide rings

* *
All blade screws tightened, secured and sealed according to * *

instruction 2036393-1 and tightening data given in the installation
manual delivered with the propeller equipment:
Tightening:_________[Nm] Arc length________[mm] or
Elongation_________[1/100 mm]
Longitudinal alignment of propeller shaft in proportion to aft peak * *
bulkhead marked with pin gauge ident no 2029240-9
Hub, shaft seals and stern tube system filled with oil acc. to MAN * *
oil specification:
Type_____________________________
No oil leakage from hub, seals or stern tube system observed * *
after__________[hours]
Hight of stern tube lub oil gravity tank above propeller * *
shaft line _____________________[mm]
Temperature sensors in stern tube fitted and functioning

* *
All aperture clearances sufficient at full ahead and astern

* *
Dismantling space between hub and rudder sufficient according to * *

propeller equipment drawing
MAN Diesel

Copyright
6P0221 Check list 2145019-7

MAN Diesel
VBS - ODF 4 (11)
2009 MAN Diesel
A4
4. Nozzle installation (if any)

Installation of nozzle according to drawing * *
Ident no: __________________________
Alignment of nozzle: * *
Clearance at 0-pitch between blade tip and nozzle:
C max____________[mm] C min:___________[mm]
C max Propeller diameter in mm / 100

C min = 5 mm
Distance from blade tip to aft end nozzle in top position: * *
T______________[mm]
Distance from blade tip to aft end nozzle in bottom position: * *
B______________[mm]
Angle = ATAN ( ( B - T) / Propeller diameter ) = ___________ [deg]

* *
NOTE!
Behind a V-shaped after body, the nozzle should be tilted 2 - 3
MAN Diesel

Copyright
6P0221 Check list 2145019-7

MAN Diesel
VBS - ODF 5 (11)
2009 MAN Diesel
A4
5. Installation of hydraulic coupling flange

and ODF (OD-unit on gear box)
Longitudinal installation dimension for coupling flange measured: * *

(I)_____________[mm] (dimension normally 100 mm)
* *
Coupling flange installed with A-measure_____________[mm]
Sealing ring (o-ring) mounted between flanges

* *
Installation of ODF according to MAN installation drawing

* *
Leak oil alarm sensor on ODF connected to sludge tank * *

(piping must be vented/open in order to avoid pressure setting in
case of closed valves etc)
MAN Diesel

Copyright
6P0221 Check list 2145019-7

MAN Diesel
VBS - ODF 6 (11)
2009 MAN Diesel
A4
6. Shafting
Longitudinal position of propeller shaft with coupling flange * *
according to propeller equipment drawing:
W measure _______________[mm]
GAP/SAG readings: Alignment according to alignment drawing/ * *
Plant spec data
Ident no______________________________
GAP/ SAG 1: (Count from aft) * *
GAP___________[mm] /SAG ___________[mm]

GAP___________[mm] /SAG ___________[mm]
GAP___________[mm] /SAG ___________[mm]
GAP___________[mm] /SAG ___________[mm]
All flanges connected and bolts tightened according to instruction: * *
2036393-1 and tightening data given on propeller equipment
drawing.
Measured bearing reactions: jack up tests (if any)

* *
Bearing no 1: Fwd stern tube bearing (Count from aft) * *

Calculated reaction________________ [kN] (kN/10 = tons)
Measured reaction ________________ [kN] (kN = tons x 10)

Bearing no 2: (Count from aft) * *



Intermediate shaft bearings filled with lub oil: * *
Type_______________________________
Intermediate shaft bearings connected to cooling supply: (X) * *
LT_____ or Sea water_____ (if bearings with cooling coil)
Temperature sensors for intermediate bearings connected * *
and checked (if any)
MAN Diesel

Copyright
6P0221 Check list 2145019-7

MAN Diesel
VBS - ODF 7 (11)
2009 MAN Diesel
A4
7. Hydraulic Power Unit (HPU)

HPU filled with oil acc. to MAN oil specification: * *
Type_____________________________
Servo oil cooler connected to cooling system: (X) * *
LT _________(standard) or Sea water __________ (optional only)
Drip tray pipe connected to sludge tank

* *
Servo main oil pipes A and B and emergency control pipes * *

EP and ER lead to ODF (OD-unit on gear box)
Servo pump units, serial nos, voltage and frequency: * *
El-motor 1, serial no:______________________________
Voltage___________[V] & Frequency_____________[Hz]
El-motor 2, serial no:______________________________

Ship voltage and frequency connected to servo pumps * *
Start the servo pumps and check that direction of rotation are in * *
accordance with the arrows marked on the electrical motors
MAN Diesel

Copyright
6P0221 Check list 2145019-7

MAN Diesel
VBS - ODF 8 (11)
2009 MAN Diesel
A4
8. Initial start-up: without engine running

Pipe work and flushing carried out according to MAN Diesel * *
specification, Ident no 2141332-5
Connect the two test pressure gauges to the measuring *
points MA (astern) and MB (ahead) on the valve block
Pitch the propeller to mechanical end stop and check/adjust that *
max servo oil pressure is set to 70 bar on the safety valve.
Disconnect the two electrical plugs on the proportional valve *
and check that the pressure adjusting valve is set to approx 25 bar.
Reconnect the two electrical plugs on the proportional valve and *

check that the pressure switches for start of stand-by pumps are
set to 8 bar and pressure alarm low is set to 15 bar.
Adjust the electrical closed loop parameters (Dead zone P8 & Gain *
P5) according to installation manual.
Adjust the electrical propeller pitch positioning (Zero P7, Ahead P3 & *
Astern P4) according to installation manual.
(Basic adjustment according to Propeller equipment drawing and
Plant specific data, Propeller. To be found in both Installation manual
and Instruction book).
Adjust pitch scale on ODF (OD-unit on gear box) *
Check that the propeller can operate freely from mechanical full *
ahead to full astern
Check that 2-pump operation is working (stand-by pump is starting *
as booster pump when handle position is changed rapidly from 0 to
full ahead/astern) and time relay is set to 180 sec.
Electronic instruments on HPU in operation: *
Pressure instrument :___(X)
Temperature instrument :___(X)
Pitch instrument :___(X)

Various performance measurements: *
Servo Oil temp _____________[ C]
Ahead to Astern Astern to Ahead
Operating pressure _____________[bar] _______________[bar]
Back pressure _____________[bar] _______________[bar]
Operating time _____________[s] _______________[s]

MAN Diesel

Copyright
6P0221 Check list 2145019-7

MAN Diesel
VBS - ODF 9 (11)
2009 MAN Diesel
A4
9. Quay trials
Check that emergency / transport screws are removed from the * *
ODF (OD-unit on gear box) and this is ready for operation
Start up HPU and engine. Run for at least 1 hour at 0-pitch. Check * *
for any abnormal noises and leakage's
Readjust propeller zero pitch position with the propeller running *
Readjust pitch scale on ODF (OD-unit on gear box) *
Temperature of servo oil after 1 hour at 0-pitch: *
Temp_____________[ C]
Temperatures of stern tube bearings after 1 hour at 0-pitch: *
Aft_______________[ C] Fore______________[ C]
Temperatures of intermediate bearings after 1 hour at 0-pitch: *
No 1_________[ C] No 2_________[ C] No 3_________[ C]

MAN Diesel

Copyright
6P0221 Check list 2145019-7

MAN Diesel
VBS - ODF 10 (11)
2009 MAN Diesel
A4
10. Sea trials

Test & adjustments of AT2000 PCS according to ident no *
2051749-7
In combined pitch control mode measure max servo pressure and *
time from 0 pitch to full ahead and from 0 pitch to full astern:
Max Pahead_________[bar] & Max Pastern_________[bar]
Time 0->ahead_______[sec] &Time 0->astern_______[sec]

In constant speed control mode measure max servo pressure and *
time from 0 pitch to full ahead and from 0 pitch to full astern:
Max Pahead_________[bar] & Max Pastern_________[bar]
Time 0->ahead_______[sec] &Time 0->astern_______[sec]

In constant speed control mode check that the propeller can operate *
from full astern to full ahead pitch and vice versa:
Max servo pressure observed____________________[bar]

Final settings of potentiometers in closed loop servo: *
Dead zone (P8)_______ Gain (P5)_______
Zero pitch (P7)_______ Ahead (P3)_______ Astern (P4)_______
Jumper settings W1_________ W2________ (High/Low)

Ship data: *
Draft aft______[m] Draft fore______[m]
Weather conditions: (X) *
Hard____ Moderate____ Light____
Overall impression of propeller noise & vibration level: (X) *
Very low___ Low___ Normal___ High___ Very high____
Temperature measurements: *
Stern tube AFT_______[ C] FORE__________[ C]
ODR surface_________[ C] Sensor_________[ C] (If any)
ODL surface_________[ C] (If any)
Intermediate bearing 1_______[ C] 2_______[ C] 3_______[ C]
Servo oil temperature________[ C]

Pitch measurements: *
Max ahead______[mm] Zero______[mm] Max astern______[mm]
Additional measurements/readings:
MAN Diesel

Copyright
6P0221 Check list 2145019-7

MAN Diesel
VBS - ODF 11 (11)
2009 MAN Diesel
A4
11. Final check and hand over
Check all pressure and return filters and clean/change if needed

*
Check for any leakage's

*
Check oil levels in tanks

*
Signing of " Zero Pitch Certificate "

* *
Signing of " Certificate of sea trials "

* *
Additional remarks:
________________________________________________________________________
________________________________________________________________________
________________________________________________________________________
________________________________________________________________________
________________________________________________________________________
SIGNATURE/ DATE/
Signature of customer (authorised person and position or authorised representative)

SIGNATURE/ DATE/
Signature of MAN Diesel commissioning engineer

MAN Diesel A/S
14 December 2010
1.02 Propeller Equipment
Drawing ident no Description Part ident no Item Date of update

no
Addendum 1.02.1 Addendum for propeller equipment
2 15 64 86-6.0 Propeller equipment, VBS1080

2 15 67 06-1.0 Oil system for stern tube and seals
Item6486(1).doc  Item list for propeller equipment and oil
system.
Missing  Stern tube, complete
2 05 71 02-3.3  Gravity oil tank, 75 L, for stern tube and hub 2057092-5 150
2 04 34 59-2.2 Propeller hub and blades assembly
Item3459(1).doc  Item list for hub and blades assembly
708 230-8.7  Level alarm for stern tube tank, LSL3954 708234-0 190
2 06 51 37-6.1 Arrangement for temperature sensor,
TE3951
Item5137(1).doc  Item list for temperature sensor, TE3951
2 06 51 38-8.1 Arrangement for temperature sensor,
TE3952
Item5138(1).doc  Item list for temperature sensor, TE3952
539600  Shaft grounding assembly with mV-meter 708337-1 200
and amplifier for alarm outputs
Make: BAC
Metric Version  Torquemeter, dimension sketch 2157039-2 201
Revision 8 shaft diameter: 328 mm
Manual  Manual for torquemeter 2157039-2 201
Make: Binsfeld Engineering Inc.
Type: TorqueTrak Revolution
Installation  Strain gauge installation 2157039-2 201
2 12 76 78-8.1  Locking device, LM40 202
M0189-1  Installation manual 202
Make: Dellner Brakes
Dellner  Foundation forces calculation 202
2 03 63 93-1.8 Tightening instruction for screws and bolts
for propeller equipment - 11 pages
2 04 58 72-3.1 Instructions for Hydraulic operated fit/tie-bolt -
15 pages
2 05 77 48-2.1 Tightening torque for screws and bolts -
3 pages
 MAN B&W Supply
MAN Diesel A/S
14 December 2010

no
Missing Plant specific data and data for alignment of
shaft line, see also page 3 10E1-01
2 05 07 10-7.0  Pin gauge, arrangement 2029240-9 210
3 10A1-01 Delivery, inspection and storage of propeller
equipment
3 10B1-01 Fitting oil lubricated stern tube
(3 pages)
3 10C2-01 Fitting the propeller equipment, (2 pages)
3 10D2-01 Lubricating oil system, (2 pages)
3 10E1-01 Alignment of shafting
(2 pages) See also "Plant specific data"
3 10F1-01 Fitting the zinc anodes to propeller and stern
10 303A-01 Work card 10 303A-01 Disassembling
hydraulic coupling flange (3 pages)
10 304A-01 Work card 10 304A-01 Assembling hydraulic
coupling flange (3 pages)
10 306-01 Work card 10 306-01 Fitting of propeller
blade (2 pages)
Missing Instruction manual for Simplex Compact
stern tube seals, incl. grease pump manual
Aft seal, type/size: SC2BED/450
Forward seal, type/size: SC2Z/400
SAC:3-564-2158-  Aft seal with parts list 182
000.0
SAC:3-662-0238-  Forward seal with parts list 122
000.0
SAZ:3-195-5432- Diagram of stern tube lubrication
000.2
SAZ:4-195-3962- Tank arrangement, forward seal
000.0
SAZ:3-195-3893-  Oil tank, 30 l, for aft seal with parts list
000.1
SAZ:3-195-3888-  Oil tank, 15 l, for forward seal with parts list
000.2
7-195-0470-000.1  Net cutter, size A, (4 pcs)
 MAN B&W Supply

MAN Diesel A/S
14 December 2010

no
---oooOOOooo---
End of Section 1.02 - Propeller Equipment
 MAN B&W Supply

MAN Diesel A/S
13 December 2010
Addendum 1.02.1 Propeller Equipment
Lubricating oil system for propeller equipment

The propeller equipment with Blohm+Voss shaft seals are recommended to operate on the oil types
according to our oil specification list in section 1.01
For vessels operating in cold conditions it is recommended to use SAE 30 oil types.
Before an oil type is chosen it should be checked whether the shaft seal manufacturer recommends it -
see the Blohm+Voss Instruction manual.
Aft stern tube seal

With reference to the Blohm+Voss instruction manual, please note the following regarding the aft seal:
The seal is to be installed on the propeller shaft and attached to the propeller hub by the yard.
Zinc anodes are to be fitted by the shipyard.
Oil chambers are to be filled with lubricating oil or grease - depending of seal type - by the shipyard.
Measurement of bearing clearance to be measured by the shipyard with the wear-down gauge
supplied together with the stern tube seal.
---oooOOOooo---
End of propeller equipment
 MAN B&W Supply

MAN B&W Diesel A/S
9 December 2010/HAK
Item list for drawing number:
2 15 64 86-6.0 - Propeller Equipment, VBS1080
2 15 67 06-1.0 - Oil system for stern tube and seals Edition 1
Item no Description Number
101 * Hub and shaft assembly, VBS1080/ODG330 1

102 ** 2-parted rope guard 1
104 Hexagon socket head cap screw with nylon lock, M24 12
105 ** Hexagon screw with nylon lock, M20 12
110 ** Locking screw, M12 6
111 ** Stern tube bearing, aft 1
112 ** Stern tube bearing, fore 1
113 ** Locking screw, M12 6
115 Gasket 1
116 Hexagon socket head cap screw, M10 24
117 Gasket 1
118 Hexagon screw, M10 24
122 Inboard stern tube seal, complete 1
135 Stern tube 1
136 Sealing ring 1
137 Hexagon screw, M10 24
138 Sealing flange 1
139 Adapter flange 1
140 Oil box 1
141 Alignment ring 1
150 Gravity tank for stern tube and hub oil, 75 litres 1
151 Three-way cock, T-port in plug, G1 1
153 Thermometer, 0 - 100 ºC / 32 - 212 ºF 1
154 Thermometer pocket with screw 1
160 Coupling flange, ODG330 complete 1
162 Hydraulic fitted bolt 8
163 Hydraulic tightening bolt 2
165 Hexagon socket head cap screw, M10 9
166 Sealing ring 1
170 ** Adjustable elbow coupling, ø15 3
171 ** Pipe for pressure control system, ø15 2
172 ** Pipe for grease supply, ø15 1
173 Banjo coupling, ø15 5
174 Reducing adaptors 1
175 Reducing adaptors 1
176 Straight male stud coupling, ø6 1
177 Reduction nipple muff, M36, G1/2 3
178 Nut, M36 3
179 Banjo coupling, ø25 1
181 Washers (For space between rope guard, item 102 16
and net cutters)
182 Outboard stern tube seal, complete 1
190 Level alarm – LSL3954 1
200 Earthing device, Make: BAC 1
Y:\Projects\MBD-F\P-21100\P-21145-46 CCCC Shanghai Dredging Co.,

Ltd\InstallationManual\InstallationManual_PDF\Drawings_Volume_1\1.02\Word\item6486(1).docx
MAN B&W Diesel A/S
9 December 2010/HAK
2 15 64 86-6.0 - Propeller Equipment, VBS1080
2 15 67 06-1.0 - Oil system for stern tube and seals Edition 1
201 Torque meter, Make: Binsfeld Engineering Inc. 1

202 Locking device, Make: Dellner 1
* See separate item list.

** Mounted in the stern tube, item no 135.

Ltd\InstallationManual\InstallationManual_PDF\Drawings_Volume_1\1.02\Word\item6486(1).docx
MAN B&W Diesel A/S
2010-12-13/HAK

2 04 34 59-2 - Propeller hub/shaft assembly, VBS 1080 Edition 1
16 Blade screw 28
16A Stainless steel, ø8 mm 2m
17 Sealing ring 4
18 Slide ring 4
61 Plug screw 28
80 Propeller blade 4
101 Propeller hub/shaft assembly, complete 1

Ltd\InstallationManual\InstallationManual_PDF\Drawings_Volume_1\1.02\Word\item3459(1).doc
MAN B&W Diesel A/S
2010-12-13/HAK
2 06 51 37-6 – Arrangement for temperature sensor, forward Edition 1
1 Terminal box 1
2A Temperature sensor TAH62 - TE3951 1
3 Cable gland 1
4 Nipple for sensor 1
5 Gasket 1
6 Sealing ring 2
7A Cable pipe TAH62 - TE3951 1

MAN B&W Diesel A/S
2010-12-13/HAK
2 06 51 38-8 – Arrangement for temperature sensor, aft Edition 1
1 Terminal box 1
2B Temperature sensor TAH63 - TE3952 1
3 Cable gland 1
4 Nipple for sensor 1
5 Gasket 1
6 Sealing ring 2
7B Cable pipe TAH63 - TE3952 1

MANUAL FOR
SHAFT GROUNDING ASSEMBLY

WITH mV-METER
METER AND AMPLIFIER
FOR ALARM OUTPUTS
BAC ORDER NO: 539600

Copyright: BAC Corrosion Control A/S
BAC CORROSION CONTROL

Færøvej 7 - 9 · DK-4681 Herfølge · Denmark
telephone +45 7026 8900 · telefax +45 7026 9700
e-mail:
mail: info@bacbera.dk · web-site: www.bacbera.dk
SHAFT GROUNDING ASSEMBLY............................................................................................................. 1
1 GENERAL DESCRIPTION .................................................................................................................................. 3
2 INSTALLATION INSTRUCTION ......................................................................................................................... 7
3 GENERAL DATA ............................................................................................................................................. 16
3.1 Components .......................................................................................................................................... 16
3.2 List of components ................................................................................................................................ 22
3.3 Silver Brush drawing .............................................................................................................................. 23
3.4 Installation instruction........................................................................................................................... 24
3.5 Installation instruction picture .............................................................................................................. 25
3.6 Principdiagram for mounting ................................................................................................................ 26
3.7 Principdiagram for montage.................................................................................................................. 27
4 SHAFT-HULL MILLIVOLTMETER ASSY............................................................................................................ 28
5 ISOLATION AMPLIFIER 2204 ........................................................................................................................ 29
6 CONTROLBOX, PLACEMENTS OF HOLES ....................................................................................................... 37
7 MAINTENANCE OF SHAFT-GROUNDING SYSTEMS ....................................................................................... 38
8 BAC SHAFT GROUNDING DEVICES ................................................................................................................ 39
9 DOCUMENTATION ON CD ............................................................................................................................ 40
Side 2 EDB No 53 960 0 vers 3

BAC Corrosion Control
1 GENERAL DESCRIPTION
1.1 With Amplifier for alarm
This system is a precautionary measure installed,

in order to reduce the electrical potential between
the propeller shaft and hull to below 80 mV, and
thus prevent spark erosion damage to the main
bearings and journals of the main engine. (A
reading between 5 and 50 mV is considered as
normal).

With Amplifier for alarm
1. The system consists of the following main

components:
A. A silver alloy slip ring is mounted on the

intermediate shaft.
B. Brush holders with silver/graphite brushes.
C. Grounding wire and grounding plate.
D. Monitoring box with mV-meter and alarm

output (optional).
The silver/graphite brushes are running on the slip

ring. The two earthing brushes are connected to
the hull through the grounding wire and the
grounding plate welded to the hull. The
monitoring brush is connected to the monitoring
box.
2. Functioning and checking of the earthing/

measuring device.
The meter normally reads 150 mV at full scale. If

readings are above 150 mV, push the button on
the front of the meter. The meter will now read
1500 mV at full scale.
The meter will read ”0” when the shaft is at rest.

When the shaft is turning at sea, a reading of
between 5 and 80 mV indicates proper grounding,
although readings below 50 mV should be
obtained with clean and properly contoured
brushes.

With Amplifier for alarm
We will advise you to set a delay up to 5 min.

or the alarm to avoid errors during
manoeuvring of the engine.

Readings of ”0” when the shaft is turning at
sea, indicates a defective mV-meter or loose or
broken cable connections.
Checking the earthing device must be done

when the shaft is rotating at sea and should be
carried out once a month.
Release the earthing brushes from their contact

with the slip ring; this should give high
pulsating voltages of 100-400 mV reading on
the meter. This indicates that the measuring
circuit is in order. When the brushes are
brought back to contact with the slip ring, the
reading should fall below the 80mV limit. You
can also read the result on the computer
It is important that the silver/graphite brushes

are moving correctly in the brush holders with
a spring load of 500-600 gr.
In some cases the copper lead on the brush

will corrode, so it is recommendable to coat
this lead with grease.
It is recommended that the readings of the mV-

meter be recorded once a day in the engine
logbook.

2 INSTALLATION
NSTALLATION INSTRUCTION
2.1
The slip ring usually located about
450 mm in front of the shaft coupling
2.2
Sand the area on the shaft between the two
straps, until a bright steel surface appears.
2.3
Clean the grinded area

2.4
Starting with the 45° end, warp the silver
band around the shaft so that the excess
overlaps the 45° angle. Mark the edges,
scribe a line between them
2.5
Cut the silverband
2.6
Lightly smooth skive joint with fine file to
eliminate any roughness

2.7
Spray presavation oil on the shaft
2.8
Apply el-tape
tape in 3 strips on the silver band
2.9
Assemble the 3 stainless steel band straps
and apply the silver band with one band on
the middle tape

2.10
Assemble the 2 other stainless steel band
2.11
Remove the middle stainless steel band and
remove el-tape
2.12
Clean for oil and dirt before applying
Silicon and tape

2.13
Apply silicone longitudinal on the edge of
the silver band in both sides
2.14
Seal the silicone with a wet finger all the
way around in both sides
2.15
Wrap sensitive tape on one of the steel
bands to make it absolutely tight

2.16
Wrap sensitive tape on other steel
bands to make it absolutely tight
2.17
Cut the sensitive band so you can see the
silverband between the two steel bands
2.18
The finish mounting of the shaft grounding
before finishing the silver band

2.19
Cut app. 2 mm of the edge of the glass
brush
2.20
Clean the silver band with glass brush
2.21
Grounding plate must be welded as
close as possible, in order for the wires
to be as short as possible.

2.22
Ø12mm shaft are welded on the stand
2.23
Mount the shaft holder
2.24
Mounting the silver graphite brush

2.25
Done
2.25
Done

3 GENERAL DATA
3.1 Components
539171
Voltmeter for shaft-hull potential
Difference without amplifier for
alarm
539172
Voltmeter for shaft-hull potential
difference without amplifier for
alarm

539170
Slip ring. Silver alloy band,
63,5 mm wide and approx.
100 mm longer that the
circumference of the shaft.
539184 & 539185

EL tape + pressure sensitive
tape
539180 & 539182

Holding straps. The
permanent
holding straps are made of
Stainless
Steel.
539254
St. steel shaft 12.0 x 180mm

539265
Brass shaft holder
539263 & 539262

Brass and ISO bushing
for shaft
539465
Brush box

539105
Silver graphite brush
539230
Grounding plate
Place as close to the brush
as possible
536354 & 536352

35mm cable socket with
10mm hole

520600 & 526060
10mm cable socket with
10mm hole
539125
Glass brush
94116
Silicone

94118
Preservation Oil ML300
94119
Metal Cleaner 500ml

3.2 List of components

3.3 Silver Brush drawing

3.4 Installation instruction

3.5 Installation instruction picture

3.6 Principdiagram for mounting

3.7 Principdiagram for montage

4 SHAFT-HULL MILLIVOLTMETER ASSY

5 ISOLATION AMPLIFIER 2204
Input galvanically separated from output and supply Current – or voltage input.
Signal conversion.
Current – and voltage output.
24 VDC supply or 24/115/230 VAC
applicable
5.1 Applications
Galvanic separation of analogue signal (ground loop elimination).
Measurement of floating signals.
Signal conversion within the ranges: 0…10 VDC or 0…50 mA on the input and
0…20 mA and 0…10 VDC in fixed ranges on the output.
5.2 Description
The 2204 uses microprocessor technology for the selection of gain and zero offset,
yet the signal conditioning is analogue with a fast response time of less than 25 ms.
5.3 Technical characteristics

In standard ranges, the 2204 is programmable by use of internal dipswitches within
the input – and output ranges of the order schedule. Provided that front adjustments
are still sealed, the unit needs no adjustment after programming. AC-supplied units
are galvanically separated between input, supply, and output.
5.4 Input
Current or voltage in standard or special ranges within the measuring range.
Standard input voltage: 0/0.2…1 V, 0/0.5…2.5 V and 0/2…10 V.
Input resistance: type. 10 MΩ.
Standard input current: 0/1…5 mA or 0/4…20 mA.
Input resistance: norm 50 Ω (0/4…20 mA).

5.5 Output
The output can be ordered for standard current and voltages or special versions within
the signal range.
5.6 Standard output current

(Pin 3) 0/4…20 mA and 0/1…5 mA acc. to order current limit: 23…28 mA.
5.7 Standard voltage output

(Pin 2) is achieved by short-circuiting pins 2 and 3. For voltage signals in the ranges
0…1 VDC, a 50 Ω shunt (DP 2-1) is applied; in the ranges 0…10 VDC, a 500 Ω
shunt (DP 2-2) is applied. Using both signals simultaneously, the mA loop to ground
must go through the internal shunt.
Fine adjustment of 0 and 100 % is possible at the front ± 10 %, but please note that
the basic calibration is thereby lost.

5.8 Electrical specifications
Specification range:
(@ - 200 C to + 600 C)
Common specifications:
Supply voltage 24 VDC ± 20 %
24/115/230 VAC, 50…60 Hz
Max. Consumption (24 VDC) 1.3 W
Max. Consumption (24/115/230VAC) 2.7 W
Isolation, test/operation 3.75 kVAC/250/ VAC
Linearity error < ± 0.1 % of span
Temperature coefficient < ± 0.01 % OF SPAN/0 C
Signal/noise ratio min. 60 dB
Effect of supply voltage change < ± 0,002 % of span/%V
EMC-immunity influence < ± 0.5 % of span
Response time (0…90%) < 25 ms.
Relative air humidity 0…90% RH (non cond.)
Dimensions (HxWxD) 80.5 x 35.5 x 84.5 mm
Tightness IP 50
Weight DC/AC 125 g / 275 g
5.9 Input
Current input:
Measurement range 0…50 mADC
Min. measurement range (span) 4 mADC
Max. Offset 20 % of selected max.value
Input resistance nom. 50 Ω

Voltage:
Measurement range 0…10 VDC
Min. measurement range (span) 0.2 VDC
Max. Offset 20 % of selected max. Value
Input resistance 10 M Ω
5.10 Output
Current output:
Signal ranges 0…5 mA / 0…20 mA
Min. measurement range (span) 4 mA / 16 mA
Load (max) 20 mA/600 Ω /12 VDC
Load stability < ± 0.01 % of span/100 Ω
Current limit 23…28 mA
Voltage output through internal shunt:

Signal ranges 0…0.25 V/0…1 V/0…2.5 V/0…10 V
Min. measurement range (span) 0.2 V / 0.8 V / 2.0 V / 8.0 V
Load (min) 500 kΩ
Output resistance 50 Ω /500 Ω

5.11 Observed authority requirements Standard
EMC 89/336/EEC, Emission EN 50 081-1

Immunity EN 50 082-2
LVD 73/23/EEC EN 61 010-1
PELV/SELV IEC 364-4-41 and EN 60 742
Of span = of the presently selected range

5.12 Order
TYPE INPUT OUTPUT SUPPLY
2204 0…20mA : A Special :0 24 VDC :D
4…20mA : B 0…20mA :1 24…230 VAC &
Our Standard 0…1 V :C 14…20mA : 2 24…250 VDC :P

System
0.2…1 V : D 0…5mA :3
0…10 V : E 0…1 V :4
2…10 V : F 0.2…1 V :5
Special :X 0…10 V :6
2…10 V :7

5.13 Block diagram

PROGRAMMING:
INPUT DP1 (10-pole)

PROGRAMMING SW 1, 2, 3, 4, 5
SW ON SW OFF
0…5 mA
0…20 mA 1, 3 2, 4, 5
0…1 V 1, 4 2, 3, 5
0…2.5 V 2, 3 1, 4, 5
0…10 V 2, 4 1, 3, 5
2, 3, 4 1, 5
For 20 % offset on input,
set DP1 SW5 ON
e.g. input 4…20 mA 1, 4, 5 2, 3
OUTPUT
PROGRAMMING DP2 (4-POLE) SW 1 - 4 DP1 (10-pole) SW 6,7,8,9,10
SW ON SW OFF ON OFF
0…5 mA 4 1, 2, 3 7 6, 8, 9, 10
0…20 mA 3 1, 2, 4 8 6, 7, 9, 10
0…5 mA / 0…250 mV 1, 4 2, 3 6 7, 8, 9, 10
0…20 mA / 0…1 V 1, 3 2, 4 6, 7 8, 9, 10
0…5 mA / 0…2.5 V 2, 4 1, 3 6, 8 7, 9, 10
0…20 mA / 0…10 V 2, 3 1, 4 6, 7, 8 9, 10
For 20% offset output,
set DP1 SW9 ON 3 1,2,4 8,9 6,7,10
e.g. output 4…20 mA
For reversed output set DP1
SW10 ON e.g. output 20…4mA 3 1,2,4 8,9,10 5,6,7
For special ranges DP1 SW 2, 3, 4, 5, 6, 7, 8, 9 and 10 are OFF.

Please notice the setting on DP1 SW2 DP2 SW 1-4.

6 CONTROLBOX, PLACEMENTS OF HOLES

7 MAINTENANCE OF SHAFT-GROUNDING SYSTEMS
1. Always keep the system clear of dust, grease and water.
2. When cleaning the silver bands of grease and dust, an Electro cleaner should be
used.
3. When polishing the silver bands, use the glass brush, which is delivered with the
system.
Never use abrasive cloth, file or other abrasives.
4. Once a month (or when needed) clean the brushes and brush boxes of dust,
because the dust can cause the brushes to stick in the brush box and thereby cause
a bad connection between the silver band and the brush.
5. The spring pressure of the brushes should be 500-600 gr.
6. Make sure that there is always a good electrical contact at all screw- and bolt
connections.
7. Make sure that the earthing plate is in welded connection with the hull all the
times.

8 BAC SHAFT GROUNDING DEVICES
BAC NO: 539525

STANDARD SHAFT GROUNDING ASSEMBLY
This system forms connection between shaft and hull without any kind of monitoring,
which means that there is no possibility of knowing if the connection and safety of
the system is functioning correctly.
BAC NO: 539500

SHAFT GROUNDING ASSEMBLY WITH mV- METER FOR MONITORING
This system is identically with BAC Shaft Grounding for computer control, though
this system consists of a steel box with instrument for monitoring.
BAC recommends you this, as it is our most sold system.
BAC NO: 539600

SHAFT GROUNDING ASSEMBLY WITH mV- METER AND AMPLIFIER
FOR ALARM OUTPUTS
This system is identically with BAC Shaft Grounding assembly with mV-meter for
monitoring, though this system is extended with an isolation amplifier. This makes it
possible to connect the system directly to the alarm computer in the ship with a signal
on 4-20 mA or it can be used with a signal on 0-20 mA.
BAC NO: 539800

SHAFT GROUNDING ASSEMBLY FOR MAN ENGINE
With reference to specification from MAN, info no. 300155, Ident no. 0792182-1.
Shaftline earthing device.

Please note following:
When you order a BAC Shaft Grounding system the price of the silver band is
depending on the size of the shaft, and therefore the cost of the silver band will be
quoted separately. Please contact BAC; we can help you with commercial terms and
calculations.
It is very important that the Shaft Grounding system is equipped with a kind of
measuring instrument, which can show the function of the system.
BAC is able to update the different BAC Shaft Grounding systems. For instance with
a mV-meter for monitoring or amplifier for alarm output giving you a better and
precisely measure of the system.
BAC can further more offer you an alarm system to ensure that the connection
between the shaft and hull is according to BAC standard specifications.
9 DOCUMENTATION ON CD

Strain Gage Installation
Strain Gages & Strain Gage Application Kits are supplied by the
Vishay Measurements Group, Inc., Raleigh, NC. Phone: (+1) 919-365-3800.
Web: http://www.Vishay.com
Strain Gage Application Kit: GAK-2-200
1. Prepare shaft surface:

• Remove paint and other coatings; degrease as necessary.
• Rough sand with 220 grit paper then polish with 400 grit paper.
• Finish sanding with 400 grit paper and M-Prep Conditioner.
• Rinse with M-Prep Conditioner.
• Rinse with M-Prep Neutralizer and wipe dry.
2. Mark shaft surface for strain gage orientation and alignment. The strain gage should be installed
flat and square to the axis of the shaft. For a straight reference line, square to the axis, wrap a
piece of paper around the shaft, align the edges and then mark or etch the straight reference line
onto the shaft.
3. Prepare strain gage for mounting. Part # CEA-06-250US-350 is a common torque-pattern strain
gage: http://www.vishay.com/docs/11334/250us.pdf
• Remove strain gage from package.
• Apply cellophane tape to top side of gage. Use the tape as a “handle.”
4. Position strain gage before gluing:
• Tape gage in place on the shaft using reference marks on shaft and gage for alignment.
• Lift one end of tape and “hinge” back to expose bottom of gage.
• Apply an even, thin layer of catalyst to bottom side of gage and let dry.
5. Glue strain gage to surface:
• With the gage/tape still hinged back, apply bead of M-Bond 200 Adhesive where the tape
meets the shaft surface. (M-Bond 200 is a special cyanoacrylate which has been pretested
and certified for use in bonding strain gages – manufactured by Vishay Measurements Group.)
• Using Teflon film or equivalent as a non-stick barrier between your thumb and the adhesive,
press the gage/tape to shaft surface with single rolling/wiping motion of the thumb.
• Apply thumb pressure for one minute, followed by a minimum two-minute wait before removing
the cellophane tape. Bond strength increases rapidly during first five minutes.
6. Attach lead wires and protect strain gage:
• Discard Teflon film and carefully peel back cellophane tape from the strain gage.
• Tin with solder the solder pads of the strain gage plus the lead wires. Attach lead wires to
solder pads.
• Clean solder joints with rosin solvent.
• For waterproofing – Apply polyurethane coating to strain gage and solder joints.
• For mechanical protection – Cover the gage with butyl rubber or equivalent.
• For electrical shielding – Cover the strain gage and lead wires with aluminum tape or
equivalent.
• M-Coat J from Vishay Measurements Group is a two-part polysulfide liquid polymer compound
for environmental protection of strain gage installations. When fully cured, it forms a hard
rubber-like covering that provides an effective barrier against water and many other fluids. The
tough coating also protects installations from mechanical damage.
Installation, Operation and
Maintenance
Manual
with spare part lists
From Dellner Brakes AB
Locking device type LM 40
Manually operated
&
Hydraulic operated
Manual no: M0189-1
Published by:
DELLNER BRAKES AB Telephone: + 46 (0)23 - 78 30 50

Skyfallsvägen 2 Telefax: + 46 (0)23 - 77 06 90
SE-791 77 FALUN www.dellner-brakes.com
SWEDEN info@dellner-brakes.com
TABLE OF CONTENTS
1 General description __________________________________ 3

2 Installation instructions ______________________________ 4
3 Operation __________________________________________ 5
3.1 Manually operated locking device __________________________________ 5
3.2 Hydraulic operated locking device __________________________________ 6
4 Electric indicators ___________________________________ 7
4.1 Manually operated locking device __________________________________ 8
4.2 Hydraulic operated locking device _________________________________ 10
5 Hydraulic oil _______________________________________ 12
6 Recommended spare parts __________________________ 13
6.1 Manually operated locking device _________________________________ 13
7 Part lists and drawings ______________________________ 14
7.1 Manually operated locking device _________________________________ 14
7.3 Installation drawing ____________________________________________ 16
Dellner Brakes AB, 2008. All rights reserved.

The manufacturer reserves the right to modification without special notice.
Locking device type LM 40.
2
1 General description
The locking device LM is one of the three modules available in the Dellner STL-
modular system (Stopping, Turning, Locking).
The locking device is basically a plunger that is tapered and goes radial into a slot in
a brake disc / flange. The plunger movement (in / out) is generated either manually or
by a hydraulic cylinder. The locking device is equipped with proximity switches for
engaged / disengaged detection.
The locking device is also available in other sizes (see separate leaflets / manuals)
which all have a very robust and reliable design. The LM 40 achieves 250 kN in
tangential locking force.

3
2 Installation instructions
Reference drawing no. 319711-M and 319711-H.
Machine the slots in the brake disc / flange and install the locking device according to
installation drawing I0743-2 (see chapter 7.3).
The locking device is equipped with guiding holes (2x Ø8, depth 10), which can be
used to achieve the correct installing tolerances (by using slotted spring pins). Use of
the guiding holes is however optional.
If the locking device is hydraulic operated, hydraulic tubes shall be connected to the
hydraulic inlet ports P1, P2 and P3. The hydraulic tubes (not incl. in delivery), is
recommended to be seamless steel tubes according to DIN 2391/C, min. dim.
Ø12x1,5. The tubes and fittings have to be carefully cleaned internally and blown
through with compressed air. All tubes are also recommended to be “flushed” with
hydraulic oil before assembly. Observe to avoid restrictions smaller than Ø5 mm in
the hydraulic tube assembly.
NOTE: It is very important to keep the hydraulic assembly in cleanest possible

manner to avoid dirt in the hydraulic system.
For recommendations concerning hydraulic oil, see chapter 5.
For information concerning electrical installation (proximity switches S1-S4), see

chapter 4.

4
3 Operation
3.1 Manually operated locking device
Reference drawing no. 319711-M.
Engagement
1. Engage the locking device by turning the crank handle (item no. 14) CW until
stop.
2. Ensure that the locking device has been fully engaged by checking that the
plunger (item no. 2) has been fully inserted into the locking slot on the brake
disc / flange (see also chapter 4.1 regarding use of electric indicators).
3. Ensure that the end of the crank handle is located somewhere between 2 and 6
o’clock (if seen from the right on drawing no. 319711-M). If not, relocate the
crank handle by removing the M6 screw (item no. 20) along with the washer
(item no. 15). Remember to re-assemble the M6 screw along with the washer
when the crank handle has been relocated.
4. If above step 3 has been carried out properly the engaged position for the
locking device is “self secured” due to that the plunger movement is achieved
with trapezoid threads.
Disengagement
1. Disengage the locking device by turning the crank handle CCW until stop.
2. Ensure that the locking device has been fully disengaged by checking that the
plunger has been fully retracted into the cylinder housing (item no. 1) (see also
chapter 4.1 regarding use of electric indicators).
3. Ensure that the end of the crank handle is located somewhere between 6 and 10
o’clock (if seen from the right on drawing no. 319711-M). If not, relocate the
crank handle by removing the M6 screw along with the washer. Remember to
re-assemble the M6 screw along with the washer when the crank handle has
been relocated.
4. If above step 3 has been carried out properly the disengaged position for the
locking device is “self secured” due to that the plunger movement is achieved
with trapezoid threads.

5
3.2 Hydraulic operated locking device
Reference drawing no. 319711-H.
Engagement
1. De-pressurize the hydraulic inlet port P1, located on the “fail safe” safety lock
cylinder (item no. 22).
2. De-pressurize the negative hydraulic inlet port P3, located on the hydraulic
cylinder (item no. 13).
3. Engage the locking device by pressurizing the positive hydraulic inlet port P2
(min. 100 bar, max. 200 bar), located on the hydraulic cylinder.
4. Ensure that the locking device has been fully engaged by checking that the
plunger (item no. 2) has been fully inserted into the locking slot on the brake
disc / flange (see also chapter 4.2 regarding use of electric indicators).
5. Ensure that the engaged position of the locking device has been secured i.e.
that the “fail safe” safety lock has been engaged (see chapter 4.2 regarding use
of electric indicators).
NOTE: When the locking device has been engaged, the hydraulic inlet port P2
must be kept pressurized and the hydraulic inlet port P1 must be kept de-
pressurized until disengagement of the locking device.
Disengagement
1. Unsecure the engaged position of the locking device by pressurizing the

hydraulic inlet port P1 (min. 100 bar, max. 200 bar), located on the “fail safe”
safety lock cylinder.
2. Ensure that the engaged position of the locking device is unsecured i.e. that the
safety lock is in disengaged position for plunger movement (see chapter 4.2
regarding use of electric indicators).
3. De-pressurize the positive hydraulic inlet port P2, located on the hydraulic
cylinder.
4. Disengage the locking device by pressurizing the negative hydraulic inlet port
P3 (min. 100 bar, max. 200 bar), located on the hydraulic cylinder.
5. Ensure that the locking device has been fully disengaged by checking that the
plunger has been fully retracted into the cylinder housing (item no. 1) (see also
chapter 4.2 regarding use of electric indicators).
NOTE: When the locking device has been disengaged, the hydraulic inlet port P3
must be kept pressurized until engagement of the locking device.
6
4 Electric indicators
Both the manually and hydraulic operated locking device are equipped with
proximity switches for detection of engagement / disengagement. See below figure
4.1 for electric wiring diagram and technical data.
Standards IEC 60947-5-2 Ambient temperature –25…+70 °C

Polarity PNP range, TA
Rated operating distance, sn 2,0 mm Temperature drift of sn ≤ 10 %
Hysteresis ≤ 10 % sn Short-circuit prot. Built-in
Standard target 12 x 12 x 1 mm Voltage reversal prot. Built-in
Repeat accuracy 0,1 mm * Induction protection Built-in
Supply voltage range, UB 10…30 VDC Shocks and vibration IEC 60947-5-2 / 7.4
Max. ripple content ≤ 20 % UB Cable length Max. 300 m
Output current ≤ 200 mA Weight Approx. 50 g
Output voltage drop ≤ 2,0 V at 200 mADegree of protection IP 67
No-load supply current ≤ 10 mA EMC protection:
IEC 60255-5 5 kV
Leakage current ≤ 0,1 mA IEC 61000-4-2 Level 2
Switching frequency ≤ 3’000 Hz IEC 61000-4-3 Level 3
Oscillator frequency 330 kHz IEC 61000-4-4 Level 3
Time delay before availability ≤ 10 msec. Housing material Chrome-plated brass
LED Built-in Sensing face PBTP
Figure 4.1 * (UB = 20…30 VDC, TA = 23 °C ± 5 °C)

7
The switches used on the manually operated locking device are shown on drawing
no. 319711-M and additional information is shown in the below figure 4.1.1.
Switch Type Output Recommended Switch use

setting (dim. A)
S1 Engagement
DW-AS-604-M12-120 NC 21,5 ± 0,5 mm
S2 Disengagement
Figure 4.1.1
Detection of engagement
Switch S1 detects engagement.
Signal from the switch means “Locking device fully engaged”. It is however
recommended that an ocular check is carried out to ensure that the plunger has been
fully inserted into the locking slot on the brake disc / flange.
If the signal is lost the locking device has started disengagement.
The recommended setting for the switch is shown in the above figure 4.1.1. The
setting might however need to be finally adjusted at commissioning.

8
Detection of disengagement
Switch S2 detects disengagement.
Signal from the switch means “Locking device fully disengaged”. It is however
fully retracted into the cylinder housing.
If the signal is lost the locking device has started engagement.
The recommended setting for the switch is shown in the above figure 4.1.1. The
setting might however need to be finally adjusted at commissioning.

9
The switches used on the manually operated locking device are shown on drawing
no. 319711-H and additional information is shown in the below figure 4.2.1.
Switch Type Output Recommended Switch use

setting (dim. A)
S1 Engagement (plunger)
21,5 ± 0,5 mm
S2 Disengagement (plunger)
DW-AS-604-M12-120 NC
S3 Disengagement (safety lock)
31 ± 0,5 mm
S4 Engagement (safety lock)
Figure 4.2.1
Detection of engagement
Switch S1 detects engagement of the plunger.

Switch S4 detects engagement of the “fail safe” safety lock cylinder,
Signal from switch S1 means “Plunger in engaged position”.

Signal from switch S4 means “Locking device fully engaged and secured”. It is
however recommended that an ocular check is carried out to ensure that the plunger
has been fully inserted into the locking slot on the brake disc / flange.
If the signal is lost from switch S4 the locking device has been unsecured and
therefore can be considered to have started disengagement.
If the signal is lost from switch S1 the plunger has started disengagement.
The recommended settings for the switches are shown in the above figure 4.2.1. The
settings might however need to be finally adjusted at commissioning.

10
Detection of disengagement
Switch S2 detects disengagement of the plunger.

Switch S3 detects disengagement of the “fail safe” safety lock cylinder,
Signal from switch S3 means “Safety lock in disengaged position for negative
plunger movement” (plunger disengagement).
Signal from switch S2 means “Locking device fully disengaged”. It is however
fully retracted into the cylinder housing.
If the signal is lost from switch S2 the plunger has started engagement.
If the signal is lost from switch S3 the safety lock has been engaged and therefore
negative plunger movement (plunger disengagement) should be stopped in order to
prevent internal parts in the locking device from being damaged. Positive plunger
movement (plunger engagement) can however be carried out while the safety lock is
engaged.
The recommended settings for the switches are shown in the above figure 4.2.1. The
settings might however need to be finally adjusted at commissioning.

11
5 Hydraulic oil
Figure 5.1 shows the average viscosity versus temperature curves for the most
commonly used oils subdivided in three groups, each one with a different viscosity.
Manufacturers of hydraulic pumps and motors find their best operating conditions
with oil having a viscosity around 30 cSt at operating temperature. Since the average
operational temperature of hydraulic circuits is about 50°C, the oil often used is the
oil corresponding to curve B.
Table 5.1
Curve ISO VG standard
A 32
B 46
C 68
Figure 5.1
We, Dellner Brakes AB, recommend a conventional hydraulic fluid based on mineral
oil, which shall be compatible with nitrile rubber (used materials in seals). The oil
shall at least fulfil ”Vickers M-2950-S (mobile hydraulic systems)” and at least have
a purity 20/17 according to ISO 4406.
Hydraulic oil shall be chosen so that viscosity at working temperature in your system
is 30 cSt. Table 5.2 shows example of suitable oils.
Table 5.2
Manufacturer Type (ISO VG 32) Type (ISO VG 46)
BP Bartran 32 Bartran 46
TEXACO Rando HD 32 Rando HD 46
SHELL Tellus oil 32 Tellus oil 46

12
6 Recommended spare parts
Reference drawing no. 319711-M.
Table 6.1.1
Description Art. no. Item no. Quantity remark
Proximity switch 318556 17 2 pcs. / locking device
Contact 218423 21 2 pcs. / locking device
Reference drawing no. 319711-H.
Table 6.2.1
Description Art. no. Item no. Quantity remark
Hydraulic cylinder 319728 13 1 pcs. / locking device
Hydraulic cylinder 319731 22 1 pcs. / locking device
Proximity switch 318556 17 4 pcs. / locking device
Contact 218423 26 4 pcs. / locking device

13
Rev Ändring Datum Införd Godk.
1 Dim. A changed. 20071205 BA
16 21
S2 17
1
3
S1
4
Denna handling får inte kopieras utan vårt skriftliga medgivande och dess innehåll får inte yppas för tredje man och inte heller användas för något obehörigt ändamål.
2 21 2 218423 Contact PG7

8 20 1 007991006016 MF6S 6x16 8.8 Fzb
19 19 6 100912006055 MC6S 6x55 12.9
9 18 4 000912012040 Mc6S 12x40 8.8 Fzb
11 10 17 2 318556 Proximity switch NC
16 1 319406 Plug
15 1 319168 Plate
14 1 319180 Crank handle
13 1 319725 Locking nut
12 1 319167 Bearing
Use Loctite 270, threadlocking on position "19". 11 2 319724 Plate
Use Loctite 603, bushlocking on positions "3" and "4". 10 2 319723 Bearing
Lubricate Tr. screw and nut. 9 1 319722 Tr. screw
7 10 Lubricate plunger, bushes and inside cylinder. 8 1 319720 Nut
11 13 15 20 Recomended grease: Autol Top 2000 or equvalent. 7 1 319715 Flange
12 18 Position "3" should be mounted whit the joint in 6 1 215032 Stabilisation screw
14 position "3 or 9 a clock" 5 1 319183 Lifting eye bolt M12
4 1 319719 Bush
3 1 319714 Bush
Pos. 1-6 is included 2 1 319713 Plunger
in Bace Unit 319711. 1 1 319712 Cylinder
ITEM NO. QTY. PART NO. DESCRIPTION
Konstr./Des. Ritad Kontr. Skala Vikt Ersätter/Replace Ers.av/Replaced by
A2 BA Drawn
BA Control
PM Scale
1:3 Weight
1 Pos. Type Inst.dim A Signal position Tightening Torque

Mounting instructions E
S1 NC 21,5 Plunger Out Pos. Torque [Nm]
19 17 LM40-M Datum/Date
319711-M
S2 NC 21,5 Plunger In
A 0,5
2007-09-14
Ritn. nr
18 80 Draw. no.
Denna handling är upphovsrättsligt skyddad och får inte, utan This document is copyright legislationed protected and must
tillstånd från Dellner Brakes AB, delges eller överlämnas till not, without permission from Dellner Brakes AB, be given or
utomstående. Överträdelse medför ansvar. handed over to any outsider. Trespass give rise to responsibi-
File:
lity.
1 Hydraulic port info added. Dim. A changed. 071204 BA
25
27
22
P1
S4
S3 17 16
5
21
26
23
7 24
1 S2 14 3 ±0,3
3
S1
4
27 1 8145-00-140-1 Silencer
26 4 218423 Contact PG7
25 4 000912006100 MC6S 6x100 8.8 Fzb
6
24 1 319733 Rod
23 1 319732 Distance
22 1 319731 Hydraul cylinder
21 1 319730 Spring
20 4 000912012040 Mc6S 12x40 8.8 Fzb
19 4 319412 Nordlock M12
Use Loctite 270, thread locking on positions "12" and "24". 18 6 100912006020 MC6S 6x20 12.9
Use Loctite 603, bush locking on positions "3" "4" and "7". 17 4 318556 Proximity switch NC
16 1 319729 Flange
Lubricate plungers, bushes and inside cylinder. 15 20 200091 Disc Spring
P3 Lubricate all disc springs separately and thoroughly
before assembling. 14 1 319727 Plunger
Mount the disc springs in 10 packets, 2 times stacked. 13 1 319728 Hydraul Cylinder
P2 Recomended grease: Autol Top 2000 or equvalent. 12 1 100912012090 MC6S 12x90 12.9
11 1 319718 Spacer tube
2 Instructions for preintentioning of the disc springs "15":
(Use Loctite 270 threadlocking on screw "12"). Preintend the 10 1 101466013000 Plate
15 disc springs by tightening "12" slowly by hand, until 9 1 319717 Flange
8 spacer tube "11" is fixed. Then tight the screw lightly by hand. 8 1 319716 Driving bush
11 10 Control measure the gap between "2" and "8" : 3 ±0,3 mm.
12 7 1 319726 Bush
9 Position "3" should be mounted whit the joint in 6 1 215032 Stabilisation screw
18
13 position "3 or 9 a clock" 5 1 319183 Lifting eye bolt M12
19
20 4 1 319719 Bush
3 1 319714 Bush
Pos. 1-6 is included 2 1 319713 Plunger
in Bace Unit 319711. 1 1 319712 Cylinder
ITEM NO. QTY. PART NO. DESCRIPTION
A2 BA Drawn
BA Control
PM Scale
1:3 Weight
Pos. Type Inst.dim A Signal position Tightening Torque
1
Pos. Torque [Nm]
S1
S2
NC
NC
21,5
21,5
Plunger Out
Plunger In 18 17 Mounting instructions E
LM40-H
A 0,5
S3 NC 31 Lock plunger Up 20 80 Datum/Date
2007-09-14 319711-H
Ritn. nr
S4 NC 31 Lock plunger Down Draw. no.
Denna handling är upphovsrättsligt skyddad och får inte, utan This document is copyright legislationed protected and must
tillstånd från Dellner Brakes AB, delges eller överlämnas till not, without permission from Dellner Brakes AB, be given or
utomstående. Överträdelse medför ansvar. handed over to any outsider. Trespass give rise to responsibi-
File:
lity.
(Brake disc/Flange) 48,50
A R21
R3
10°
57,87
42
10° R3
65
Disc center
0,3 A Slot 1:2

Distance from disc center to LM40 front plane = Disc radius +3 mm 1 mm. 69,50
G1/4"
Hydraulic inlet:
G1/2"
237
G1/2"
186
130
(Guide holes)
170
240 22 180
448
394
31 178
Manualy operated:
1 B
B
118
(Brake disc/Flange)
Hole for fastening screws Hole for fastening screws
Guide holes Ø8 Depth10 (2x). M27 8.8 (2x). Screws not M20 8.8 (2x). Screws not
Spring pins Ø8 recommended. supplied by Dellner Brakes AB. supplied by Dellner Brakes AB.

A2 BA Drawn
BA Control Scale
1:3 Weight
Instalation instruction E
LM 40 Datum/Date
2008-01-23 I0743 -2
Ritn. nr
Draw. no.
Maskinbearbetning enligt Denna handling är upphovsrättsligt skyddad och får inte, utan This document is copyright legislationed protected and must
TB 318555 där ej annat anges. tillstånd från Dellner Brakes AB, delges eller överlämnas till not, without permission from Dellner Brakes AB, be given or
Ytjämnhet där annat ej anges: Ra 6,3. utomstående. Överträdelse medför ansvar. handed over to any outsider. Trespass give rise to responsibi-
File:
Skarpa kanter brutna. lity.
Scale: Size: Type:
: A4 MAN Diesel
Propeller Equipment
Info. No.: Description: Ident. No.:
Tightening Instruction for Screws 2 03 63 93-1

Final User Info. No.: Final User Description: Final User Ident. No.:
Material / Blank:
Basic Standards (MBD SB) & Suppl. Drawing No.: EN21C Surf. roughness Projection:
EN21F-m Tolerances Mass (kg): Final User Material:
Date Des. Chk. Appd. A.C. Change / Replacement C.No

Replaced by Ident. No.: 9
20081120 KEB KEB Word template updated 8
20081029 KEB KEB Exceptional case added re special handling of propeller blade screws 7
20061115 EVA EVA Header and footer updated 6
20060627 KEB KEB Special handling of propeller blade screws, re-fitting propeller blades 5
20040623 KEB KEB Further instructions for mounting of blade screws added 4
20030312 TAL KEB Lubrication of blade screws added 3
20010830 EVA KEB Transferred to word document 2
19960329 EVA KEB Welding data added /2-6989 1
19951012 EVA KEB /2-6571 0
Similar Drawing No.: Replacement for Ident. No.:
Copyright ©, 1997 MAN Diesel
This drawing is the property of MAN Diesel and is to be treated as confidential by the party to whom it has been submitted by MAN Diesel, and is
not to be disclosed to third party without the specific prior written permission of MAN Diesel
IMPORTANT
This instruction contains important information regarding tightening, lubricating,
sealing and securing of screw connections, as well as special handling of propeller
blade screws during re-fitting of propeller blades.
This information is necessary when installing and overhauling the propeller

equipment. The given instructions have to be carefully followed when tightening up
the propeller equipment in order to ensure a correct assembling of the equipment.
Contents Page
Tightening procedure ................................................................................... 2
Lubrication and sealing of screws ................................................................ 6
Securing of screws ....................................................................................... 7
Special handling of propeller blade screws (re-fitting propeller blades)……11
2 03 63 93-1.8 Page 1(11)

T:\drawings\20363\93-1p11m.docx
MAN Diesel
Tightening procedure
For MAN propeller equipment, 3 different methods of screw tightening are used i.e.:
1. Tightening by torque wrench.

2. Pretightening by torque wrench and additional tightening by turning the screw a
specified arc length.
3. Turning the screw until a specified elongation of the screw is achieved.
Note
Flange and bearing surfaces are to be cleaned and free of damages. Flange surfaces
are to be degreased and bearing surfaces to be oiled.
2 03 63 93-1.8 Page 2(11)

MAN Diesel
1. Tightening by torque wrench
Adjusting torque
Torque wrench
After adjusting the torque wrench to the torque specified under tightening data all
the screws in the connection are cross tightened. After this first tightening one (1)
and only one (1) bolt is completely loosened and then retightened by the torque
wrench to the specified torque.
This second cross tightening is repeated until all the screws in the connection are
tightened.
Note
Mark the screws both after the first and second tightening in order to make sure that
all bolts are tightened correct.
2 03 63 93-1.8 Page 3(11)

MAN Diesel
2. Pretightening by torque wrench and additional tightening by turning the

screw a specified arc length
Pretightening Pretightening
o-mark o-mark
Arch Arch
length length
Additional Additional
tightening tightening
Stop mark Stop mark
Hexagon screw Unbrako screw / socket screw
After adjusting the torque wrench to the torque specified under tightening data all
the screws in the connection are cross pretightened by the torque wrench. Now all
the screws are additionally cross tightened to the specified arc length by slugging
spanner or a hydraulic tool according to the above sketch.
After this first tightening one (1) and only one (1) screw is completely loosened and
retightened according to the above description - remember to mark both new 0-
mark and stop-mark.
This second cross tightening is repeated until all the screws in the connection are
tightened.
Note
all the screws are tightened correct.
2 03 63 93-1.8 Page 4(11)

MAN Diesel
3. Turning the screw until a specified elongation of the screw is achieved

(Propeller blade screws)
Dial
Dialgauge
gauge Gauge pin pin
Gauge
Dial
Dialgauge holderholder
gauge Screw
Screw Stop screw
Stop screw
Tightening screw to a prescribed elongation
First of all make sure that the centre hole in the screw as well as the contact face
for the gauge holder is clean and the stop screw is mounted.
All the screws in the connection are tightened by hand (max 50 Nm).
One (1) of the screws in the connection is supplied with the measurement
equipment i.e. the gauge pin and the dial gauge with holder. The dial gauge is
adjusted to zero (0) and the dial gauge with holder is removed. The screw is now
tightened by slugging spanner or a hydraulic tool until the specified elongation is
obtained - remember to make check measurements during the tightening in order
not to overtighten and damage the screw connection. Be aware that the dial gauge
pointer is moving counter clockwise.
This procedure is repeated for all the screws in the connection in such a way that
the screws are cross tightened.
After this first cross tightening one (1) and only one (1) screw is completely
loosened and retightened according to the above description. This second
tightening is repeated until all the screws in the connection are tightened.
Note
all the screws are tightened correct.
2 03 63 93-1.8 Page 5(11)

MAN Diesel
Lubricating and sealing of screws
Before assembling a threaded joint the threads and contact faces have to be
cleaned and lubricated (irrespectively of the thread is with nylon lock or not).
All screws in an MAN B&W propeller equipment have to be lubricated with:
MOLYKOTE PASTA GN+
The molykote pasta has to be applied in a very thin layer by use of a brush.
NB! The following procedure should be used for propeller blade screws:
MOLYKOTE GN+ is carefully stirred till paste consistency is achieved. If dried up,
ordinary lubricating oil is added before stirring.
At start, all surfaces (threads and below head) should be dry and free from grease,
degreased by solvent. *Newly delivered blade flanges and screws from Alpha are
ready for final lubrication and mounting. However, inspect the threads before
mounting very carefully for any damage – if any, these are to be removed by use of
a smooth cut file followed by polishing with smooth abrasive cloth.
MOLYKOTE GN+ is added to the blade screw with a brush, after which it is
polished into the surface with a cloth.
A new thin coating of MOLYKOTE GN+ is added to the blade screw thread and
below the head with a brush.
The blade flange thread is wiped with a cloth in the best possible way. Inspect the
threads very carefully for any damage – if any, these are to be removed by use of a
threaded tap before being carefully applied a thin coating of MOLYKOTE GN+ with
a toothbrush or similar * (a normal paint brush cannot be used for this purpose).
IMPORTANT
- Land the blade screws very carefully in the flange, in order not to damage the
thread inlet.
- Never use any kind of high speed tools or air impact spanners on blade screws.
- Turn the blade screws by hand, all the way down to the bottom position. Never
use tools on a blade screw, which can not be turned by hand – but unscrew it and
investigate the cause.
2 03 63 93-1.8 Page 6(11)

MAN Diesel
Sealing
Additionally some of the screws have to be sealed by a silicone sealing compound

under the screw head.
In those cases only the threads have to be lubricated.
Screws to be sealed can be seen under tightening data. As sealing compound is

used:
RHODORSIL SEALANT 7306

or similar.
Securing of screws
For MAN propeller equipment, 3 different methods of screw securing are used i.e.:
1. Wire securing
2. Weld securing
3. Nylon lock securing
Note
The screws have to be correctly tightened before securing. Do not overtighten or
loosen screws in order to get a correct alignment of wire holes, cross flats etc.
2 03 63 93-1.8 Page 7(11)

MAN Diesel
1. Wire securing
1 2 3
4 5
6
1. Insert wire, dimension according to tightening data, grasp the upper end of the
wire and bend it around the head of the screw, then under the other end of the
wire. Be sure that the wire is tight around the head.
2. Twist the wire clockwise until it is just short of the hole in the second screw.
Keeping the wire under tension, twist it until tight. When the wire is tight, the wire
is to have approximately 7-10 twists per 25 mm.
3. Insert the uppermost wire in the second screw and pull it tight.
4. Bend the lower wire around the screw and under the one protruding from the
screw.
5. Keeping the wire under tension, twist it min. 3 twists counter clockwise until tight.
6. During the final twisting motion, bend the wire along the screw head. Cut off
excess wire.
Any tendency of the screws to loosen will be counteracted by a tightening of the

locking wire. Do not secure more than four screws in a series, unless otherwise
specified.
2 03 63 93-1.8 Page 8(11)

MAN Diesel
2. Weld securing
Welding
Stainless steel wire
Propeller blade connection
Welding data for securing of blade screws
Steel wire (mm) Electrode dim. (mm) Electrode type
Ø5 Ø2.5
Cromarod 316LP or
Ø8 Ø3.25 Cromarod 308L or
OK 61.30
Ø10 Ø3.25
Welding
Steel wire
Flange connections
2 03 63 93-1.8 Page 9(11)

MAN Diesel
Steel wire, dimension according to tightening data, is welded on to the screw heads
according to the above sketches.
Any tendency of the screws to loosen will be counteracted by a tightening of the

steel wire welded on to the screw head.
3. Nylon lock securing

Screws are delivered from MAN with the nylon lock mounted - however, when
refitting screws we recommend to renew the nylon locks. If not possible, it is
recommended to renew the screws.
The new nylon lock is to be sealed with loctite type 242 or similar and after
mounting to be grinded close to the thread as shown on the above sketch.
Nylon lock
Nylon locked screw
Note
The nylon material must be in quality PA6-6 or similar.
2 03 63 93-1.8 Page 10(11)

MAN Diesel
Special handling of propeller blade screws, re-fitting
Steel exposed to cathodic protection by zinc anodes in seawater will absorb

hydrogen.
High tensile strength steel, as propeller blade screws, can be sensitive to hydrogen
embrittlement in form of delayed fracturing during dismounting and re-fitting of
propeller blades (re-use of blade screws).
IMPORTANT !
In order to avoid the risk of delayed fracturing due to hydrogen

embrittlement, the blade screws MUST either be re-newed or heat
treated as follows:
4 hours at 250 deg C.
Note !
The time stated is after complete heat penetration of the screws
Exceptional Case !
---------------------------
Blade screws marked/stamped "H" in the threaded end, need not to be heat
treated as described above.
2 03 63 93-1.8 Page 11(11)

VBS–propeller–Mk3
Delivery
The propeller equipment comprises a four– Inspection and storage
bladed propeller complete with propeller
Before delivery the propeller equipment is
shaft, stern tube and seals. Furthermore all
inspected, preserved and packed. However,
screws, gaskets and valves (not pipes) to-
all parts should be checked for damage or
gether with necessary special–purpose
faults and reported immediately.
tools are included in the delivery.
The propeller equipment must be carefully
The stern tube can be omitted partly, entirely
stored, prior to installation preferably in a
or special design supplied. Other compo-
dry, heated room. The recipient is respon-
nents, for example, intermediate shafts,
sible for any damage caused by incorrect
shaft bearings, bulkhead–seals, shaft
handling and/or storage.
brake, or propeller nozzle can be included in
the supply. Propeller shafts, coupling flanges, inter-
mediate shafts etc are preserved with dini-
trol paste prior to dispatch from Alpha and
this can be removed with kerosene or petrol.
2001–08–15
Release 3 10A1-01 page 10–11

Fitting stern tube – oil lubricated

The stern tube is designed to be installed The oil box is machined for tight fitting in the
from aft. It is of welded construction and ma- bulkhead with an interference of 0–0.02
chined. A 5 mm fitting allowance is left for mm.
final installation machining. The installation length for the stern tube is
The stern tube is delivered with stern tube checked – it should not deviate by more than
liners fitted. Guard, oil box, gaskets, bolts, S " 2.5 mm.
gravity tank, and valves are also included in The stern tube with gasket is pressed into
the supply. position, the oil grooves of the stern tube
bearings being in horizontal position. Seal-
Installation ing rings are to be placed in the grooves on
front end of the stern tube, before the oil box
The stern tube must be fitted with a tight fit.
with gasket is pressed into position.
The propeller boss is measured and the
stern tube is finish machined with an inter- Molykote GN is applied to the bolts before
ference of 0.02–0.05 mm. tightening in to the required torque, see data
If the bore in the boss is rough or out of round sheet in para. 3 10.
then the bore should be tighter. The contact Bearing temperature sensors may be re-
face of the boss for the stern tube flange has quired and fitted in the stern tube.
2001–07–01
to be flat and square to shaft line, so a leak-
proof assembly is obtained. The bore is See propeller equipment drawing.
chamfered.
Fig 10.1
S
2032543–2.1
Assembled stern tube – oil lubricated
page 10–12 Release 3 10B1-01

Pressing force for stern tube Epoxy chocks

The following formula can be used for calcu- Stern tube and oil box may be located in
lating of the approx. force required: epoxy resin but precautions to provide
adequate cooling of the stern tube may be
F+
(p E
2
m)
ǒ
L 1 * ǒdńDǓ
2
Ǔ U necessary.
The use of epoxy resin has to be acceptable
to the owner and MAN B&W Alpha Diesel,
F = Pressing force in Newton whilst the installation and design have to be
E = 210,000 N/mm2 approved by the classification society in-
volved.
µ = 0.15 (steel/steel)
d = Inside diameter at the stern tube (mm)
D = Outside diameter at the stern tube
(mm)
L = Total length of the carrying outside
diameter of the stern tube (mm)
U = Interference fit between the inside
diameter of the stern boss and the
2001–07–01
outside diameter of the stern tube
Fig 10.2
groves for sealing ring

sterntube oil groove
oil box
seen from A
gasket gasket
2033637–3.0
Installation guidance for stern tube
Release 3 10B1-01 page 10–13

Maintenance A + 301 * 400 mm D + A ) 0.7 )0.05

*0
The stern tube requires no maintenance, A + 401 * 500 mm D + A ) 0.8 )0.15
*0
but care should be taken that the lubricating
oil is not contaminated by water or impu- A + 501 * 600 mm D + A ) 0.9 )0.15
*0
rities. With good lubrication the life of the
white–metal bearings can be 100,000 hours
or more. The max permissible wear is 1.5 Stern tube liners delivered
mm. separately
The clearance of a new stern tube bearing When supplying loose stern tube liners they
is indicated in the table below where A = have to be fitted with the following press fit:
shaft diameter and D = inside diameter of
stern tube bearing. Outside diam. 100 – 300 300 – 700
liner
A + 100 * 200 mm D + A ) 0.5 )0.05
*0 Interference +0.02 to +0.03 to
+0.03 +0.05
A + 201 * 300 mm D + A ) 0.6 )0.05
*0
2001–07–01
page 10–14 Release 3 10B1-01

Fitting propeller equipment

The propeller hub and propeller shaft are To enable a check following launching, test
normally delivered assembled, with the after marks indicating the longitudinal position of
seal fitted, see page 15–37, where the pro- the propeller shaft inside the ship should be
peller equipment is shown as standard de- made.
sign. Before launching, both stern tube and pro-
Before installing the propeller shaft into the peller hub must be filled with lubricating oil.
stern tube ensure the stern tube has been Use the plug screw in the hub as venting for
carefully cleaned inside and that there are the stern tube system.
no loose paint, swarf, rust, sand or other Check that all bolts have been correctly tigh-
impurities remaining. The stern tube oil tank tened and secured.
and pipe connections must also be cleaned.
After filling the sterntube with oil check that
Care should be taken to ensure that the pro- there are no signs of leakage.
peller shaft and stern tube seals are also
carefully cleaned. Check the fitting and location of zinc
anodes.
Damage during guarantee period can often
be the result of inadequate cleaning prior to Check installation, alignment and corrosion
installation. protection of the nozzle, if fitted.
2001–08–15
During installation, care must be taken not to Add servo oil (filling point see instruction
damage the liners, which should be well manual for gearbox) when the ship is in
greased, if the stern tube is oil lubricated. water and the propeller shaft system is final-
ly installed. Rotate the propeller (approx 100
When the propeller shaft is in position, the rpm) and give order to ahead/astern a few
aft’r seal is attached and the for’d seal fitted. times. The remaining air will escape through
(See separate instruction manual for stern the gearbox.
tube seals.)
Before assembling of servo oil pipes be-
To ensure correct functioning of the seals it tween gear and propeller the coupling
is important that the mounting dimensions flange is to be pulled back. On long unsup-
indicated on the installation drawing are ob- ported shaft overhang, a lift jack must be
served. placed to support the shaft before dismantl-
ing the coupling flange. This is to prevent the
servo oil tube to carry the shaft gravity load
and thus possible damage.
Release 3 10C2-01 page 10–15

The servo oil pipes are connected to each During sea trials check, not only the stern
other by thread and screwed–on flange. The tube bearing temperatures, but also the
distance between flanges must approx. 12 stern tube and stern tube seals.
mm and the bolts tightened to the specified
On completion of sea trials, check the
torque acc. to chapter 3 10. For information
tightening torques of all power transmitting
about the remaining servo oil pipe connec-
coupling bolts in the shaft line.
tions, see page 15–39.
Fig 10.3
12 mm
2001–08–15
AINS
Servo oil pipe connection
page 10–16 Release 3 10C2-01

Lubricating oil system

The stern tube seal, the mechanical parts in drained off, it is recommended to fill oil di-
the hub and the liners are oil lubricated by a rectly into the propeller hub through the
oil system, which includes a gravity tank pla- screwed plug holes in the propeller hub to
ced above the normal water line. ensure the hub is properly vented and com-
pletely filled.
Filling with oil The stern tube is then filled with oil from the
gravity tank. Due to the high viscosity of the
Before un–docking, the system has to be
oil it is advisable to warm the oil so that it
filled with an approved lubricating oil accord-
flows easier.
ing to our oil list.
When filling the propeller equipment with oil
for the first time, or when the oil has been
Fig 10.4
2001–07–01
AINS
VBS propeller – oil lubricated stern tube
Release 3 10D2-01 page 10–17

The aft seal is filled with oil in accordance In case of leakage an emulsifying oil can be
with the seal manufacturer’s recommenda- used to reduce oil loss and maintain a satis-
tions. For seals with lip rings it is important factory lubrication should sea water enter
the chambers between the rings are filled the stern tube.
with oil. The gravity tank supplying oil to the
for’d seal should also be filled with oil.
Oil quantity
Oil quantity in the propeller equipment is
Note given on data sheet. The oil quantity does
Check for leakage before undocking. not include piping from gravity tank to oil
box.
Oil types For stern tube seals: see manufacturer’s
separate manual.
Plants supplied with seals of the lip ring type,
can use oil according to the recommended
lubricating oil list. Oil control
Other lubricating oils, may be used if the In service the oil level in the gravity tank
condition of the viscosity oil does not exceed should be checked daily.
approx 200 cSt at 40_C and the pour point
is in the range of –10_C.
2001–07–01
page 10–18 Release 3 10D2-01

Alignment of shafting
The following should be checked before The GAP/SAG measurements for your spe-
alignment: cific plant are given on the plant specific data
1. That the vessel is floating preferably in sheet.
its normal loaded condition. Generally the shaft line must be straight in
2. That there are no undue temperature the horizontal plane, within a tolerance of ±
differences between the ship and pro- 0.05 mm unless otherwise stated.
pulsion plant. After tightening down the intermediate shaft
3. That all major weldings in the founda- bearings and/or gearbox:
tion area are completed and tempera- 1. re–check the alignment
tures normalised.
2. assemble control rods/servo oil pipes
4. That the installed dimensions and
positions for the stern tube seals are 3. bolt together the flanges
correct. 4. apply rust inhibitor
Alignment procedure GAP/SAG definitions

The alignment procedure is based on the GAP is the horizontal distance between
GAP and SAG method using precalculated free, angled flanges measured in mm.
2001–07–01
measurements between the disconnected
SAG is the vertical difference between the
flanges, see fig 10.6.
angled flanges measured in mm.
Before alignment it is important that not only
The GAP/SAG measurements may be
the flanges, but also the connecting rods/
taken with feeler gauges.
servo oil pipes running in the shafting are
fully disconnected. In the example fig 10.6 the GAP and SAG
are at the bottom of the flanges.
Fig 10.6
SAG
GAP
Set–up when measuring GAP/SAG
page 10–20 Release 3 10E1-01

As an alternative fig 10.7 shows the SAG

measurement when measured with a dial
gauge connected to one flange.
Note
When using dial gauge for the SAG
measurement, be aware that the difference
in dial gauge readings must be two times the
given SAG value.
Example: SAG = 0.2 mm
equals a difference in dial gauge readings
of 2 x 0.2 mm = 0.4 mm.
Fig 10.7
Dial gauge for

SAG measurement
2001–07–01
Feeler gauge
for GAP measurement
GAP/SAG measurement
Release 3 10E1-01 page 10–21

Fitting zinc anodes to propeller and stern

The propeller hub has been fitted with a zinc Zinc anodes should not be fitted to the stern
anode on the propeller cap to protect the of the vessel within the hatched area as indi-
propeller against galvanic corrosion. On cated below. Fitting zinc anodes within this
some stern tube seals, small zinc anodes area disturbs the flow of water to the pro-
are fitted to the chrome steel liner, which is peller and thus increase the risk of propeller
electrical insulated from propeller and pro- vibrations and cavitation erosion. Further-
peller shaft, especially to protect the pro- more, zinc anodes should not be fitted to
peller against corrosion. shaft brackets of twin–screw vessels within
At each docking these anodes should be in- this hatched area.
spected and replaced if necessary.
Fig 10.7
Min.D
2001–07–01
1.1 x D
D
ÏÏÏ
ÏÏÏ
AINS
Restricted area zinc anodes
Release 3 10F1-01 page 10–21

Work card 10 303A–01

Disassembling hydraulic coupling flange (ODG –type)
Safety precautions Man power Tools

Engine stopped and
blocked for start
Lifting tools – lever chain
Propeller shaft locked for hoist
rotation Key spanner
Allen key
Propeller shaft locked for Working time: 4 hours
Eye bolt
axial movement Capacity: 2 men
See plate: 3 4510
Shut–off stern tube
lubricating oil system Hydraulic tools
See plate: 3 4505
Hydraulic power unit
stopped and blocked
2003–03–03
Replacement and
Data wearing parts
Plant specific data: Chapter 3 05 Plate no: 3 1005
Starting position: Propeller shaft installed in sterntube.
Fig 10.12 Injectors
Procedure
1. Remove the screws (4) fig 10.12 and Venting
fig 10.13 and move the locking ring (3) 2
and the O–ring (5) aft.
2. Check if the locating mark (100 mm 1
mark) is intact.
3. Measure the exact distance from the 4
aft end of the coupling to the locating
mark on the propeller shaft and note it 3
for later use when reinstalling the
coupling flange. 5
Mark on shaft
Hydraulic coupling flange
Release 10 303A-01 page 10–25

4. Secure the propeller shaft to ensure 7. Connect the hydraulic pump to

that the propeller shaft does not slide chamber “C”, see fig 10.13, and fill
out of the stern tube. chamber “C” with SAE 30 oil. Plug the
5. Dismantle the assembling screws in venting hole when oil without air
the propeller flange except two. comes out.
6. Turn the shaft to bring the holes for in- 8. Raise the pressure to about 80 bars.
jectors into position 12 o’clock and re-
move the plug screws for chamber “C”
and the injectors.
Fig 10.13
1. Injectors 2.
Venting screw SAE 90 oil

SAE 30 oil Muff SAE 30 oil
Seal flange (2)
Nut (1)
2003–03–03
Screw (4)
Locking ring (3)

100 mm
Seal ring (5)
A ....
A ....
Mark on shaft
Filling plug C
SAE 30 oil
Distance for push–up
stamped on coupling muff
10 303 ODG
Hydr. pump
Hydraulic coupling flange
page 10–26 Release 10 303A-01

9. Install injector 1 and fill the oil container Fig 10.14

for injector pump 1, with SAE 90 oil.
10. Operate the pump until all air has es-
caped in the front of the muff and oil
comes out of the hole for injector 2.
11. Change the oil for injector 1 to SAE 30.
12. Install injector 2 and fill the oil container
with SAE 30 oil. The lifting beam
and the shaft
13. Operate both pumps simultaneously must be aligned
and keep pumping until the muff be- so they are
comes loose. This is indicated on the in line.
pressure gauge on the pump con-
nected to chamber “C” by a sudden
rise in indicated pressure.
Warning
Keep well clear of the coupling flange and at
no time stand in the vicinity astern of the
coupling when hydraulic pressure is applied
2003–03–03
to loosen the muff.
Wear safety glasses when using high pres-

sure hydraulics.
14. Keep operating both injector pumps, Lifting arrangement for coupling flange
while a second person slowly opens
the valve on the hydraulic pump allow-
Note
ing oil from chamber “C” to escape to
the oil coontainer of the hydraulic Coupling flanges for shafts larger than
pump and allowing the muff to slide 350 mm diameter have additional venting
slowly down the cone. screws located between the injectors. In this
case both injectors and vent screws must be
used for pumping and venting.
Note
As a precaution, remove the filling plug from
the oil container of the hydraulic pump, be-
cause the oil container may not be big
enough to hold the volume of oil coming
from chamber “C”.
15. Clean and oil the propeller shaft aft of
the coupling flange before pushing the
flange to the aft.

Work card 10 304A–01

Assembling hydraulic coupling flange (ODG – type)

Engine stopped and
blocked for start
Propeller shaft locked for Hydraulic tools
rotation See plate: 3 4505
Propeller shaft locked for Working time: 4 hours Lifting gear

axial movement Capacity: 2 men Key spanner
Hexagonal spanner
Shut–off stern tube Eye bolt
lubricating oil system See plate: 3 4510
stopped and blocked
2003–03–03
Replacement and
Data wearing parts
Plant specific data: Chapter 3 05 Plate no: 3 1505
Starting position: Check that O–ring for sealing flange are fitted and without damage.
Procedure
1. Clean thoroughly the whole of the lo-
cating and surrounding areas of the Note
shaft and the inside surface of the We strongly recommend that a lifting beam
coupling. All joining surfaces must be with carriage is fitted above the propeller so
free of any lub oil. when the coupling flange is lifted, it is cor-
The shaft may be lubricated with a mix- rectly aligned with the propeller shaft.
ture of 70% gas oil and 30% mineral oil.
2. Fit the lifting gear on the coupling
flange with the “0” mark in top and posi-
tion the flange as shown in fig 10.15.

8. Slide the coupling flange over the shaft

Note as far as necessary to make space
Before lifting check that the weight does not enough to assemble the servo oil
exceed the SWL of the lifting gear/beam, pipes. Regarding this subject, see
see Plant specific data chapter 3 05. page 10–15.
9. Slide the coupling flange in direction
3. Use the lifting arrangement to take the ahead, while the lifting gear is carrying
weight off the coupling flange before the weight of the coupling flange, until
attempting to move the coupling flange the aft of the coupling flange is 100 mm
along the shaft. See fig 10.16. ahead of the mark in the propeller
4. Loosen and remove the screws (4) shaft, or to make contact with the
and remove the locking ring (3), and flange on the gearbox or intermediate
the O–ring (5) from the coupling shaft, see fig 10.15.
flange, see fig 10.15. 10. Fit a number of coupling bolts to make
5. Place the locking ring and the O–ring full contact between the flanges.
on the shaft. 11. Remove the plug screws for chamber
6. Align the coupling flange with the shaft, “C” and for the injectors. Connect the
see fig 10.16. hydraulic pump to chamber “C” and in-
stall the injector (1) fig 10.15.
7. At low temperatures it is advisable to
2003–03–03
heat the coupling flange to approx
20_C for an easier fit. 1. Injectors 2.
Fig 10.15 Venting SAE 90 oil

screw SAE 30 oil Muff SAE 30 oil
Seal flange (2)
Nut (1)
Screw (4)
Locking ring (3)

100 mm
Seal ring (5)
A ....
A ....
Mark on shaft
Filling plug SAE 30 oil C
Distance for push–up

stamped on coupling
10 303A–01
muff
Hydr. pump
Fitting hydraulic coupling flange
page 10–30 Release 10 304A-01

19. Install the remaining coupling bolts.

Note 20. Check the tightening of the nut (1), fig
Coupling flanges for shafts larger than 10.15. It must be tightened hard
350 mm diameter have additional venting against the seal flange (2), fig 10.15.
screws located between the injectors. In this
case both injectors and vent screws must be Note
used for pumping and venting.
There must be a clearance between nut (1)
and locking ring item (3).
Warning
Wear safety glasses when using high pres-
Warning
sure hydraulics.
Keep well clear of the coupling flange and at
12. Use the hydraulic pump to fill chamber no time stand in the vicinity astern of the
“C” with SAE 30 oil. Plug the venting coupling when applying hydraulic pressure
hole in top of chamber “C” when oil to remove the muff.
without air comes out of the hole and
raise the pressure to about 80 bars. 21. Push the O–ring on the propeller shaft
against the coupling flange and fit the
13. Fill the oil container for injector (1), fig locking ring with the screws (4), fig
10.15, with SAE 90 oil and operate the 10.15.
injector until all air has been pressed
22. Protect the coupling flange and pro-
2003–03–03
out in the front of the muff and oil

comes out of the hole for injector (2), peller shaft with anti–corrosive oil or
fig 10.15. equivalent. The corrosion prevention
must be maintained to ensure easy
14. Install injector (2) and fill the oil con-
dismantling of the coupling in the fu-
tainer with SAE 30 oil. Fill the oil con-
ture. Furthermore, the screw plugs in
tainer for injector (1) with SAE 30 oil.
the muff must be fitted waterproof and
15. Operate the two injectors simulta- the threads of the nut (1), fig 10.15,
neously while an assisting person op- must be treated with anti–corrosive oil.
erates the hydraulic pump to push up
the muff. The pressure in chamber “C” Fig 10.16
is not allowed to exceed 500 bars.
16. The correct distance “A” for push up is
stamped on the muff, see fig 10.15.
17. When the muff has reached the right
position the pressures in the two injec-
tors are to be released. The pressure
in chamber “C” is maintained another
20 to 30 minutes to ensure that the
muff will remain in the position it has
been brought to. Check that the muff
keeps position when the pressure in
chamber “C” is released.
18. Remove the injectors and disconnect Lifting arrangement for coupling flange
the hydraulic pumps. Fit the plug
screws.

Work card 10 306–01

Fitting of propeller blade

Engine stopped and
blocked for start
Propeller shaft locked for
rotation
Lifting tool
Working time:
Propeller shaft locked for Spanner for blade screw
Approx 3 hours/blade
axial movement Lifting eye screw
Capacity: 2 men
See plate: 3 4510
Shut–off stern tube
lubricating oil system
stopped and blocked
2001–05–10
Replacement and
Data wearing parts
Plant specific data Chapter 3 05
Plate no: 3 1505
Tightening data sheet: Chapter 3 10
Starting position: Scaffolding etc prepared to achieve adequate working conditions.
Fig 10.27
Procedure
1. Carefully clean and inspect hub,
flanges, blades and sealing rings for any
damage which may have occurred dur-
ing either transport or handling at the
ship yard. If there is any damage, it must
be repaired or new parts must be used.
2. Turn the propeller hub to position the
blade base horizontal.
3. Place the o–ring and the flat sealing
ring in the groove around the blade
3 10D1–03–VBS
base.
Lifting gear
Release 10 306-01 page 10–41

4. Fit the lifting gear on the blade and lift 7. Follow the Tightening instruction for
the blade into position. The guide pin screws (chapter 3 10) in order to
and the recess ensure that the blade is tighten the blade screws.
positioned correctly 8. Fill the equipment with lubricating oil
when all the blades have been fitted.
Note 9. Inspect over as long a period as pos-
Before lifting check that the weight does not sible that the blade/hub connection is
exceed the SWL of the lifting gear/beam, not leaking when the stern tube is pres-
see Plant specific data chapter 3 05 or the surized from the stern tube lub oil tank.
weight stamped on the blade foot. 10. Secure the blade screws by welding
according to Tightening instructions
5. Oil the top of the flat sealing ring and for screws 2036393–1 and Tightening
bearing surface, see fig 10.28. data sheet.
6. Clean the blade screws and lubricate

thread and contact face with a thin
layer of MOLYCOTE GN+.
Fig 10.28
2001–05–10
Blade
Blade foot
Bearing surface
Recess
Guide pin Flat sealing ring

Blade screw
O–ring
Hub
VB WC 10 305–01
Flange
Fitting propeller blade
page 10–42 Release 10 306-01

User Manual
Installation and Operating Instructions
Lubrication System QLS 401
6141b 03
U.S. Patent-No. 6,244,387, German Regist ration Design No. 29923765.6

609 3b04
810-55374-1I
Subject to modifications
Form 403439 2.1EN-38020-I10 Section - Q 3 Page - 19

User Manual
This User Manual was compiled on behalf of

- the manufacturer - by
Lincoln GmbH EdiDoc GmbH
Heinrich-Hertz-Str. 2-8 Erzberger Str. 8
D-69190 Walldorf D-68753 Waghäusel
All rights reserved.

Any duplication of this User Manual, in its entirety or in part,
by whatever means is prohibited without the prior consent in
writing of Lincoln GmbH.
Subject t o modifications without prior notif ication.
Phone: +49 (6227) 33-0

Fax: +49 (6227) 33-259
E-Mail: Lincoln@lincolnindustrial.de
© 2010 by
Page 2 of 46 2.1EN-38020-I10 Form 403439

User Manual
Table of Contents
Page Page
Introduction Identification Guide

Explanat ion of Symbols Used ................ ...................... ...... 4 VDC .................. ...................... ...................... ............... .... 14
User’s Responsibility ...... ....................... ...................... ...... 4 VAC .................. ...................... ...................... ............... .... 15
Environmental Protection ...................... ...................... ...... 4
Service ..... ........ .............. ....................... ...................... ...... 4 Operati on
Lubrication System ................. ...................... ............... .... 16
Safety Instructions Pressure Relief Valve ............. ............... ....... ............... .... 16
Appropriate Use ............. ....................... ...................... ...... 5 Low-level control ..................... ...................... ............... .... 17
Misuse ...... ........ .............. ....................... ...................... ...... 5 Monitoring relay ...................... ...................... ............... .... 17
Exclusion of Liability . ....................... ...................... ...... 5
General Safety Instructions ................... ...................... ...... 5 Setting and Operation
Regulation for Prevention of Accidents . ...................... ...... 5 General ............. ...................... ............... ....... ............... .... 18
Operation, Repair and Maintenance ...... ...................... ...... 5 Factory Settings ................ ...................... ............... .... 18
Operation / Maintenance .................. ...................... ...... 6 Operator keys ... ...................... ...................... ............... .... 18
Operation with bayonet plug ............ ...................... ...... 6 Display Mode .... ...................... ...................... ............... .... 19
Repair . ........ .............. ....................... ...................... ...... 6 Programming Mode ................ ...................... ............... .... 21
Disposal .................... ....................... ...................... ...... 6 Operating Mode ...................... ...................... ............... .... 25
Dangers due to electric current ........ ...................... ...... 6
Installation ........ .............. ....................... ...................... ...... 6 Maintenance, Repair and Tests
Maintenance ..... ...................... ............... ....... ............... .... 28
Installation Instructions Filling of the reservoir ........ ...................... ............... .... 28
Pump ........ ........ .............. ....................... ...................... ...... 7 Repair ............... ...................... ...................... ............... .... 28
Pumps with mounted metering device ... ...................... ...... 7 Electrical Connection .............. ...................... ............... .... 29
Cross-porting of the SSV Divider Blocks ..................... ...... 7 Tests ................. ...................... ...................... ............... .... 29
Single Output ............ ....................... ...................... ...... 7
Double and Multiple Outputs ............ ...................... ...... 7 Troubleshooting .................... ............... ....... ............... .... 30
Check valve .............. ....................... ...................... ...... 7
Direct (internal) feedback feature .......... ...................... ...... 8 Technical Data
Pumps with external metering device .... ...................... ...... 8 Rating ............... ...................... ...................... ............... .... 33
Lubrication Points ........... ....................... ...................... ...... 8 Electrical Data ... ...................... ...................... ............... .... 34
Installing Zerk Locks onto Grease Fittings ................... ...... 8 Electrical Connection
Connection of Feed Lines ...................... ...................... ...... 9 Connection of the membrane keypad ...... ............... .... 34
First filling of a lubrication system .......... ...................... .... 10 Terminal 15 and 30 ........... ...................... ............... .... 34
Electrical Connection ...... ....................... ...................... .... 10 Connecting Diagrams ........ ...................... ............... .... 35
Option for metric fittings .. ....................... ...................... .... 11 Dimensions ....... ...................... ...................... ............... .... 38
Description .................... ....................... ...................... .... 12 Service Parts ... ...................... ...................... ............... .... 39
EC Declaration of Conformi ty ............. ....... ............... .... 45
Lincoln worldwide ................. ...................... ............... .... 46
Keep this user information always at hand

at the place of work of the pump!
Form 403439 2.1EN-38020-I10 Page 3 of 46

User Manual
Introduction
Explanation of Symbols Used

The following description standards are used in this manual: Furthermore, you will find the following text symbols in this
Safety Instructions manual:
Structure of safety instructions: Listing of applicable statements
Pictogram - Subpoint of applicable statements
Signal word 1. Det ermination of the number or sequence of contents
Danger text Â Procedural instruction
- Danger not e
- How to avoid danger
User's Responsibility
The following pictograms are used in this manual and are To ensure the safe operat ion of the unit, the user is responsi-
combined with the corresponding signal words: ble for the following:
1. The pump / system shall be operated only for the in-
tended use (see next chapter "Safety Instructions") and
its design shall neither be modified nor transformed.
2. The pump / system shall be operated only if it is in a
proper functioning condition and if it is operated in accor-
dance with the maintenance requirements.
1013 A94 4 273a0 0 6001a 02 3. The operating personnel must be familiar with this User
- ATTENTION - ATTENTION - NOTE Manual and the safety instructions mentioned within and
observe these carefully.
- CAUTION - CAUTION - IMPORTANT
The correct inst allation and connection of tubes and hoses, if
- WARNING - WARNING not specified by Lincoln GmbH, is the user's responsibility.
The signal words give the seriousness of danger if the follow- Lincoln GmbH will gladly assist you with any questions per-
ing text is not observed: taining to the installation.
ATTENTION refers to faults or damages on

machines.
Environmental Protection
CAUTION refers to bad damages and possi- Waste (e.g. used oil, detergents, lubricants) must be dis-
ble injuries. posed of in accordance with relevant environmental regula-
WARN ING refers to possible dangerous inju- tions.
ries.
NOTE indicat es improved operation of the Service
device.
IMPORTANT indicat es special operating fea- The personnel responsible for t he handling of the pump /
tures of the device. system must be suitably qualified. If required, Lincoln GmbH
offers you full service in t he form of advice, on-site installation
Example: assistance, training, etc. We will be pleased to inform you
about our possibilities to support you purposefully.
ATTENTION! In the event of inquiries pertaining t o maintenance, repairs
and spare parts, we require model specific data to enable us
When making use of other than the tested
to clearly identify the components of your pump / system.
spare parts, serious damage may affect
Therefore, always indicate the part, model and series number
your device.
of your pump / system.
Therefore, for the operation of your device
always use original parts made by Lincoln
10 13A94
GmbH.
Page 4 of 46 2.1EN-38020-I10 Form 403439

User Manual
Safety Instructions
Appropriate Use Regulations for Prevention of Accidents
The lubricat ion system QLS 401 has been designed for initial To prevent accidents, observe all city, state and federal
and retrofit installation. It has been designed for: safety regulations of the country in which the product will
the automatic lubrication of machines and systems be used.
the automatic lubrication of commercial vehicles and con- Avoid the operation with
struction machines
- unapproved parts.
the automatic lubrication of hydraulically driven units and - insufficient or contaminated lubricants.
devices.
The lubricat ion system QLS 401 is able to deliver greases up General Safety Instructions
to NLGI - class 2 or fluid greases of NLGI - class 000 or 00.
Lubrication systems QLS 401
Use the QLS 401 exclusively to supply lubricants.
- are designed state-of-the-art.
The QLS 401 is adequate for intermittent operation only.
- can be assembled for safe operation.
The QLS 401 is adequate for feeding max. 18 lube points
- must be filled regularly without air inclusions with clean
per operating cycle.
lubricant recommended by the manufacturer (see “List
Do not use QLS 401 with SSV divider block in bottom of Lubricants” 2.0-40001).
mounting position for mobile applications. Do not install
the system with machines exposed to shock. Incorrect use may result in bearing damage caused by
poor or excessive lubrication.
Do not overpressurize reservoir when filling the pump.
Refill QLS 401 pump with clean lubricant.
Misuse
Each outlet needed must be equipped with an appropriate
Any use of the QLS 401 that is not expressly mentioned in check valve.
this User Manual will be regarded as misuse.
IMPORTANT
If the QLS 401 is used or operated in a different manner other
than specified, any claim for warranty or liability will be null Do not paint the pump!
and void. Before painting a machine or commercial
NOTE vehicle, remove or cover the pump com-
6001a0 2 pletely.
If personal injury or material damage oc-
curs as a result of inappropriate operation, Any modifications must be subject to prior consultation
e. g. if the safety instruct ions are ignored or with t he manufacturer of the QLS 401.
6001a0 2 resulting from an incorrect installation of the
QLS 401, no claims or legal actions may be
taken against Lincoln GmbH. Operation, Repair and Maintenance
Exclusion of Liability
ATTENTION!
The manufacturer of the centralized lubrication system
Malfunction because of dirt!
QLS 401 will not accept any liability for damage:
When executing any maintenance or repair
Caused by insufficient lubricant
works on the QLS 401, ensure absolute
- due to irregular filling of the reservoir cleanliness.
- due to wrong programming of the internal or external
controller 1013A94
- due to wrong planning and layout of the downstream lu-

bricant distribution. WARNING!
caused by the use of contaminated lubricant s. Before maint enance or repair of pumps
due to the use of lubricants which are not or are only switch off their power supply.
conditionally pumpable in centralized lubrication systems.
caused by connection to a wrong supply power.
427 3a00
caused by an environmentally inadequate disposal of
used or contaminated lubricants or parts that were in ATTENTION !
touch with lubricants.
After the fault message * EE * the f ollowing
caused by unauthorized modification of system compo-
programming may result in poor lubrica-
nents.
tion:
caused by the use of unapproved part s (voids the pump - Pause time (P1 & P2) ………… < 6 hours
warranty). - Number of lube times (P3) ….. > 1 / cycle
1013A94
CAU TION!
It is not allowed to use the pump in poten-
tially explosive fields.
1013A94
Form 403439 2.1EN-38020-I10 Page 5 of 46

User Manual
Safety Instructions, continuation
Operation/Maintenance Operation with bayonet plug

Lincoln Quicklub centralized lubrication systems
must be operated only with installed pressure relief valve. CAU TION!
must be operated wit h attached or connected SSV meter-
If the protective-conductor terminal is not
ing device make Lincoln GmbH.
connected or interrupted, dangerous touch
must be refilled in regular intervals with clean and recom- voltages may occur on the equipment!
mended 1) lubricant without air entrapments.
1)
see recommendation of the user or the manufacturer of the 4273 a00
machine or the vehicle & List of Lubricants (2.0-40001)
operate automatically. However, a regular check (approx. Protective measures t o be applied for appropriate operation
every 2 days) should be made to ensure that lubricant is with bayonet plugs:
emerging from all lubrication points. "Functional extra-low voltage with safe isolation" /
"Protective Extra-Low Voltage" (PELV)
Standards:
DIN EN 60204 Teil1: 2007-07 / IEC 204-1 /
DIN VDE 0100 Teil 410: 2007-06 / I EC 364-4-41
Repair Disposal
Repairs should only be performed by authorized personnel Dispose of used or contaminated lubricants as well as of parts
that were in touch with lubricant according to the legal regula-
who are familiar with t he repair instructions.
tions pertaining to environmental protection. Make sure to
observe the safety dat a sheets of the lubricants used.
Dangers due to electric current Installation

CAUTION! Any safety equipment already f itted to the machine:
The pump must be installed only by quali- - should not be modified or made ineffective;
fied personnel. The connection (N/L/PE) of - should only be removed for the purpose of fitting the
the supply voltage must be done according system;
to VDE 0100 and VDE 0160. Install a pro- - must be reinstalled after fitting the system.
tective and lock out device for isolating and Keep Quicklub centralized lubrication systems away from
427 3a00 disconnecting t he pump. Before installing sources of heat. Adhere to the operating temperature.
or work on the pump, disconnect and
lock out the incoming power. Use only original Lincoln spare parts (see Parts Catalog
2.0-20001) or parts approved by Lincoln.
WARNING!
Adhere to:
Failure to observe the safety instructions, e. g. touching elec- - the installation instructions of the machine manufacturer
trically charged parts when the pump is opened, or improper as regards all drilling and welding procedures.
handling of the pump may cause serious injury or death. If the - the specified minimum distances between the boreholes
values specified in the Technical Data are exceeded, the and the upper/lower rim of the frame or between two
device may overheat. It may damage the pump and thus impair boreholes.
the electric safety.
IMPORTANT
Â Route supply lines professionally.
Â Firmly bolt together pressurized com-
ponents.
6001 a02
ATTENTION! Â Consider the torsion torques.
Control p.c.b. and motor always work with
24 VDC even if the pump is connected to
alternating current. NOTE
Consider residual ripple of max. ±5 % In case of rear-mounted lubricant meter-
when connecting motor and control p.c.b. ing devices:
4273a0 0
(in relation to the operating voltage acc. to For transporting outlet 2 of the metering
DIN 41755). 6001a0 2 device was equipped with a check valve.
Make sure to remove it before assembly,
as it cannot be used when operating.
Page 6 of 46 2.1EN-38020-I10 Form 403439

User Manual
Installation Instructions
Pump
Mount pumps in such way t hat access is provided to refill and
test the pump. Use drilling template to mark and drill mount-
ing holes of the pump. Drilling template and mounting bolts
are included in the package.
Pumps with mounted metering device

Determination of the output by cross-porting of outlets
1) Single output
A single out put is the lubricant quantity fed to the lube
point by a piston per stroke and outlet port. It amounts to
approx. 0.2 cm³, see outlet 6 (fig. 1-1).
2) Double or multiple outputs

Outputs can be increased by simply plugging the unused
out let ports with closure plugs (fig. 2, provided in the ac-
cessory kit).
Lubricant from a plugged out let is redirected to the next
out let on the same side of the SSV divider block in de-
scending numerical order (see fig.1).
Example, see fig. 1:
By closing
1014 b00
- of outlet 4, outlet 2 receives the double quantity
- of outlets 5 and 3, outlet 1 receives the triple amount of
Fig. 1-1 Single double and triple lubricant output lubricant. The connecting conduit from outlet line 1 to
(on back side mounted divider block) outlet line 2 and to the return line (R) is closed by
0x-3x Outlet quantity (single, double, etc.) clamping rings (A) of the check valve.
1-6 Outlet numbers
A Clamping ring of the check valve (see Fig. 3)
Unused lubricant can be internally fed back to the reser-
B Grease supply voir, see paragraph ‘’direct internal feed back feature”.
C Enclosed grease
R Return to reservoir
ATTENTION!
NOTE If outlet 2 (fig. 1-1) is connected to a
Maximum int ernal combination of outlets: lubrication point, outlet 1 must not be
SSV 6 = 3 / SSV 12 = 6 / SSV 18 = 9 closed, see clamping ring (A) in out let 2.
Further combinations are possible outside 6001 a02
6001a0 2 the met ering device by means of a tee-
piece only.
Closure plug
Â Install a closure plug in each outlet port that is not re-
quired.
4163 a98
Fig. 1-2 Closure plug (also provided in the accessory kits)
Check valve
Â For connection between pressure plastic tubes or high-
pressure plastic hoses and SSV divider outlets.
Â Install a check valve in each outlet port that is required.
4180 a02
Fig. 1-3 Check valve, push-in type

A Clamping ring (brass)
Form 403439 2.1EN-38020-I10 Page 7 of 46

User Manual
Installation Instructions, continuation
Direct (internal) feedback feature

All pumps with back-mounted SSV metering device
have the capability to feed unused lubricant back inter-
nally from closed outlets directly to the reservoir (see R,
fig. 1-4).
This procedure will start automatically, if outlet port 2 is
plugged wit h a closure plug.
For lubricant return of crossported outlets always start
with the smallest outlet numbers:
- Outlets with even numbering: ………… e. g. 2, 4, 6
- Outlets with odd numbering: ................ e. g. 1, 3, 5
Lubricant quantities of odd outlet numbers can only be
returned through the internal combination of outlets 1
and 2.
As shown in Fig. --4, the quantities of outlets 1, 2 and 4
(3xR) are returned to the reservoir.
The remaining outlets are to be used f or the connection t o
the lube point or for increasing the lubricant quantity (dou-
ble or triple), comp. fig. 1-1.
4188b 99
ATTENTION!
Fig. 1-4 Internal feedback of supplied lubricant, only on back-side
mounted SSV divider blocks Do not plug outlets number 1 or 2 (hori-
zontally positioned outlets) on bott om-
0x-2x Outlet quantity (single, double, etc.) mounted lubricant metering devices SSV
1-6 Outlet numbers 8, 12 or 18.
A Clamping ring (brass) of the check valve In this case there exists the possibility to
B Grease supply 1 013A94
return unneeded lubricant quantities ex-
C Enclosed grease ternally f rom the metering device. To do
R Return line bore
so, use relief line connect ion R.
Pumps with external metering device

The pump can also be operated with an external metering
device.
To provide a directly connected lube point with lubricant or
to distribute the lubricant via a downstream progressive
syst em a connection block 1 (fig. 6-3) with P pressure and
R return connection is provided.
Lubrication Points
Installing Quicklinc fittings into lube points
Â Replace the existing lubrication fitting at the lubrication
point by the corresponding Quicklinc push-in fitting.
Zerk-Lock Connection
NOTE
I f the lubricat ion fitting cannot be replaced,
t he Zerk-Lock connection is available as
an alternative.
6 001a02
The Zerk-Lock fitting consists of the Zerk-Lock body, insert

and a Quicklinc fitting.
Â Place the Zerk-Lock body over the grease fit ting and
place the staking tool firmly against the Zerk-Lock insert.
4200a 99 4201a 99 Â Strike the tool sharply with a hammer until the Zerk-Lock
Fig. 2-1 Place the Zerk-Lock Fig. 2-2 Installation of Zerk- insert partially crimps onto the grease fitting (necessary
body over the grease Locks with staking tool only for US version).
nipple
Page 8 of 46 2.1EN-38020-I10 Form 403439

User Manual
Â Screw the Quicklinc f itting into t he Zerk-Lock body and

tighten until part resists further tightening (about 1-1/2
turns).
NOTE
Quicklinc hex. is 12 mm.
Zerk-Lock body hex is 1/2 ’’.
600 1a02
Â Move t he Zerk-Lock and tube fitting from side to side on

the grease fitting to insure the Zerk-Lock is firmly seated.
420 2a99
Fig. 2-3 Screwing Quicklinc fitti ng into the Zerk-Lock body
Connection of Feed Lines

Â Lay feed lines to each lubrication point with the shortest
possible route. Make sure to observe the minimum bend-
ing radius.
Â Measure, cut and route the feed lines (included in the kit).
NOTE
Avoid sharp bends of the plastic tubing
and the moving parts of the machine that
could damage the lubrication lines. Mini-
60 01a02 mum bending radius is 50 mm (2 in.).
Â Secure the lubrication lines to the machine using nylon
ties, clamps or straps provided in the accessory kit.
Â If the feed lines are not primed, prime all lubrication feed
4 203a99 lines before connecting them to the lube point (see para-
graph “First Filling of a lubrication system”).
Fig. 3-1 Feed line installed in the Quicklinc fitting
Â Connect the feed lines directly to the check valves of the

divider block and to the Quicklinc fittings of the lube point.
NOTE
Push the ends of the feed lines firmly into
the Quicklinc fittings until they are fully
seated in the body of the fitting. The
60 01a02 primed feed lines are marked with white
lines (fig. 3-2) to facilitate installation.
Â Cut off the pressure plastic t ube uprightly at one of the
white lines before it is mounted.
Â Then insert the feed line into the fitting up to the next
white mark.
4157 a07 This will ensure a correct installation of the feed line in the
threaded tube fitting.
Fig. 3-2 Feed line insert into the check valve up to the next white
mark
Form 403439 2.1EN-38020-I10 Page 9 of 46

User Manual
First filling of a lubrication system

Â Fill t he empty reservoir up to the ”Max.” marking via the
filling nipple 1.
Let the QLS run until lubricant leaks from the metering
device outlets.
Â If necessary fill the lubrication lines via the filling nipple 5
of the metering device with an ext ernal pump.
IMPORTANT
The filling nipple 5 can be removed tempo-
rarily to check the lubricant output.
600 1a02
IMPORTAN T
When filling the reservoir, vent bore 2
must not be closed:
- in order to enable the escape of air
6001 a02 - in order not to impede the proper suc-
tion behaviour of the pump during opera-
tion
6221 b05
Fig. 4-1 Fill reservoir up to the “Max.“ marking

1 Filling nipple ATTENTION !
2 Vent bore Risk of bursting if the reservoir is over-
3 Stirring paddle
fill ed! When filling the reservoir by means
4 Fix paddle
5 Nipple for emergency lubrication of pumps with a large delivery volume do
not exceed the max. filling mark.
1013A94
NOTE
In case of rear-mounted lubricant meter-
ing devices:
For transporting outlet 2 of the metering
6001a0 2 device was equipped with a check valve.
Make sure to remove it before assembly,
as it cannot be used when operating.
Electrical Connection
Â Connect cables acc. to connection diagram (see chapter
„Technical Data“).
CAUTION!
Observe safety instructions in chapt er
„Maintenance …“, paragraph „Electrical
Connection“!
4273a0 0
Page 10 of 46 2.1EN-38020-I10 Form 403439

User Manual
Option for metric fittings (not included in the accessory kits)

SSV Connecting tube fitting, screw-type and push-in type
1- Ferrule nut
2 Cutting ring
423 9a99
3 Valve body with sealing and ferrule
Fig. 5-1 Screw-type check valve
Connection of the pressure plastic tube or the high-pressure hose

Â For high-pressure hose (Ø 4.1 x 2.3 mm) use check
valve A (fig. 5-2) with reinf orced collets 1a and smooth
flange (part no. 226-14091-4)
Â For pressure plastic tube (Ø 6 x 1.5 mm) use check
valve B (fig. 5-2) with standard collets 2a and knurled
flange (part no. 226-14091-2)
A Check valve with reinforced collets

B Check valve with standard collets
1a Smooth flange
1009a 98
2a Knurled flange
Fig. 5-2 Different types of check valves
NOTE
On construction machines or agricultural
machines use high-pressure hoses as f eed
lines. In such cases, the check valves of
600 1a02 the sub-metering devices must have a
reinforced collets and a smooth flange.
IMPORTANT
Connect only high-pressure hoses
4 156a9 8
(Ø 4.1 x 2.3 mm) wit h threaded sleeve and
Fig. 5-3 Check valve with reinforced collets and high-pressure hose hose stud t o the check valves with rein-
600 1a02 forced collets.
Mounting of the threaded sleeves and hose studs onto the hi gh-pressure hose
Â Screw threaded sleeve 1 (fig.5-4) count erclockwise onto
the high-pressure hose 2 until the illustrated dimension of
11 mm is reached.
IMPORTANT
Oil parts 1, 2 (inner surface of hose) and 3
well before screwing them together.
600 1a02
Â Then screw the hose stud 3 into the threaded sleeve 1.

1 Threaded sleeve
2 Main line
1028a 96 3 Hose stud
Fig. 5-4 Pre-assembly of the threaded sleeves and hose studs onto
the main line
Form 403439 2.1EN-38020-I10 Page 11 of 46

User Manual
Description
Lubrication System QLS 401

The QLS 401 is a complete compact lubrication system
for a maximum of 18 lubrication points per operating
cycle.
The pump has three basic configurations:
- SSV metering device mounted on the rear (see fig. 6-1)
- SSV metering device mounted on the bottom (see
fig. 6-2)
- Pump without the SSV metering device attached re-
spectively with external met ering device SSV KNQLS
(see fig. 6-3)
Standard lubrication lines are high-pressure hoses
(Ø 6x1,5 mm; 1/4 in.) for pumps with the SSV metering
device attached.
The QLS 401with the SSV metering device mounted on
the bottom has the capability of using also steel tubing as
lubrication lines if necessary.
NOTE
4198b 04 The function of the QLS 401 is independ-
Fig. 6-1 QLS 401 with rear mounting position of the SSV devider ent of the SSV metering device's mount-
block ing position.
600 1a02
1 Proximity switch
2 Control pin
3 SSV metering device
4 Nipple for emergency lubri cation
A signal from the pump timer starts the electric motor and
the pumping element starts pumping the lubricant to the
SSV divider block.
When all lubrication points have received lubricant, an
internal proximity switch 1 (fig. 6-1) turns the motor off,
completing one operating cycle.
If the pump does not complete the cycle within the max.
allowed cycle time, the alarm indication ”Er” will be dis-
played as a f lashing light in the keypad window (see
paragraph „Display Mode“). The QLS 401 does not start
automat ically anymore.
max. cycle time of the VDC version ....... .......... 25 minutes
max. cycle time of the VAC version ....... .......... 15 minutes
4199b 07
Fig. 6-2 QLS 401 with bottom position of the SSV divider block
1 Connecting block
2 Manifold
3 SSV metering device
4 Nipple for emergency lubrication (1/8’’)
5 Plug (1/8’’) for
P external pressure line
R external return line
Page 12 of 46 2.1EN-38020-I10 Form 403439

User Manual
Description, continuation
An ext ernally connected lubricant divider SSV KN QLS is

equipped with the same proximity switch as a QLS with
mounted SSV metering device.
The proximity swit ch is provided with a connecting cable
of 2 m lengths and a connecting plug which must be con-
nected to the socket 4 (fig. 6-3) of the QLS 401.
The socket is integrated in the housing instead of the
proximity switch and is connected to t he control p.c.b.
NOTE
The function of the QLS 401 is independ-
ent of the mounting position of the prox-
imity switch.
600 1a02
There are available the following externally connectable di-

vider valves SSV KN QLS: Part no.:
- SSV 6 KN QLS 619-28945-1
- SSV 8 KN QLS 619-28946-1
6178b 04 - SSV 10 KN QLS 619-28949-1
Fig. 6-3 QLS 401 without mounted SSV divider block with connec- - SSV 12 KN QLS 619-28950-1
tion for external SSV divider valve KN QLS - SSV 14 KN QLS 619-28951-1
1 Connecting block - SSV 16 KN QLS 619-28952-1
2 Closure plug
- SSV 18 KN QLS 619-28953-1
3 Nipple for emergency lubrication, R 1/8’
4 Connecting socket for SSV KN QLS
P For feedline to external SSV KN QLS
R Return line connection
Form 403439 2.1EN-38020-I10 Page 13 of 46

User Manual
Identification Code – QLS 401 VDC

Code examples: P40100400114
P40162400154
P401 6 2 4 1 0 1 5 4
Pump 401 for grease . ....................... ...................... ............ P401
SSV Metering Device

1 & 4)
External, SSV 6, SSV 8 ................ ...................... ............ 0
1 & 4)
External, SSV 12, SSV 18 ............ ...................... ........... . 1
SSV 6 (back mounted) . ....................... ...................... ............ 3
SSV 8 (bottom mount ed) .................... ...................... ............ 4
SSV 12 .. ........ .............. ....................... ...................... ............ 6
SSV 18 .. ........ .............. ....................... ...................... ............ 9
1)
Note: F or external metering device application only use specific SSV metering devices...
KNQLS.
SSV Metering Device Position, arrangement of the outlets
4)
External metering device ................. ...................... ............ 0
Back mounted (vertical order of lines) ...................... ............ 1
2)
Bottom mounted (horizontal order of lines) ............ ............ 2
2)
Note: Do not use QLS 401 with bottom mounted SSV metering device for mobile appli cations and in
areas which are exposed to shock.
Operating Voltage
3)
12 VDC ........ .............. ....................... ...................... ............ 2
24 VDC 3) ........ .............. ....................... ...................... ............ 4
3)
Note: see „El ectrical Connection
Reservoir
1 liter reservoir without low-level control ................... ............ 0
1 liter reservoir with low-level control .. ...................... ............ 1
2 liter reservoir without low-level control ................... ............ 2
2 liter reservoir with low-level control .. ...................... ............ 3
Number of possible connections

- 1A = 1 connection (square-type plug) left, power supply 0
- 2A = 2 connections (square-type plugs)
1 connection left, power supply
1 connection right, fault indication .................. ............ 1
- 1A = 1 connection (bayonet plug) left, power supply;
fault indication ... ....................... ...................... ............ 2
T ype of Plug Connector
* Square-type plug, DIN 43650 design A (industrial application) 1
** Bayonet plug, DIN 72585-1, 4-pole (mobile application) 5
Electrical Connectors
With socket, without cable * ................ ...................... ............ 1
With socket and 10 m cable * ............. ...................... ............ 5
With socket and 10 m cable ADR * 6
With socket and 10 m cable ** ............. ...................... ............ 7
With socket and 10 m cable, ADR ** 8
Control p.c.b.
Terminal board without time control 4 ) .. ...................... ............ 0
Control p.c.b.S4:
NC contact or NO contact (programmable), monitored
- 1-5 cycles .... .............. ....................... ...................... ............ 4
4)
Note: Regarding pump models without divider block, it is only possibl e to control or close the lubrication system with external control or
PLC. They are listed in a separate selection guide and are assigned with special part numbers (650-…).
(Accessory kits see ”Technical Data”)
Page 14 of 46 2.1EN-38020-I10 Form 403439

User Manual
Identification Code – QLS 401 VAC

Code examples: P40100800114
P40162800114
P401 6 2 8 0 0 1 1 4
Pump 401 for grease . ............... ....................... ................... P401
SSV Metering Device

1) & 4 )
External, SSV 6, SSV 8 ...... ....................... .............. ..... 0
1) & 4)
External, SSV 12, SSV 18 ... ....................... .................. . 1
SSV 6 (back mounted) . ............... ....................... ................... 3
SSV 8 (bottom mounted) ............ ....................... .............. ..... 4
SSV 12 .. ...................... ............... ....................... ................... 6
SSV 18 .. ...................... ............... ....................... ................... 9
1)
Note: F or external metering device application only use specific SSV metering devices...
KNQLS.
SSV Metering Device Position, arrangement of the outlets

External metering device 4) ......... ....................... .............. ..... 0
Back mounted (vertical order of lines) ............... ................... 1
2)
Bottom mounted (horizontal order of lines) ..... .............. ..... 2
2)
Note: Do not use QLS 401 with bottom mounted SSV metering device in areas which are exposed to
shock.
Operating Voltage
3)
120 VAC (only with control p.c.b.) ................... .............. ..... 6
230 VAC 3 ) (only with control p.c.b.) ................... .............. ..... 8
3)
Note: Standard 120 and 230 VAC pump model s for industrial applications are n o t supplied with 10-meter
(30’) electrical cable.
Reservoir
1 liter reservoir without low-level control ............ .............. ..... 0
1 liter reservoir with low-level control ................. .............. ..... 1
2 liter reservoir without low-level control ............ .............. ..... 2
2 liter reservoir with low-level control ................. .............. ..... 3
Number of possible connections

- 1A = 1 connection (square-type plug) left, power supply 0
- 2A = 2 connections (square-type plugs)
- 1 connection left, power supply
- 1 connection right, fault indication ……………… 1
T ype of Plug Connector

* Square-type plug, DIN 43650 design A ........... .............. ..... 1
Electrical Connectors
With socket without cable * ......... ....................... .............. ..... 1
Control p.c.b.
Control p.c.b. S4:
NC contact or NO contact (programmable), monitored
- 1 cycle i.V.m. SSV 12, SSV 18
- 1 to 3 cycles with SSV 6, SSV 8 ...................... ................... 4
4)
Note: Regarding pump models without di vider block, it is only possible to control or close the lubrication system with external control or
PLC. They are listed in a separate selection guide and are assigned with special part numbers (650-…).
(Accessory kits see ”Technical Data”)

Form 403439 2.1EN-38020-I10 Page 15 of 46

User Manual
Mode of Operation
Lubrication System
The QLS operates according to operating cycles (pause
and lubricating times).
With standard setting the pause time begins the cycle,
and then the lubricating time occurs.
This can be changed by reprogramming the start stage
(see “P6“,paragraph “Programming Mode”).
A division of the lube points (option) via sub-metering
devices and one main metering device (SSV 6, SSV 8) is
possible only up to max. 18 points per operating cycle.
In this case, set the number of cycles of the main meter-
ing device according to the number of lube points or the
lubricant need (see P3, paragraph “Programming Mode”).
- QLS AC-version:
SSV 6 & SSV 8 …………………………….. to 1 - 3 cycles
SSV 12 & SSV 18 …………….……………………. 1 cycle
- QLS DC-version:
SSV 6, 8, 12 & 18 ……………………… …… 1 to 5 cycles
B-Q401-030a 09
Fig. 7-1 QLS schematic

1 Low level (option) 2 Proximity switch
3 Keypad with display 4 Control unit
5 Pump unit 6 SSV 6, 8, 12, 18
Pressure Relief Valve The QLS is prot ected with a pressure relief valve
(cartridge).
The pressure relief valve limits the pressure build-up in
the QLS. It opens at an overpressure of 205 bar (3000
psi).
If t he pressure relief valve is actuated, this indicates that
the system is malfunctioning. The lubricant flows back into
the reservoir (hardly visible from outside).
When the monitoring time of 15 minutes (VAC version)
respectively 25 minutes (VDC version) has elapsed, the
pump switches off. On the display of the membrane key-
pad appears the flashing fault indication * Er *.
Fig. 8-1 Pressure relief valve (cartridge) in housing 4 304a00

Page 16 of 46 2.1EN-38020-I10 Form 403439

User Manual
Mode of Operation, continuation
Low-Level Control
Reservoir filled
The stirring paddle rot ates clockwise during the lubricating
time.
The entry of the stirring paddle B (Fig. 8-1) into the lubri-
cant presses the pivoted guiding plate with the round so-
lenoid 1 inwards to orbit A.
The solenoid switch 2 (Fig. 8-2) cannot be activated.
Control cam 3 (Fig. 8-1) guides the round solenoid with the
pivoting guiding plate automatically outwards, in the direc-
tion of the reservoir wall. When leaving the control cam, the
lubricant presses against the guiding plate and moves the
solenoid inwards again (B).
Fig. 8-1 Switching parts of the low-level control 6398b0 7 NOTE

(reservoir filled) The switch parts of t he low-level control
1- Guiding plate with round A- Inner orbit of the round (items 1 to 3) cannot be used with fluid
solenoid solenoid greases.
3- Control cam B- Position of the guiding plate 60 01a02
(entered) In this case, use a float magnetic switch.
… for grease: When the reservoir is empty
NOTE
The flashing signal * LL * starts as soon as
the solenoid has activated the solenoid
switch six times contact-free.
6 001a02
When passing the control cam 3 (Fig. 8-2) the solenoid

remains in the outer orbit C and thereby passes the sole-
noid switch 2. The solenoid activates the solenoid switch
contact-free and so initiates a low-level indication.
When the stirring paddle rotates on the outer orbit C there
is no counterpressure by lubricant.
The guiding plate with the round solenoid 1 remains un-
entered (D).
Fig. 8-2 Continuation: Switching parts of the low-level 6397b0 7
control (when the reservoir is empty)
1- Guiding plate with round C- Outer orbit of the round
solenoid solenoid
2- Sol enoid switch D- Position of the guiding plate
3- Control cam (unentered)
Monitoring relay The monitoring relay signalizes a low-level or fault indica-

tion (only in combination with optional connector X2, see
electrical connection diagrams).
In t he first case the relay picks up (normally open con-
tact).
In t he second case the relay releases (normally closed
contact, broken-wire interlock).

The signal is available via a potential free contact.
The monitoring relay is released upon acknowledgement
of t he fault. The flashing light changes into permanent
signal.
Form 403439 2.1EN-38020-I10 Page 17 of 46

User Manual
Setting and Operation
General
NOTE
The QLS is factory-fit with the printed cir-
cuit board.
Factory Settings
6 001a02
Programmi ng step Factory setting Description Fig.
6h 6 hours Pause time 12-1
4215a9 9
0 min 0 minutes Pause time 12-4
4217a9 9
Number of metering device cycles per operating cycle:
1 cycle 1 cycle (metering device cycle) 12-7
4218a9 9
Signal output of t he fault relay:
no no (normally open) Signalizing during t he failure 12-10

or low-level signal where applicable
6252b0 4 (option)
Differentiation fault indication (ER) / low-Level control (LL):
–– –– Permanent signal (on, no differentiation) 12-13
6255b0 4
Start phase:
SP SP Start with pause time 12-17
4299a0 0
T ab. 9-1 Factory parameter settings

Operator Keys
Key Function Key Function
Key for modifying the

Key for switching to the
parameters in the pro-
next programming step
gramming step
4 222a99 4214 a99
Fig. 9-1 Key for modifying Fig. 9-2 Key for switching
Other functions: Other functions:

In the operat ing mode: In the display mode:
.......... ...................... ........... Trigger additional lubrication ........... ............. Confirm low-level indication/ malfunction
In the programming mode: I In the programming mode:

- Continuous activation . ............ Quick increasing of counter ........... .................. Change to the next parameter set ting
- Individual activation .... .......... Increase counter by one digit
.......... ................. Change between two possible settings In the operating mode:
.......... ................. Confirm modifications of programming ........... ...................... .............. Display of current settings
.......... ...................... ........ Terminate programming mode
Page 18 of 46 2.1EN-38020-I10 Form 403439

User Manual
Setting and Operation, continuation

Three possible modes of operation and settings can be se- Display mode
lected on the keypad: Programming mode
Operating mode
Display Mode
Without power supply the display is dark.
As soon as voltage is applied to the pump, the keypad is
automatically in ”display mode”.
The operating st ates are displayed alphanumerically via
the segments and LEDs in the display.
In the display mode the user receives information on
functions and malfunctions of the QLS.
Functions (segment, rotat ing segment display) or malfunc-
tions are displayed with the following codes:
Fig. 10-1 Membrane keypad 42 28c06
Display
A test display is shown when voltage is applied, all seg-
ments and decimal points are illuminated for 2 seconds.
Afterwards the centralized lubrication pump is ready for
2 sec. operation. Via machine contact or driving switch the per-
manent sequence of pause and lubricating times can be
4207a 99 started and stopped.
Fig. 10-2 Display test
NOTE
EP: Error PAD If *EP* is displayed after the display test ,
this means, there is a malfunction of the
operating keys (Fig. 9-1 & 9-2).
4227a 99 6001 a02
IMPORTANT
If * EE * and * EC * is displayed, this indicates a malfunction
EE: Error EEPROM of the control p. c.b..
Wit h the fault indication * EE * the control p.c.b. has to be
6574b 05 replaced immediately.
Wit h the fault indication * EC * all customer specific parame-
ters will be reset to factory setting (see Tab. 9-1).
EC: Error COUNTER Afterwards re-programming or correction of t he parameters
P1 to P– and af ter triggering an additional lubrication the
pump is ready for operation again.
B-Q400 -040e 09
Should the fault indication * EC * appear again, the control
Fig. 10-3 Fault indications of the pump p.c.b. has to be replaced immediately.
Display The right-hand segment (On/h) indicates the available

voltage supply during the pause time.
As soon as another message is displayed, the segment
turns off.
After the pump is switched off and on again, the control
p.c.b. operates from the point where it had been int er-
427 9a00 rupted (e. g. after the power supply was interrupted).
Fig. 10-4 Display with segment for pause time NOTE
If the interruption of power supply hap-
pens after starting within 1 minute the
control p.c.b. will re-start the sequence of
6001 a02
pause and lubricating times from the be-
ginning.
Form 403439 2.1EN-38020-I10 Page 19 of 46

User Manual
Display The lubricateng time is displayed as a rotating segment.

The monitoring time starts together with the lubricat ing
time.
If at the beginning of a lubricating time (aft er the pause
time or in the case of an additional lubrication) there exists
a funct ional fault, the control unit does not receive any
4209a9 9 feedback from the proximity switch. Af ter the monitoring
Fig. 10-5 Rotating segment for lubricating time time (15 mi nutes with AC-version or 25 minutes with DC-
version) the pump switches off. On the membrane keypad
there appears the flashing signal * Er * (functional fault).
Display
In t he display mode the membrane keypad shows * Er *

as flashing signal for an unacknowledged malfunction.
4210a9 9
Fig. 11-1 Display for a fault indication
In t he Display Mode a low-level signal is announced by

the flashing display * L1 *.
If the cause of t he low-level signal has not been remedied,
finally there appears the flashing display * LL *.
6264 b04 If a low-level signal occurs during the lubricating time, the
current operating cycle is still completed.
Before that the fault can be confirmed (see operator key

fig. 11-3). Furthermore, you cannot change into the pro-
4211a9 9
gramming mode.
If both signals appear at the same time, the displays * Er *
Fig. 11-2 Announcing and display of a low-level control * LL *
and * LL * f lash alternately.
An active fault or low-level signal can be deleted only by
IMPORTANT triggering an additional lubrication (see paragraph „Oper-
If a malfunction * Er * or a low-level indica- ating Mode“) and a subsequent proper lubricat ion proce-
tion is present, the pump does not switch dure.
on automatically any longer. The pump can If after triggering an additional lubrication the fault or low-
only be switched on by pressing the level signal still exist, the fault * ER * or low-level * LL *
6001a0 2
pushbutton for additional lubrication (see indication appears on the display of the membrane key-
operator key fig. 13-2). pad again.
Press
To acknowledge a malfunction:
The flashing display changes into a continuous light by
pressing the button (acknowledging). To acknowledge,
press t he button only briefly (< 2 sec.).
Messages that have been acknowledged but have not yet
< 2 sec. been remedied flash again after the pump is switched off
421 4a99 and on again.
Fig. 11 >I To acknowledge a malfunction
Page 20 of 46 2.1EN-38020-I10 Form 403439

User Manual

Programming Mode
Press Display
4222 a99 4 214a9 9 Start programming mode
Â To access to the programming mode, press both but-
tons at the same time > 4 seconds, so that “P1” appears
in the display.
Range of setting P1 & P2:

> 4 sec. - min. pause time DC ………………………………... 4 minutes
- min. mause time AC …………………… …………. 20 minutes
- max. pause time ……….…………….. 59 hours & 59 minutes
When releasing the two buttons, the currently set value ap-
42 15a99
pears (fig. 12-2).
Fig. 12-1 Start programming mode
P1: Setting of pause time (h)
Example: Factory sett ing …………………………… …. 6 hours
Factory setting
The field “hour“ is indicated by a decimal point on the
42 81a00 righthand.
Fig. 12-2 Factory setting of pause time“P1“ (hours)
Â Press button.
Â Settings are made in one direction:
………… ………………………… ……. 0, 1, 2, 3,....59 hours
4222 a99
Button pressed once .......................... increases by 1 hour
Button pressed cont inuously ....... ............. quick sequence
Example: …………..…………… …………………. 12 hours
42 16a99
Fig. 12-3 Modifying the pause time “P1“ (hours)
Â Press button, so that “P2“ appears in t he display.
4214 a99
When releasing the button, the currently set value appears
42 17a99
(fig. 12-5).
Fig. 12-4 Switching to pause time “P2“ (minutes)
P2: Setting of pause time (min)
Example: Factory sett ing …………………………… . 0 minutes
Factory setting
The field “minut e“ is indicated by a decimal point on the
62 70b04 lefthand.
Fig. 12-5 Factory setting of pause time “P2“ (minutes)
Â Press button.
Â Settings are made in one direction:
.……………………………………… 0, 1, 2, 3,....59 minutes
Button pressed once .......................... increases by 1 hour
Button pressed cont inuously ....... ............. quick sequence
4222 a99
Example: ……………..………… ……………….. 30 minutes
NOTE
42 20a99
Fig. 12-6 Modifying the pause time “P2“ (minutes)

The minimum pause time is 4 respect ively
20 minutes. For settings < 4 respectively
< 20 minutes (wit hout input of hours) there
6001 a02 automatically appears “. 04“ respect ively
“. 20“ in the display provided the pro-
gramming sequence has been carried out
completely. (siehe “P–“).
Form 403439 2.1EN-38020-I10 Page 21 of 46

User Manual
Press Display
4214 a99

42 18a99 (fig. 12-8).
Fig. 12-7 Switching to the number of metering devi ce cycles per
operating cycle “P3“ (max. 5)
P3: Setting of metering device cycles per operating cycle
If lube points are divided via sub-divider valves (SSV 6) and a
Factory setting main divider valve (SSV 6, SSV 8), a maximum of 18 (24)
lube points must not be exceeded.
Example: Factory sett ing …………………………… …. 1 Cycle
42 19a04
Fig. 12-8 Factory setting of metering device c ycles per operating

cycle “P3“
Â Press button.
Settings are made in one direction:
- QLS AC version:
4222 a99
SSV 6 & SSV 8 …..……………………. 1 to 3 cycles
SSV 12 & SSV 18 …………………….. 1 cycle
- QLS DC version:
42 19a99
SSV 6, 8, 12 & 18 …………………….. 1 to 5 cycles
Fig. 12-9 Modifying the number of metering device cycles per
operating cycle “P3“ (1-5)
Press Display
4214 a99

62 52b04 (fig. 12-11).
Fig. 12-10 Switching to the output signal “P4“ (nc or no)
P4: Setting of the output signal on the monitoring relay
Factory setting
Example: Factory sett ing …..……… ……... no (normally open)
62 54b04
Fig. 12-11 Factory setting of the output signal “P4“
Â Press button.
Â The setting changes bet ween: .….………… ……... no & nc
4222 a99
P4 example ……………………………….. nc (normally closed)

62 53b04
Fig. 12-12 Modifying the output signal “P4“
Page 22 of 46 2.1EN-38020-I10 Form 403439

User Manual
Press Display
4214 a99

62 55b04 (fig. 12-14).
Fig. 12-13 Switching to the differentiation between fault and
low-level indication “P5“
P5: Setting the differentiation between fault and
low-level indication
Factory setting
Example: Factory sett ing …....................... ... no differentiation

62 56b04
between fault and low-level indication
Fig. 12-14 Factory setting of the external signal “P5“
Â The output signal on t he monitoring relay for the ext ernal

fault indicat ion “P4“ is set as a normally open contact
(no).
4222 a99
Â Press pushbutton to change the external signal into an
intermittent signal.
62 57b04
Fig. 12-15 Modifying the external signal “P5“
Low-Level * LL * Fault indication * ER *
On On
Then, low-level signals are visible as intermittent signals and
functional faults have priority as permanent signals (On).
Off Off
Intermittent signal Permanent signal
Â The output signal on t he monitoring relay for the ext ernal

fault indicat ion “P4“ is set as a normally closed contact
(nc).
Â Press the pushbutton to change the ext ernal signal into an
4222 a99
intermittent signal.
62 58b04
Fig. 12-16 Änderung des Ausgangssignals “P5“
Low-Level * LL * Fault indication * ER *
On On Then, low-level signals are visible as intermittent signals and

functional faults have priority as permanent signals (Off ).
Off Off
Intermittent signal Permanent signal
Form 403439 2.1EN-38020-I10 Page 23 of 46

User Manual
Press Display
4214 a99

42 99a00 (fig. 12-18).
Fig. 12-17 Switching to the start phase “P6“ (SO or SP)
P6: Program start phase
Factory setting
Example: Factory sett ing …………………………… ………. SP
Pump with st arting pause time (Start Pausetime)
62 59b04
Fig. 12-18 Factory setting of the start phase “P6“
Â Press button.
Â The setting changes bet ween:

4222 a99 ………………… SP starting pause time (St art Pause time)
& ..….. SO starting lubricating t ime (Start Lubricating time)
62 60b04
Fig. 12-19 Modifying the start phase “P6“ (SO)
Press Display P–: Compl eting the programming
Â Press button, so that “P–“ appears in t he display.

IMPORTANT
In order to avoid a wrong program, make
sure to always carry out the programming
4214 a99 order completely, i. e. setting of P1 to “P–“
6001 a02 (“Completing the programming”).
422 1a99
Â Press this key to complete the programming and to save

the entered parameters.
NOTE
4222 a99 If this button is not pressed within
30 seconds, the changed parameters are
427 9a00 not saved and the previous programming
Fig. 12 >I Completing the programming “P–“ 6001 a02 remains valid.
IMPORTANT
After completion of the programming,
check the parameter settings in the oper-
ating mode once again.
Page 24 of 46 2.1EN-38020-I10 Form 403439

User Manual
Operating Mode
Display Starting operating mode
IMPORTANT
The operating mode is accessible only
during the pause time, and cannot be
operated during the lubricating time.
6001 a02
427 9a00 4209a9 9

Precondition: When voltage is applied, the right segment
is lit. (fig. 13-1).
Fig. 13-1 Starting operating mode
Press Display
Triggering an additional lubricati on
Â Press key (fig. 13-2) > 2 sec. to trigger an additional lubri-

>2 sec cation.
4222 a99
The lubricat ing time start s. A rotating segment is visible
on the display during the whole lubricating time. At the
same t ime the pause time is reset.
420 9a99
Fig. 13-2 Triggering an additional lubrication
Press Display Display of parameters and states
Â Press button, so that “PP“ appears in the display.

NOTE
The following display sequence is shown
4214 a99 twice and is cancelled after 40 seconds.
The change of display occurs every two
42 23a99 6001 a02 seconds.
Fig. 13-3 Starting the display of parameters and states Example:
PP = 12 h 30 min
rb = 05 h 10 min
Display
af ter two sec. after two sec.
12 . Pause time 12 hours
421 6a99 . 30 Pause time 30 minutes
42 20a99
Fig. 13-4 Display pause time (hours & minutes)

Form 403439 2.1EN-38020-I10 Page 25 of 46

User Manual

Display
af ter two sec. rP residual pause time
42 24a99
05 . pause time 5 hours
422 5a99
. 10 pause time 10 minutes
42 26a99
Fig. 13-5 Display residual pause time (hours & minutes)
Display
AC number of the automatically triggered operating

af ter two sec. cycles, countable up to 9999 cycles. Then counting
starts from the beginning again.
42 77a00
af ter two sec. after two sec. Example 0625 cycles:
06 . displayed with factor 100 06 as 600
428 1a00
. 25 displayed with factor 1

42 80a00
Fig. 13-6 Display of automatically triggered operating cycles
Display
UC number of manually triggered additional lubrications

af ter two sec. countable up to 9999 cycles. Then counting starts
from the beginning.
42 78a00
af ter two sec. after two sec. Example 0110 cycles:
01 . displayed with factor 100 01 as 100
429 7a00
. 10 displayed with factor 1

42 26a99
Fig. 13-7 Display of manually triggered additional lubrications

Page 26 of 46 2.1EN-38020-I10 Form 403439

User Manual

Display
af ter two sec. after two sec. EC number of the current p.c.b. fault indications “EC“
(Error-Counter), countable up to 99 cycles. Then
counting start s from the beginning again.
Example 05 fault indications “EC“:
B-Q4 00-0 40e09 05 displayed as factor 1
B-Q400- 040a09
Fig. 13-8 Display Error Counter “EC“

P3 Number of metering device cycles per operating cycle
Example 3 metering device cycles:

421 8a99
3. Displayed with factor 1

42 19a99
Fig. 13-9 Display of metering device cycles per operating cycle

P4 P4: Programming the output signal
Display of the output signal:

625 2b04
nc normally closed
62 53b04
Fig. 13-10 Display of the output signal

P5 Differentiation between fault and low-level indication
Differentiation between * Er * and * LL *:
625 5b04 –– no differentiation
62 56b04
Fig. 13-11 Display of the differentiation between fault and

low-level indication

P6 Programming of the st art phase
Starting with lubricating time (SO) or pause time (SP):
429 9a00 SO Lubricating time
62 60b04
Fig. 13-12 Display of the start phase

– After double passage of the displayed

parameters and states the right-hand
af ter two sec.
segment appears at the of the operating
mode.
4279 a00
Fig. 13 >I Termination of the operating mode (… pause time)
Form 403439 2.1EN-38020-I10 Page 27 of 46

User Manual
Maintenance, Repair and Tests
Maintenance
The maintenance is essentially limited to refilling the res- NOTE
ervoir wit h clean lubricant in good time. However, check
Whenever work is done on the centra-
regularly whether the lubricant is really dispensed to all
lized lubrication system, particular atten-
the lubrication points.
tion should be paid to absolute cleanli-
Also check the main lines and lubricant feed lines for 60 01a02 ness. Dirt in the system will cause prob-
damage and replace them, if necessary. lems.
For cleaning the system use benzine or petroleum. Do not
use tri-, perchloroethylene or similar solvents.
Also do not use polar organic solvents such as alcohol,
methylacohol, acet one or similar.
Filling of the reservoir

Â Fill the reservoir up to the ”Max.” mark via the filling nip-
ple 1 (fig. 14-1).
Â Avoid cavities in the lubricant when filling.
IMPORTANT
The grease must be f ree from impurities
and must not be liable to change its consis-
tency in the course of time.
600 1a02
NOTE
If the reservoir has been completely emp-
tied, the pump may require priming and a
longer runtime to reach the full lubricant
600 1a02
output. Therefore, if the occasion arises
trigger additional lubrications manually
(fig. 13-2).
IMPORTAN T
When filling the reservoir, vent bore 2
must not be closed:
6221b 05
- in order to enable the escape of air
Fig. 14-1 Fill pump reservoir up to the “Max.“ mark 6001 a02 - in order not to impede the proper suc-
1 Filling nipple tion behaviour of the pump during opera-
2 Vent hole tion
3 Stirring paddle
4 Fix paddl e
5 Nipple for emergency lubrication ATTENTION !
NOTE Risk of bursting if the reservoir is over-
fill ed! When filling the reservoir by means
If necessary, please observe the chapter "
of pumps with a large delivery volume do
First filling of a lubrication system".
not exceed the max. filling mark.
6001a 02 1013A94
Repair
For repair work on the QLS use only original Lincoln CAUTION!
spare parts. By operating the drive motor without the
Using non-Lincoln parts voids the pump warranty.
reservoir installed, there is a risk of injury

by the eccentric gear.
Never use the lubrication system QLS
without inst alling the reservoir!
6445 b05
Page 28 of 46 2.1EN-38020-I10 Form 403439

User Manual
Maintenance, Repair and Tests, continuation
Electrical Connection
Operation with bayonet plug
WARNIN G!
Before maintenance or repair of pumps CAU TION!
switch off their power supply.
If the protective-conductor terminal is not
Consider the safety instructions (page 5 connected or interrupted, dangerous touch
and 6)! voltages may occur on the equipment!
4273a0 0
CAUTION! 4273 a00
Before starting, make sure that the general

power supply is off. The device must never Protective measures t o be applied for appropriate operation
be connect ed or disconnected when the with bayonet plugs:
power is on. The protective conductor must "Functional extra-low voltage with safe isolation" /
always be connected. Take care that this "Protective Extra-Low Voltage" (PELV)
line section is undamaged and conforms to Standards:
standards and the contacts are safe. DIN EN 60204 Teil1: 2007-07 / IEC 204-1 /
DIN VDE 0100 Teil 410: 2007-06 / I EC 364-4-41
NOTE
The protection IP6K9K is guaranteed when
the socket (X1:, X2: & X3:) is tight ened on
the housing cover with flat packing.
6001a0 2
NOTE
Consider the contact protection measures
for connecting the high- or low-level control
(see chapt er “Mode of Operation” / para-
graph „Low- or High-level Control”).
Â Make sure of the connection and the type of construction

of your QLS 401.
- type of connection (VDC / VAC) ATTENTION!
- low-level indication Control p.c.b. and motor always work with
- type of connection plug 24 VDC even if the pump is connected to
- monit oring of metering device via external or internal alternating current.
cycle switch Consider residual ripple of max. ±5 %
Â Connect the electrical wires according to the following when connecting motor and control p.c.b.
4273a0 0
electrical connecting diagrams (see chapter „Technical (in relation to the operating voltage acc. to
Data“). DIN 41755).
Tests
Test Run /
Triggering an Additional Lubrication
Display To check the pump operation it is possible to perform an
additional test (see Fig. 13-2).
During the lubricating time
- the stirring paddle is rotating
- a rotating segment is displayed (see Fig. 14-3)
42 09a99 - the control pin is moving to the left or to the right side
Fig. 14-3 Display with rotating segment : Lubricating time (Fig. 9-3)
- lubricant comes out of the lubrication points
Form 403439 2.1EN-38020-I10 Page 29 of 46

User Manual
Troubleshooting
NOTE
For functional check: see paragraph „Tests“ / „Operational test / Triggering an Additional Lubrication“
6 001a0 2
Fault: Pump motor doesn’t run

Cause: Remedy … by service personnel
WARNING!
Disconnect the power supply before starting any maintenance or
repair works.
4273a0 0
Power supply interrupted. Green Â Check the volt age supply to the pump/fuses. If necessary, eliminate the fault or
decimal point On/h on display is not replace the fuses.
lit. Â Check the feedline from the fuses to the plug of t he pump and then to the control
p.c.b.
Power supply from control p.c.b. to Â Trigger an additional lubrication (fig. 13-2). Check voltage supply from the control
motor interrupted. Electric motor de- p.c.b. to the motor.
fective.
Control p.c.b. defective Â Replace control p.c.b.
Keypad or button is defective Â * EP * display at the keypad flashes. Replace housing with keypad.
Motor doesn’t run … Â Check connections according to conneting diagram (bridge 15/30 must exist).
despite rotating segment in display
Fault: Pump does not deliver lubricant

Cause: Remedy … by operator personnel
Reservoir is almost empty. * LL * Â Fill up the reservoir with clean lubricant. Let the pump run (initiate an additional
display at the keypad is flashing. lubrication, see fig. 13-2) until lubricant shows at all lube points.
Pump does not deliver lubricant an
control pin at SSV metering device NOTE
does not move.
Dependent on the ambient temperature and/or sort of lubricant
output. Therefore, trigger several additional lubrications.
6001a 02

Air pockets in lubrication system Â Trigger an additional lubrication several times (see paragraph „To trigger an addi-
tional lubrication“, see fig. 13-2). Lubricant must dispense at lubrication points
without air bubbles.
Unsuitable lubricant has been used Â Renew t he lubricant (see User Manual „Lubricants“, 2.0-40001-).
Suction hole of the pump element Â Remove pump element. Check suction hole for foreign particles. If there are any,
clogged remove them.
Pump piston worn Â Replace pump element.
Check valve in the pump element Â Replace pump element.
def ective or clogged
Other damages Â For repair return the pump to the factory.
Page 30 of 46 2.1EN-38020-I10 Form 403439

User Manual
Troubleshooting, continuation
Fault: Pump either does not switch off
Proximity switch is not dampened, Â Trigger additional lubrication (fig. 13-2). Check whether the control pin moves
i.e. centrically (± 1.2 mm difference) over the switching surface of the initiator.
- the control pin does not move Â
Check t he distance and adjust if necessary.
within the switching range of the - Between the control pin and the switching surf ace of the initiator (max. 0.5 mm;
initiator, 0.02 in.).
- the distance between the control - Distances between the switching surface of the initiator and the upper edge of
pin and the initiator surface is more the fixing nut:
than 0.5 mm (0.02 in.). 16 –0.2 mm (0.62+/-0.08 in.) when the metering device is mounted at the back
12,7 ±0,1 mm (0.5 +/-0.004 in.) when the metering device is mounted at the bot-
tom
Â Tightening torque of the nut 1,5 Nm (1.10 ft-lb.) and fix with Loctite 274 or similar.
Fault: Pump runs continuously

P Programming of pause time in step Â Switch off pump (power supply) by removing left-hand side socket from plug.
P1 was set to‘’00”. Programming of Â Press both buttons of keypad:
further steps to P– was not carried 4 222a9 9 4214a9 9
out.
Pump starts running immediately.
The proximity switch switches off the
cycle for two minutes. Then, pump
runs continuously.
> 5 sec.
Â Swit ch on pump (power supply) by replugging left-hand side socket.

Â Release both pushbuttons after approx. 5 seconds.
Â The factory-set pause time of 6 hours is automatically reset.
Â Afterwards new setting of pause time is possible.
Fault: Fault indication * EE *

Control p.c.b. under fault interfer- Â In case of fault indication * EE * the control p.c.b. has to be replaced immediat ely.
ences
Fault: Fault indication * EC *

Control p.c.b. under fault interfer- Â * EC *: Eliminate the fault interferences.
ences - With the fault indication * EC * all customer specific parameters will be reset to
factory setting (see Tab. 9-1).
- Afterwards re-programming or correction of the parameters P1 to P– and after
triggering an additional lubrication the pump is ready for operation again.
Â Should the fault indication * EC * appear again, the control p.c.b. has to be replaced
immediately.
Form 403439 2.1EN-38020-I10 Page 31 of 46

User Manual
Troubleshooting, continuation
Fault: Blockage in the downstream progressive system
Bearings, lines or metering device clogged Determine the cause of the blockage as described in the
Mounting position of metering device: bottom following example and eliminate it.
- In the case of metering devices SSV 8,12 and 18, the out-Â Let the pump run (refer to ”trigger an additional lubrication”,
lets 1 and/or 2 are closed. fig. 13-2).
Mounting position of metering device: rear Â Disconnect all feed lines D (fig. 15-1) of the metering device
- In the case of metering devices SSV 6, 12 and SSV 18, one after the other. If oil shows under pressure the block-
outlet 1 is closed and outlet 2 is connected t o a lube age is located in the line of outlet 3 or in the connect ed
point. bearing point.
The fault can be identified as follows: Â Pump through the blocked line or bearing point using a
a) Fault indicat ion ”Er” flashing on the keypad display. hand pump.
b) The indicator pin at the metering device piston does NOTE
not move.
To check the individual outlets, leave all
outlets disconnected for a while, since only
one piston stroke is executed with each
6 001a02 motor revolution. Several strokes are re-
quired for a full cycle of all metering devices.
Â Check pressure relief valve (see chapter „Operation“) Re-

place it, if necessary.
A pressure relief valve

B pump
C SSV 12 metering device
D feed lines
423 2a04 R return line
Fig. 15-1 Example of a QLS
Metering device is blocked Â Replace the metering device or clean it as follows:
- Remove all t hreaded tube fitt ings.
- Unscrew the piston closure plugs.
- Remove the piston, if possible, with a soft mandrel
IMPORTANT (smaller than Ø 6 mm, 0. 24 in).
The pistons are individually fit in the bores of the metering device. After removing the pistons, mark them in
order to reinstall them in the right direction and position. They may not be interchanged.
6001a 02 - Thoroughly clean the metering device body in a grease-
dissolving detergent and dry it with compressed air.
- Clean through the material passages (Ø 1.5 mm, 0.59 in)
at the t hread ends of the piston bores using a pin.
- Clean the metering device once more and dry it thor-
oughly.
- Reassemble the metering device.
Fault: Differing lubricant amounts at the lubricati on point


Lubricant metering not correct Â Check the lubricant metering acc. to the lubrication chart.
Â Adjust / optimize t ime setting.
Time sett ing incorrect Â Check the lubricant metering acc. to the lubrication chart.
Â Adjust / optimize t ime setting.
Page 32 of 46 2.1EN-38020-I10 Form 403439

User Manual
Technical Data
Rating 1)
2)
Adm. operating temperature ................ ...... –25 °C ... +70 °C
Maximum operating pressure 1)
(pump without metering device) ............ ................. ~ 205 bar IMPORTANT
Number of outlets ........... ....................... ............... 6, 8, 12, 18 The rating listed refers to grease of NLGI
Output per outlet and cycle .................... ................. ~ 0,2 ccm grade 2 measured at 20°C, backpressure
Output of the pump (wihtout SSV) ......... .......... ~ 1,0 ccm/min 100 bar and nominal voltage 12/24 V
Reservoir capacity .......... ....................... ...................... ... 1l, 2l (motor). Any differing pressures or tem-
6001 a02
Lubricant 3) ....... .............. ............ greases up to NLGI grade 2 peratures result in dif ferent lubricant
Protection . ........ .............. .................. DIN 40050 T9: I P6K 9K out puts. Any system design must be
Reverse polarity protection of the operating voltage inlets yes based on the above values compete.
2)
Lines IMPORTANT
Plastic tube........ .............. ....................... Ø 6x1,5 mm (1/4 in.) The specified “admissible operating
- Min. bending radius ..... ....................... ...................... 50 mm temperature” refers to t he pump and the
- Bursting pressure at 20 °C ................. ................. ~ 210 bar components of the entire lubrication
6001 a02 system, but not to the lubricant to be
Tightening Torques supplied.
Therefore, please observe that the transportation of the
Electric motor on housing ...................... ...................... .. 3 Nm
lubricant in a system depends on t he lubricant’s flow prop-
Pump element in housing ...................... ...................... 25 Nm
erties. The “admissible operating temperature of the lubri-
Closure plug (piston) in metering device ..................... 18 Nm
cant” may differ from t he system operating temperature and
Closure plug (outlets) in metering device .................... 15 Nm
has to be verified separately! For applicable lubricants also
Outlet fitting in metering device
see User Manual 2.0-40001, chapt er “Approved lubricants”.
- screw-type ..... .............. ....................... ...................... 17 Nm
- push-in type ... .............. ....................... ...................... 12 Nm
3)
Compression nut onto outlet fitting, screw-type IMPORTANT
- plastic tube .... .............. ....................... ...................... 10 Nm The pump reservoirs are factory-primed
- steel tube ....... .............. ....................... ...................... 11 Nm with lubrication grease Renocal FN745
Indicator pin in metering device ............. ...................... 18 Nm (down to –25 °C) and EP additives make
Mounting of the metering device (M6, 8.8) .................. 10 Nm Fuchs. This composition is compatible to
6001 a02
most of the commercial greases and
Accessory Kits helps to prevent faults. If requested by the
customer, the pumps can either be
Inch-Size Kits: .. .............. ....................... .................... Part no:
primed with another t ype of lubrication
- SSV 6 / 8 ....... .............. ....................... ............ 550-36971-1
grease or be supplied without priming.
- SSV 12 .. ........ .............. ....................... ............ 550-36971-2
- SSV 18 .. ........ .............. ....................... ............ 550-36971-3
Metric Size Kits: .............. ....................... .................... Part no:

- SSV 6 / 8 ....... .............. ....................... ....... 550-36970-1 ***
- SSV 12 .. ........ .............. ....................... ....... 550-36970-2 ***
- SSV 18 .. ........ .............. ....................... ....... 550-36970-3 ***
*** Lube f ittings must b e ordered sep ara te ly
External Interfaces
Input Output
Power supply Display mode / Operating mode
- see “Connection diagrams“: X1 - see Fig. 10-1 ff / - see Fig. 13-1 ff
Machine contact Feed lines
- ON & OFF with external switch / sensor - see „Installation Instructions“ (Fig. 1-1 ff)
External cycle switch (if any) Alarm contact
- for external met ering device (see Fig. 6-3) - Signal output after low-level or fault indication
(see “Connection Diagrams”)
Modifying and switching key of the membrane keypad
- see Fig. 9-1 & Fig. 9-2 Low-level control * LL *
Filling reservoir - Function (see Fig. 8-1 & Fig. 8-2)
- see Fig. 4-1 & Fig. 14-1, pos. 1 - Display (see Fig. 11-2)
- Programming (see Fig. 12-13 ff)

Emergency lubrication
- see Fig. 4-1 & Fig. 14-1, pos. 5 Fault indication
- Display * EP *, * EE *, * EC * (see Fig. 10-3)
Programming - Display * Er * (see Fig. 11-1)
- see Fig. 12-1 ff - Programming (see Fig. 12-13 ff)
Form 403439 2.1EN-38020-I10 Page 33 of 46

User Manual
Technical Data, continuation
4)
Electrical Data IMPORTANT
4) The pump motor is suitable for
Motor intermittent operation only.
5)
NOTE
Electric data AC (alternate current) 6001 a02
All data depends on operating voltage,
Operating voltage ........... ............... .. 120 VAC, 60 Hz +/-10% ambient temperature and max. operating
Operating current, max. .. ............... ....................... ......... 1,0 A pressure.
Operating voltage ........... ............ 230 VAC, 50/60 Hz +/-10% 6)
NOTE
Operating current, max. .. ............... ....................... ......... 0,5 A
The p umps correspond to the fo llowing
EMC dire ctives:
Relay for malfunction AC 5) A)
- for vehicles ………. EMC 2009/19/ EC
Malfunction / Low-level indication
- for industry ………... EMC 2004/108/EC
- Switching voltage ........ ............... . max. 230 VAC/ 125 VDC A)
marked with the EC approval symbol (e-icon) on the type
- Switching current ......... ............... ........... max. (resistive) 2A
identification plate.
- Switching capacity ....... ............... ........... max. 100 VA/80 W
Electric data DC (direct current)

Operating voltage ........... ............... .......... 12 V, - 20%/+ 30 % Electrical Connection
Operating voltage ........... ............... .......... 24 V, - 20%/+ 30 % Connection of the membrane keypad
5)
Relay for malfunction DC
Malfunction / Low-level indication
- Switching voltage ........ ............... .......... max. 48 VAC/ VDC
- Switching current ......... ............... ........... max. (resistive) 2A
- Switching capacity ....... ............... ........... max. 100 VA/80 W
Residual ripple in relation to the operating voltage ............. .....

... ............... ...................... ............... .............. DIN41755: ± 5%
6)
EMC
EMC 2009/19/EC (vehicles)
EMC 2004/108/EC (a) & b) see “Declaration of conformity”)
b) Noise immunity acc. to .............. ........... DIN EN 61000-6-1
a) Noise immunity acc. to .............. ........... DIN EN 61000-6-2
b) Emitt ed interference acc. to ....... ........... DIN EN 61000-6-3
a) Emitt ed interference acc. to ....... ........... DIN EN 61000-6-4
Correkt B-Q 401-050h0 8
1- Control p.c.b.
Time Setting 2- Connection plug for membrane keypad
Range of pause time ...... ............... .......... Increment 1 minute Terminal 15 and 30
- VDC ....... ...................... ............... ...... 4 minutes to 60 hours
- VAC ....... ...................... ............... .... 20 minutes to 60 hours
Factory setting
- Pause Time ................. ............... .................. 6 hours / cycle
Number of lubricating cycles

- VDC ....... ...................... ............... ..................... 1 to 5 cycles
- VAC SSV 6 / SSV 8 .... ............... ..................... 1 to 3 cycles
- VAC SSV12 / SSV18 .. ............... ....................... ....... 1 cycle
Min. pause time .............. ............... ....................... .. 4 minutes

Max. lubricating time ...... ............... ....................... .. 4 minutes
Timer memory ................ ............... ....................... ...................

... ............... ...................... ............... .. indefinite over EEPROM
Terminals 15/30 bridged B-Q 401-052a0 9

1- Control p.c.b. (delivery configuration & spare parts version)
1a - with Bridge between terminal 15 and 30
Page 34 of 46 2.1EN-38020-I10 Form 403439

User Manual
Power supply: Direct current 12 VDC or 24 VDC with square-type plug

- with integrated control unit (terminals 15/30 bridged), attached metering device and alarm contact (normally open):
B-Q401-051x10
- with integrated control unit (terminals 15/30 bridged), external metering device and alarm contact (normally open):
B-Q401-051y10
AK - Alarm contact Imax - Max. current 2 A U max - Max. voltage 48 V \- Minus

F1 - Fuse Internal / External: M- Motor Option:
- 12 VDC: 6 A - CS Cycle switch - 12 VDC - LL Low-level control
or - 24 VDC: 3 A or - 24 VDC - X9 external cycl e switch

- MK Machine contact
mKp - Membrane keypad mP - Microprocessor P- Pump housing
PCB - Control p.c.b. X1 - Square-type plug, left X2 - Square-type plug, right
rt - red sw - black br - brown or - orange

bl - blue
Form 403439 2.1EN-38020-I10 Page 35 of 46

User Manual
Power supply: Alternate current 120 VAC (60 Hz) or 230 VAC (50/60 Hz) with square-type plug
- with int egrated control unit (terminals 15/30 bridged), attached metering device and alarm contact (normally open):
B-Q401-052x10
- with int egrated control unit (terminals 15/30 bridged), external metering device and alarm contact (normally open):
B-Q401-052y10
AK - Alarm contact Imax - Max. current 2 A U max - Max. voltage 230 VAC \- Minus
- 120 VAC: 1,5 A - CS Cycle switch - 120 VAC, 60 Hz - LL Low-level control
or - 230 VAC: 1,0 A or - 230 VAC, 50/60 Hz - X9 external cycl e switch

mKp - Membrane keypad mP - Microprocessor P- Pump housing PCB - Control p.c.b.
X1 - Square-type plug, left X2 - Square-type plug, right
hb - light blue gr/gb - green/yellow br - brown or - orange

bl - blue sw - black
Page 36 of 46 2.1EN-38020-I10 Form 403439

User Manual
Power supply: Direct current 12 VDC or 24 VDC with bayonet plug

- with integrated control unit (terminals 15/30 bridged), attached metering device and alarm contact (normally open):
B-Q401-053x10
- with integrated control unit (terminals 15/30 bridged), external metering device and alarm contact (normally open):
B-Q401-053y10
AK - Alarm contact Imax - Max. current 2 A U max - Max. voltage 48 V \- Minus

- 12 VDC: 6 A - CS Cycle switch - 12 VDC - LL Low-level control
or - 24 VDC: 3 A or - 24 VDC - X6 external cycl e switch

- MK Machine contact
mKp - Membrane keypad mP - Microprocessor P- Pump housing
PCB - Control p.c.b. X1 - Bayonet plug
rt - red sw - black br - brown or - orange

bl - blue gb - yellow ws - white
Form 403439 2.1EN-38020-I10 Page 37 of 46

User Manual
Dimensions
Pump with 1 litre and 2 litre reservoir Rear-mounted SSV metering device
4233a 99
Number of outlets Dimensions A in mm

6 60
12 105
18 150
Bottom-mounted SSV metering device
2012b 95
Number of outlets Dimensions A in mm

8 90
12 105
B-Q401-040a0 8
18 150
Page 38 of 46 2.1EN-38020-I10 Form 403439

User Manual
Serivce Parts
Explosion view for bottom mounted SSV metering devices (horizontal outlets) with low-level
control, square-type plugs and 2 litre reservoir
B-Q401-060w 08
(Parts list see page 40)
Form 403439 2.1EN-38020-I10 Page 39 of 46

User Manual
Serivce Parts, continuation
Parts list for bottom mounted SSV metering devices (horizontal outlets) and low-level control
Pos. Designation Kit Single Qty. Part no. Pos. Designation Kit Single Qty. Part no.
Part Part
1 1 litre reservoir, assy. x 1 550-34179-1 Bayonet plug, onl y VDC (see page 41)
2 litre reservoir, assy. x 1 550-34179-4 11 Housing cover for x 1 550-34179-3
2 Stirring paddle with stripping rubber VDC, plug 1A1.0
- for 1 litre reservoir x 1 550-32945-1 11.1 Socket wit h 10 m cable x 1 664-34045-1
for bayonet plug or
- for 2 litre reservoir x 1 550-33229-1
2.1 Stripping rubber x 1 450-70430-1 11.2 Bayonet plug x 1 664-34045-2
3 Pin (fix paddle) x 1 450-71380-1 12 Proximity switch x 1 550-36980-1
4 Intermediate bottom x 1 450-71379-1 13 Control p.c.b.
5 Eccentric gear x 1 550-34178-8 1-5 cycles12/ 24 VDC x 1 550-36983-7
6 Shaft SSV 6 & SSV 8
- for 1 litre reservoir x 1 550-34178-7 - 1-3 cycles 120 VAC x 1 550-34199-2
7 Pressure relief valve, x 1 235-14343-1 SSV 12 & SSV 18
cartridge
- 1 cycle 120 VAC x 1 550-34199-1
8 Pump element, assy. x 1 650-28856-1 - 1 cycle 230 VAC x 1 550-34199-3
Ø 6 mm
15 Motor, 12 VDC x 1 550-36982-1
9 Sealing parts for x 1 550-36979-5 Motor, 24 VDC x 1 550-36982-2
pump element
Motor, 120 VAC x 1 550-36982-3
10 Housing x 1 550-32959-1
Motor, 230 VAC x 1 550-36982-4
Square-type plug (see page 39)
15.1 Motor connect ion VDC x 1 664-36968-7
11 Housing cover for x 1 550-34178-5
direct current VDC, 15.2 Motor connect ion VAC x 1 664-36968-1
plug 1A1.0 16 Hydraulic lube fitting, x 1 251-14109-2
A2 AR 1/8
or VDC, plug 2A1.0 x 1 550-34178-4
17 Adapter M 22x1,5 (a) x x 1 304-19619-1
and VAC, plug 1A1.0 x 1 550-34178-3
G 1/8 in.(i)
or VAC, plug 2A1.0 x 1 550-34178-2
18 O-ring Ø 5 x1, 5 mm x 3 219-12222-2
11.1 Socket 2 with 10 m x 1 664-36078-9 19 Banjo bold x 1 226-13777-2
cable, for remote 20 Sealing ring aluminum x 2 226-13780-1
control
21 Manifold x 1 550-36979-6
11.4 Appliance plug 2 for x 1 664-36968-6
22 Hydraulic lube fitting x 1 251-14073-9
remote control, VDC
RV, A2 AR 1/8
Appliance plug 2 for x 1 664-36968-5
23 Connecting block x 1 550-36979-7
remote control, VAC
24 SSV divider block
power supply, VDC SSV 8 – K x 1 619-37586-1
SSV 12 – K x 1 619-37587-1
Appliance plug 1 for x 1 664-36968-3
power supply, VAC SSV 18 – K x 1 619-37588-1
11.6 Socket 1 with 10 m x 1 664-36078-7 25 Piston plug with seal- x 1 519-32123-1

cable for power ing for control pin
supply 26 Magnetic switch x 1 234-10423-2
11.7 Screw with washer x 1 201-14434-1
assy. Sealing kit for QLS 401 x 1 550-34178-1
Page 40 of 46 2.1EN-38020-I10 Form 403439

User Manual
Explosion view for bottom mounted SSV metering device (horizontal outlets), low-level con-
trol, bayonet plug and 1 litre reservoir
B-Q401-060u 08
(Parts list see page 40)
Form 403439 2.1EN-38020-I10 Page 41 of 46

User Manual
Explosion view for rear mounted SSV metering devices (vertical outlets), low-level control,
bayonet plug and 2 litre reservoir
B-Q401-060b 08
(Parts l ist see page 43)
Page 42 of 46 2.1EN-38020-I10 Form 403439

User Manual
Parts list for rear mounted SSV metering devices (vertical outlets) and low-level control
Pos. Designation Kit Single Qty. Part no. Pos. Designation Single Qty. Part no.
Kit
Part Part
1 1 litre reservoir, assy. x 1 550-34179-1 Bayonet pl ug, onl y VDC (see page 42)
2 litre reservoir, assy. x 1 550-34179-4 11 Housing cover for x 1 550-34179-3
2 Rührflügel mit Abstreifer VDC, plug 1A1.0
- for 1 litre reservoir x 1 550-32945-1 11.1 Socket with 10 m cable x 1 664-34045-1
for bayonet plug or
- for 2 litre reservoir x 1 550-33229-1
2.1 Stripping rubber x 1 450-70430-1 11.2 Bayonet plug x 1 664-34045-2
3 Pin (fix paddle) x 1 450-71380-1
4 Intermediate bottom x 1 450-71379-1 12 Proximity switch x 1 550-36980-1
5 Eccentric gear x 1 550-34178-8 13 Control p. c.b.
6 Shaft 1-5 cycles 12/24 VDC x 1 550-36983-7
- for 1 litre reservoir x 1 550-34178-7 SSV 6 & SSV 8
7 Pressure relief valve, x 1 235-14343-1 - 1-3 cycles 230 VAC x 1 550-34199-4
cartridge SSV 12 & SSV 18
8 Pump element, assy. x 1 650-28856-1 - 1 cycle 120 VAC x 1 550-34199-1
Ø 6 mm - 1 cycle 230 VAC x 1 550-34199-3
9 Sealing parts for x 1 550-36979-5 15 Motor, 12 VDC x 1 550-36982-1
pump element
Motor, 24 VDC x 1 550-36982-2
10 Housing x 1 550-32959-1
Motor, 120 VAC x 1 550-36982-3
Square-type plug (see page 44)
11 Housing cover XN Motor, 230 VAC x 1 550-36982-4
and VDC, plug 1A1.0 x 1 550-34178-5 15.1 Motor connection VDC x 1 664-36968-7
or VDC, plug 2A1.0 x 1 550-34178-4 15.2 Motor connection VAC x 1 664-36968-1
and VAC, plug 1A1.0 x 1 550-34178-3 16 Hydraulic lube fitting, x 1 251-14109-2

A2 AR 1/8
or VAC, plug 2A1. 0 x 1 550-34178-2
17 Adapter M 22x1,5 (a) x x 1 304-19619-1
11.1 Socket 2 with 10 m x 1 664-36078-9 G 1/8 in.(i)
cable, for remote
control 18 O-ring ø 5 x1, x 2 219-12222-2
5 mm
remote control, VDC 19 SSV divider block
Appliance plug 2 for x 1 664-36968-5 SSV 6 - K x 1 619-37589-1

remote control, VAC SSV 12 - K x 1 619-37590-1
11.5 Appliance plug 1 for x 1 664-36968-4 SSV 18 - K x 1 619-37591-1
power supply, VDC
20 Hydraulic lube fitting x 1 251-14073-9
Appliance plug 1 for x 1 664-36968-3 RV, A2 AR 1/ 8
power supply, VAC
21 Piston plug with seal- x 1 519-32123-1
11.6 Socket 1 with 10 m x 1 664-36078-7 ing for control pin
cable for power sup-
26 Magnetic switch 234-10423-2
ply
11.7 Screw with washer x 1 201-14434-1
Sealing kit for QLS 401 1 550-34178-1
assy.
Form 403439 2.1EN-38020-I10 Page 43 of 46

User Manual
Explosion view for rear mounted SSV metering devices (vertical outlets), low-level control,
square-type plugs and 1 litre reservoir
B-Q401-060h 08
(Parts l ist see page 43)
Page 44 of 46 2.1EN-38020-I10 Form 403439

User Manual
Original Language
D GB F E I
EG- EC Declaration Déclaration CE Declaració n CE Dichiarazione CE
Kon formitätserklärung of conformity de conformité de con formid ad di conformità
Hiermit erklären wir, dass die Herewith we declare that the Par la présente, nous décla- Por la presente, declaramos Si dichiara che il prodotto da
Bauart von model of rons que le produit ci-dessous que el modelo suministrado noi fornito
QLS401
in der von uns gelieferten in the version supplied by us dans la version dans laquelle en la versión suministrada nella versione da noi fornita
Ausführung den Bestimmun- corresponds to the provisions nous le livrons est conforme corresponde a las è conforme a tutti i requisiti
gen allen einschlägigen of all pertinent fundamental aux réglementations régissant disposiciónes de los requisitos basilari prescritti in termini di
grundlegenden Sicherheits- health and safety require- toutes les exigences fonda- pertinentes y fundamentales sicurezza e di salute, incluse
und Gesundheitsanforderun- ments, including all modifica- mentales de sécurité et celles de salud y seguridad en su le modific he vigenti al
gen entspricht, einschließlich tions of this directive valid at relatives à la santé, y compris redacción vigente en el momento della dichiarazio-
deren zum Zeit punkt der the time of the declaration. les amendements en vigueur momento de instalación. ne.
Erklärung geltenden Ände- Applied harmonized stan- au moment de la présente Normas armonizadas Norme armonizzate applica-
rungen. dards in partic ular: déclaration. utilizadas, partic ularmente: te in particolare:
Angewendete harmonisierte Normes harmonisées, notam-
Normen, insbesondere: ment :
Maschin enrichtlinie Machinery Directive Directive machines Directiva de máquinas Direttiva Macchine
2006/42/EG 2006/42/EC 2006/42/CE 2006/42/CE 2006/42/CE
DIN EN ISO 12100 – Teil 1 & 2 – Part 1 & 2 – Parties 1 & 2 – Parte 1 & 2 – Parte 1 e 2
Sicherheit von Maschinen Safety of machinery Sécurité de machines Seguridad de máquinas Sicurezza delle macchine
Grundbegriffe, allgemeine Basic terms, general design Notions fondamentales, directi- Términos básicos, axiomas Concetti basilari, principi
Gestaltungsleitsätze guidelines ves générales d’élaboration generales de diseño guida generali
DIN EN 908
Pumpen und Pumpen geräte Pumps and pump units Pompes et grou pes Bombas y equipos de Pompe e dispositivi
für Flüssigkeiten for liquids de pompes p our liquides bombas para líquidos di pompag gio per liquidi
Allgemeine sicherungs- Exigences en matière Prescripci ones generales Requisiti generali di sicurezza
General safety requirements
technische Anforderungen de sécurit é technique referente a la seguridad tecnica
EMV-Richtlinien EMC directives Réglementations CEM Directivas CEM Direttive EMC

2009/19/EG 2009/19/EC 2009/19/CE 2009/19/CE 2009/19/CE
Kraftfahrzeug Automotive véhicules automobile vehículo autoveicolo
2004/108/EG 2004/108/EC 2004/108/CE 2004/108/CE 2004/108/CE
DIN EN 61000-…
Fachgrundnormen: Generic emission standards: Normes fondamentales : Normas especiales fundam.: Norme specific he fondam.:
- Störaussendung - Emitted interference - Emission de parasites - Emisión de interferencias - Emissione di interferenze
… Teil 6-4 a) … Part 6-4 a) … Partie 6-4 a) … Parte 6-4 a) … Parte 6-4 a)
… Teil 6-3 b) … Part 6-3 b) … Partie 6-3 b) … Parte 6-3 b) … Parte 6-3 b)
- Störfestigkeit - Noise immunity - Résistance aux brouillages - Resistencia a interferencias - Resistenza alle interferenze
… Teil 6-2 a) … Part 6-2 a) … Partie 6-2 a) … Parte 6-2 a) … Parte 6-2 a)
b) b) b) b) b)
… Teil 6-1 … Part 6-1 … Partie 6-1 … Parte 6-1 … Parte 6-1
a) a) a) a) a)
für Industriebereiche for industrial environment pour domaine industriel para áreas industriales per settore industria le
b)
für Wohnbereich, Geschäfts- b) for residential, commercial b)
pour domaines de l’habitation, b) para áreas resi denciales, b)
per il settore residenziale,
und Gewerbebereiche sowie and light industry des magasi ns et de l’artisanat comerciales e industriales commerciale, industria le e
Kleinbetriebe ainsi que des petites tanto como pequeñas per le piccole imprese
entrepris es empresas
Doku mentations- Responsable du Service Encargado/a de la Responsabile della
Documentation agent
b evollmächtigter de documentation documentación do cumentazione
Wolfgang Studer • Heinrich-Hertz-Str. 2-8 • 69190 Walldorf
Lincoln GmbH
Heinrich-Hertz-Str. 2-8
D-69190 Walldorf
Wall dorf Aug 18, 2010, ppa. Dr.-Ing. Z. Paluncic
Director Research & Development
Form 403439 2.1EN-38020-I10 Page 45 of 46

User Manual
Lincoln’s Global Distribution and Service

Network – The Best in Our Industry –
Whatever service is required – selecting a lubricating system, customised system installation or t he supply of top qualit y prod-
ucts – you will always be best advised by the staff of the Lincoln offices, representatives and contract dealers.
Systems dealers
Our systems dealers have the most extensive specialised knowledge in our industry. They plan your installations t o suit your
specifications with exactly the combination of Lincoln components that you need. They then build the installations at your op-
erat ion with experienced technicians or work closely wit h your personnel to ensure that everything goes smoothly.
All dealers have the complete range of pumps, distributers, monitoring devices and accessories in stock and meet our exact ing
demands with their specialised knowledge about products, installations and service. Whenever and wherever you need our
experts, from St. Louis to Singapore, Walldorf and worldwide, Lincoln’s first-class systems dealers are at your service.
Find out where the nearest Lincoln distribution and service office to you is located:
Americas: Lincoln Industrial One Lincoln Way Phone: (+1) 314 679 4200
St . Louis, MO 63120-1578 Fax: (+1) 800 424 5359
USA Home: www.lincolnindustrial.com
Europe/Africa/Asia: Lincoln GmbH Heinrich-Hertz Straße 2-8 Phone: (+49) 6227 33-0
69190 Walldorf Fax: (+49) 6227 33-259
Germany E-Mail: lincoln@lincolnindustrial.de
Asia/Australia/Pacific: Lincoln Industrial 3 Tampines Central 1 Phone: (+65) 6588-0188

Corporation # 04-05 Abacus Plaza Fax: (+65) 6588-3438
Singapore 529540 E-Mail: sales@lincolnindustrial.com.sg
D IN EN ISO 9001
by DQS
R eg.-Nr. 799
© Copyright 2010
D IN EN ISO 1 4001
by G UT
LUBRICATION RECOMMENDATION
Chapter 195-3
LUBRICATION OIL LIST FOR STERN TUBE SEALS
The SIMPLEX-COMPACT seal is fitted with sealing rings of NBR ( Perbunan ) or

FKM ( Viton ) depending on the operating conditions.
The following list is an recommendation list regarding stern tube seals only. It is
inapplicable to the behaviour with regards to gears, clutches, roller bearings or
other components of the propulsion system.
The technical data has been provided by the oil companies.
The suitable sealing material is given for every oil listed and marked
correspondingly " x ".
Oils marked with " * " have to be used in consultation with Blohm + Voss
Industries only due to restriction in application.
Oils marked with " ** " are, in particular, environmentally friendly lubricants. The
usage is currently limited, therefore the oils should be used in consultation with
Blohm + Voss Industries only.
We ask to inform us if oils / lubricants which are not listed are to be used. We
shall test these lubricants accordingly.
Blohm + Voss Industries GmbH Page 1 / 11
E_195-3 Rev. 07/2007

Chapter 195-3
Visc.
for use with SAE General use:
cSt. 40°C
LUBRICATION OIL LIST
Hydraulic Oil
FKM (Viton)
(Perbunan)
Engine Oil
Product Name
Gear Oil
Bio Oil
Other
NBR
Agip
Acer 100 x x 100 x x
Cladium 120 SAE30 x x 30 108 x
Cladium 400 SAE30 x 30 108 x
Ote 68 x 64 x x
Ote 80 x 80 x x
BP
Bartran 320 x 318 x
Bartran 460 x 460 x
Bartran HV 68 x x 66 x
Bartran HV 100 x x x
Energol DL-MP 30 x x 30 110 x
Energol DL-MP 40 x x 40 148 x
Energol DS 3-153 x x 30 110 x
Energol DS 3-154 x x 40 148 x
Energol GR-XP 68 x x 66 x
Energol GR-XP 220 x x x
Energol GR-XP 680 x x x
Energol HLP 46 x x 46 x
Energol THB 68 x x 68 x
Energol THB 100 x x 96 x
Energol IC-HFX 203 x x 30 102 x
Energol OE-HT 30 x x 30 110 x
E_195-3 Rev. 07/2007

Chapter 195-3
Visc.
cSt. 40°C
Hydraulic Oil
FKM (Viton)
(Perbunan)
Engine Oil
Product Name
Gear Oil
Bio Oil
Other
NBR
Caltex ( Chevron Corp. )
Meropa Lubricant 150 x x 150 x
Regal Marine 77 x x 77 x
Regal Oil R&O 100 x x 96 x
Regal Oil R&O 68 x x 66 x
RPM Delo 100 Oil 20-20W x x 20/20W 61 x
RPM Delo 100 Oil 30 x x 30 94 x
RPM Delo 300 Oil 20-20W x x 20/20W 60 x
RPM Delo 300 Oil 30 x x 30 97 x
Delo 1000 Marine Oil 30 x x 30 110 x
Castrol
215 MX Super x x 30 103 x
220 MX Super x x 40 136 x
Alpha SP 68 x x 68 x
Alpha ZN 100 x x 100 x
Coral 2 x x 222 x
Hyspin AWH - M100 x x 100 x
Castrol CDX 30 x x 30 103 x
Marine MLC 30 x x 30 107 x
Marine MLC 40 x 40 139 x
Castrol MPX 30 x x 30 103 x
Nato 0-274 x x 30 101 x
Perfecto T 68 x x 68 x
Perfecto T 100 x x 96 x
RX Super 30 x x 30 108 x
MHP 153 x x 30 102 x
MHP 154 x 40 136 x
E_195-3 Rev. 07/2007

Chapter 195-3
Visc.
cSt. 40°C
Hydraulic Oil
FKM (Viton)
(Perbunan)
Engine Oil
Product Name
Gear Oil
Bio Oil
Other
NBR
TLX Plus 203 x x 30 102 x
Chevron ( FAMM distribution )

Delo 1000 Marine Oil x x 30 112 x
Gear Compound EP 100 x x 100 x
Gear Compound EP 150 x x 150 x
Mechanism LPS 46 x 46 x
Mechanism LPS 68 x x 68 x
Turbine Oil GST 100 x x 100 x
Turbine Oil GST 68 x x 68 x
Veritas 800 Marine 30 x x 30 114 x
Pinnacle Marine Gear 220 x 220 x
Citgo
Aquamarine Oil 46 ** x 46 x x
Aquamarine Oil 68 ** x 68 x x
ExxonMobil ( ex Esso and Mobil Oil )

Essolube X 3 SAE 30 x x 30 103 x
Essolube X 3 SAE40 x x 40 149 x
Exxmar 12 TP 30 x x 30 110 x
Exxmar 12 TP 40 x x 40 146 x
Exxmar 30 TP 30 x x 30 110 x
Exxmar 30 TP 40 x x 40 146 x
Exxmar XA x x 30 110 x
Nuto H 68 x x 68 x
E_195-3 Rev. 07/2007

Chapter 195-3
Visc.
cSt. 40°C
Hydraulic Oil
FKM (Viton)
(Perbunan)
Engine Oil
Product Name
Gear Oil
Bio Oil
Other
NBR
Spartan EP 100 x x 100 x
Spartan EP 320 x 320 x
Stermar 220 x 220 x
Teresstic 32 x x 32 x
Teresstic 68 x x 68 x
UNIVIS N 100 x x 100 98 x
Mobil Delvac 1330 x x 30 106 x
Mobil Delvac 1340 x x 40 145 x
Mobil Delvac 1630 x 30 90 x
Mobil Delvac 1640 x 40 132 x
Mobil DTE 15 M x x 46 x
Mobil DTE 16M x x 68 x
Mobil DTE Oil Extra Heavy x x 146 x
Mobil DTE Oil Heavy x x 95 x
Mobil DTE Oil Heavy Medium x x 65 x
Mobil DTE Oil BB x x 50 218 x
Mobilgard M50 x x 40 142 x
Mobilgard 300 x x 30 111 x
Mobilgard M 440 x x 40 143 x
Mobilgard ADL 40 x x 40 141 x
Mobil Sterntube Lubricant * x 385 x
Mobilgear 626 x x 68 x
Mobilgear 600 XP 68 x x 68 x
E_195-3 Rev. 07/2007

Chapter 195-3
Visc.
cSt. 40°C
Hydraulic Oil
FKM (Viton)
(Perbunan)
Engine Oil
Product Name
Gear Oil
Bio Oil
Other
NBR
Mobilgear SHC XMP220 * x 220 x
Mobilgear SHC XMP320 * x 320 x
Mobil Vacuoline 528 x x 150 x
Fuji Kosan
Fukkol AD Turbine 68 x x 68 x
Fukkol Hydrol X-100 x x 100 x
Fukkol Marine 312 x x 30 106 x
Fukkol Marine 320 x x 30 105 x
Fukkol SAE ACE 307 x x 30 107
General Sekiyu K.K.

See ExxonMobil Products
Idemitsu
Daphne Super Gear Oil x x 150 x
Ina Maziva Rijeka Croatia

Gorgonela S 30 x x 30 106 x x x
Gorgonela S 40 x x 40 147 x x x
Rubella 30 x x 30 107 x x x
Rubella 40 x x 40 148 x x x
Sagartia 30 x x 30 106 x x x
Sagartia 40 x x 40 147 x x x
Turbo 32 x x 32 x
Turbo 46 x x 46 x
E_195-3 Rev. 07/2007

Chapter 195-3
Visc.
cSt. 40°C
Hydraulic Oil
FKM (Viton)
(Perbunan)
Engine Oil
Product Name
Gear Oil
Bio Oil
Other
NBR
Irving Oil
Marine LSX 530 x x 30 103 x
Marine MTX 1230 x x 30 107 x
Marine MTX 1240 x 40 139 x
Kendall Noviol b.v.

F-L Select Motor Oil x x 30 103 x
F-L Select Motor Oil 20W20 x x 20/W20 68,2 x
Kenoil R&O AW 68 x x 20/W20 67,6 x
Super-D III Series 3 Motor Oil x x 30 106,4 x
Kyodo Oil Co. / Japan Energy Corp.

See TOTAL LUBMARINE / INDUSTRIE
NESTE
Vaihteisto 220 EP x x 220 x
Vaihteisto 320 EP x x 305 x
Nippon Oil Co.

Diamond Marine T 104 x 30 96 x
Diamond Marine T 203 A x 40 145 x
Diamond Marine T 303 A x x 30 95,5 x
Diamond Marine T 304 A x 40 141 x
MDL PS 30 (ren. Super MDL PS 30) x x 30 106
MDL HDS 30 (ren. Super MDL HDS 30) x x 30 109
E_195-3 Rev. 07/2007

Chapter 195-3
Visc.
cSt. 40°C
Hydraulic Oil
FKM (Viton)
(Perbunan)
Engine Oil
Product Name
Gear Oil
Bio Oil
Other
NBR
Petrobras Distribuidora
Lubrax MD-300 SAE 30 x x 30 113 x
Lubrax MD-400 SAE 30 x x 30 111 x
Marbrax CAD-308 x x 30 103 x
Marbrax CAD-65-OF x x 30 114 x
Marbrax CCD-310 x x 30 109 x
Marbrax TR-86 x x 111 x
Marbrax HV-68 x x 68 x
Reginol
Gear Gl 1 x x 80 142 x
Hykraft 150 x x 137 x
Hykraft 68 x 20 64 x
Industrygear EP 100 x 99 x
Shell
Argina S 30 x 30 104 x
Argina S 40 x 40 139 x
Argina T 30 x x 30 104 x
Argina X 40 x x 40 146 x
Arginia XL 40 x x 40 139 x
Gadinia 30 x x 30 104 x
Gadinia 40 x x 40 139 x
Gadinia AL30 x x 30 101 x
Gadinia AL40 x x 40 138 x
Melina 30 x x 30 104 x
Melina 40 x x 40 145 x
Melina S 30 x x 30 104 x
Omala 68 x x 68 x
Omala 100 x x 100 x
Omala 150 x x 150 x
E_195-3 Rev. 07/2007

Chapter 195-3
Visc.
cSt. 40°C
Hydraulic Oil
FKM (Viton)
(Perbunan)
Engine Oil
Product Name
Gear Oil
Bio Oil
Other
NBR
Omala 220 x x 220 x
Omala 320 x 320 x
Rimula 30 x x 30 118 x
Sirius 15W-40 x 40 101 x
Rimula X 15W-40 x x 40 105 x
Sirius X 30 x x 30 101 x
Sirius X 40 x x 40 139 x
Tellus 100 x x 100 x
Morlina 100 x 100 x
Morlina 46 x 46 x
Tellus T 100 x x 100 x
Tellus T 68 x x 68 x
Turbo T 46 x x 49 x
Turbo T 68 x x 63 x
Turbo T 78 x x 76 x
Vitrea 68 x x 68 x
Vitrea 100 x x 100 x
Vitrea 220 x 220 x
Omala EPB 150 ** x 150 x x
Showa Shell Sekiyu K.K.

See Shell Products
Statoil
Statoil Sternway 220 x 220 x
Statoil Loadway EP 150 x x 150 x
Statoil Loadway EP 100 x 100 x
Statoil HydraWay HMA 68 x x 70 x
Statoil HydraWay HMA 100 x x 100 x
Statoil MarWay 1030 x x 106 x
Statoil MarWay 1040 x x 137 x
E_195-3 Rev. 07/2007

Chapter 195-3
Visc.
cSt. 40°C
Hydraulic Oil
FKM (Viton)
(Perbunan)
Engine Oil
Product Name
Gear Oil
Bio Oil
Other
NBR
Teboil
Teboil Ward L10T x x 30 110 x
Terrosolve
EnviroLogic 215 Gear Oil ** x 40 150 x x
EnviroLogic 210 Gear Oil ** x 30 100 x x
EnviroLogic 3100 ** x 30 100 x
Texaco ( FAMM distribution )

Meropa 100 x x
Meropa 150 x
Meropa 220 x x
Meropa 320 x x
Meropa 460 x 150 x
Rando HD 68 x x 68 x
Regal R&O 100 x x 92 x
Regal R&O 68 x x 68 x
Taro 30 DP x x 30 99 x
Taro 40 DP x x 40 145 x
Taro 16 XD x x 40 139 x
Taro 40 XL x x 40 145 x
Ursa Oil ED 30 x x 30 97 x
Ursa Oil ED 40 x x 40 173 x
Ursa Super Plus 30 x x 30 102 x
Ursa Super Plus 40 x x 40 160 x
TOTAL LUBMARINE ( ex Elf Marine )

Atlanta Marine 30 x x 30 105 x
Atlanta Marine D 3005 x x 30 105 x
Aurelia XL 3030 x x 30 110 x
Disola M 3015 x x 30 110 x
E_195-3 Rev. 07/2007

Chapter 195-3
Visc.
cSt. 40°C
Hydraulic Oil
FKM (Viton)
(Perbunan)
Engine Oil
Product Name
Gear Oil
Bio Oil
Other
NBR
Disola M 4015 x x 40 145 x
Disola MT 30 x x 30 110 x
Turbine T 100 x x 30 95 x
Turbine T 68 x x 20 71 x
Elf Epona Z 150 x x 148 x
TOTAL INDUSTRIE
Rubia H 30 x x 30 100 x
Rubia H 40 x x 40 150 x
Rubia S 30 x x 30 100 x
Rubia S 40 x x 40 155 x
Biohydran TMP 100 ** x 100 x x
Vickers Leeds
Hydrox 21 (2024) x 50 273 x
Hydrox 550 (2018) x x 20/30 70 x
Hydrox 8 EP (2019) x x 105 x
Hydrox EP 150 x 150 x
Hydrox Bio 68 ** x 20 68 x x
Wisura
Dimol HD x x 30 105 x
Panta SAE20 x x 20 60 x
E_195-3 Rev. 07/2007

Chapter 195-3
The SIMPLEX-COMPACT seal is fitted with sealing rings of NBR ( Perbunan ) or FKM ( Viton )
depending on the operating conditions.
The suitable sealing material is given for every grease listed and marked correspondingly " x ".
for use with

GREASE-LIST
FKM (Viton)
(Perbunan)
Product Name NBR Remarks
BP
Energrease MP-MG 2 x x
Castrol
Spheerol SX 2 x x
Klüber
Klüberbio M 72-82 - x**
Microlube GL 262 - x*
Microlube GL 261 x x*
Stabutherm GH 461 x** x*
Petamo GHY 133 N - x
Altemp Q NB 50 - - Approved for use as mounting grease
Staburags NBU 12K x -
Staburags NBU 30K x x**
ExxonMobil
Mobilux EP 2 x -
Mobilgrease XHP 222 x x
Shell
Alvania EP (LF) 2 - - Approved for use as mounting grease
Aseol Aquares EP 2 x x*
Retinax LX2 x x
SRS 4000 x x*
* At continuous use with T >100°C please consult Blohm + Voss Industries

** Application in consultation with Blohm + Voss Industries only
E_195-3 Rev. 02/2010

MAN Diesel A/S
14 December 2010
1.03 Propeller servo system
Drawing ident no Description Part ident no Item Date of

no update
Addendum 1.03.1 Addendum for propeller servo system
2 05 81 35-2.1 Main dimensions and dismantling, ODF220

2 15 27 83-9.0 ODF220 Complete, (3 pages)
Item2783(1).doc  Item list for ODF complete
2 15 28 82-2.0 Assembling procedures ODF220
2 05 50 74-7.5 ODF220, servo system installation
Item5074(1).doc  Item list for ODF installation
1 32 94 13-2.1  Ball valve, G3/4, 2 pcs 1329413-2 18
2 15 35 24-6.0 Servo oil system, diagram
2 04 94 93-4.5 Hydraulic power pack, dimension sketch 15
2 15 63 73-9.0  Servo oil pump Mounted on 16
power pack
3 50A2-01 Servo control system

3 50D2-01 Pitch control system, (2 pages)
3 50 F2-01 Emergency operation, (3 pages)
2 14 13 32-5.4 Flushing procedure
The “Item no” refer to drawing no 2 15 35 24-6.0
---oooOOOooo---
End of Section 1.03 - Propeller servo system
 MAN B&W Supply

MAN Diesel A/S
9 December 2010
Addendum 1.03.1 Propeller servo system
Comments to servo oil system, diagram 2 15 35 24-6.0
Cooler data:
Cooling fresh water flow : 6 m^3/h
Delta P : 0.19 bar
Heat exchange : 12.5 kW
Temperature, max. Inlet : 38 °C
Delta T : 1.8 °C
---oooOOOooo---
End of Propeller servo system
 MAN B&W Supply

MAN B&W Diesel A/S
14 December 2010/HAK
2 15 27 83-9.0 – ODF220 Complete Edition 1
The ODF220 unit will be delivered as show as “Deliv-

ery package”
ODF220 unit, housing 1

Sensor housing 1
The following items are not mounted on the ODF unit

at delivery.
02 Screw, M16x40 8
18 Sealing ring, ø3 1
41 Screw, M4x25 3
42 Magnet disc for sensor 1
51 Nut, M20 6
65 Screw for leak oil sensor 1
66 Leak oil sensor housing, complete 1
67 Adapter for leak oil sensor 1
68 Screw, M3x10 3
93 Stay bolt, M20 6
For assembling of the ODF unit, please see drawing no 2152882-2.0

MAN Diesel

Copyright
3P7902 Assembly procedure ODF 2152882-2

MAN Diesel
A4 ODF220 & ODF270 1 (2)
2010 MAN Diesel

20100505 MMA AFP 00
01
02
03
Assembling procedures ODF

Two main components have to be presents: delivery package with servo oil pipe and
aluminium housing with feed back sensor. All assembling instructions are according to
ODF complete drawing.
1. Check that the recesses on the gearbox housing and shaft are clean and free off burrs.
2. Check the radial circular run-out tolerance, the perpendicular tolerance and the
horizontal dimension from gear shaft to housing according to the plant specific
drawing sent to gear supplier.
3. Add Loctite 242 to stay bolts pos. 93 and mount them in the gearbox thrust shaft.
4. Mount the O-rings pos. 17 and 18 on the delivery package. To be sure that the O-ring
pos. 18 doesn’t fall off during assembling, some grease is added in the groove!
5. Silicone paste Rhodorsil Mastic 7306 pos. 81 is put on the gearbox housing.
6. Now the delivery package can be mounted. First the servo oil pipe is put into the gear
shaft. Next step is to guide the package on to the stay bolts, and push the whole
package up to the gearbox shaft and gearbox housing.
7. Turn the gearbox thrust shaft, until the wanted position of servo oil inlet is obtained.
Allowable positions are shown on the ODF installation drawing.
8. Mount 8 screws M16 x 40 pos. 02 only by hand.
9. Now remove cover pos. 75 by removing screws pos. 12, 76 and 77.
10. Tighten the screws M16 x 40 pos. 02 with a wrench.

MAN Diesel

Copyright
3P7902 Assembly procedure ODF 2152882-2

MAN Diesel
ODF220 & ODF270 2 (2)
2010 MAN Diesel
A4
20100505 MMA AFP 00
11. Add Molycote GN+ paste pos. 83 on the stay bolts.
12. Add Loctite 572 pos. 84 on the contact surfaces for the cap nuts pos. 51.
13. Tighten up the cap nuts to 220 Nm.
14. Magnet disc pos. 42 to be mounted on the fore end of the servo oil pipe. Add Loctite
242 pos. 80 to 3 screws M4 x 25 pos. 41 and mount them in the servo oil pipe.
15. Now the last component i.e. the aluminium housing with feed back sensor can be
mounted. Mount the O-ring pos. 11 on the aluminium housing. Turn the housing until
the wanted position of the inspection glass pos. 37 is obtained. Reuse the 10 screws
M10 x 35 pos. 12 and tighten them with a wrench.
16. Mount the housing for leak oil sensor pos. 66. Again look at ODF installation drawing.
Plug screw and gasket pos. 63 and 64 to be removed. Special screw M16 x 40 with
ø10mm hole pos. 65 to be tightening.
17. Adapter / cover for leak oil sensor pos. 67 goes into the housing pos. 66, and the 3
screws M3 x 10 pos. 68 to be mounted.
18. Leak oil sensor pos. 401 to be attached into the adapter pos. 67.
19. Tacho sensor pos. 402 has to be mounted. Plug screw pos. 57 to be removed, but keep
gasket pos. 58!
All screws and contact surfaces have to be lubricated with Molycote GN+ paste to
ensure correct initial tension. The tighten up torques is shown in the following table:
Tighten up torques
Screw size M3 M4 M10 M16 M20
Torque [Nm] 1,2 1,6 26 112 200
2010-12-10/HAK
2 05 50 74-7 – Servo system installation, ODF220 Edition 1
1 High pressure hose 1” 2

6 Cap nut 2
7 Nipple G1 / G3/4 2
8 Ball valve 2
Emergency The emergency tool panel to be delivered with the 1

tool items 02, 03, 04, 05, 09, 10, 12, 13, 14, 15 and 16
mounted.
Dimension of panel 340 x 240 x 75 mm
11 Screw, M6 x 12 4

Servo control system

The servo oil system consists of a servo unit From the power pack the hydraulic oil is trans-
and a power pack. The power pack includes mitted to the piston by means of the oil distri-
oil tank, pumps, valves, cooler, filter and butor ring and pipes in the shaft boring.
control equipment.
The servo piston moves the propeller blades
The function of the servo unit is to adjust and to the desired pitch. At the same time the ex-
control the propeller pitch. cess oil is led back to the power pack by
The servo unit is an integrated part of the means of a steel pipe.
end of the propeller hub. Built–on pressure switches and a tempera-
ture sensor provide alarms for low servo oil
The oil distributor is full–floating inside the
pressure, high servo oil temperature and
ODF unit.
control for automatic start–up of the pumps.
Rotation of the distributor is prevented by me-
ans of two nipples connected to the ODF Valves
housing.
All connections to the oil distributor ring Servo
must be flexible, to be able to carry out pumps
emergency operation if necessary.
Valve
2003–03–03
The electrically driven servo oil pumps draw block

oil from the tank via filter to the valve block.
Through the valve block pressure oil is lead to Cooler
the oil distributor ring. The pressure oil flows
to one side of the piston and the oil on the Pressure
filter
other side is returned back to the servo oil
tank. The return oil flows through cooler and Return oil
filter. filter
The servo piston is moved by hydraulic pres-

sure oil, which is supplied from the power Servo oil
tank
pack.
Fig 50.1
Servo piston
2 04 00 22–5.0, AINS
Hub Stern tube Propeller shaft
Propeller and power pack
Release 3 50A2-01 page 50–57

Pitch control system Control system

Fig 50.2 An electrical signal from a lever on one of the
ship’s remote control panels is transmitted
13 12 21 8 7 22
to the control box located on the hydraulic
power pack. In this a PD–controller is lo-
cated – see servo oil diagram.
The controller acts on the proportional valve
item 7 which distributes hydraulic oil to
B
ahead or astern. The controller receives
EP A feed–back signals from the feed–back
ER transducer. The propeller pitch is achieved
by means of the moving servo oil pipe in the
X41 X74
hollow propeller shaft.
For description of control unit and adjust-
ment procedure of electronic parts refer to
page 82–65 .
Hydraulic power pack/servo system
2003–03–03
The hydraulic power pack supplies the
A necessary oil pressure to the servo piston
B through the propeller shaft/servo oil pipe.
ER EP
The power pack is built as a tank unit. It is
25 25 equipped with two pumps.
ASTERN AHEAD
On the servo oil diagram the connections
23 between the different components are
Feed–back shown. From the pump the oil is led to a
transmitter valve block with the valves item 7, 8 and 21.
The maximum system pressure is adjusted
on the valve item 21. The valve is a safety
valve for the system. If the system pressure
increases above the adjusted value the oil is
drained to tank.
The oil is distributed by means of the valve
AINS
item 7 to the servo piston through the pilot

check valves item 23 in the ODF unit.
Power pack & feed–back transmitter
The valve item 7 is equipped with two sole-
The propeller pitch is hydraulically operated. noids controlled electrically by the PD–con-
The system contains two main components. troller in the control box. It is possible to
A hydraulic power pack and a feed–back operate the propeller pitch manually by the
transmitter, see fig 50.2. push buttons on the end of the solenoids.
page 50–58 Release 3 50D2-01

The double check valve item 22 changes Pitch control/feed–back system

position depending on which of the pipes A
In the pitch control system there are one dis-
or B is pressurized. This pressure is trans-
placement transducer with 2 independent
ferred to the valve, item 8 which increases
signals.
the pressure to ahead or astern if needed.
Item 8 must be adjusted during sea trials. One for feed–back signal to the control sys-
tem. The other signal for indication of pro-
From the valve item 8 and gate T on valve 7
peller pitch. The transducer for feed–back
the return oil is led to the cooler.
has first priority. If malfunction occurs on this
The oil is returned through the cooler the re- transducer it is possible to use the trans-
turn valve item 13, and the filter item 12 back ducer for indication as feed–back trans-
to the oil tank. ducer, by changing the wire connections.
Install the power pack near the ODF unit. It
is necessary to extend the EP and ER SAE–
flanges male connectors with pipes. It must
be possible to join the flexible connections
item 25 to the valves at EP and ER.
Before the first operation make sure that
pipes connecting the power pack and the oil
sleeve and extended emergency pipes are
2003–03–03
extremely clean.
Adjustment of solenoid valve:

1. Check that the pumps start and stop
when activating the level alarms and
that the alarms function accordingly.
2. Flush servo oil pipes to the ODF unit.
3. Mount test manometer on valve block.
Connection “A”: ahead
Connection “B”: astern
4. Move the servo piston to max. ahead
and adjust max. servo oil pressure to
60 bar on the safety valve.
5. Dismount the plugs on the valve sole-
noids and adjust the servo idle pres-
sure to 15 bar.
6. Remount plugs and adjust
pressostates 1PSL57 and 2PSL57 for
start of stand–by pumps to 8 bar.
7. Electrical adjustment of closed loop
parameters and zero pitch according
to specifications section 82.
Release 3 50D2-01 page 50–59

Emergency operation
Set the propeller pitch according to the fol- C. Manual operation of the proportional
lowing priority levels: valve located on the hydraulic power
A. Normal operation from levers on remote pack. Refer to page 82–74.
control panels in the ship. D. Emergency setting of propeller pitch.
B. Back up operation from control panel on If it is not possible to control the propeller
the main bridge. pitch according to A, B and C the propeller
pitch can be set for emergency running i.e.
D refer to the next page.
2003–03–03
page 50–60 Release 3 50F2-01

Fig 50.3 Emergency setting of propeller

pitch.
Emergency operation of ODF oil distribution
box. For VBS propellers, in connection with
gearbox front mounted oil distribution box.
1. Stop the servo oil pumps on the hy-
draulic power pack.
2. Dismount the hoses item 1 from the
ODF and remove the cover with nipples
item 2.
3. Remove plug screw item 3 to empty the
Normal operation
ODF housing from oil.
4. Remove cover item 4 to be able to read
the pitch setting.
5. Locate the emergency panel item 5. It
5
consists of two male and female quick
couplings, one nipple carrier and one
double head socket spanner.
2003–03–03
6. Mount the male quick couplings with

nipple item 6. Use the socket spanner.
ER
EP Caution: check that the sealling
rings are fitted in the groove on the
1 nipples.
7. Connect the female quick couplings
item 7 with the hoses.
7
8. Connect the hoses to ER and EP.
2
9. Join the two male and female quick
8
couplings.
6
10. Start one pump on the power pack and
set the propeller pitch, by operating the
4
valves ER/EP, to desired valvue. The
pitch can be read out through the in-
spection glass.
11. Stop the pump.
12. Disconnect the female quick couplings.
The non–return valves in the shaft end
confine the oil in the astern/ahead
AINS _ 2055074–7.1
chamber and lock the servo piston into

3 the set pitch position.
Emergency operation
Release 3 50F2-01 page 50–61

13. Romove one of the male quick coup- does not receive oil for lubrication dur-
lings and replace it with the nipple ing this operation.
carrier item 8. Again use the socket 15. If the propeller pitch changes during a
spanner. Caution: check that the long period of emergency operation it
sealing ring is fitted in the groove on can be necessary to re–pump period-
the nipple. ically. The shaft rotation must be
14. The propeller can now be rotaded. The stopped. Re–join the male and female
oil sleeve rotates with the shaft because quick couplings during pumping.
the nipple carrier acts as driving pin. Remember to disconnect the hoses be-
This is important because the oil sleeve fore rotating the propeller shaft, and
mount the nipple carrier again.
2003–03–03
page 50–62 Release 3 50F2-01

MAN Diesel

Copyright
3P0102 Production & Flushing of hydraulic pipe work 2141332-5

MAN Diesel
A4 VBS - ODS & ODF 1 (4)
2010 MAN Diesel

20090107 KEB KEB 00
20090408 KEB KEB Z4 New template 02
20100201 KEB KEB Z4 Flushing of leak oil return pipe ODF added 03
20100216 KEB KEB Z4 Instruction reference for flushing kit added 04
Production and flushing of hydraulic pipe work
General
In this specification "pipe work" is referred to as the connecting pipe work between
hydraulic power units, tanks and actuators.
The pipe work of the hydraulic system should be regarded as a major component in the
function of the system.
The pipe work must be in accordance with both the actual plant specific "servo oil system –
circuit diagram" as well requirements from the actual classification society.
Production
The hydraulic pipe work can be produced either by prefabrication in the workshop or on-site.
Technical and practical considerations however, often result in a combination of both
methods being employed.
Cleaning and treating after welding
All pipes for the hydraulic system must be cleaned both mechanically and chemically on
completion of manufacture.
If there is a longer period between cleaning and mounting, the pipes must be preserved and
their ends must be closed. Plastic plugs or caps in vivid colours are most suitable for this
purpose !
Finally, the entire pipe work must be thoroughly flushed and pressure tested, before the
servo system is put into operation.
MAN Diesel

Copyright

MAN Diesel
VBS - ODS & ODF 2 (4)
2010 MAN Diesel
A4
Flushing procedure
Hydraulic Power Unit (HPU)
HPU - Return filter

ER EP A B
Flushing Filter
≤ 20 µm
(Yard supply)
ER EP
A B
ODS/ODF
Leak oil return pipe (ODF)

MAN Diesel

Copyright

MAN Diesel
2010 MAN Diesel
A4
1) Yard to prepare servo system / HPU for commissioning i.e. cleaning, preparing of tools,
flushing filters (≤ 20 µm), necessary amount of oil etc.
2) Before filling the HPU with oil, check through the inspection cover, that the tank is
completely free from impurities.
3) Fill the HPU with the specified type of oil through filter.
4) At ODS/ODF connect the EP to B and ER to A using the supply hoses.

5) At HPU disconnect the pipes A and B from the valve block.
6) Blind A and B on valve block.
7) Connect the pipes A and B at HPU.
8) At HPU disconnect the pipe ER and insert flushing filter with check bag (≤ 20 µm).
Optional the HPU build-on return filter can be used, equipped with a MAN flushing kit
(instuction for use of flushing kit, item id. 2151485-1).
9) Start both servo pumps and flush the system. Check bag to be inspected first time
after 30 minutes.
10) Servo system is clean when check bag is free of visible impurities after a flushing
period of minimum 2 hours.
Several 2-hour periods can be expected, depending on actual yard pipe quality.
11) When system is clean, re-establish the servo system. Please observe the cleanliness
of connections at both HPU and ODS/ODF.
IMPORTANT NOTES !
During flushing please observe oil level in HPU as well oil temperature, if necessary
top-up with oil and run cooling pump if oil temperature > 60 °C.
"System clean" must be verified and approved by MAN Diesel commissioning engineer.
MAN Diesel

Copyright

MAN Diesel
2010 MAN Diesel
A4
Special for ODS type propeller – Flushing of "Drain oil tank"

1) Check that drain oil tank is free from impurities.
2) Clean piping by use of a pneumatic projectile gun / compressed air.
Special for ODF type propeller – Flushing of "Leak oil return pipe"
1) Clean leak oil return pipe by use of a pneumatic projectile gun / compressed air.

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MAN Diesel

1.01 General data

1.02 Propeller equipment, VBS1080

1.03 Servo system

Section Description Drawing no. Remarks Init. Date of update

End of Section - Updates

1.01 General data

Drawing ident no Description Part ident no Item Date of

End of Section 1.01 - General data

Addendum 1.01.1 General data

End of General data

 MAN B&W Supply

Info. No.: Item Name: Item Id.:

3P0106 Propeller lub oil spec - common system 2148085-8

Oil types & Viscosity grades

Approved oil types/viscosity grades according to the following tables:

All Continuous Continuous

Biodegradable oil: (emulsifying)

All Continuous Continuous

Info. No.: Item Name: Item Id.:

3P0106 Propeller lub oil spec - common system 2148085-8

Additional important oil properties

 Rust protection acc. to ASTM D665 A&B or similar  Pass

Compatibility, used materials:

 Mineral oils: NBR (Nitrile/Perbunan) 168h at 100°C - DIN 51524-2  Pass

Compatibility, stern tube/shaft seals:

 Oil (stern tube) approved by stern tube/shaft seal manufacturer/supplier  Pass

Info. No.: Item Name: Item Id.:

Oil types & Viscosity grades

Approved oil types/viscosity grades according to the following table:

* IMPORTANT NOTE for selecting biodegradable oil

Before selecting biodegradable oil, HPU compatibility MUST be verified by MAN.

Info. No.: Item Name: Item Id.:

3P0106 Propeller servo oil specification 2148088-3

Additional important oil properties

Minimum requirements for

 Viscosity Index VI acc. to ISO 2909  Pass ≥ 95

Compatibility, used materials:

 Mineral oils: NBR (Nitrile/Perbunan) 168h at 100°C - DIN 51524-2  Pass

Dispatch conditions of propeller equipment Maintenance intervals

Minimum protection during storage must be by

MAN Diesel do however recommend indoor storage

Dispatch conditions of electronic equipment Installation works

Provided the sealing has been properly maintained

The electronic equipment can be put into operation

Info. No.: Item Name: Item Id.:

6P0221 Check list 2145019-7

Date Des. Chk. A.C. Revision Change Chg. Not. Rev.

Check list for commissioning of propeller type

Handling of this checklist:

Request of commissioning personnel:

Contacts at MAN Diesel:

Order Management Department

Info. No.: Item Name: Item Id.:

6P0221 Check list 2145019-7

2. Components: extent of delivery,

Info. No.: Item Name: Item Id.:

6P0221 Check list 2145019-7

Stb propeller ......: Anticlockwise or Clockwise

Port propeller......: Anticlockwise or Clockwise

Tightening:_[Nm] Arc length[mm] or

GAP_[mm] /SAG _[mm]

Voltage_[V] & Frequency___[Hz]

Voltage_[V] & Frequency___[Hz]

Operating pressure _[bar] ___[bar]

Back pressure _[bar] ___[bar]

Operating time _[s] ___[s]

No 1_____[ C] No 2_[ C] No 3_____[ C]

Max Pahead_[bar] & Max Pastern_[bar]

Time 0->ahead_[sec] &Time 0->astern_[sec]

Max Pahead_[bar] & Max Pastern_[bar]

Time 0->ahead_[sec] &Time 0->astern_[sec]

Zero pitch (P7)___ Ahead (P3)_ Astern (P4)_____

Jumper settings W1_ W2 (High/Low)

ODR surface_[ C] Sensor_[ C] (If any)

Intermediate bearing 1___[ C] 2_[ C] 3_____[ C]