SCHOTTEL

Schottel Far East (Pte) Ltd. - 23, Gul Drive - Singapore-629471 - Tel. [phone] - Fax [phone]

Email: [e-mail] - [e-mail] - [e-mail]

Business Registration No. 197200803H - GST Reg. No M2-0013869-4

DISMANTLING PROCEDURE SRP 3030 CP

Vessel:

Shipyard: Keppel Singmarine, Singapore

Hull No.: 298

Year completed: 2006

SCHOTTEL unit: 2 x SRP 3030 CP (CW/CW)

SRP serial No: SRP-500030/SRP-500031

Classification: BV I + HULL +MACH TUG

SCHOTTEL reference: 14100393

SFE reference: SFE-10.356

A Documentation Reference

• SCHOTTEL Service Manual 14100393-1

• Drawing 1151745 - SRP 3030 CP

• SCHOTTEL Operating-, Mounting and Maintenance Instructions

B General Remarks

Work Safety

Work Safety and Environmental Safety Rules have to be followed, in particular those applicable to:

• handling of heavy weights

• work with high pressure hydraulics

• welding and hot work procedures

• prevention of oil spills

• work on compressed air systems

• work on AC and DC electrical systems

• safety procedures and precautions with regards to work on rotating equipment such

as shafting, cardan shafts etc., general accident prevention procedures

• SCHOTTEL safety instructions

Workmanship

The standard of workmanship should follow applicable rules, practices and procedures for work on heavy machinery. Proper standards for work on mechanical, electrical, pneumatic and hydraulic systems should be applied.

Please refer always to the relevant technical documentation such as drawings, plans, diagrams, operating, maintenance and service instructions prior to starting the work. Familiarize yourself with the work process on the basis of such documentation. If in doubt, please contact the SCHOTTEL service department for additional information or assistance.

Mark all components in position or record setting prior to removal. Make sure that components can be

re-adjusted or positioned in the original position. Check all components after re-assembly prior to initial operating for proper tightening so that safe operation is ensured.

Tools and materials must be fit for the purpose and - where applicable - should be calibrated, tested and

certified properly. All materials used should meet the required and specified properties and must be either

genuine or equivalent to the original materials.

Personnel assigned to this type of work should be experienced with this type of equipment and should

be skilled and - where applicable - certified to carry out such work.

Spare Parts

Generally, SCHOTTEL recommends strictly the use genuine parts in order to maintain proper function of the system.

This applies in particular to such items like bearings, power transmitting parts, sealings and manufactured

items. All components of the SCHOTTEL drive are carefully selected to meet the design and certification requirements as well as the quality requirements for a marine propulsion system.

Please contact SCHOTTEL for recommendations on spare parts.

Generally, every time components are dismantled, new seals, gasket and O-rings must be applied.

In case of dismantling major components, you may carefully inspect components such as bearings and - if in doubt - replace such components on a pre-caution basis as the unit may not be dismantled for a long period of time.

Propeller shaft and - if required - steering tube seals should be replaced after five years and/or once they are accessible. You should in any case inspect the sealing liners carefully for wear and tear - it is most of the time not sufficient to replace the seals only.

Maintenance

We recommend to monitor the condition of your thruster by periodically carrying out oil analysis right from the beginning of operation. Oil samples may be taken on a 3 monthly basis in the beginning and should be properly

documented.

Particular attention should be paid to water, iron and copper as well as the lubrication characteristics as it may

deteriorate after some time.

Otherwise a basic maintenance plan should be followed for preventive maintenance.

C SCHOTTEL SRP design features

The SCHOTTEL Rudderpropeller SRP 3030 CP is a 360 deg steerable propulsion unit featuring a CP propeller.

The unit offers a compact design incorporating all functions required for vessel propulsion including a

clutch, the steering mechanism and a suitable gear reduction.

The unit consists of the following major components:

• Lower section with lower gearbox, CP propeller and nozzle

• Steering mechanism with steering gear, steering tube, vertical power transmission shaft

• Upper gearbox with header tank and clutch

• Support section with peripherial equipment (hydraulic pumps, steering motors, coolers

and other peripherials)

The support section is permanently welded into the hull so that thrust and other loads applied to the

propulsion unit are transmitted into the hull at an optimum.

The basic technical data can be taken from the SCHOTTEL service manual.

D Dismantling/Removal of Components

D.1 Propeller Blade and Nozzle Removal

CAUTION: If in drydock, position thruster IN ANY CASE so that the propeller is facing towards the BOW

or SECURE thruster in position as it may rotate/flip over!!!!

D.1.1 - Preparation

- boat drydocked, block height approx. 1.2 - 1.5 m

- scaffolding in place

- lifting eyes welded to the hull as required

- suitable chainblocks, straps and lifting devices for propeller blades available

- handgrinder available

- suitable toolset, ratchets, sockets (hex and allen wrenches) available

- pneumatic tools to remove gap fillings

- suitable tank (clean) to drain 6000 l lube oil, transfer pump and hoses

D.1.2 - Procedure/General Description

D.1.2.1 Propeller Blade removal

Reference dwg.

• removal of propeller blades reqruies the unit to be drained of lube oil

• remove locking devices for propeller blades bolts (cut with grinder)

• remove 6 propeller blade bolts

• for re-assembly, replace all O-rings, in particular also the propeller blade seals

and torque bolts properly. Blades must be assembled in the same place as removed

(see marking blade No. 1 - 4 at blade and hub opening)

D.1.2.2 Nozzle Removal

Reference dwg. 1151745 - SRP 3030 CP

Removal of the nozzle should usually been done after removal of the propeller blades.

• support nozzle suitably with chainblocks

• remove bolts Pos. 132

• remove plugs and bolts Pos. 40 - 43

• remove nozzle from lower section of the thruster

• when welding at the nozzle please keep in mind that nozzle has been protected against corrosion

with protection oil from inside

D.2 Lower Section/Lower Gearbox Removal

CAUTION: If in drydock, position thruster IN ANY CASE so that the propeller is facing towards the BOW

or SECURE thruster in position as it may rotate/flip over!!!!

D.2.1 - Preparation

- boat drydocked, block height approx. 1.2 - 1.5 m

- scaffolding in place

- lifting eyes welded to the hull as required

- suitable chainblocks, straps and lifting devices available

- handgrinder available

- suitable toolset, ratchets, sockets (hex and allen wrenches) available

- pneumatic tools to remove gap fillings

- suitable tank (clean) to drain 6000 l lube oil, transfer pump and hoses

D.2.2 - Procedure/General Description

Reference drawing

1151745 - SRP 3030 CP

1145166 - lower gearbox - weight approx.

Removal of the lower section (stem section and lower gearbox) requires removal of the nozzle and

propeller blades (for better accessibility and handling only). Furthermore the unit must be completely drained

of lube oil.

TYPICALLY the lower gearbox is removed after the upper gearbox and the vertical power transmission shaft

is removed. If this is not intended, the vertical power transmission shaft MUST BE SECURED and should - if

possible - remain in place so that it will not slip off the the splined shaft end of the upper gearbox.

The rear gearbox cap has to be opened and removed. The CP feedback cable has to be completely disconnected (inner and outer cable). When removing the gearbox, care has to be taken that the cable does not get damaged. Furthermore, the vertical power transmission shaft will drop with the gearbox. if not so, the shaft

must be secured in any case against dropping.

- remove propeller blades as described under D.1.2.1

- remove nozzle as described under D.1.2.2

- remove aft gearbox cap Pos. 5, dwg. 1145166. Have drums ready as a significant amount of oil

may be inside the cap. Drain and avoid spillage.

- Remove Teleflex cable, inner and outrer cable from gearbox - see detail “U” dwg. 1151745

When removing the gearbox make sure cable does not get damaged

- support lower gearbox suitably

- loosen bolts Pos. 39 dwg 1151745 carefully while supporting the gearbox.

CAUTION: the vertical shaft Pos. 3, dwg. 1151745 is not secured against dropping. SECURE the shaft adequately.

- remove lower gearbox

D.3 Upper Section - Peripherial Equipment

D.3.1 - Preparation

- suitable chainblocks, straps and lifting devices for propeller blades available

- suitable toolset, ratchets, sockets (hex and allen wrenches) available

- pneumatic tools

- tools for oil-hydraulic fitting (SKF annular piston, high pressure pumps etc.)

- suitable tank (clean) to drain lube oil, transfer pump and hoses

D.3.2 - Procedure/General Description

Reference dwg. 1151745 SRP 3030 CP

D.3.2.1 Drive Shaft/Power transmission

• block/prevent engine from starting accidently. Make sure propeller is not trailing.

• open flange connection of aft cardan shaft/intermediate shaft

• open flange connection toward the clutch. Make sure that cardan shaft is secured and handled

properly when removing. Refer to relevant manual.

• remove V-belts for clutch PTO

• remove the clutch drum as a complete assembly. Replace air seal/gromet for re-assembly

• the clutch hub is fitted by oil-hydraulic fit. Safety instructions and procedure for

removal to be observed. Remove hub with high pressure pumps (apply bracket to stop hub when removing)

D.3.2.2 Hydraulic motors

CAUTION: If in drydock, position thruster IN ANY CASE so that the propeller is facing towards the BOW

or SECURE thruster in position as it may rotate/flip over!!!!

• remove all pipe from hydraulic motors

• open hydraulic motor flange (remove Pos. 76-79, detail C-C, dwg. 1151745), remove

motors and planetary gears to the top by pulling the assembly up as a whole

D.3.2.3 Other Peripherial Equipment

• remove remaining piping for oil cooler

• remove air connection at the back of the input shaft (Pos. 148)

• remove cable connections from feedback units for CP and Steering.

Make sure that all power supplies are turned OFF and mark cable properly for later

re-connection.

• remove all cable connection form connection box of SRP. Make sure that all power supplies are turned OFF and mark cable properly for later re-connection.

• if upper gearbox removal is required, removal all cable connection form the upper gearbox.

Make sure that all power supplies are turned OFF and mark cable properly for later re-connection.

• The hydraulic pump aggregate can be removed as a complete unit (SRP upper portion must be drained).

D 4 Upper Gearbox

D.4.1 - Preparation

- suitable chainblocks, straps and lifting devices available

- suitable toolset, ratchets, sockets (hex and allen wrenches) available

- pneumatic tools

- cardan shaft removed

- all other peripherial equipment removed (see item D.3.2)

- gearbox drained below well cover level

- deck opening cut

- crane assistance as required to pull up gearbox

- all cables pipes, hoses etc. removed from upper gearbox

D.4.2 - Procedure/General Description

Reference drawing 1145869 - upper gearbox - weight approx. 5000 kg

• remove bolts Pos. 180, 181 from upper gearbox flange connection

• the upper gearbox can be pulled to the top as a complete assembly

An suitable opening must be cut into the aft deck so that the complete gearbox

can be removed through the opening.

• Make sure that vertical shaft Pos. 3 dwg. 1151745 is secured, remains in place and is not

pulled up with the gearbox. CAUTION: the shaft may drop as it is hanging due to friction in the

splined to the upper gearbox shaft connection only.

D 5 Steering Mechanism, Steering Tube and Vertical Power Transmission Shaft

D.5.1 - Preparation

- Boat drydocked

- suitable chainblocks, straps and lifting devices available

- suitable toolset, ratchets, sockets (hex and allen wrenches) available

- pneumatic tools

- upper gearbox removed

- power transmission shaft Pos. 3 dwg. 1151745 removed (as required)

- all other peripherial equipment removed (see item D.3.2)

- thruster drained (completely or below well cover level)

- deck opening cut

- crane assistance as required to pull up steering gear and lower stem section

- all cables pipes, hoses etc. removed from well cover

D.5.2 - Procedure/General Description

Reference dwg. 1151745 SRP 3030 CP

- remove CP feedback mechanism Pos. 112 - 131, details X and Z dwg. 1151745

- disassemble CP oil supply unit Pos. 50 - 59 as per detail Z dwg. 1151745

through the upper gearbox opening

- remove steering feedback box Pos. 67 - 74 as a complete assembly with the gear drive

- disconnect pipe Pos. 188 - 190 from steering support

- CAUTION: Support stem section Pos. 8/complete lower part of thruster adequately from below prior

to opening flange connection Pos. 44 - dwg. 1151745. Lock stem section IN PLACE.

- Open flange connection Pos. 12 and pull up steering gear assembly (top plate Pos. 9, 4-point

bearing and steering support) as a complete assembly.

- Remove oil pipe connection Pos. 191 - 192 and lower stem section carefully.

E Re-Assembly of Components

In the following, some general hints will be give. Basically the re-assembly process is done in the opposite

order of the disassembly

All seals and O-rings must be replaced with original parts. Suitable sealants must be applied.

Parts shall not be forced into position and must be easily moveable where applicable.

Corresponding checks must be carried out during the assembly process.

Surfaces and environment must be adequately clean and degreased before applying sealants.

Bolts qualities and torques must be adequate and in accordance with the descriptions in the SCHOTTEL

documentation..

Where applicable, it is recommend to test components during the assembly for proper function (e. g. the

oil supply for the CP system might be tested for tightness before continuing the assembly etc.)

If in doubt, contact the SCHOTTEL service department for assistance.

E.1 - Preparation

- Boat drydocked

- suitable chainblocks, straps and lifting devices available

- suitable toolset, ratchets, sockets (hex and allen wrenches) available

- pneumatic tools

- upper/lower geabox overhaul completed

- stering gear mechanism - overhaul completed

- all other peripherial equipment overhauled

- deck opening cut

- crane assistance as required to pull up steering gear and lower stem section

- scaffolding available as required

- oil hydraulic tools and torque wrenches/torquing tools available as required

E.2. - Procedure/General Description

Reference dwg. 1151745 SRP 3030 CP

• Install stem section c/w pipe connections

• Install steering gear assembly with top plate and tigthen flange connection to stem section

• Install lower gearbox - support lower portion

• Install power transmission shaft Pos. 3

• Install CP mechanism - detail Z

• Install upper gearbox

• Install propeller blades/nozzle

• Install clutch (hub to be mounted applying heat, DO NOT USE OIL HYDRAULIC METHOD)

• Install peripherial equipment on top plate

F Re-Commissioning

• Connect all piping, cabling and air supply in accordance with SCHOTTEL diagrams

• Fill up lube oil, hydraulic oil, planetary gears

• Pressure test unit with 0.5 bar sustained over 6 hours (during night, no exposure to sun light)

Check for leaks from outside

• Function test CP mechanism (using electric CP pump)

• Rotate input shaft by hand and check

• Check air supply for correct pressure

• Test alarm points

• Adjust CP feedback

• Adjust steering feedback

• Test Steering for proper function

• Undock vessel

• Test clutch function (w/o running engine)

• Connect shaftline. Observe SCHOTTEL instructions for cardan shaft installation

• Start engine, check steering and CP function

• Carefully engage clutch a number of times at idle speed

• Check lube oil level at upper gearbox/header tank (with clutch engaged) to be correct

• Carefully operate unit during initial re-commissioning

• Check temperatures, noise, vibration level, carry out seatrial and monitor

parameters, function and temperatures permanently/periodically as required

This procedure is a brief description of the dis-assembly process and re-assembly process only.

Processes may vary - depending on the actual situation.

We recommend in any case that the SCHOTTEL Service is contacted in the initial planning stages

and sufficiently prior the dis-assembly to scheduled service personnel and ensure parts availability.

SCHOTTEL Far East - 26.08.2006

SCHOTTEL Far East (Pte) Ltd. - Singapore

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