SCHOTTEL SV 1 User manual

en TDO--Ge 1/8
Safety and Enviromental Protection Regulation “SV 1” 3 348/98 1099236
Safety and Environmental Protection Regulation ”SV 1”
Table of Contents
Preliminary remark 2.........................................................
1 Safety regulations 3.........................................................
2 Transport and storage 3.....................................................
Transport 3.................................................................
Storage 4...................................................................
3 Installation, Starting--up and Operation 4.....................................
Installation of SCHOTTEL Products 4..........................................
Starting--up and operation (general) 4..........................................
Starting--up and operation of control systems 5..................................
4 Maintenance and installation 5...............................................
5 Removing the underwater gears of SRP 7....................................
6 Welding 8..................................................................
7 Noise protection 8..........................................................
8 Use of appliances causing noise fields 8.....................................
9 Environmental protection regulations 8......................................

Operating, Mounting and Maintenance Instructions
en
TDO--Ge
2/
8Safety and Enviromental Protection Regulation “SV 1” 3 348/98 1099236
Preliminary remark
These ”Safety and Environmental Protection Regu-
lations” shall provide the operator or technician re-
sponsible for operating, servicing, installing or re-
placing SCHOTTEL products, with information and
assistance. For this purpose, these regulations and
the accompanying operating and installation instruc-
tions must be read, understood and observed.
It must be ensured that the relevant regulations and
instructions are readily available to everyone en-
gaged in operation, maintenance and installation.
We assume no liability for damages and breakdowns
in operation which result from the failure to com-
ply with these regulations and the accompanying
operating and installation instructions.
It is assumed that the user and/or technician is famil-
iar with the product in question and has been
instructed on any possible risks involved.
As SCHOTTEL products are subject to further devel-
opment, we reserve the right to make any technical
alterations.
Where deviations between the German text and the
foreign language text occur for idiomatic reasons, the
German text is authoritative.
The regulations and instructions quoted in this vol-
ume apply within the area of the Federal Republic of
Germany.
In other countries, the statutory provisions applicable
there shall be observed.
Observe protection mark in accordance to DIN 34!
”The passing on or copying of these documents, their
utilization and the disclosure of their contents is pro-
hibited, unless explicitly granted. All acts contrary to
this entitle us to claim for compensation. All rights re-
served in the case of a patent being granted or a de-
sign being registered.
References to pictorial illustrations in the text appear
in brackets.

en TDO--Ge 3/8
Safety and Enviromental Protection Regulation “SV 1” 3 348/98 1099236
1 Safety regulations
The safety regulations must always be used in com-
bination with the relevant operating and installation
instructions.
SCHOTTEL products are to be employed only for the
use stipulated in the delivery cope.
Any use other than this is considered contrary to reg-
ulations. The SCHOTTEL--Werft is not liable for dam-
ages resulting from this. The risk, in this instance, is
borne solely by the user.
The operator or technician is obliged to refuse to
carry out any work on SCHOTTEL products which
does not comply with the regulations.
In the event of a fault, the cause must be established
immediately. If the fault cannot be defined or rectified
in a correct and competent manner, it must be elimi-
nated by qualified personnel.
To prevent accidents caused by slipping, negotiable
parts must be kept free of oil and grease.
In addition to the safety and environmental regula-
tions listed in these provisions, the safety regulations
of the trade association as well as the relevant regu-
lations for the prevention of accidents must be obser-
ved.
2 Transport and storage
Transport
SCHOTTEL products which, due to their weight, can-
not be lifted without the use of auxiliary equipment,
must be fixed to a raising harness only at the lifting
points provided. If necessary, ask about possible lift-
ing points at the SCHOTTEL--Werft.
Both raising harness and hoist must be selected in
accordance to the load to be lifted.
Do not walk or stand below raised loads.
To prevent damage to bearings and gearwheels,
gears must be braced.
Example
The SRP should be braced against the direction of
rotation of operation with a pretension of 5000 to
6000 N (1/1).
Use wooden edge protection for the propeller.
Figure 1
1

Operating, Mounting and Maintenance Instructions
en
TDO--Ge
4/
8Safety and Enviromental Protection Regulation “SV 1” 3 348/98 1099236
Storage
The interior areas of the SCHOTTEL products in
question are preserved, following the trial run on the
test stand. Corrosion protection is sufficient for
approx. 6 months, when stored in dry environments
(no sea climate).
Prior to launching y prior to every intial start--up it is
necessary to top up oil
To this effect it is necessary to observe the different
operating instructions.
If a SCHOTTEL unit is put out of operation or re-
moved due to damage, then the unit must be filled
with fresh oil during the storage period, in order to
prevent damage through corrosion.
When storing in the open and/or with considerable
changes in ambient temperature, pressure relief
must be maintained for oil--filled units, as well as for
empty units (e.g new units).
This means:
In the case of units equipped with a vent valve,
the same be opened.
In case of units equipped with a mushroom--type
vent, pressure compensation is already main-
tained.
In the case of units which are only preas-
sembled, a provisional pressure compensation
device with dust protection must be installed at
a pipe connection.
ATTENTION
The storage of electric components, for instance in-
strument panels, switch cabinets etc. in the open is
prohibited.
3 Installation, Starting--up and Operation
Installation of SCHOTTEL Products
Before commencing installation, check that the
delivery is complete. All parts must be installed
and/or removed in a competent manner.
The installation of SCHOTTEL products requires
that:
Only those personnel who possess sufficient
technical expertise and the required equipment
shall be employed.
The installation proposals of SCHOTTEL--Werft
shall be observed, and/or requested as necess-
ary.
The relevant technical regulations shall be ob-
served.
Regulations of acceptance authorities under pri-
vate law and/or public law shall be complied
with.
Starting--up and operation (general)
The operating instructions of the relevant provisions
must be observed.
Before putting SCHOTTEL products into operation,
a check must be made for obvious defects and to en-
sure that all protection devices (e.g. cover plates) are
installed soundly. Defective units may not be put into
operation.
Units with defective instruments, pilot lamps and/or
control elements may not be put into operation.
The operator must make absolutely sure that no one
is located within the danger zone of the unit before
putting this into operation.
The indicating instruments must be checked for cor-
rect functioning directly after starting--up, if neces-
sary the unit must be switched off again.

en TDO--Ge 5/8
Safety and Enviromental Protection Regulation “SV 1” 3 348/98 1099236
Moving parts must be protected. If necessary, these
protection devices must be fitted subsequently.
Do not refuel in non--ventilated rooms and only when
the engine is switched off.
Smoking is prohibited when refuelling.
Never check fuel level with an open flame.
Combustion engines may only run in rooms where
adequate ventilation is ensured.
Exhaust fumes are highly dangerous!
Never smoke or handle open fire in the vicinity of in-
flammable materials.
Starting--up and operation of control
systems
An emergency stop of the ship is possible at all times;
in the case of twin--propulsion units, both SRP pro-
pulsion units should be swivelled to the outside by
180°.
The speed of the drive engines must be reduced be-
fore starting the control procedures for extreme ma-
noeuvres (if necessary down to idling speed).
4 Maintenance and installation
Only tight--fitting, non--defective tools may be used.
”Worn out” spanners slip.
Maintenance and installation work may only be car-
ried out on units not in operation.
Maintenance and installation work on electrical com-
ponents may only be carried out when the unit is dis-
connected. Pipes and hoses under pressure must
neither be tightened nor slackened.
Screw locking compound, sealing compound, oils,
acids, detergents and preservatives must not come
into contact with skin and eyes.
Should an accident occur however, despite taking all
precautions, then a doctor must be seen immediate-
ly.
Always wear protective glasses when cleaning parts
with compressed air.
Benzine or any other easily inflammable substances
may not be used for cleaning the unit or its compo-
nents. Fuels and other materials required for opera-
tion must be stored only in containers which cannot
be mistaken for drink containers.
The handling of hot oil runs the risk of burning.
Do not heat oil, the oil or the vapors may ignite.
Smoking is prohibited when checking the acid level
of the batteries. Do not check the acid level of the bat-
teries using an open flame. Charge batteries in well--
ventilated rooms only.
The fixing screw must be tightened with the appropri-
ate torque in accordance to design, and secured
against accidental loosening in a suitable manner.
Please observe the relevant operating and installa-
tion instructions.
During maintenance and repair work in the area
of rotary shaft seals and bearing races, these
must not be damaged.
Rotary shaft seals and bearing races must not be
painted over.
Protect them against heat, welding splashes and
abrasion dust, covering them if necessary.

Operating, Mounting and Maintenance Instructions
en
TDO--Ge
6/
8Safety and Enviromental Protection Regulation “SV 1” 3 348/98 1099236
SCHOTTEL products which, due to their weight, can-
not be lifted without the use of auxiliary equipment,
must be fixed to a raising harness only at the lifting
points provided. If necessary, ask about possible lift-
ing points at SCHOTTEL--Werft.
Components to be removed which, due to their
weight, cannot be lifted without the use of auxiliary
equipment, must be supported accordingly and fixed
to the raising harness at the lifting points provided for
this purpose. If necessary, ask about possible lifting
points at SCHOTTEL--Werft. The raising harness
and hoist must be selected in accordance to the load
to be lifted.
Do not walk or stand under raised loads.
Unauthorized conversions and alterations to
SCHOTTEL products are prohibited.
Spare parts and assessories not supplied by the
SCHOTTEL--Werft are also not checked or accepted
by us. The installation and/or use of such parts may,
therefore,have a possible negative influence on the
design features of our products, so that the active
and/or passive safety of these is reduced.
SCHOTTEL--Werft is excluded from any liability
whatsoever for damages resulting from the use of
such parts.
When removing propellers and flanges which have to
be pressed on and off hydraulically, these must be
secured against falling down with the pressure plate
(2/2) specified.
Do not walk or stand in front of the pressure
plate!
Figure 2
2

en TDO--Ge 7/8
Safety and Enviromental Protection Regulation “SV 1” 3 348/98 1099236
5 Removing the underwater gears of SRP
When removing the underwater gear--box, the power
transmission shaft (3/4) may remain in the surface
gear--box and drop down later uncontrolled ! There-
fore, lower underwater gearbox a little and turn the
surface gear--box to and fro at the power inlet (3/3)
until the shaft sinks down to the underwater gear--
box. Remove underwater gear--box together with the
power transmission shaft.
Figure 3
3
4

Operating, Mounting and Maintenance Instructions
en
TDO--Ge
8/
8Safety and Enviromental Protection Regulation “SV 1” 3 348/98 1099236
6 Welding
When carrying out welding work to or in the vicinity
of SCHOTTEL products, the earthing terminal must
be connected directly at the position of welding, so
that no current can flow uncontrolled via bearings,
bevel gears or similar.
7 Noise protection
Units may only be put into operation when all noise
protection facilities have been properly installed and
closed.
In the case of units where operators or mechanics
are exposed to a noise level of ≥85 dB (A), noise
protection must be worn and used.
8 Use of appliances causing noise fields
Use of walkie--talkies, mobile phones as well as other
noise field generating appliances within the immedi-
ate proximity of SCHOTTEL--steering systems may
cause breakdowns, and possibly to the failure of the
electronical steering unit.
Installation of external components into the
SCHOTTEL made steering electronics may cause
system breakdowns. Therefore it is absolutely
necessary to settle details with SCHOTTEL prior to
taking any action.
9 Environmental protection regulations
The relevant environmental protection regulations
must be observed.
Substances causing damage to the environment (i.e.
oils, acids, preservatives and detergents) must be
collected and disposed of in a non--polluting manner;
the relevant laws governing water pollution control
must be complied with.
Used filter cartridges must be collected in a separate
container marked for this purpose and disposed of in
a non--polluting manner.
When carrying out maintenance or assembly work
on products which have to be filled with oil or fuel, the
seals and washers removed should be replaced by
new ones. Following maintenance and assembly
work, the unit and its connections must be checked
for tightness.
Old batteries must be disposed of in a non--polluting
manner.
Before transporting any SCHOTTEL products con-
taining oil, the latter must be drained off first.

en TDO--rg 1/1Preservation Instructions 3 641/02 1104097
Preservation Instructions
The preservation takes place at the manufacturing
plant after the test run or after the assembly of the
component groups resp. and protects the equipment
for a period of 6 months.
Should the equipment not be used before the expira-
tion of this period, the preservation must be repeated
as described below:
SCHOTTEL Rudder propeller / Jet /
Transverse Thrusters
Internal parts:
Fill the gear--box with anti--corrosion oil SHELL oil
S.7294, SAE 30 and crank the power transmitting
parts, to ensure that all internal parts are splashed
with oil. Drain the anti--corrosion oil afterwards.
Steering gear:
Fill the steering gear--box with anti--corrosion oil
SHELL oil S.7294, SAE 30 and crank the steering,
to ensure that all internal parts are splashed with oil.
Drain the anti--corrosion oil afterwards.
SCHOTTEL -- Clutches
BMK 80, K 155, K 305 and K 350:
The clutches must be filled with preservation oil
SHELL oil S.7294, SAE 30 and cranked without load,
to ensure that all internal parts are splashed with oil.
The anti--corrosion oil may be drained off afterwards.
Mechanical clutch:
Cover all open plain parts inside the clutch housing
with preservation oil SHELL oil S.7294, SAE 30. This
must be carried out while the clutch is disengaged. It
must, however, be assured that the friction surfaces
stay free of oil. The clutch must be stored in disen-
gaged condition.
SCHOTTEL Hydraulic Systems
Internal parts:
Flush the system with the ESSO rust preservation
MZ45 and make sure that all internal parts are cove-
red. Perform all control functions without load. Drain
the preservation oil after. Hydraulic cylinders must
generally be stored with the piston completely retrac-
ted.
General
Fitting surfaces and plain parts:
In case of damage to conserved fitting surfaces,
these surfaces must be cleaned with one of the fol-
lowing solvents: paraffin, solvent naphtha, diesel,
wax remover or similar.
The surfaces must subsequently be sprayed or
coated with VALVOLINE TECTYL 846 K--19.
For storage in seaworthy packaging, the complete
system and all loose items must be welded in plastic
foil at the manufacturing plant. If the packaging mate-
rial is damaged, silica gel units must be attached to
the equipment and the packaging material must be
sealed again air tight.
ATTENTION
!
Before the assembly of fitting surfaces or plain parts
it must be assured that all conserved surfaces are
cleaned with one of the following solvents:
e.g.:
-- P a r a f f i n
-- White spirit
-- Diesel
-- Wax remover

en Coating Specifications for Underwater Components Made of Ferrous CastingsMIX−Fr 08/1834 1/21098053
Coating Specifications for Underwater Components Made
of Ferrous Castings
This documentation contains information about coating underwater components. Ferrous cast parts and steel parts
that come into contact with petroleum are coated according to the following standard coating system.
Preparing the Substrate for the Primer Coat
Before coating, the substrate should be prepared according to SCHOTTEL Specification SNQ-602 (cast steel GS)
or SNQ-603 (spheroidal graphite iron GGG and GGG + Ni)
Primer Coat
Material Dry-film thickness ID no.
KO Synthal epoxy primer, grey 2222, chromate-free
(normally applied by supplier of castings)
35 - 45 mm
(according to.
SNQ-602/603)
1034997
Observe before applying top coat:
DRust should be manually removed (ST 3) from shipping and assembly damage according to DIN 55928.
DUse the material listed above and retouch the primer to the specified layer thickness.
NOTE
Before applying the final coat, thoroughly clean parts with HAKU 1025-800 cold degreaser (KLUTHE/ID
no. 1017753), leaving no residue.
Then rinse off the cleaned parts using fresh water.
Always observe applicable technical bulletins and safety data sheets.
When retouching damage to the coating system, ensure that individuals layers are structured the same as intact
surfaces. The HEMPEL system can be used without any modifications as a repair coat on the old KZA or EGA
system, etc.
Final Coat (3 Layers)
Material Dry-film thickness ID no.
1st
HEMPADUR 4514A, black (19990), 2-component cured
epoxy paint*
80 - 100 mm1140424
or
INTERSHIELD KZA 352, black, 2-component cured epoxy
paint
80 - 100 mm1087070
2nd
HEMPADUR 4514A, reddish brown (50630), 2-component
cured epoxy paint*
80 - 100 mm1140425
or
INTERSHIELD KZA 351, red, 2-component cured epoxy
paint
80 - 100 mm1087069
3rd
HEMPADUR 4514A, black (19990), 2-component cured
epoxy paint*
80 - 100 mm1140424
or
INTERSHIELD KZA 352, black, 2-component cured epoxy
paint
80 - 100 mm1087070
* To be used with curing agent 97430 (ID no. 1140426)

enCoating Specifications for Underwater Components Made of Ferrous
Castings
MIX−Fr 109805308/18342/2
Layer thick-
ness
[micron]
Theoretical
spreading rate
Methods of application
Product name
(incl. grade
number)
Sur-
face
[%]
Colour Colour
no.
Wet Dry [m2/l] Brush Airless Recom-
mended
nozzle
orifice
Recom-
mended
nozzle
pressure
[bar]
HEMPADUR
4514A
F/C Black 19990 200 125 4.8 (X) X .019”-
.023” 250
HEMPADUR
4514A
F/C Reddish
brown
50630 200 125 4.8 (X) X .019”-
.023” 250
HEMPADUR
4514A
F/C Black 19990 200 125 4.8 (X) X .019”-
.023” 250
T/U: Touch-up
F/C: Full coat
DLT: Dry-layer
thickness 375 X: Preferred (X): Possible
Recoat Interval with Ventilation N/R = Not recommended
Grade
number
DLT Recoat with
grade number
40 °C30 °C20 °C10 °C0 °C-10 °C
[micron]
min. max. min.
[h]
max.
[days]
min.
[h]
max.
[days]
min.
[h]
max.
[days]
min.
[h]
max.
[days]
min.
[h]
max.
[days]
4514A 125 4514A N/R N/R 4 23 5 30 10 60 22 90 43 90
4514A 125 4514A N/R N/R 4 23 5 30 10 60 22 90 43 90
Product Information
Product Colour
no.
Vo−
lume
so−
lids
Cu−
ring
agent
Mixing ratio Pot life
20 °C
Dry to
touch
20 °C
Flash
point
Thin−
ner
Application notes
min. temp.
[%] [h] [h] [°C] [°C]
HEMPADUR
4514A
Reddish
brown
50630 60 97430 3:1 1 4 25 08450 -10
HEMPADUR
4514A
Black 19990 60 97430 3:1 1 4 25 08450 -10

en Coating Specifications for Underwater Components Made of SteelMIX−Fr 08/1833 1/31098071
Coating Specifications for Underwater Components Made
of Steel
This documentation contains information about coating underwater components. Steel components that come into
contact with petroleum are coated according to the following standard coating system.
Preparing the Substrate for the Primer Coat
The surfaces must be prepared for the paint coat according to DIN 8200 “Abrasive Blasting Technology”.
According to sec. 3.2 of DIN 8200, the surfaces should be treated by either compressed air blasting (sec. 2.1.1) or
centrifugal blasting (sec. 2.2).
The use of liquid carriers or liquid blasting agents is not permitted.
The surfaces must have a degree of cleaning of Sa 2 1/2 according to DIN 55928, part 4.
Primer Coat
Material Dry-film thickness ID no.
PRIMER HEMPADUR 15570 light grey (12430)
mixed according to directions (3:1) with
45 - 50 mm1140428
HEMPEL curing agent 95570 1140430
Layer thick-
ness
[micron]
Theoretical
spreading rate
Methods of application
Product name
(incl. grade
number)
Sur-
face
[%]
Colour Colour
no.
Wet Dry [m2/l] Brush Airless Recom-
mended
nozzle ori-
fice
Recom-
mended
nozzle
pressure
[bar]
HEMPADUR
15570
F/C Reddish
grey
12430 100 50 10.8 (X) X .019”-
.021” 175
Recoat Interval with Ventilation N/R = Not recommended
Grade
number
DLT Recoat with
grade number
40 °C 30 °C 20 °C 10 °C 0 °C -10 °C
[micron]
min. max. min.
[h]
max.
[days]
min.
[h]
max.
[days]
min.
[h]
max.
[days]
min.
[h]
max.
[days]
min.
[h]
max.
[days]
15570 50 4514A N/R N/R 3 23 4 30 7 60 16 90 32 90
Product Information
Product Colour
no.
Vo−
lume
so−
lids
Cu−
ring
agent
Mixing ratio Pot life
20 °C
Dry to
touch
20 °C
Flash
point
Thin−
ner
Application notes
min. temp.
[%] [h] [h] [°C] [°C]
HEMPADUR
15570
12430 54 95570 3:1 2 3 25 08450 -10

enCoating Specifications for Underwater Components Made of SteelMIX−Fr 109807108/18332/3
Observe before applying final coat:
DRust should be manually removed (ST 3) from shipping and assembly damage according to DIN 55928.
DUse the material listed above and retouch the primer to the specified layer thickness.
NOTE
Before applying the final coat, thoroughly clean parts with HAKU 1025-800 cold degreaser (KLUTHE/ID
no. 1017753), leaving no residue.
Then rinse off the cleaned parts using fresh water.
Always observe applicable technical bulletins and safety data sheets.
When retouching damage to the coating system, ensure that individuals layers are structured the same as intact
surfaces. The HEMPEL system can be used without any modifications as a repair coat on the old KZA or EGA
system, etc.
Final Coat (3 Layers)
Material Dry-film thickness ID no.
1st
HEMPADUR 4514A, black (19990), 2-component cured
epoxy paint*
80 - 100 mm1140424
or
INTERSHIELD KZA 352, black, 2-component cured epoxy
paint
80 - 100 mm1087070
2nd
HEMPADUR 4514A, reddish brown (50630), 2-component
cured epoxy paint*
80 - 100 mm1140425
or
INTERSHIELD KZA 351, red, 2-component cured epoxy
paint
80 - 100 mm1087069
3rd
HEMPADUR 4514A, black (19990), 2-component cured
epoxy paint*
80 - 100 mm1140424
or
INTERSHIELD KZA 352, black, 2-component cured epoxy
paint
80 - 100 mm1087070
* To be used with curing agent 97430 (ID no. 1140426)
Layer thick-
ness
[micron]
Theoretical
spreading rate
Methods of application
Product name
(incl. grade
number)
Sur-
face
[%]
Colour Colour
no.
Wet Dry [m2/l] Brush Air-
less
Recom-
mended
nozzle ori-
fice
Recom-
mended
nozzle
pressure
[bar]
HEMPADUR
4514A
F/C Black 19990 200 125 4.8 (X) X .019”-
.023” 250
HEMPADUR
4514A
F/C Reddish
brown
50630 200 125 4.8 (X) X .019”-
.023” 250
HEMPADUR
4514A
F/C Black 19990 200 125 4.8 (X) X .019”-
.023” 250
T/U: Touch-up
F/C: Full coat
DLT: Dry-layer
thickness
375 X: Preferred (X): Possible

en Coating Specifications for Underwater Components Made of SteelMIX−Fr 08/1833 3/31098071
Recoat Interval with Ventilation N/R = Not recommended
Grade
number
DLT Recoat with
grade number
40 °C 30 °C 20 °C 10 °C 0 °C -10 °C
[micron]
min. max. min.
[h]
max.
[days]
min.
[h]
max.
[days]
min.
[h]
max.
[days]
min.
[h]
max.
[days]
min.
[h]
max.
[days]
4514A 125 4514A N/R N/R 4 23 5 30 10 60 22 90 43 90
4514A 125 4514A N/R N/R 4 23 5 30 10 60 22 90 43 90
Product Information
Product Colour
no.
Vo−
lume
so−
lids
Cu−
ring
agent
Mixing ratio Pot life
20 °C
Dry to
touch
20 °C
Flash
point
Thin−
ner
Application notes
min. temp.
[%] [h] [h] [°C] [°C]
HEMPADUR
4514A
Reddish
brown
50630 60 97430 3:1 1 4 25 08450 -10
HEMPADUR
4514A
Black 19990 60 97430 3:1 1 4 25 08450 -10