SMD HT 230BA User manual

Curvetech Technical Manual - Ref : ENG-MAN-1012.HT230BA.03
CURVETECH HT 230BA
HYDRAULIC THRUSTER
TECHNICAL MANUAL
SMD Reference : ENG-MAN-1012.HT230BA.03.doc

Curvetech Technical Manual - Ref : ENG-MAN-1012.HT230BA.03
Issue 3 Confidential and copyright property of Soil Machine Dynamics Limited. All rights reserved.
MANUAL
REVISIONS AND ADDITIONS
DATE ISSUE REVISION MOD NO
February 1997
February 1999
February 2005
1
1
1
-
0
3
-
CN 00473 Page 5.2 - Removal of
Distributor, 5.4 & 5.5 - Sorted
Layout
-

Curvetech Technical Manual - Ref : ENG-MAN-1012.HT230BA.03
Issue 3 Confidential and copyright property of Soil Machine Dynamics Limited. All rights reserved.
CONTENTS
1.0 GENERAL DESCRIPTION
2.0 PERFORMANCE DATA
2.1 Product Specification
2.2 Performance Characteristics
3.0 INSTALLATION
3.1 Thruster Mounting
3.2 Motor Hydraulic Connections
3.3 Bearing Housing Connection
3.4 Thruster Seals
4.0 MAINTENANCE PROCEDURES
4.1 General Maintenance
4.2 Hydraulic Motor
4.3 Bearing Housing
4.4 Storage
5.0 SPARES AND WARRANTY
5.1 Spare Parts
5.2 Service/Returns Procedure
5.3 Damage in Shipment
5.4 Warranty
5.5 Specifications

Curvetech Technical Manual - Ref : ENG-MAN-1012.HT230BA.03
Issue 3 Confidential and copyright property of Soil Machine Dynamics Limited. All rights reserved.
1.0 GENERAL DESCRIPTION
This document describes the installation operation and maintenance of the
HT 230-2 Curvetech Thruster. Curvetech thrusters have been designed to
propel the new generation of high, powered ROV’s, ploughs and similar
underwater platforms. Other thrusters in the SMD Hydrovision Curvetech
range are the HT 500, HTE 380, HTE 300 and HT 230. Please contact
SMD Hydrovision for further information on these products.
The HT 230-2 is fitted with a 230mm diameter high pitch propeller and a
hydraulic motor with a fixed displacement of 9.84 cc/rev.
The low revving, high torque thruster design provides exceptionally high
efficiency and approximately equal forward and reverse thrust. The thruster
is fitted with an integral mounting pedestal, which can be readily interfaced
to the customer’s equipment.

Curvetech Technical Manual - Ref : ENG-MAN-1012.HT230BA.03
Issue 3 Confidential and copyright property of Soil Machine Dynamics Limited. All rights reserved.
2.0 PERFORMANCE DATA
WARNING: ONLY OPERATE THE THRUSTER MOMENTARILY ON
DECK AS THE THRUSTER MAXIMUM RPM WILL BE
EXCEEDED WHEN OPERATED OFF LOAD (IN AIR).
2.1 PRODUCT SPECIFICATION
Refer to drawing HT-230-D-023.
Description : Hydraulic Thruster
Part Number : HT 230-2
Hydraulic Motor Manufacturer : Volvo Hydraulics
Motor Type : F11-10
Displacement : 9.84 cc/rev
Motor Connections : Supply/Return Lines; ¾” BSPP.
Case Drain Connection : Choice from 2 x 3/8” BSPP
Bearing Housing Connection : Choice from 4 x 1/8” BSPP
Hydraulic Oil Type : Mineral Oil, Shell Tellus or
equivalent between 10 and 100
centistokes
Maximum Recommended Bulk : 50° c
Oil Temperature
Pressure : Continuous = 350 bar
Intermittent = 420 bar
Flow : Up to 40 LPM. Typically 28 LPM.
Refer to performance charts in
section 2
Thrust : Forward > 190 Kgf
Reverse > 185 Kgf
Refer to performance chart in
section 2.
Propeller Diameter : 230mm
Dimensions : Refer to drawing HT-230-D-023

Curvetech Technical Manual - Ref : ENG-MAN-1012.HT230BA.03
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Mounting Method : Integrated Pedestal
Weight (air) : 14 Kg
(seawater) : 10 Kg
2.2 PERFORMANCE CHARACTERISTICS
The hydraulic system pressure and available flow determines the thrust
produced by the HT 230-2 thruster. To assist the customer identify the
thrust performance when fitted to his system the attached performance
characteristics are provided.
To identify thrust, calculate the pressure available at the thruster motor
considering all pressure drops in the system. From the graph, read off
thrust at the calculated motor pressure and read off flow at this thrust. This
gives the pressure, thrust and flow operating point of the thruster. As
forward and reverse thrust is approximately equal, this operating point is
valid for both directions of operation.
The performance data provided is for a single thruster operating in open
water at a depth, which eliminates the effect of cavitation. Restriction of the
water flow through the thruster due to the platform frame, buoyancy or other
assemblies will reduce the thrust from the open water thrust data.
Allowance should be made for this derating when designing the system.

Curvetech Technical Manual - Ref : ENG-MAN-1012.HT230BA.03
Issue 3 Confidential and copyright property of Soil Machine Dynamics Limited. All rights reserved.
3.0 INSTALLATION
3.1 THRUSTER MOUNTING
The thruster is mounted off the main pedestal base, please refer to the
attached drawing HT-230-D-023.
The recommended fasteners for the pedestal base mounting are M12 or 2
inch 316 stainless steel bolts washers and nyloc nuts tightened to a torque
of 35 Nm.
Considerable force can be transferred from the thruster, through the
pedestal to the platform mounting brackets and the customer must ensure
bracketry is adequate.
3.2 MOTOR HYDRAULIC CONNECTIONS
A. Direction of Rotation (F11-10 Motor)
When looking into the propeller end of the shaft apply pressure to
port PB for clockwise rotation or pressure to port PA for counter
clockwise rotation.
B. Supply/Return Line Connections
The 2 supply/return line ports designated PA and PB are designed to
mate with a ¾” BSPP fitting.
Suitably pressure rated st/st hydraulic pipe or hydraulic hose can be
used to connect to the motor. If pipe is used considerable care must
be taken in mounting the thruster to ensure vibration etc does not
damage the pipe coupling. Hydraulic hose tails approximately 0.5m
long are more convenient and overcome potential problems with
direct hard piping. The hose should be routed to minimise the water
flow restriction through the thruster. Hydraulic hose will reduce
pressure spikes before they reach the motor and are flexible enough
to allow service and bleeding of the motor and bearing housing by
unbolting the thruster to align it for bleeding without disconnecting
the supply/return lines. This is useful for thrusters fitted in certain
configurations.

Curvetech Technical Manual - Ref : ENG-MAN-1012.HT230BA.03
Issue 3 Confidential and copyright property of Soil Machine Dynamics Limited. All rights reserved.
C. Case Drain Connection
The case drain returns oil which has leaked through the motor
assembly to the motor case. This oil must be returned to tank (LP
reservoir) to ensure the case drain pressure remains below the
motor return line pressure.
A d inch hydraulic hose should be used and connected to a low
position d inch BSPP case drain port on the motor. This hose
should be a minimum of 0.5m long to match the main hoses and
should be similarly routed to minimise water flow restriction through
the thruster.
The standard motor shaft seal can accommodate up to 2.0 bar (29
psi) pressure from the case drain oil to the bearing housing oil and 0
bar pressure from the bearing housing oil to the case drain oil.
Please contact SMD Hydrovision if alternative pressure rating is
required.
The following considerations should be noted.
1. The drain line must be connected in a way, which ensures all
air can be bled from the motor and hose.
2. For installations where the motor shaft is vertically mounted,
the thruster should be bled to remove all air before mounting
the thruster as it is very difficult to remove all air after the
thruster is mounted.
3. There are special considerations associated with the case
drain in multiple motor installations and the following should
be addressed.
The case drains should not be commoned together unless the pipe
is increased in size to take into account the extra flow from the
additional case drains. Negligible back, pressure at the case drain
must be maintained.
Failure to comply introduces the possibility of pressurising a motor
case to a level higher than return port pressure, which may result in
damage of the motor. This could occur, for example, if the motor is
unloaded whilst other motors in the system are functioning normally.

Curvetech Technical Manual - Ref : ENG-MAN-1012.HT230BA.03
Issue 3 Confidential and copyright property of Soil Machine Dynamics Limited. All rights reserved.
3.3 BEARING HOUSING CONNECTION
The bearing housing must be oil filled for lubrication and pressure balance
to the ambient pressure. In order to provide pressure balance with the
ambient pressure the bearing housing oil feed must be connected to a
hydraulic pressure compensator or to the hydraulic system reservoir which
should already be pressure balanced. This results in the bearing housing
pressure being at ambient plus the small pressure (typically 5-15 psi)
generated by the pressure compensator.
As shown in sketch HT 230-D-023, the bearing housing has 4 x 1/8inch
BSPP ports which can be used for the pressure balance connection. The
ports selected for bleed and oil connection will depend on the mounting
configuration of the thruster. It is essential that all air is bled from the
bearing housing prior to operation. This may take say 15 minutes and will
be assisted by hand turning the propeller. The bleed point must be
uppermost to ensure trapped air pockets are not created.
Option 1 is for the bearing housing connection branched from the motor
case drain and option 2 is for the bearing housing separately compensated.
Separate compensation can be either an individual compensator for each
thruster or a single compensator commoned to each thruster bearing
housing.
Option 1 has the advantage of low cost installation and negligible differential
pressure across the motor shaft seal but the disadvantage of contamination
of the main system hydraulics if the propeller shaft seal allows water
ingress.
Option 2 has the advantage of no contamination of the main system
hydraulics if the propeller shaft seal allows water ingress but the
disadvantage of higher installation cost and the possibility of differential
pressures between the motor case drain and the bearing housing which
exceeds the rating of the motor shaft seal. If the motor shaft seal pressure
is exceeded oil will flow between the bearing housing and motor case drain.
This option is favoured by the majority of our customers.
As an aid to inspecting the condition of the bearing housing oil, the
customer may consider fitting either clear hose or a viewing bowl to the line
between the bearing housing and compensator. It is also recommended
that a low level alarm is fitted to the bearing housing compensator.

Curvetech Technical Manual - Ref : ENG-MAN-1012.HT230BA.03
Issue 3 Confidential and copyright property of Soil Machine Dynamics Limited. All rights reserved.
3.4 THRUSTER SEALS
WARNING: ONLY OPERATE THE THRUSTER MOMENTARILY ON
DECK AS THE THRUSTER MAXIMUM RPM WILL BE
EXCEEDED WHEN OPERATED OFF LOAD (IN AIR).
The thruster has rotary seals on the propeller shaft to seal between the
seawater and the bearing housing oil and on the motor shaft to seal
between the bearing housing oil and motor case drain oil.
Static seals are also fitted to the bearing housing ports, the bearing housing
seal retainer, the bearing housing and motor interface, and 2 seals are fitted
within the motor.
The location of seals is shown on the attached F11-10 motor service
manual and the thruster general assembly drawing HT-230-D-024.
The propeller shaft rotating seal arrangement is shown in HT-230-D-024. It
consists of a PTFE seal facing towards the seawater and a nitrile lip seal
facing towards the bearing housing oil. The seals are mounted back to
back and run on the same seal ring mounted on the shaft. This provides a
pressure rating of 2.5 bar (36 psi) from bearing housing to seawater and 10
bar (145 psi) from seawater to bearing housing.
Important - The void between the 2 back to back seals must be completely
filled with grease to ensure no air is trapped between the seals.
The motor shaft seal consists of a single lip seal with backing ring which
can accommodate zero pressure from the bearing housing to the motor
case drain and 2 bar (59 psi) pressure from the motor case drain to the
bearing housing.
A 15 bar (217 psi) high, pressure seal is available as an option. Contact
SMD Hydrovision for details.
Refer to section 4 for guidance on changing seals.

Curvetech Technical Manual - Ref : ENG-MAN-1012.HT230BA.03
Issue 3 Confidential and copyright property of Soil Machine Dynamics Limited. All rights reserved.
4.0 MAINTENANCE PROCEDURES
4.1 GENERAL MAINTENANCE
Inspection of the condition of the thruster should be performed between
each deployment of the system. The following should be considered in
association with the customers standard inspection procedures.
1. Pedestal fixing to the frame
2. Fatigue of bracketry
3. Thruster fasteners secure
4. Damage to hoses/piping
5. Leaks/damage to hydraulic fittings
6. Compensator oil level
7. Physical damage to propeller, nozzle, etc
8. Leaks at seals
9. Excessive noise during operational test
10. Ensure all air is bled from the motor and bearing housing
11. Propeller shaft play
12. Damage to protective coatings
4.2 HYDRAULIC MOTOR
Except for replacement of the thruster motor shaft seal, maintenance and
repair by the customer is not recommended. A faulty unit should be
returned to SMD Hydrovision as advised in section 5.2.
A torque of 45 Nm should be applied to the motor fasteners.
4.3 BEARING HOUSING
Maintenance tasks on the bearing housing can be grouped into the
following.
A. Replace the Bearing Housing Shaft Seal
B. Replace the Bearing Housing Seals and Seal Ring

Curvetech Technical Manual - Ref : ENG-MAN-1012.HT230BA.03
Issue 3 Confidential and copyright property of Soil Machine Dynamics Limited. All rights reserved.
C. Replace Bearings Mounted in the Bearing Housing.
Bearing Life : The bearing system is designed for in excess of
20,000 hours of continual operation. Water
ingress, contamination and external mechanical
force on the shaft can significantly reduce this
life. It is suggested all bearings are replaced
after 4000 hours of operation.
Shaft Seal Life : It is recommended the shaft seals and seal
wear ring are replaced after 1000 hours of
operation. The seal ring is part of the shaft
assembly but is identified in the parts list under
consumable spares and tools.
Note : Thrusters fitted with standard seals will require
a replacement seal retainer (item 7) to allow
fitting of the high performance seals.
A. BEARING HOUSING SHAFT SEAL REPLACEMENT
The replacement of bearing housing shaft seals only requiring KT
3002-2V seals can typically be implemented with the thruster
mounted on the vehicle. If the seal wear ring is to be replaced go to
the next procedure ‘BEARING HOUSING SEALS AND SEAL RING
REPLACEMENT’.
" Refer to drawings HT-000-D-001 and HT-230-D-024.
" Remove the propeller cap and fixing nut. Items 18, 34, 6, 21,
22.
" Using the propeller puller bar (tools 1 and 2) draw the
propeller (8) from the shaft (28) and remove the key (32).
" Verify the bearing housing compensator has been drained.
" Remove the seal retainer (7) by removing the screws (18, 34)
and jacking the seal retainer from the bearing housing using
the screws (18) in the threaded holes of the seal retainer.
" Inspect the seal ring (5) for wear. If grooves have formed on
the ring it is recommended the seal ring is replaced as
described in procedure ‘BEARING HOUSING SEALS AND
SEAL RING REPLACEMENT’ attached.
" If the seal ring is not worn take items 61, 62, 13, 7 to a work
bench to replace the seals and refer to HT-000-D-001 Sheet
2.

Curvetech Technical Manual - Ref : ENG-MAN-1012.HT230BA.03
Issue 3 Confidential and copyright property of Soil Machine Dynamics Limited. All rights reserved.
" STEP 1: Hold seal ring lightly in a vice and tap out old seals
using a soft hammer and tool 3. Remove old hydraulic
sealant and other residue.
" STEP 2: Lightly smear hydraulic sealant on the outer ring of
the PTFE seal (62) and the seal mounting area of the seal
retainer. Using the insertion tool (tool 3) and a vice push the
PTFE seal (62) correctly orientated fully into the seal retainer.
Remove excess hydraulic sealant with a clean cloth.
" STEP 3: Pack the back face of the PTFE seal with a
seawater resistant grease (typically Advanced Lubrication
SW2 grease). Ensure all air pockets removed.
" STEP 4: Push the lip seal (61) correctly orientated against the
PTFE seal as shown. Use the tool (tool 3) and a vice to push
the lip seal fully home against the PTFE seal.
" Remove excess grease with a clean cloth and smear extra
grease to fill all voids on the inner face of both seals. Ensure
adequate grease so no air pockets will remain when the seals
are pushed onto the shaft seal ring.
" Replace ‘O’ ring (13) fitted to the seal retainer and return to
the thruster.
" Gently align the screw holes of the seal retainer with the
bearing housing threads and evenly push the lip seal onto the
seal ring.
" Fit the washers and screws (34, 18) and evenly screw the
seal retainer to the bearing housing as shown in drawing HT-
230-D-024.
" Replace the propeller key (32) and propeller (8) and the
washer (22) and nut (21).
" Replace the propeller cap (6, 34, 18).
" Ensure the following:
— Fasteners Torque: Nm lb fft
Item 18, 37 5 = 4
Item 25 34 = 25
Item 19 34 = 25
Item 21 280 = 206
Item 20 6 = 4.5
Pedestal Mounting Bolts 55 = 40

Curvetech Technical Manual - Ref : ENG-MAN-1012.HT230BA.03
Issue 3 Confidential and copyright property of Soil Machine Dynamics Limited. All rights reserved.
— Complete thruster assembly is mechanically secure
and shaft rotation is satisfactory.
B. BEARING HOUSING SEALS AND SEAL RING REPLACEMENT
For replacement of the seal ring it is advised the thruster bearing
housing be removed from the thruster pedestal for maintenance in
the workshop. If the motor is connected using flexible hose the motor
can be left connected to the vehicle if desired.
" Refer to the drawings attached.
" Remove the propeller cap and fixing nut. Items (18, 34, 6,
21, 22).
" Using the propeller puller bar (tools 1 and 2) draw the
propeller (8) from the shaft (28) and remove the key (32).
" Verify the bearing housing compensator has been drained
and disconnect the hose connection to the bearing housing.
" If the motor is to stay attached to the vehicle, remove the
screws and nuts (19, 42, 40) holding the motor to the bearing
housing.
" Pull the motor (11) apart from the bearing housing assembly
(29) and remove the ‘O’ ring (12).
" If the motor is to be left attached to the bearing housing, note
the orientation of the motor PA and PB inlet ports and mark
hoses and ports for reconnection. Drain the main system
compensator before disconnecting the main and case drain
hoses.
" Remove the bearing housing assembly (29) from the pedestal
(9). Remove items (24, 23, 25).
" Slide the bearing housing assembly up and out of the
pedestal and take the assembly to the maintenance
workshop.
" Remove the seal retainer (7) by removing the screws (18,34)
and jacking the seal retainer from the bearing housing using
the screws (18) in the threaded holes of the seal retainer.
Seal Replacement
" STEP 1: Hold seal ring lightly in a vice and tap out old seals
using a soft hammer and tool 3. Remove old hydraulic
sealant and other residue.

Curvetech Technical Manual - Ref : ENG-MAN-1012.HT230BA.03
Issue 3 Confidential and copyright property of Soil Machine Dynamics Limited. All rights reserved.
" STEP 2: Lightly smear hydraulic sealant on the outer ring of
the PTFE seal (62) and the seal mounting area of the seal
retainer. Using the insertion tool (tool 3) and a vice push the
PTFE seal (62) correctly orientated fully into the seal retainer.
Remove excess hydraulic sealant with a clean cloth.
" STEP 3: Pack the back face of the PTFE seal with a
seawater resistant grease (typically Advanced Lubrication
SW2 grease). Ensure all air pockets removed.
" STEP 4: Push the lip seal (61) correctly orientated against the
PTFE seal as shown. Use the tool (tool 3) and a vice to push
the lip seal fully home against the PTFE seal.
" Remove excess grease with a clean cloth and smear extra
grease to fill all voids on the inner face of both seals. Ensure
adequate grease so no air pockets will remain when the seals
are pushed onto the shaft seal ring.
" Replace ‘O’ ring (13) fitted to the seal retainer.
Shaft Wear Ring Replacement
" If the motor is attached, remove screws and nuts (19, 42, 40)
and pull the motor (11) apart from the bearing housing
assembly (29) and remove the ‘O’ ring (12)
" Remove the rear bearing retainer (37, 34, 3) by using the
screws in the threaded holes in the bearing retainer to jack if
off the bearing housing.
" Pull the shaft out from the rear of the bearing housing and
remove the thrust washer and roller bearing (41).
" Take the shaft and slide the collar retainer (tool 5) over the
seal ring (5). Fit the seal ring removal collars (tool 4) to the
seal ring with the lip engaged between the seal ring and the
adjacent bearing inner ring. Slide the collar retainer over the
removal collars.
Using the seal ring puller (tool 8) pull the seal ring off by placing the
puller legs behind the collar retainer and the jacking screw against
the propeller end of the shaft.
" Clean the shaft thoroughly and degrease to remove all
sealant or other residue from the area of the seal ring.
Apply LOCTITE 601 or equivalent retaining compound to the

Curvetech Technical Manual - Ref : ENG-MAN-1012.HT230BA.03
Issue 3 Confidential and copyright property of Soil Machine Dynamics Limited. All rights reserved.
shaft where the seal ring will fit.
" Fit the seal ring insertion collars (tool 6) to the new seal ring
(5) and slide the collar retainer (tool 5) over the insertion
collars.
" Slide the new seal ring and tools onto the taper end of the
shaft.
" VERIFY NEW SEAL RING (5) ORIENTATION IS CORRECT
WITH LARGEST CHAMFER AT THE PROPELLER END OF
THE SHAFT.
" Fit the spline peg (tool 7) to the spline of the shaft.
" Fit the seal ring puller legs behind the collar retainer and
position the puller screw against the shaft spline peg.
" Draw the new seal ring up the shaft using the puller ensuring
the seal ring moves evenly on the shaft until the seal ring
butts against the bearing inner ring.
" Remove all tools from the shaft, clean all residue and inspect
the new assembly.
Reassembly
Ensure the following during assembly, which is the reverse of the
disassembly procedure.
New ‘O’ rings (12, 13) fitted
No air is trapped in the area between the 2 shaft seals and the seal
ring.
Fasteners Torque : Nm lb fft
Item 18, 37 5 = 4
Item 25 34 = 25
Item 19 34 = 25
Item 21 280 = 206
Item 20 6 = 4.5
Pedestal Mounting Bolts 55 = 40
Complete thruster assembly is mechanically secure and shaft
rotation is satisfactory.

Curvetech Technical Manual - Ref : ENG-MAN-1012.HT230BA.03
Issue 3 Confidential and copyright property of Soil Machine Dynamics Limited. All rights reserved.
C. Replace Thruster Bearings
Refer to drawing HT-230-D-024.
It is recommended that a bearing housing with worn or corroded
bearings should be replaced with a new bearing housing assembly
and the old unit returned to SMD Hydrovision for refurbishment.
If it is impractical to return the assembly the customers engineering
workshop should replace the bearings considering the following:
" Manufacture suitable removal and insertion tools for use with
a hand or hydraulic press.
" Ensure the housing and shaft are cleaned prior to fitting new
bearing rings/bearings.
" Install bearings with a suitable bearing fit compound.
4.4 STORAGE
Thrusters are shipped assuming they will be fitted to a system within 12
weeks. This assumes no extraordinary storage conditions as no special
precautions are taken for long term storage.
If the thruster is to be stored for longer than 12 weeks, the customer should
fill the motor and bearing housing with hydraulic oil. The propeller should
be rotated by hand every month. If the thruster is stored for more than 12
months it is advised the rotary seals be replaced prior to operation.