VariProp DF-160 User manual

Formular-Nr.:71 Rev.-Nr.:07 03/18 -1-
Manual for the Feathering Propeller
DF-160 and DF-180
Installation on the shaft page 2
Operation page 4
Pitch adjustment LH ( left-hand rotation propeller ) page 5
Pitch adjustment RH ( right-hand rotation propeller) page 6
Defining and checking adjustments page 7
Removing from the shaft page 8
Servicing page 9
Torque settings prop-nut page 10

Formular-Nr.:71 Rev.-Nr.:07 03/18 -2-
INSTALLATION on the shaft
The VARIPROP is delivered assembled, greased and ready for installation.
He may not be disassembled, otherwise the warranty claim goes out!
BLUE FIT CHECK of PROPELLER: The propellers are manufactured to close tolerances and
therefore care must be taken when handling and mounting. Prior to mounting it may be necessary to
check the blue fit of the propeller to guarantee a close fit to taper size. If the blue fit is unsatisfactory
due to temperature differences it may be necessary to ream the propeller to suit. Therefore please use
the grinding paste supplied with the propeller.
It must be noted however that all blue fits will have been 70 to 80% of the taper lenght.
MOUNTING: First slide the prop on the shaft without key. Mark the shaft with a grease-pen at the prop end.
After tightening the shaft nut very strongly ( torque-setting see page10 ) the mark must disappear. If not, the
key is binding and the top or the sides of the key must be filed down. Light must be shining through on the
top of the key when looking into the hub from astern. You may have to move your eye vertically to see it.
Before fitting the VARIPROP onto the shaft, check key
and keyway in the propeller hub. Take care that the key
is the proper dimension and that the hub slides
completely onto the shaft (see below). Also check the
nut on thread of the shaft before fitting the prop. If you
can not screw the nut the complete length of the
thread, because of a little damage to the thread,
carefully use a triangle file to bring it down to a good fit.
Remove the housing cap with zinc anode (2) and the
nut (4). Fit the propeller onto the shaft strongly. Tighten
the nut (4) with LOCTITE low (pink) onto the shaft
( torque-setting see page 10 ) and secure it with the
lock pins (3). Fit the housing cap with anode (2).
Make sure that the propeller is always protected from
electrolytic corrosion by changing the anode (2) latest
every year! May not be necessary in freshwater. After
the VARIPROP has been fitted properly check that the
blades rotate freely from the forward stop to the
reverse stop. The shock absorber function can be felt !
See servicing page 9.
Only two of the three lock-pin holes can
be used, depending on the final position
of the shaft-nut flange ( 3 ).
Carefully align the lock-pins (3) straight. They must go
in easily. If not, try first to tighten the propnut a little
further until they do. If impossible, back off the nut a
little. The lock-pins should be hand tightened only.
If overtightened they may strip.
3

Formular-Nr.:71 Rev.-Nr.:07 03/18 -3-
INSTALLATION on the shaft
ATTACHING THE HOUSING CAP with ZINC-ANODE:
First, insert all three housing cap screws (1, also page 8) loosely, then tighten securely in succession.
Use LOCTITE low (pink) and observe the little washers.
ENGINE DRY TEST:
Please consider that a dry test of the engine MUST NOT be done while the VARIPROP is fitted onto
the shaft ! The VARIPROP needs water pressure on the blades, otherwise the prop could be
damaged !!

Formular-Nr.:71 Rev.-Nr.:07 03/18 -4-
OPERATION
The VARIPROP feathers automatically when the shaft rotation is stopped. After engine start-up and shifting
into gear the blades will engage in either forward or reverse.
THE BEST WAY TO FEATHER THE PROPELLER IN THE SAILPOSITION IS:
VARIPROP sailposition with mechanical gear-box:
 Power at 3 to 4 knots in forward.
 Stop the engine, turn it off and engage the transmission in reverse to stop the freewheeling of the shaft.
Now engage in Neutral again.
VARIPROP sailposition with hydraulic transmission:
 Power at 3 to 4 knots in forward.
 Stop the engine while still engaged in forward. The remaining oil pressure of the transmission will stop
spinning the shaft to feather the blades in the sailposition.
If the propeller is not feathered in the sailposition the shaft will freewheel like with a fixed propeller.
In that case start the engine again and repeat the steps above.
Once the prop is feathered, it is better to shift the transmission to neutral.
DO NOT stop the engine while it turns in reverse. In this case the blades will stay in the reverse position and
will not feather. You can actually use this feature to drive a shaft generator.
Please note that 98% of our delivered VARIPROP propellers for hydrolic gear boxes feather into
sailing position without a shaft lock as you turn off the engine with forward gear still clutched in.
This procedure generates higher oil pressure and prevents shaft rotation. This small-scale friction is
usually enough to feather the propeller instantly into sailing position. If this procedure does not
work, you most likely need to fit a shaft lock. For large yachts, equipped with a propeller from our
VARIPROP XLS range, we highly recommend to fit a shaft lock to ensure the propeller feathers and
stays in sailing position.
TROUBLE SHOOTING: If the propeller does not work in forward or reverse go systematically through the
points below:
 Check low idle of the engine. It should be 800 to 900 rpm in idle.
 Check shifting movement of the transmission lever. Make sure that the shifting travel is
not too short. The amount of lever travel, as measured at the pivot point of the actuating
lever, between the neutral position and end positions for forward and reverse can be found
in the owners manual of your transmission. A larger amount of lever travel is in no
way detrimental.
 Check the clutch discs of the transmission. They could be worn out.
WARNING: It is important to follow the instructions below carefully so as to avoid excessive load and shock
to the gears, shortening their life.
 When going from ahead to astern or the opposite, it is necessary to idle down and shift at low
rpm’s (max.1200rpm) between gears to allow smooth reversing of rotation without binding. This
will substantially lengthen the service life of your propeller gears.
 When going from ahead to astern or the opposite, you can hear the turning-noise of the feathering blades.
This is normal and not a problem or a defect of your VARIPROP.
 The propeller body must always be completely filled with a high viscosity grease. We recommend synthetic
grease typ TW.2 GEL or mineral multi-purpose grease EP/SAL 8 (see servicing page 9 )
 The propeller must be protected from electrolytic corrosion by fitting the usual zinc anodes on the shaft
plus the prop anode. We recommend the replacement of the anode once a year.
 If you want to protect your VARIPROP with Antifouling, use only Antifouling which needs a
primer first. Otherwise chemical interaction and decomposition could occur. Our recommendation is Velox
TF plus including a primer ( offers also protection against electrolyses ), available from your VARIPROP
distributor.

Formular-Nr.:71 Rev.-Nr.:07 03/18 -5-
PITCH ADJUSTMENT „LH“
GERNAL: The pitch adjustment is very simple on the VARIPROP, and can be done in or out of the water in
a matter of few minutes. It is not necessary to pull the propeller from the shaft.
Propeller in the drawing below is for a left hand rotation VARIPROP LH.
NOTE: It is quite possible to set the pitch
continuously variable and independently
for forward and reverse. The turning of the
adjusting screws (2) & (4) by quarter a
revolution (90°) changes the pitch
approx. 1,5“. This will change the engine
revolution by approx. 150.
ATTENTION: Never remove the set
screws of the shock absorber !!
The following description refers to the view towards astern for a left hand VARIPROP.
A. Adjusting the forward pitch: B. Adjusting the reverse pitch:
1. Remove the set screw (1). Use the 4mm Allen- 1. Remove the set screw (3). Use the 4mm Allen-
type key supplied with the prop. type key supplied with the prop.
2. Turn the adjusting screw (2) which is marked as 2. Turn the adjusting screw (4) which is marked as
“AH” or “V” with the 8mm Allen-key as follows: “AS” or “R” with the 8mm Allen-key as follows:
2a. Increasing of pitch approx. 3“ max.: 2a. Increasing of pitch approx. 2“ max.:
- Turn the adjusting screw (2) clockwise. - Turn the adjusting screw (4) anti-clockwise.
( see “NOTE” above and page 7) ( see “NOTE” above and page 7)
- Secure set screw (1) with LOCTITE low (pink) - Secure set screw (3) with LOCTITE low (pink)
Lock set screw strongly. Lock set screw strongly.
2b. Reducing of pitch approx. 2“ max.: 2b. Reducing of pitch approx. 3“ max.:
- Turn the adjusting screw (2) anti-clockwise. - Turn the adjusting screw (4) clockwise.
( see “NOTE” above and page 7). ( see “NOTE” above and page 7).
- Secure set screw (1) with LOCTITE low (pink) - Secure set screw (3) with LOCTITE low (pink).
- Lock set screw strongly. - Lock set screw strongly.
+ +
--
V= AH (Ahead)
R= AS (Astern)
.
adjustment markings
Markings to check
and determine
degree of pitch
ad
j
ustment
Adjusting screws
( 2 & 4 )
Set screws ( 1&3 )
3
4
2
1
Set screws shock
absorber

Formular-Nr.:71 Rev.-Nr.:07 03/18 -6-
PITCH ADJUSTMENT „RH“
GERNAL: The pitch adjustment is very simple on the VARIPROP, and can be done in or out of the water in
a matter of few minutes. It is not necessary to pull the propeller from the shaft.
Propeller in the drawing below is for a right hand rotation RH.
NOTE: It is quite possible to set the pitch
continuously variable and independently
for forward and reverse. The turning of the
adjusting screws (2) & (4) by quarter a
revolution (90°) changes the pitch
approx. 1,5“. This will change the engine
revolution by approx. 150.
ATTENTION: Never remove the set
screws of the shock absorber !!
The following description refers to the view towards astern for a right hand VARIPROP.
A. Adjusting the forward pitch : B. Adjusting the reverse pitch :
1. Remove the set screw (1). Use the 4mm Allen- 1. Remove the set screw (3). Use the 4mm Allen-
type key supplied with the prop. type key supplied with the prop.
2. Turn the adjusting screw (2) which is marked as 2. Turn the adjusting screw (4) which is marked as
“AH” or “V” with the 8mm Allen-key as follows: “AS” or “R” with the 8mm Allen-key as follows:
2a. Increasing of pitch approx. 3“ max.: 2a. Increasing of pitch approx. 2“ max.:
- Turn the adjusting screw (2) clockwise. - Turn the adjusting screw (4) anti-clockwise.
( see “NOTE” above and page 7) ( see “NOTE” above note and page 7)
- Secure set screw (1) with LOCTITE low (pink). - Secure set screw (3) with LOCTITE low (pink).
- Lock set screw strongly. - Lock set screw strongly.
2b. Reducing of pitch approx. 2“ max.: 2b. Reducing of pitch approx. 3“ max.:
- Turn the adjusting screw (2) anti-clockwise. - Turn the adjusting screw (4) clockwise.
( see “NOTE” above and page 7). ( see “NOTE” above and page 7).
- Secure set screw (1) with LOCTITE low (pink). - Secure set screw (3) with LOCTITE low (pink).
- Lock set screw strongly. - Lock set screw strongly.
R= AS (Astern)
V= AH (Ahead)
+ +
--
.
adjustment markings
Markings to check
and determine
degree of pitch
ad
j
ustment
Adjusting screws
( 2 & 4 )
Set screws ( 1&3 )
3
4
1
2
Set screws shock
absorber

Formular-Nr.:71 Rev.-Nr.:07 03/18 -7-
Defining and checking pitch adjustments
It is quite possible to set the pitch continuously variable and independently for forward and reverse. The
turning of the adjusting screws (2) & (4) at pages 5 & 6 by quarter a revolution ( 90° ) changes the pitch
approx. 1,5“.That means a half turn ( 180° ) changes the pitch by 3” etc..
For a check of pitch adjustments there are markings on the hub face under the housing cap.
To return to original factory pitch settings, line up “AH” or “V” resp. “AS” or “R” markings on the hub face.
Example:
check adjustments ahead inner marking has moved
original factory pitch setting pitch has been increased ahead
ahead
check adjustments astern inner marking has moved
original factory pitch setting pitch has been decreased astern
astern
NOTE :
 If the engine does not reach the desired RPM reduce the pitch.
 If the engine exceeds the desired RPM increase the pitch.
 1,5” of pitch reduction / increase results in approx. 150 engine revolutions increase / reduction.
p
lus
minus
markings
line up
markings
lined up

Formular-Nr.:71 Rev.-Nr.:07 03/18 -8-
VARIPROP REMOVAL
The puller system is delivered with the VARIPROP.
The system includes only two parts :
(1) The puller nut and
(2) the hexagonal head bolt
1.) In order to remove the VARIPROP you must first remove the
housing cap with zinc anode.
2.) Remove both lock pins (3) and the prop nut (4, see page 2)
3.) Screw the puller nut completely into the hub
4.) Now screw the hexagonal head bolt into the nut and turn the
bolt against the shaft until the VARIPROP comes off the taper.
Never use a hammer to remove the prop from the taper !
NOTE : Never dismantle the VARIPROP yourselves !!
Disassembly and reassembly require special tools and technical know-how only
available at the factory or their approved service centres.

Formular-Nr.:71 Rev.-Nr.:07 03/18 -9-
SERVICING
The VARIPROP needs to be greased up a minimum of every 2 – 3 years, depending on the engine hours
run, or whenever the boat is hauled. The VARIPROP body should always be completely filled with a high
viscosity grease of a hydrophobic nature. Remove the cap screw (5) and screw in the lubricating nipple
which is supplied with the tools. Remove the “grease out“ screw (6). During filling with grease rotate the
propeller from forward stop to reverse stop to allow the grease to work through the propeller. Stop to pump
when grease comes out at the opened “grease out “ port.
Factory supplied special grease EP/SAL is recommended and available from your VARIPROP distributor.
Avoid regular white grease (sterntube-grease ) !
Shock-absorber: The integrated hydraulic shock-absorber reduces unpleasant operating noises. The pitch
stops are substantially protected against wear. At rotating the blades by hand, you can feel the shock-
absorber function. This “heavy” turning at the absorber area is normal and necessary for the function !
Zinc anode: Make sure that you always keep the zinc anode in good condition. The VARIPROP must be
protected by a lot of zinc, so also use a zinc anode onto the shaft if possible. Use fine sandpaper to clean the
aft of the end boss and the forward face of the Variprop-anode to give the zinc good contact with the
propeller.
Ca
p
- screw
Stop greasing if grease
comes out here!
Tools supplied with your VARIPROP DF-160:
lubrication ni
pp
le
1x Manual
1x puller system
1x allen key 3mm
1x allen key 4mm
1x allen key 6mm
1x allen key 8mm
1x grease nipple G1/4”
1x small plastic bottle
with Loctite low (pink)
6
5

Formular-Nr.:71 Rev.-Nr.:07 03/18 -10-
Torque settings for the prop-nut
( page2, Fig.1, part-no.4 )
Standard – thread Fine - thread
SUBJECT TO TECHNICAL ALTERATIONS; ERRORS and MISPRINTS
M 20 x 2,5
BSW 3 / 4 “ – 10 125 Nm / 95 ft/lb
UNC 3 / 4 “ - 10
M 24 x 3
BSW 1 “ – 8 210 Nm / 155 ft/lb
UNC 1 “ - 8
M 20 x 1,5
BSF 3 / 4 “ – 12 135 Nm / 100 ft/lb
UNC 3 / 4 “ - 16
M 24 x 2
BSF 1 “ – 10 225 Nm / 165 ft/lb
UNF 1 “ - 12
M 30 x 3,5
BSW 1 1/8“ – 7 350 Nm / 255 ft/lb
UNC 1 1/8” - 7
UNC 7 / 8 “ - 9 160 Nm / 115 ft/lb
M 27 x 3 315 Nm / 230 ft/lb
M 30 x 2 430 Nm / 315 ft/lb
M 36 x 3 490 Nm / 360 ft/lb
M 42 x 3 530 Nm / 390 ft/lb
UNC 1 1/2“ - 6 390 Nm / 290 ft/lb
BSW 1 1/4“ - 7
UNC 1 ¼” “- 7 350 Nm / 255 ft/lb