Technical Information & Installation Instructions

Transcription

1 Technical Information & Installation Instructions For Thrust Bearings HDL 680, HDL 700(HT) & HDL 780(HT) CV shafts CV42 & CV60 Svenska Uni-Cardan AB P. O. Box 3100, SE Skärholmen SWEDEN A member of GKN Automotive Driveline Division

2 Contents General information 3 Selecting correct Aquadrive shaft system 3-6 Aquadrive with thrust bearing assemblies 4 Aquadrive without thrust bearing 5 Torsional vibration analysis 6 Adapters for output and sterndrive input couplings 6 Installation of the thrust bearing 7-10 Dimensions of the thrust bearing support plate 7 Positioning the thrust bearing support plate 8 Laser alignment 8 Ensure the propeller shaft is straight 8-9 Installation of the thrust bearing assemblies HDL 680, HDL 700 & HDL Installation of the CV drive shaft Installation angles of Aquadrive CV42 (HDL 600) and CV60 (HDL 700) 10 Compound angle graph 10 Aquadrive CV shaft V-length 10 Measuring the CV shaft installation lengths 12 Aquadrive CV joint pivot points 12 Checking the Aquadrive CV joint angles 13 Fixed angle jig 13 Variable angle jig 14 Installing the Aquadrive CV shaft 14 Installation of the propeller shaft 15 Thrust bearing units with clamp coupling 15 Tightening the clamp coupling bolts 15 Corrosion protection 15 Service and Maintenance 15 Running in Aquadrive installations 16 General data 16 Torque settings for high tensile stainless bolts 16 Torque settings for stainless bolts in rubber mounts 16 Thrust bearing Max RPM / Max static torque 16 2

3 AQUADRIVE SMOOTHER, QUIETER WITH TOTAL VERSATILITY. Heavy duty Aquadrive thrust bearing. Aquadrive CV shaft Thrust bearing support plate Gearbox adapter Aquadrive resilient engine mount General information The Aquadrive system is well proven and has been developed over 20 years in order to reduce noise and vibration being transmitted through the structure and into the craft. The constant velocity joint at the ends of each unit isolate the engine vibrations from the rigidly mounted propeller shaft and allow the engine to be suspended on extra soft Aquadrive resilient mounts. A further advantage of the Aquadrive system is that the constant velocity joints (CV joints) accommodate a certain amount of misalignment between the engine/gearbox output coupling and the propeller shaft. Unlike conventional universal joints, the angle of misalignment does not have to be equal at each CV joint, (joint angles are restricted by the power being transmitted and the maximum shaft speed). We will be pleased to advise on maximum joint angles for your particular application. This ability to absorb misalignment can enable a simpler installation to be achieved by avoiding the need for precise engine alignment when using the Aquadrive system in a conventional straight installation. The designer also has greater freedom to install the engine in a lower position to reduce the vertical center of gravity and minimize the space taken up by the engine compartment. Selecting correct Aquadrive shaft system In addition to the following information, please refer to our product brochure which lists the full range of units available together with design details for selecting an Aquadrive suitable for your particular installation. Machined adapters can be provided to enable the Aquadrive shafts to be connected to the output coupling of the engine/gearbox and the input coupling of sterndrives, jets or V drive / U drive gear boxes. Your Aquadrive distributor provide a technical telephone or advice service and will be pleased to answer your questions and help you select the correct Aquadrive shaft system. The drawings shown in this installation manual are for general guidance only. On request, we can provide separate detailed drawings of any of the Aquadrive units. 3

4 Aquadrive with thrust bearing assemblies These units are for installing between a conventional propeller shaft and gearbox output coupling. They comprise an Aquadrive shaft and thrust bearing assembly. For the majority of installations, the propeller shaft is connected directly into the back of the thrust bearing assembly, using the machined clamp coupling provided. (These are supplied already machined for the majority of metric or British shaft diameters up to 70mm). For larger installations, or where it is necessary to be able to end for end shafts with machined tapers, flanged thrust bearing assemblies for connection to the propeller shaft half coupling can be provided. The thrust bearing housing is resiliently mounted onto a support plate constructed between the engine beds. This support plate must be strong and rigid enough to absorb the maximum loading that can be expected without any flexure or movement. STRAIGHT INSTALLATION ANGLED INSTALLATION Joint angles subject to engine power and shaft RPM. Thrust bearing support plate Thrust bearing resilient mounts Heavy duty Aquadrive thrust bearing Aquadrive shaft Gearbox adapter 4

5 Aquadrive shafts without thrust bearing Aquadrive shafts units can be supplied separately without the thrust bearing assembly for installation between engine/gearbox output coupling and sterndrive jet unit V drive U drive, etc. The exploded view of an Aquadrive constant velocity joint is for information only. We recommend that units are returned to your local distributor when servicing is required. 5

6 Torsional vibration analysis When Aquadrive units are being installed into an existing vessel, it is often not practical to have a T.V.A (Torsional Vibration Analysis) carried out since the mass elastic data of the driveline is not available. However, as with any shaft system being built into a new boat a T.V analysis is generally recommended. Normally the yacht or boat builder will arrange for this T.V.A to be carried out since he has the full installation data required. On request we will be pleased to provide all necessary information and mass elastic data regarding our Aquadrive assemblies. Your distributor can advise individual customers regarding the need for such analysis and can offer assistance when required. Adapters for output and sterndrive input couplings It will be necessary to fit adapter plates to all couplings. We can provide suitable adapters machined to fit standard gearbox output flanges and standard input flanges on many sterndrives, jets, V drives and U drives. Alternatively, we can supply adapters to suit your special requirements, machined to dimensions provided by the designer or installer. Aquadrive alloy steel adapters should be handled with care. Damages on the coating of lacquer may lead to reduced corrosion protection. When installing the adapters, always check the fit of the piloting recess before assembly. If the adapter is supplied with threaded studs, these must be removed to check the face to face pilot fit. The piloting spigot should fit the recess neatly without movement, but on no account should be so tight as to require the adapter being forced onto the coupling face. All fasteners supplied are high tensile quality. Exposed bolts and nuts are stainless. Additional fasteners supplied by the boat yard or installer should be of the same quality. All bolts should be tightened to the settings tabled at the back of these instructions and secured with thread locking liquid where appropriate. M16 cap headed bolts require a heavy duty allen key adapter to enable them to be tightened to the proper setting. 6

7 Dimensions of the thrust bearing support plate Aquadrive thrust bearing units are not supplied with a support plate since no two boats are the same. This support plate must be provided by the boat yard or installer. The material used will depend on the hull structure material. Preferably, it should be made of blasted and dry-galvanized steel. This gives an excellent durability and adherence if the plate is glassedin with GRP-layers. Other examples of possible materials are marine playwood, encapsulated in multiple layers of GRP or thick aluminum plate. The important point is that the support plate must be capable of taking the full propeller thrust with adequate safety margins for shock loading and must be rigid enough not to flex at full power. Model A B C D E Model A B C D E HDL680 mm HDL780 mm HDL / / / / / 8 HDL / / / / / 32 inch HDL700 mm HDL / / / / / 8 inch inch 7

8 Positioning the thrust bearing support plate This strong plate has to be able to take the full thrust of the propeller without flexing. It also has to be positioned accurately and transverse to the propeller shaft, to provide for good alignment before assembling the thrust bearing unit. When positioning the thrust bearing and supporting plate, it s critical to ensure that the available space for the CV shaft corresponds to the correct V length, allowing for the required plunge movement within the constant velocity joints. (See section on measuring the V lengths of the Aquadrive). The thrust bearing unit fits behind the supporting plate and pushes against it with the thrust of the propeller. (i.e. it goes on the aft side of the plate). When finally securing the support plate using the thrust bearing assembly, it is recommended to replace the rubber bushings with solid steel alignment bushings to prevent the unit or assembly from moving or sagging. On completion of the work, the steel bushings are replaced with the original resilient rubber mounts. The way that the thrust bearing support plate is positioned and mounted into the vessel will depend on the type and construction of the craft. It will also depend on whether it is being assembled into a new build installation or being retrofitted into an existing boat. The following methods of positioning the supporting plate are suggested for guidance only. Laser alignment The support plate can be positioned very accurately using laser alignment equipment. The technique would require two rigid extension brackets to be bolted transversely to the faces either side of the support plate. Each bracket would hold a laser target. The laser would be fired through targets supported in the P brackets and/or stern tube and the support plate adjusted until the computerized readout indicate that all targets were inline. The extension brackets on the support plate are required to give sufficient separation between the two targets. If you wish to use this method of positioning the support plate, we recommend you employ the services of a specialist laser alignment company. Ensure the propeller shaft is straight For correct installation it is essential to ensure the propeller shaft is straight. Position two V blocks or rollers at the propeller shaft bearing points and measure with a clock gauge or dial indicator at the coupling position. It s also advisable to check just forward of the propeller taper, particularly with an existing shaft, to ensure the shaft is running true and so avoid vibration due to a bent shaft. 8

9 9

10 Installation of the bearing assemblies HDL 680, HDL 700 & HDL 780 These units use resilient mounting bushings that compress to the required setting when the mounting bolts are tightened to the correct torque setting. (See table of bolt diameters at back of instructions). After tightening, check that the bushings compress equally. Installation angles of Aquadrive CV shafts CV 42 (HDL 600) & CV 60 (HDL 700) Aquadrive can be installed straight in line or with the constant velocity joints running at angles within certain permitted limits. Max recommended angles are dependent on the power being transmitted and the maximum shaft speed. It is important that neither joint exceeds its maximum permitted angle. While there is no need to run the two joints at equal angles, it will obviously prolong the life of the CV joints to do so. The ability of an Aquadrive CV shaft to run at different joint angles can be very useful. Particularly, this applies when assembling into a normal in line installation, since it allows the unit to be installed without the usual need for precise engine alignment. Your distributor will advice on permitted joint angles dependent on the power being transmitted and the shaft speed. The following information is provided as a guide for equal angle installations. For applications with data beyond the table below, please contact your distributor for advice. The r.p.m. values below refer to shaft speed after given gearbox reduction and not the engine speed. Aquadrive CV shafts RPM / Max deflection per joint. CV 42 (HDL 600) CV60 (HDL 700) rpm 8.0 degrees 4.0 degrees rpm 6.0 degrees 3.5 degrees rpm 5.0 degrees 3.0 degrees rpm 4.0 degrees 2.5 degrees rpm 3.0 degrees 2.0 degrees The Aquadrive CV shafts can also run with a compound angle where the joint angle are in a different plane to one another. i.e. the gearbox output flange and shaft are misaligned horizontally as well as vertically. The above table of joint angles still applies providing that the effective compound angle is used. The effective compound angle can be calculated from the following graph when the installation is misaligned both vertically and horizontally. The accurate formula for calculating the compound angle is: ß comp = arc tan[ tan 2 (ß hor ) + tan 2 (ß ver )] 10

11 Compound angle graph EXAMPLE: Vertical angle = 6 degrees Horizontal angle = 4 degrees Effective Compound angle of joint = approx. 7 degrees. Aquadrive CV shaft V-length Aquadrive CV shafts can be supplied at a short standard length, or can be custom-made to suit your particular requirements of extended length. Such custom-made tubular CV shafts should only be assembled and balanced by approved and authorized companies. Every tubular CV shaft is supplied fully balanced and has a small balancing plate spot welded onto the side of the main shaft tube. It is important that this balancing plate is not removed or disturbed. The V- length, ( V is for vital). Whether the CV shaft is one of our standard lengths, or custom made to suit your requirements, it is vital that they have sufficient plunge movement within the joints and installed in the center of this movement. This plunge movement is to allow the engine to vibrate backwards and forwards on its soft mounts and for the thrust bearing to move forward on its resilient bushings. The V- length is the measurements from the adapter face coupled to the output flange of the gearbox and the input flange of the thrust bearing (alternatively sterndrive / jet / V-drive etc., with adapter mounted). Each series of CV shaft does have a small assembly tolerance, which is shown below. This must not be exceeded and it is vital to ensure that the plunge movement is maintained. Aquadrive CV shaft standard V-lengths (minimum operation lengths). Aquadriveshaft Minimum V-length Assembly tolerance CV 42 (HDL 600) 270 mm / 10 5 /8 ± 3 mm / ± 1 /8 CV 60 (HDL 700) 370 mm / 14 9 /16 ± 3 mm / ± 1 /8 11

12 Measuring the CV shaft installation lengths On a perfectly true inline installation, it would be possible to take the one simple dimension between adapter and thrust bearing, or adapter and adapter. However, in practice it is always best to take four length dimensions at degrees around the flanges and then divide the sum of these dimensions by four. This calculated intallation V-length dimension allows for angular misalignment of the flanges and has to meet the CV shaft V-length (within the ±3 mm (±1/8 ) tolerance). CV shafts without end caps: V-length measurements are taken between flange faces including the 2 mm (5/64") recesses. CV shafts with end caps: V-length measurements are taken between flange faces excluding pilot recesses. V length= A+B+C+D 4 Aquadrive CV joint pivot points The Aquadrive CV joints pivot as shown below. The pivot point distance for: CV 42 (HDL 600)=28,4mm (1 1 / 8 ) CV 60 (HDL 700) =40 mm (1 37 / 64 ). 12

13 Checking the Aquadrive CV joint angles For checking installations transmitting relatively small horse power with modest joint angles, it is acceptable to use straight edges to ensure the joints are in line sideways and that the crossing point is approximately equal between the two joints. The joint angle can be checked with a bevel gauge. For the larger angles it is good working practice to use a jig to accurately determine the angles of each joint. We will be pleased to advise if a jig is recommended dependent upon parameters of the particular installation. CAUTION! Do not exceed angle limits for a single joint Uneven distribution= reduced life Even distribution= optimum life (Note! angles are exaggerated.) Fixed jig Fabricated at correct V length. Flat on flange for spirit level. Remove T bar and jig can be compressed to lift off spigots. Spigots to suit thrust bearing input flange or adapter. Jig faces set up at correct angles measured at the pivot point position. A fixed jig is generally used with a new build installation where the engine/gearbox position is designed to suit a particular angle. The jig is bolted onto the thrust bearing coupling (or sterndrive/ V drive etc). The flange is turned until it is level athwartships using the flat and spirit level. The engine/gearbox output coupling adapter face is then aligned accurately with the jigs forward flange, as if it where a conventional shaft coupling. The jig is manufactured at the correct V-length and the Aquadrive CV joints will run precisely at the same angles as the jig. Removing the locating bolt allows the jig to contract to enable the flanges to be lifted clear of the spigots or piloting recesses. 13

14 Variable angle jig A variable jig can be used when fitting an Aquadrive into an existing vessel where the exact joint angles cannot be pre-determined. In this instance, the variable jig ensures that the joints do not exceed their maximum permitted angles. Again, the jig is manufactured to suit the correct V-length for the CV shaft. Depending upon the particular pivot distance, it is sometimes better to manufacture the jig to fit between the two flanges without the adapters. This allows a greater distance between the jig face and the pivot point. The jig is bolted directly to the input and output flanges and the engine alignment adjusted until suitable angles are achieved at both joints. The jig is then removed and the adapters mounted before the CV shaft is installed. Installing the Aquadrive CV shaft Install the Aquadrive CV shaft between the thrust bearing flange (or sterndrive/v-drive adapter) and the adapter, bolted onto the gearbox output coupling. Use the thread lock liquid provided (or equivalent) on the securing bolts and tighten to the torque setting for the bolt diameter as the standard table on the back page. With the Aquadrive installed, it is essential to ensure that each joint has an equal plunge movement. With the Aquadrive CV 42 (HDL 600) and CV60 (HDL 700) series CV shafts, the joints are normally supplied without end caps and fit directly onto the adapters which are supplied with grease reservoirs. When installing CV shafts with no end caps, each joint should be applied with the self-adhesive gasket and packed with the special high-temperature grease supplied. Cleanliness is of utmost importance and the quantity of grease is critical to avoid over filling the joint. (Your local distributor will advise). Like smaller CV-shaft models, Aquadrive CV42 (HDL 600) series CV shaft is also available as a pre-assembled unit, already packed with special high temperature grease. 14

15 Thrust bearing units with clamp coupling - Installation of the propeller shaft. Measure the bored depth of the clamp coupling and mark off this measurement onto the propeller shaft. The shaft must be put into the full depth of the coupling. It is always good practice to slightly chamfer the shaft leading edge if the shaft and remove any burs. The shaft should be a neat fit and if the alignment is correct will slide straight into the coupling. Good alignment of the propeller shaft into the clamp coupling is vital importance for the performance and life of the thrust bearing. If the coupling clamp has been closed up, there may be some difficulty in getting the shaft to enter the bore of the coupling. (Provided of course that the correct coupling has been selected for the shaft diameter some metric and imperial sizes are very close to one another but are not a direct match). The bolts can be removed and the bore of the coupling expanded slightly by screwing the two rear bolts in from the threaded side against a small steel plate in the clamping slot. Tightening the clamp coupling bolts Corrosion protection On completion of the installation, we recommend that the whole exterior of the Aquadrive assembly, including CV shaft, thrust bearing unit and adapter, is protected with two coats of an anti-corrosion paint. Service and Maintenance The taper roller thrust bearing assemblies may eventually require greasing with an EP bearing grease at long intervals, dependent upon shaft speed. Do not add grease too soon - damages could occur. Your local distributor will advise on this and on any maintenance required to the Aquadrive CV joints. (Usually, joint maintenance is only required on commercial craft with high annual service hours). 15

16 RUNNING IN Aquadrive installations - sea trails As with all new mechanical components it is necessary to run in a new Aquadrive installation for a short period before using maximum revolutions. We recommend running at idle for 30 minutes, 50% of max RPM for 30 minutes and building up to maximum RPM after 2 hours. High power and / or high-speed installations may require extended running in. In such cases, the Aquadrive CV shaft can be run in prior to final installation in a machine shop to avoid long sea trials. Your local distributor will advise. Other than checking that bolts remain proper tightened, the only concern is the operating temperatures of the CV joints and thrust bearings. Joints and bearing may run a little hot to start with, the temperature dropping as the component bed in. Your local distributor will advise on these matters prior to the craft running initial sea trials. Torque settings for high tensile stainless bolts Bolt diameter Torque (Nm) Torque(lbft) M M M Torque settings for stainless bolts in rubber mounts Bolt diameter Torque (Nm) Torque(lbft) M Thrust bearing Max RPM / Max static torque Thrust bearing Max. rpm Max. cont. torque Max. static torque HDL 680 / HDL rpm Nm Nm HDL rpm Nm Nm IN THE EVENT OF ANY QUESTIONS, PLEASE CONTACT: Local distributor: Svenska Uni-Cardan AB, P O box 3100, SE Skärholmen SWEDEN info@unicardan.se 16