Deep Sea Seals Ltd.

TECHNICAL MANUAL
FOR

TYPE EJ SEAL

ManeBar EJ Inboard Seal

with Solid Cooled Seat for Oil Lubrication Systems

Based on Tabulated G.A. Drawings:

H 70000
H.70060

This Manual is protected by copyright vested in Deep Sea Seals Limited and may contain information that is confidential to that Company. The Manual is supplied to the customer for its personal use
and no part of the Manual may therefore be copied, lent or otherwise disclosed to any third party without the prior written consent of the Company.

Ó1998, Deep Sea Seals Limited. All Rights Reserved.

TM-EJ-04 ISSUE B Issue Date: 8 APRIL 2003

 CONTENTS
SECTION SUBJECT PAGE

1. SPECIFICATIONS/TECHNICAL DATA ........................................................................... 3

2. INTRODUCTION .............................................................................................................. 5

3. DESCRIPTION OF THE EQUIPMENT............................................................................. 6

4. STORAGE AND HANDLING............................................................................................ 7

5. PREPARATION................................................................................................................ 8

6. HEAD TANK LOCATION ................................................................................................. 9

7. SPECIAL INTERFACING REQUIREMENTS ................................................................. 10

8. INSTALLATION.............................................................................................................. 12

9. TESTING ........................................................................................................................ 17

10. NORMAL OPERATION .............................................................................................. 18

11. LUBRICATION SYSTEM............................................................................................ 19

12. RECOMMENDED LUBRICANT LIST......................................................................... 20

13. PROBLEM SOLVING – LEVEL ‘a’ ............................................................................ 21

14. MAINTENANCE.......................................................................................................... 33

15. SPARE PARTS AND THEIR STORAGE.................................................................... 39

16. ATTACHMENTS ......................................................................................................... 40

TM-EJ-04 ISSUE B Page 2 of 40

1. SPECIFICATIONS/TECHNICAL DATA

WORKS ORDER NO. :

OWNER :
VESSLE NAME :
YARD :
YARD No. :

STERNTUBE/SHAFT SEALS
Aft/Outboard Seal Forward/Inboard Seal(s)
Type: Type:
Size:# Size:#
Drawing No.: Drawing No.:

STERNTUBE BEARINGS
Aft STB Mid STB Fwd STB
Size:# Size:# Size:#
Drawing No.: Drawing No.: Drawing No.:

INTERMEDIATE/LINE SHAFT BEARINGS

Type: Type:
Size:# Size:#
Drawing No.: Drawing No.:

LUBRICATION SYSTEM
Drawing No.:
System Components
Fwd seal Tank Aft seal Tank
Drawing No.: Drawing No.:
Header Tank Drain/Observation Tank
Drawing No.: Drawing No.:
Air control unit
Drawing No.:
Lub Oil Pump set Filter/Strainer Unit
Drawing No.: Drawing No.:
Oil Flow Meter Water Flow Meter
Drawing No.: Drawing No.:
Pressure Gauge/Panel Units Valves
Drawing No.: Drawing No.:

TM-EJ-04 ISSUE B Page 3 of 40

 BULKHEAD SEALS
Type: Type:
Size:# Size:#
Drawing No.: Drawing No.:

ACCESSORIES
#
#

The drawings contained in this manual as well as the drawings provided for
information and assembling purposes, remain the property of DEEP SEA SEALS
LTD.
They may not be copied or reproduced in any way, used by or shown to third parties
without the written consent of DEEP SEA SEALS LTD.

TM-EJ-04 ISSUE B Page 4 of 40

2. INTRODUCTION

2.1. The equipment described in this manual and the materials selected are the result of
many years of research and experience in this field.

2.2. However, the care and attention paid during installation, testing, operations and
maintenance, do to a large extent determine the long term operational reliability of
the equipment.

2.3. Thus, whilst it is our policy to allow the Installation and Maintenance of this
equipment to be carried out by 3rd parties (in accordance with the guidance
contained within this Technical Manual) we would always recommend that one of
our Service Engineers is present to oversee any Installation or Maintenance.

2.4. When using this manual refer to the general arrangement drawing(s) in
Section 16, which give the dimensions and data for the correct assembly and
operation of the equipment.

2.5. There is no automatic provision to up-date this manual. However, the supply of a
complete new assembly will be accompanied by the latest revision/issue Manual
and Drawing(s).

2.6. For further assistance please contact one of the Deep Sea Seals companies listed
below:

UNITED KINGDOM USA

Deep Sea Seals Ltd. Wärtsilä Lips Inc.

4 Marples Way 3617 Koppens Way
Havant Chesapeake
Hants PO9 1NX VA 23323

Tel: 44 (0) 2392 492123 Tel: 1 757 385 5275

Fax: 44 (0) 2392 492470 Fax: 1 757 487 3658

NETHERLANDS JAPAN

Wärtsilä Propulsion Netherlands BV Japan Marine Technology Ltd.

Lipsstraat 52 Sigma Bldg, 3-7-12 Shibaura
5151 RP Drunen Minato-ku
Tokyo, 108-0023
Tel: 31 416 388299 Tel: 81 (0) 35442 2211
Fax: 31 416 374853 Fax: 81 (0) 35442 2260
Telex 232-4593

TM-EJ-04 ISSUE B Page 5 of 40

3. DESCRIPTION OF THE EQUIPMENT

3.1. ManeBar "EJ" seals are members of the "E" series family of Rubber Bodied Radial
Face Type seals.

3.2. The "EJ" seals described in this Technical Manual are non-split Inboard units for
use with Oil lubrication systems in Fixed or Controllable Pitch Propeller -
applications.

3.3. The resilient rubber body of the "EJ" seal has an integral "face" which rotates with
the shaft against a static (solid) "seat" assembly. The seat (which contains an
internal cooling annulus) is fixed to the Inboard end of the sterntube. It is by the
continuous rubbing contact between the rotating face and the stationary seat that
the "seal" is achieved. This contact is sustained by compression of the resilient
rubber body applied at Installation and maintained by the Drive Clamp Ring.

3.4. EJ seals are sized in 10 mm steps or increments as shown on the Tabulated G.A.
Drawing. However every seal is finish machined to the suit the "specific" shaft
diameter to which it will be fitted.

3.5. This combination provides a simple but very effective sealing arrangement capable
of accommodating both radial a axial shaft movements.

TM-EJ-04 ISSUE B Page 6 of 40

 4. STORAGE AND HANDLING

4.1. All assemblies and components have been carefully inspected before shipment.

4.2. Each component is suitably packed and protected to prevent damage or

deterioration during shipment, transit or storage. Any specific storage or handling
requirements will be clearly identified on the package label(s).

4.3. Goods should be examined on receipt to verify the contents and their condition.

4.4. Deep Sea Seals should be immediately advised of any damage or discrepancy in
the scope of supply. Damage clearly due to handling in transit should be notified to
the carrier along with a claim for damages (copy to us).

4.5. Keep goods in their original packing until just prior to installation in order to best
protect them.

4.6. If goods have to be stored for long periods, they should be kept in their original
packing, stored flat and unobstructed in a dry, cool and dark environment. To
ensure a satisfactory life expectancy for any rubber components, exposure to
sunlight, ultraviolet light and ozone should be prevented.

4.7. Care must be taken during handling to prevent any mechanical damage occurring
due to dropping, crushing etc. Particular care and attention should be paid to the
running/sealing surfaces of the face and seat.

TM-EJ-04 ISSUE B Page 7 of 40

 5. PREPARATION

5.1. Remove all burrs and sharp edges over which the seal must pass. The surface of
the shaft, local to the seal, should be clean and to the specified diameter and
tolerance.

5.2. Ensure that all mating faces with the seal, i.e. the end face of the sterntube/housing
is machined to the following parameters:

# Surface finish - 6.3 µm Ra or finer.

# Flatness - 0·08 mm.

# Perpendicularity Seal Size: FIM (Measured outside the bolting P.C.D.)

50 - 110 0·2 mm
120 - 250 0·35 mm
260 - 320 0·5 mm

The forward end of the Sterntube must be machined to accept the main seat
securing screws as detailed on the G.A. Drawing.

5.3. All mating surfaces should be clean with no debris or old joint material, etc. present.

5.4. Ensure that all items listed on the G.A. Drawing as "Customer Supply" e.g. joints,
fasteners, are available and sized as shown on the G.A. Drawing. Note: Joints
must have the same bore, overall diameter, holes etc as the seat or component to
which they will be fitted. Thus the bore of the joint must be small enough to fully
cover and seal the cooling water annulus in the back of the seat.

5.5. Make sure that the end of the bearing does not stand proud of the sterntube as this
will distort the seat.

5.6. Due to the non-split nature of the EJ seal, the propeller shaft must be removed,
withdrawn or de-coupled to allow the components of the seal to be fitted over the
shaft.

5.7. It is essential that the running surface of the face and seat are protected at all times
during storage, transit and installation to promote correct operation of the
assembled unit. Even minor damage to these surfaces can promote leakage.

TM-EJ-04 ISSUE B Page 8 of 40

 6. HEAD TANK LOCATION

For oil lubricated systems, the head tank must be positioned at such a height above
the full load water line as to obtain a minimum differential pressure on the outboard
seal of 0.3bar. This requirement shall override any information supplied in respect of
an inboard seal.

Further, the seat of the EJ oil seal must be cooled, details of these requirements also
follow.

Details for both oil and water requirements should be as per TDS 1/007, copies of
which follow – see Attachments Section 16

TM-EJ-04 ISSUE B Page 9 of 40

7. SPECIAL INTERFACING REQUIREMENTS
The EJ Inboard seal is designed so that when assembled with its clamp and the seat
plus the shaft and propeller in their final positions, the seal is compressed by the
correct amount.
EJ Seal General Dimensions
OVERALL LENGTH

SEAT
JOINT LENGTH WORKING LENGTH

Four areas of interfacing are relevant.

7.1. The Bore/I.D. of the rubber body and drive clamp ring to the shaft
The seal will be supplied with the bore of the body and d.c.r. sized to suit the stated
shaft diameter.

7.2. The Stationary Seat interface

The surface of the Sterntube to which the Seat is to be fitted must comply to the
requirements of Section 5 (Preparation).

The inner diameter of the seat is directly related to the "specific" diameter of the
shaft in question. The shaft diameter must be as stated (ordered) and within the
tolerance shown on the G.A. Drawing.

TM-EJ-04 ISSUE B Page 10 of 40

 7.3. Axial Space
Though the Inboard EJ seal does not require a "specific" Axial Space into which to
fit, the space must be sufficient.

Check that inboard of the Sterntube forward surface (or the surface to which the
seal is to be fitted) there is sufficient clear and unobstructed parallel shaft available
to fit the seal.

The length required is the Overall length of the seal (as shown on the G.A. Drawing
for the particular seal size) plus the compression to be applied to achieve the
overall length.

The compression will be shown on the Drawing and is normally 6 mm across all
seal sizes.

Thus the "Free Length" of the seal is Overall Length (which includes the 1·0 mm
joint) plus Compression.

An available axial space at least a little in excess of this is desirable.

7.4. The connection of Services to the Seat

All connections and services (usually seat cooling water) as detailed on the relevant
G.A. Drawing must be provided, ready for connection.
Section 6 and TDS 1/007 also make reference to the service connections.

TM-EJ-04 ISSUE B Page 11 of 40

8. INSTALLATION.
(Refer to relevant Drawings(s) - See Attachments - Section 16)

8.1. Axial Space

Before fitting the EJ seal, re-conform that sufficient axial space will be available in
which to fit the seal as described in Section 7.3.

8.2. Shaft
As referenced in Preparation (Section 5.6), the shaft must be arranged so that the
non-split components of the EJ seal can be fitted "over" it.

Care must therefore be taken to ensure that the Joint, Seat Assembly and Body
Assembly of the seal (The clamp is split and can be fitted around the shaft) are
correctly positioned and fitted on the shaft if this has to be done prior to the
installation of the shaft in the ship. (i.e. a cone mounted propeller shaft with a solid
forward coupling flange which has to be entered into the sterntube from inboard).

The shaft should now be fully entered into the Stertube Bearing until it protrudes
from the other side.

8.3. Seat Installation

8.3.1. Before installing the solid seat the compressed fibre joint must be fitted to
the mounting surface. A thickness of 1 mm is recommended to minimise
bolt inducted distortion. On no account should a joint of more than 2 mm be
used.
A rubber gasket must not be used.

Lightly grease both surfaces of the joint and position it on the Sterntube
ensuring that all holes are aligned with the tapings in the Sterntube Flange
forward surface. Ensure that the joint is not cut away behind the seat cooling
annulus. The joint must fully cover the annulus in order to seal it.

TM-EJ-04 ISSUE B Page 12 of 40

 8.3.2. Carefully remove any strips of tape protecting the seat or its openings and
clean the running surface to remove any traces of dirt, debris etc. Identify
Top Dead Centre for the seal and carefully position the Seat on the joint with
Top Dead Centre correctly orientated. "Lightly" secure the seat assembly in
place using the securing screws through the slots in the seat (not the 4 off
relieved slots which are used for the compression tooling (studs + square
nuts)).

8.4. Seal Body Installation

8.4.1. Where the Seal Body has not already been fitted over the shaft, it should
now be fitted.

8.4.2. Ensure the Shaft is perfectly clean etc. as described before.

8.4.3. Fit the Seal Body over the Shaft with the Face towards the Seat. Use a
twisting motion to fit the body over the shaft and soapy water only (not oil,
grease or any other lubricant) if necessary to assist in sliding the rubber body
along the shaft until the face lightly contacts the seat.

TM-EJ-04 ISSUE B Page 13 of 40

 8.5. Final Positioning
8.5.1. The Shaft should now be secured into its final running position.
8.5.2. Pull the Seal Body clear of the seat to allow the seat to be centralised.
8.5.3. Centralise the Seat to the Shaft so that it concentric to within 0·5 mm. Then
evenly and in a diagonally opposite sequence, tighten the securing screws to
the Torque specified on the G.A. Drawing.
Do not exceed this torque.
8.5.4. Clean both the seat running surface and the face of the seal using a non-
chlorinated solvent cleaner and then move the seal body again until the face
is in contact with the seat.
8.5.5. Fit the split drive clamp ring around the shaft and over the spigot at the
forward end of the rubber body. Note. For seal sizes #70 to #320 the Drive
Clamp ring vertical surface is "knurled" where it contacts the flat surface of
the rubber body.

8.5.6. Fit and evenly tighten the drive clamp ring butt securing screws (and nuts in
the case of EJ sizes #50 and #60) until the clamp ring begins to grip the
shaft. (Ensure that the clamp ring screws are evenly tightened and that an
equal space is maintained between the butts of the two halves of the clamp.

TM-EJ-04 ISSUE B Page 14 of 40

 8.5.7. Fit the compression tooling by screwing the 4 off studding bars provided into
the 4 off Square nuts and fitting these onto the recessed or relieved slots in
the seat.

Place one of the compression tools over each stud so that it fits and locates
as shown on the G.A. drawing. Then fit one washer followed by one nut onto
each piece of studding and tighten until just tight. The seal should now be at
its "Free Length" (i.e. no compression yet applied). Measure between the
clamp and the seat as shown on the G.A. drawing in 4 places and note the
figure(s).
8.5.8. Compress the seal to its "Working length" by using the now fitted
compression tooling. The Working length is the Free length less 6 mm.
Thus gently and evenly compress the seal until it has been compressed by 6
mm, from the as measured "Free Length".
Continue to monitor the length of the seal at 4 positions during compression
in order to ensure that that the seal body is "evenly" compressed.
8.5.9. Once the seal body has been correctly compressed, finally, evenly tighten
the Drive Clamp Ring butt screws (and nuts if fitted) to the torque specified
on the G.A. Drawing.
8.5.10. Remove the compression tooling including the studding and safely store all
items for future use.

TM-EJ-04 ISSUE B Page 15 of 40

 8.6. System Connections
8.6.1. The EJ seat has 2 threaded flush connections (inlet and outlet) as shown on
the G.A. Drawing, positioned either side of T.D.C.

8.6.2. As previously referenced in Section 6 and later in Section 11, the sterntube
is connected to a lubricating oil system, this is normally achieved via
connections directly into and out of the sterntube itself, not via the EJ seat.
Connect the cooling water-flush and lub oil supply/drain as appropriate
according to the T.D.S. schematics in Sections 6 and 11
Check before connection that all pipes are clean and free of scale
internally before connecting them to the seat and sterntube.

Note: It is imperative that the cooling water flush is provided to the seal in
the quantities and at the temperature shown on the G.A. Drawing and
the TDS sheets as referenced in Sections 6 and 11, (the flush figure is
a minimum) at all times whilst the shaft (and thus the seal) is dynamic
(rotating).

8.6.3. For the system (both cooling water flush and oil) requirements with regard to
pressures, flows, temperature and valve positions refer to both the G.A.
Drawing and the System Drawing TDS 1/007 (Sections 6 and 11).

TM-EJ-04 ISSUE B Page 16 of 40

9. TESTING

9.1. Seat cooling water flush annulus

Refer to Section 8.6 (System Connections) regarding pipework connections.

Test the integrity of the cooling water chamber in the aft surface of the seat by
closing the outlet valve, applying a pressure of 1.0 Bar and checking for leakage by
closing the supply valve; the pressure may drop very slowly. If there is a rapid loss
of pressure, the pipe connections and seat should be examined. If this is not the
reason for the pressure drop then the seat is not being sealed to the sterntube by its
joint or the seat itself is leaking (porous or damaged). Rectify any reasons for the
pressure drop and re-test.

9.2. Main Seal

After the Seal Body has been fitted and compressed and with the cooling water flush
and lub oil connections made as per Section 8.3 onwards, proceed to test the main
seal as follows:

Apply oil pressure to the main seal via the stern tube connections (for value see
General Arrangement Drawing). A small leakage between the face and seat is
acceptable on static test which should decrease once the seal has 'run-in'.

TM-EJ-04 ISSUE B Page 17 of 40

10. NORMAL OPERATION
During Normal Operation with the "EJ" seal functioning within parameters, all
conditions should be stable.

10.1. Stable Operating Conditions

10.1.1. Oil ingress within acceptable limits.

10.1.2. No noticeable signs of the seal overheating

10.1.3. Bearing Temperature(s) normal.

10.2. Routine Checks that should be conducted

10.2.1. Check for leakage regularly.

10.2.2. Check for signs of overheating regularly.

10.2.3. Check the cooling water flush flow rate to the seat regularly.

10.2.4. Check the position (open/closed) of the cooling water flush supply valve(s)
daily.

10.2.5. Check and record the header tank level daily – refilling if necessary.

10.2.6. Check and record the bearing/stern tube lubricant temperature daily.

10.2.7. Check the operation of any supply pumps, filters etc. (if fitted) on a daily
basis.

10.2.8. Check the cooling water flush flow alarm (if fitted) weekly for correct
operation.

10.2.9. Check the header tank alarm(s) weekly for correct operation.

10.2.10. Check the sterntube/bearing for water ingress using the sampling cock
weekly.

10.2.11. Check the face wear/length monthly. (S shaft stopped and locked).

10.2.12. Check for seal working length 3 monthly (S shaft stopped and locked).

10.2.13. Test the lubricant in accordance with the manufactures recommendations.

TM-EJ-04 ISSUE B Page 18 of 40

11. LUBRICATION SYSTEM
For an "EJ" Inboard Oil Lubricated seal, refer to Technical Data Sheet (T.D.S.) 1/007.

This defines the requirements of the system with respect to pressures and required
differentials as well as flow rates and temperatures.

The two sheets of TDS 1/007 show different systems for the requirements of the oil
system and the cooling water flush system for the seat. Between them they define the
System Requirements.

TDS 1/007 follows – see Attachments Section 16.

TM-EJ-04 ISSUE B Page 19 of 40

12. RECOMMENDED LUBRICANT LIST
For an "EJ" Inboard seal used in an "Oil " lubrication system please refer to the
following Technical Data Sheet (T.D.S.) 9/001 Sheet 4 or 4.

The T.D.S. lists recommended and acceptable oils for use with “E” series seals.

T.D.S. 9/001 Sheet 4 of 4 follows – see Attachments Section 16:

TM-EJ-04 ISSUE B Page 20 of 40

13. PROBLEM SOLVING – LEVEL ‘a’

13.1. Problems
Any problems with the “EJ” Oil lubricated) inboard seal will normally show
themselves in one of two ways.

(a) The loss of lubricant from the system.

(b) Water ingress into the lubricating system.

(c) Over heating of the seal.

(Refer to the associated causes and corrective actions in Section 13.4, 13.5 and
13.6).

13.2. Evidence
Evidence that any of the above has occurred will be demonstrated in one of the
following ways. (Also refer to the associated problem solving flow charts in Section
13.3 as indicated below).

i) A visible oil leak found during routine inspection of the seal (Flow chart
13.3.2).

ii) A low level alarm warning from the bearing header tank (Flow chart 13.3.3).

iii) A low flow in the seat cooling water flush supply activating the low flow alarm
if one is fitted (Flow chart 13.3.4).

iv) A high bearing/sterntube temperature alarm. (Flow chart 13.3.5).

v) Water or an Emulsification found during routine testing of the bearing

lubricant. (Flow chart 13.3.6).

vi) An increase in the level or overflow of the bearing header tank activating the
high level alarm (if one is fitted) (Flow chart 13.3.7).

vii) Noticeable signs of inboard seal overheating (Flow chart 13.3.8).

13.3. Flow Charts

Explanations of the above, including cause, effect and corrective actions now follow:

TM-EJ-04 ISSUE B Page 21 of 40

 13.3.1. NORMAL OPERATION

STERNTUBE MIN OIL PRESSURE = WATER HEAD + 0.3 BAR

STERNTUBE MAX OIL PRESSURE = 0.8 BAR

S STABLE CONDITIONS
S NO VISIBLE LEAKAGE INBOARD
S LUBRICANT TANK LEVEL UNCHANGED
S NO SIGNS OF SEAL OVERHEATING.
S LUBRICANT TEMPERATURE NORMAL
S LUBRICANT CONDITION GOOD.

TM-EJ-04 ISSUE B Page 22 of 40

 13.3.2. VISIBLE OIL LEAKAGE

OIL
LEAKAGE

CHECK OIL
CHECK
SYSTEM 1
PRESSURE / FLOW

HIGH CORRECT TO
YES
PRESSURE/ MEET SYSTEM
FLOW ? REQUIREMENTS

NO
CHECK
CHECK SEAL 2

IS SEAL
UNDER YES CORRECT
COMPRESSED COMPRESSION
?

NO

WORN OR
DAMAGED YES REPLACE
COMPONENTS COMPONENTS
?

RESET SYSTEM
OPERATION TO NORMAL

TM-EJ-04 ISSUE B Page 23 of 40

 13.3.3. HEADER TANK LOW LEVEL ALARM

LOW
LEVEL ALARM

CHECK CHECK HEADER TANK

1
LEVEL

IS
LEVEL NO REPAIR / REPLACE
LOW FAULTY LEVEL SWITCH
?

YES

TOP UP TANK
TO INCREASE LEVEL

CHECK
2 CHECK SEAL

IS INBOARD
SEAL LEAKING
EXCESSIVELY
NO ? YES

CHECK FOR OTHER

REFER TO
REASON(S) FOR
SECTION 13.3.2
LOW HEADER TANK LEVEL
CHECK 1 - ONWARDS
e.g. SYSTEM LOSS OR
OUTBOARD SEAL LEAKAGE

TM-EJ-04 ISSUE B Page 24 of 40

 13.3.4. LOW SEAT COOLING WATER FLUSH SUPPLY FLOW ALARM

LOW FLUSH
FLOW ALARM

CHECK VISUALLY CHECK

1 FOR WATER FLOW
THROUGH METER

IS REPAIR/REPLACE
YES
WATER FLOW FAULTY FLOW
RATE OK LEVEL ALARM

NO

CHECK FLUSH
CHECK
2 SUPPLY VALVES ARE
CORRECTLY POSITIONED

ARE
NO RESET TO
VALVES ALL
RE-ESTABLISH
SET OK
CORRECT FLOW
?

YES

CHECK FLUSH SYSTEM

CHECK
3 SUPPLY PUMP(S)
AND FLILTERS

ARE
RESET, REPAIR, CLEAN
PUMP(S), FILTERS NO
OR REPLACE DEFECTIVE
ETC. FUNCTIONING
COMPONENTS
CORRECTLY

YES

CHECK CHECK FOR BLOCKAGE / RESTRICTION

4 OR DAMAGE TO FLUSH SUPPLY LINE
RESPONSIBLE FOR LOW / NO FLOW

TM-EJ-04 ISSUE B Page 25 of 40

 13.3.5. HIGH BEARING/STERNTUBE TEMPERATURE

HIGH BEARING
STERNTUBE
TEMPERATURE

CHECK CHECK HEADER TANK

1
SUPPLY TO STERNTUBE

YES REFER TO
IS LEVEL
SECTION 13.3.3.
LOW ?
CHECK 1 - ONWARDS

NO

CHECK CHECK OPERATION OF

2 LUBRICATION CIRCULATING
PUMP/FILTERS ETC - IF FITTED

IS OPERATION NO CORRECT AS
OK ? NECESSARY

YES

CHECK CHECK BEARING

3
TEMPERATURE SENSOR

IS OPERATION NO
REPLACE IF FAULTY
O.K.?

YES
CHECK
4 CHECK OIL CONDITION

DRAIN OFF CONTAMINATED

IS CONDITION NO
OIL AND RE-CHARGE WITH
OK? FRESH OIL

YES

CHECK IF STERNTUBE PASSES

5 THROUGH A FILLED/FLOODED
AFT DRAIN TANK

YES FILL AND CHECK REASON

FOR LOW LEVEL
IF YES, IS
LEVEL LOW ?
NO
CONSULT BEARING SUPPLIER

TM-EJ-04 ISSUE B Page 26 of 40

 13.3.6. WATER OR EMULSIFICATION FROM BEARING TEST COCK

WATER
CONTAMINATION OF
LUBRICANT

CHECK CHECK
1
OUTBOARD SEAL

DAMAGED / WORN OR
YES CORRECT OUTBOARD
UNDERCOMPRESSED
SEAL
AFT SEAL?

NO

CHECK
2
INBOARD SEAL

INBOARD SEAT
COOLING WATER YES CORRECT INBOARD
LEAKING INTO SEAL
STERNTUBE

NO

CHECK SYSTEM / STERNTUBE

/ AFT PEAK FOR OTHER LOCATE AND
3
REASON FOR WATER CORRECT / REPLACE
CONTAMINATION

TM-EJ-04 ISSUE B Page 27 of 40

 13.3.7. HEADER TANK INCREASE IN LEVEL OR OVERFLOW

INCREASE IN HEADER
TANK LEVEL

CHECK CHECK OIL IN HEADER TANK

1
AND STERNTUBE

IS SIGNIFICANT YES
WATER
CONTAMINATION REFER TO 13.3.6
PRESENT CHECK 1 ONWARDS
?

NO
LOCATE REASON
CHECK OIL
FOR OIL INCREASE
CHECK SYSTEM AND
2 AND CORRECT OR
SUPPLY VALVES
REPAIR SYSTEM
HEADER TANK
FAULT

TM-EJ-04 ISSUE B Page 28 of 40

 13.3.8. OVERHEATING OF INBOARD SEAL
INBOARD SEAL
OVERHEATING

CHECK CHECK SEAT COOLING

1
WATER FLUSH RATE

IS WATER FLOW NO REFER TO 13.3.4.

RATE OK? CHECK 2 - ONWARDS

YES

CHECK CHECK SEAT COOLING WATER

2
INLET TEMPERATURE

NO

REDUCE TO BELOW
IS NO 40°c AS PER
TEMPERATURE
REQUIREMENTS
OK ?
(TDS 1/007)

YES

CHECK CHECK HEADER

3
TANK LEVEL

IS LEVEL NO REFER TO 12.3.3.

O.K.? CHECK 1 ONWARDS

CHECK OPERATION OF
CHECK
4 LUBRICATION CIRCULATING
PUMP/FILTERS ETC. IF FITTED

IS OPERATION NO
CORRECT AS NECESSARY
OK?

YES

CHECK
5 CHECK SEAL COMPRESSION

IS
NO RE-SET SEAL COMPRESSION
COMPRESSION
TO CORRECT VALUE
CORRECT?

TM-EJ-04 ISSUE B Page 29 of 40

 13.4. SECTION "A" – LUBRICANT LOSS FROM THE SYSTEM
Lubricant leakage from the Inboard seal system may be due to one or more causes.
For each, a suggested course of corrective actions follows:

CAUSE CORRECTIVE ACTION

A1 Lubricant pressure/flow too high a Reduce to that stated in the

Technical Manual.

A2 Loss of seal compression due to a As a temporary measure, increase

age or wear compression by 1 or 2 mm using the
compression tooling until
components can be replaced.

b Replace the component(s)

responsible for the loss of
compression.

A3 Insufficient compression due to a Establish the correct compression by

installation or axial shaft resetting - the drive clamp ring using
movement the compression tooling.

b Determine and rectify the causes of

excessive shaft movement.

A4 Debris between the face and a Carefully remove any debris. If no

seat. damage has occurred a good seal
should be re-established. If damage
has occurred - refer to "A5".

A5 Damage to the inboard seal. a If the seal is damaged and is leaking

then proceed as for 2a. having first
checked and carefully removed any
debris.

b Replace damaged components as

soon as is possible.

A6 Wear or damage to the outboard a Correct in accordance with the

seal. manufacturers instructions.

TM-EJ-04 ISSUE B Page 30 of 40

 13.5. SECTION “B” – WATER INGRESS INTO THE SYSTEM
Water ingress into the lubricating system may be due to one or more causes. For
each, a suggested course of corrective actions follow:

CAUSE CORRECTIVE ACTION

B1 Outboard seal leaking. a Correct in accordance with the

Manufacturers Instructions.

B2 Inboard seal seat cooling water a As a temporary measure reduce the

flush leaking into the sterntube. flush flow/pressure until the forward
seal can be overhauled. The inboard
seal temperature must be monitored.

b Replace the component(s) responsible

for the water ingress (e.g. seat joint or
damaged seat).

B3 The system is allowing water a Establish the reason and correct.

ingress via the sterntube/aft
peak tank or ingress via the
header tank / supply system.

TM-EJ-04 ISSUE B Page 31 of 40

 13.6. SECTION "C" - EVIDENCE OF OVERHEATING OF THE SEAL
As for lubricant loss and water ingress, overheating may be due to one or more
causes.
For each, a suggested cause of corrective actions follow:

CAUSE CORRECTIVE ACTION

C1 Seat cooling water flush a Increase to that stated in the

pressure/flow too low. Technical Manual.

C2 Loss of seat cooling water a Check and re-set all flush supply
flush. valves to correct position/operation.

b Check supply pump(s) and filters etc.

for correct operation.

c Check for blockage/restriction or

damage to the Flush supply line(s)
causing low/no flow.

C3 High seat cooling water flush a Reduce to that stated in the Technical
temperature Manual.

C4 Low header tank level/ loss of a Top up/refill header tank and correct
lubricant. reason for loss.

C5 Loss or reduction in lubricant a Check operation of pump / filters (if

flow/circulation. fitted). Ensure valves etc. are
correctly set and pipes are clear.

C6 Excessive compression due to a As for "A" 3a.

installation or axial shaft
movement. b As for "A" 3b.

NOTE: Where corrective actions involving material replacement refurbishment or

adjustment have rectified a situation, then any "temporary" measures taken
such as changes in lubricant pressures should be reverted to normal.

NOTE: If these Problem Solving measures fail to rectify a situation, then

assistance and further advice should be sought via one of the contact
addresses given in the front of the Technical Manual.

TM-EJ-04 ISSUE B Page 32 of 40

14. MAINTENANCE
(Refer to relevant Drawing(s) - see Section 16)

14.1. The need for "Maintenance" may be determined by several factors which are
performance related. Alternatively, though the performance of the equipment may
be perfectly satisfactory, maintenance may be carried out as part of a
planned/preventative schedule. Overhaul of the equipment may also be carried out
because it is part of a system or assembly that is itself needing or due for
maintenance!
14.2. Factors that normally determine the need for Maintenance are:

14.2.1. Performance :-

Lubricant leakage past the seal.

14.2.2. Wear :-

Normally associated with the fibre "face" in the "EJ" seal, though it does to a
lesser degree affect the ni-resist seat.

Wear is important as the loss of material means a loss of compression in the

rubber body which can lead to leakage.

Wear can be determined by measuring the distance between the seat and
the rubber body (see below).

Condition for Seal Size: Status

x
#50-#60 #70-#320
X = 5 mm X = 6 mm 'as new'

X > 3 mm X > 4 mm O.K.

X < 3 mm X < 4 mm Replace body

assembly

Normally an oil lubricated seal experiences low levels of wear.

TM-EJ-04 ISSUE B Page 33 of 40

 14.2.3. Damage:-

The seal can be damaged due to debris or physical intervention however

with an Inboard Seal this is not a common reason for Maintenance.

14.2.4. Age:-

The face and seat elements have no limitation with regard to Age. Their
"service life" will be governed by "Performance", "Wear" or "Damage".
The life limit for the EJ "rubber" body is 10 years (elapsed time - not just
operation) and renewal must be carried out every 2nd 4/5 year docking.
However, it is more likely that for operational reasons (Performance, Wear or
Damage) that the Body will be replaced "every" 4/5 year docking.

Replacement of the EJ body at least every 8-10 years is recommended as

the body is compressed on fitting and provides the necessary closing force
between the face and seat. Rubber loses "elasticity" over a period of time
and the body will develop a "permanent set" with a subsequent loss of
closing force. The rubber Inflatable seal, even if it has never been used, only
tested, should as an "emergency" seal be replaced routinely every 4/5
years.

14.3. To replace or carry out maintenance on either the "EJ" seal body or seat assembly,
the propeller shaft must be de-coupled or removed to allow removal of these non-
split items.

Note : If the shaft is to be removed - the Inboard Seal must first be

disassembled.

Proceed as follows:
Whenever replacing the seal body assembly, the seat should be removed and re-
conditioned or replaced as required.
A new seal face should not be run against a previously used seat that exhibits any
evidence of wear or grooving. If the seat cannot be restored to an "as new" surface
condition by abrading (rotary motion) with a 600 grade grit paper, it must be
machined to remove any wear track or pattern.

TM-EJ-04 ISSUE B Page 34 of 40

 14.4. Seal Disassembly

14.4.1. With the shaft stopped, locked and de-coupled ensure that the lubricating
system and the system supplying flush water to the seat are either shut down
or isolated from the seal.

Now disconnect all pipe connections to the EJ seal.

14.4.2. Install the Compression Tooling in all 4 positions (as described in Section
8.5.7.) and tighten until the Tooling is gripping the drive clamp ring.

14.4.3. Slacken but do not remove the drive clamp ring securing screws (and nuts in
the case of EJ seal sizes #50 and #60.

14.4.4. Gently and evenly (on all four fittings) release the compression on the seal
by carefully undoing the nuts on the forward end of Compression Tooling.

When the tooling goes slack, remove the nuts, washers, tools and studs
comprising the Compression Tooling from the seal and store them safely for
future use.

14.4.5. Fully undo the Drive Clamp ring screws (and nuts if fitted) and remove them
along with the two halves of the Drive Clamp Ring from the Shaft.

Put these carefully to one side for future re-use.

14.4.6. Remove the Rubber Body from the Shaft using a rotating motion. Use soapy
water "only" to lubricate the shaft if removal is difficult.

14.4.7. Undo and remove the Screws/Bolts etc. securing the seat to the Sterntube.
Retain these for future use. Now remove the seat from the Sterntube and
remove it from the shaft.

14.4.8. If the Shaft is to be removed from the Sterntube, it may be removed now!

14.4.9. Finally remove the joint and any traces of it from the Sterntube and the back
surface of the Seat.

TM-EJ-04 ISSUE B Page 35 of 40

 14.5. Seal Reconditioning

14.5.1. Drive Clamp Ring Assembly

The D.C.R. and fasteners should be re-usable. Thoroughly clean all
components. The knurling on the DCRs for seal sizes #70 and above should
be cleaned using a wire brush to remove any embedded rubber or dirt and
thus provide maximum grip and drive.

The DCR can be checked for distortion by bolting the two halves together
and measuring the bore in several places.

To correctly measure the split clamp, spacers must be inserted between the
butt surfaces of the two halves.

For DCRs for seal sizes #50 and #60 use spacers of 2.0 mm thickness. For
all larger seal sizes use 3.0 mm spacers.

With the correct spacers in place the internal diameter of the Drive Clamp
Ring should be the Shaft Diameter +0.1/ 0mm.

14.5.2. Body Assembly

The Body Assembly which incorporates the Face, is supplied as a single

component and is not considered refurbishable. The Body should be
replaced in line with the recommendations in Section 14.2 regarding
"Performance", "Wear", "Damage" or "Age".

TM-EJ-04 ISSUE B Page 36 of 40

 14.5.3. Seat Assembly

The Seat Assembly comprises the non split Seat as above.

Thoroughly clean the seat, then recondition as follows:

Remove any evidence of a running track on the sealing surface with a 600
grade grit paper using a rotary motion (paper stationary - move the Seat by
hand). If the wear track cannot be removed in this manner, it can be
machined. The machining process is a fine "turning" one, not grinding or
lapping. The surface finish to be achieved is 1.6 µm. which should then be
polished to 1.2 µm. (using a find grade grit paper as above).

The machined front surface of the seat must remain parallel to the back
flange surface to within 0.08 mm for all the sizes #50 to #320.

The amount of material that may be removed from the front running surface
is governed by the thickness of material remaining. Three areas are
relevant, the thickness between the running surface and the annulus,
between the o.d. of the two through holes to the running surface and the o.d.
of the b.s.p. tapping in the holes to the running surface.

The tapped holes are where the material is at its thinnest, however as long
as the machining is restricted to the diameter/area inside the main securing
screw slots, then more material can be removed.

The thickness of material remaining in this area should not be allowed to fall
below 5.0 mm for seal sizes #70 and upwards and 4.0 mm for seal sizes #50
and #60 after wear and machining.

Further, the “back” surface of the seat, especially the I.D. of the annulus can
suffer from erosion.

Ensure that the material remaining at the back of the seat is both flat and
sufficient outside of the annulus to support the seat and seal the annulus
when fitted with its joint.

Replace the seat if it cannot be refurbished satisfactorily.

TM-EJ-04 ISSUE B Page 37 of 40

 14.6. Seal Re-Assembly
14.6.1. With the Seat Assembly now ready for fitting, carry on with the re-assembly
of the EJ seal as described in Installation from Section 8.3 (Seat Installation)
onwards up to an including Section 9 Testing.

14.7. Maintenance with the Shaft fully installed.

Due to the non-split nature of the EJ Seal, the Maintenance that can be carried out
with the Shaft still fitted is extremely limited. It includes:
● Opening up and cleaning of the Seal.
● Inspection and measurement of the Seal.
To proceed, follow the Seal Disassembly procedure from Section 14.4 onwards,
however where reference is made to removal from the shaft of non-split items
(everything except the Drive Clamp ring Assembly) this instruction cannot be
complied with. The components can only be moved along the shaft in order to
create access space in order to carry out:
● Cleaning/Inspection/Measurement - Standard procedures.
● Joint Replacement - Disturbing the old joint will
necessitate its renewal. A correctly
sized joint with all necessary holes
must be made and it must then be
split in one position using a dove tail
cut/join in order to fit it "around” the
shaft.
● Re-assembly - Reversal of the Installation
Procedure.

TM-EJ-04 ISSUE B Page 38 of 40

15. SPARE PARTS AND THEIR STORAGE

15.1. For the "EJ" seal, as it is basically only a 3 component assembly (Body, Drive
Clamp Ring and Seat Assemblies), the requirement for "Spare Parts" is limited.

15.2. The seat is considered to be a refurbishable item using a simple machining process
as described in Section 14 (Maintenance).

15.3. .The Drive Clamp Ring assembly is considered re-usable.

15.4. The only component that may be held as a spare is a Body assembly. However
due consideration must be given to the possibly lengthy storage of rubber
components and that the rubber body can only be installed with the shaft de-
coupled or removed.

15.5. All parts held as spares should be kept in their original packaging as they will have
been inspected and packed prior to despatch as described in Section 4 (Storage
and Handling).

15.6. All components must be protected from damage or deterioration by maintaining

their original packing and careful storage to prevent physical damage (with special
care being taken of any fine machined surfaces or critical components).
All spares should be stored flat and unobstructed in a dry, cool and dark
environment, as described in Paragraph 4.6.

TM-EJ-04 ISSUE B Page 39 of 40

16. ATTACHMENTS
The following attachments are covered by this Technical Manual (TM EJ/04).

● Tabulated or Specific General Arrangement Drawing(s) *

● TDS 1/007

● TDS 9/001 (Sheet 4 of 4)

*Note: This manual is written based on the General Arrangement Drawings listed on
the front cover.

However: EJ Seals with a "specific" General Arrangement drawing which

are derived from one of the listed "Tabulated" General Arrangement drawing
are also covered by this Technical Manual.

In all instances the Drawing(s) specific to the application must be included

after this attachment page and referenced in conjunction with this manual.

All pertinent drawings should be detailed in Section 1

(Specifications//Technical Data) of this manual and appear on the Works
Order.
The attachments identified above, now follow :

TM-EJ-04 ISSUE B Page 40 of 40