Berg Propulsion BCP 950 HDX-500 CPP System Operation and Service Manual

Description

Berg Propulsion BCP 950 HDX-500 CPP System Manual

This Operation and Service Manual covers the Berg Propulsion BCP 950 controllable pitch propeller system equipped with the HDX-500 oil distributor. Supplied for equipment under Order No. 6331, Yard No. YZJ2007-827, this manual provides the complete technical documentation required to operate, maintain, and service the CPP system aboard vessels built by Yangzijiang Shipbuilding.

File Details

• Manual Type: Operation and Service Manual
• Brand: Berg Propulsion AB
• Model: BCP 950 HDX-500
• Language: English
• File Format: PDF
• Order No.: 6331
• Yard No.: YZJ2007-827

Chapters Covered

• 1. Technical Specification — Propeller and Hub, Tail Shaft, Hydraulic System
• 1. Propeller and Shafting — Type of delivery, Installation of blades, Installation of propeller shaft, Oil filling of hub, Locking of screws and plugs before launching, Check of correct mounting of blade
• 2. Hub Design — Complete hub assembly with component breakdown
• 3. Oil Pressure Coupling Type OMC — Introduction, Scope of supply, Mounting instruction, Dismounting instruction
• 4. Oil Pipes — Pipe in shaft, Installing OD-box male coupling into pipe assembly, Installing the gear shaft pipes, Examples of different possible combinations, Dismounting the propeller shaft, Mounting the propeller shaft
• 5. OD Box — Description, Design of the OD-box, Pipe connections, Installation by the yard, Installation by the Berg representative
• 6. Lubrication and Hydraulic Oil — Recommended oil types, Oil filling, Oil drainage of hub, Locking of plug
• 7. Oil Circulation — System layout and flow description
• Maintenance — Daily checks, 200-hour checks, 2000-hour/6-month checks, 5000-hour/1-year checks, 5-year overhaul, Oil level checking, Oil temperature checking, Operating pressure checking, Cooling water temperature checking, Oil filter contamination checking, Changing oil, Replacing filters, Checking threaded connections, Checking parts
• Appendix — Drawing list, Shafting arrangement, Propeller hub assembly, Propeller shaft assembly, Lubrication of sterntube and hub
• Accessories — Sterntube seals, Sterntube assembly with ropeguard, Shaft earthing device, Net cutters
• Hydraulic System — General description, Oil circulation, Pitch control unit (PCU) oil distributor, Pressure oil system, Propeller hub lubrication oil system, Recommended oil types, Emergency control and pitch blocking, Hydraulic pumps, Oil filling, Oil drainage of hub, Locking the plug
• Remote Control System (BRC800) — General, Main functions, System configuration and technical data, System units, Installation, Functions, Using the system, Maintenance, Troubleshooting
• Supervising System — Propeller system alarms
• Spare Parts — Ordering information and spare part lists
• Special Tools — Blade screw spanner, Mounting equipment for OMC Coupling, Spanner for Shaft Nut

What This Manual Provides

This operation and service manual is an indispensable resource for marine engineers, superintendents, and shipyard technicians working with Berg Propulsion CPP systems. It covers the full scope of the BCP 950 propeller hub, including detailed assembly procedures for blades and shafts, oil filling and drainage, locking of screws and plugs, and the critical check of correct blade mounting. The hub design chapter provides an exploded view with a complete parts list, while the OMC oil pressure coupling section guides technicians through the hydraulic mounting and dismounting of the flange coupling with precise drive-up measurements and pressure specifications.

The oil pipes chapter explains the four-channel pipe assembly inside the propeller shaft, including the center pipe for pitch control, peripheral pipes for lubrication return, and the procedure for installing the OD-box male coupling. Detailed instructions cover dismounting and mounting the propeller shaft with the required 100mm gap for pipe disengagement, as well as the correct use of Loctite 243 on threaded connections.

The OD box chapter describes the HDX hydraulic pitch control unit, including its oil distributor and feedback housing, pipe connections with hose lengths and dimensions for the BCP 950, and installation procedures for both yard personnel and Berg representatives. The hydraulic system section details the pressure oil system, pitch control unit operation, propeller hub lubrication oil system with moisture monitoring, emergency control and pitch blocking procedures, and recommended oil types.

Maintenance intervals are clearly defined from daily checks through to 5-year dockings, covering oil level, temperature, operating pressure, cooling water temperature, filter contamination, and visual inspection for leaks and running noises. The manual also includes the BRC800 remote control system with its main functions, system configuration, control panel operation, load control, combinator curves, and troubleshooting guidance.

Why This Manual Matters

Proper maintenance and correct servicing of a controllable pitch propeller system are essential for vessel safety, fuel efficiency, and avoiding costly downtime. This manual provides the exact torque values, pressure settings, oil specifications, and assembly tolerances required to keep the BCP 950 system operating reliably. From the 20mm drive-up marking on the OMC coupling to the 0.1mm run-out tolerance on the OD shaft, every critical specification is documented to ensure repairs are done right the first time.

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