Technical Information & Installation InstructionsFor Thrust Bearings HDL 680, HDL 700(HT) & HDL 780(HT)

CV shafts CV42 & CV60

Svenska Uni-Cardan AB P. O. Box 3100, SE 127 03 Skärholmen SWEDEN

e-mail: info@unicardan.se

A member of GKN Automotive Driveline Division

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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 780 10

Installation of the CV drive shaft 10-14

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

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AQUADRIVE –SMOOTHER, QUIETER

WITH TOTAL VERSATILITY.

Thrust bearing support plate Gearbox

adapter

Aquadrive resilient engine mount

Heavy dutyAquadrive thrust bearing.

AquadriveCV shaft

General informationThe 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. Theconstant velocity joint at the ends of each unit isolate the engine vibrations from the rigidlymounted propeller shaft and allow the engine to be suspended on extra soft Aquadriveresilient mounts.

A further advantage of the Aquadrive system is that the constant velocity joints (CVjoints) accommodate a certain amount of misalignment between the engine/gearbox outputcoupling and the propeller shaft. Unlike conventional universal joints, the angle ofmisalignment does not have to be equal at each CV joint, (joint angles are restricted by thepower being transmitted and the maximum shaft speed). We will be pleased to advise onmaximum joint angles for your particular application.

This ability to absorb misalignment can enable a simpler installation to be achieved byavoiding the need for precise engine alignment when using the Aquadrive system in aconventional “straight” installation.

The designer also has greater freedom to install the engine in a lower position to reducethe vertical center of gravity and minimize the space taken up by the engine compartment.

Selecting correct Aquadrive shaft systemIn 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 Aquadrivesuitable for your particular installation. Machined adapters can be provided to enable theAquadrive shafts to be connected to the output coupling of the engine/gearbox and the inputcoupling of sterndrives, jets or “V” drive / “U” drive gear boxes.

Your Aquadrive distributor provide a technical telephone or e-mail advice service andwill be pleased to answer your questions and help you select the correct Aquadrive shaftsystem. The drawings shown in this installation manual are for general guidance only. Onrequest, we can provide separate detailed drawings of any of the Aquadrive units.

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Aquadrive with thrust bearing assembliesThese units are for installing between a conventional propeller shaft and gearbox output

coupling. They comprise an Aquadrive shaft and thrust bearing assembly. For the majorityof installations, the propeller shaft is connected directly into the back of the thrust bearingassembly, using the machined clamp coupling provided. (These are supplied already machi-ned for the majority of metric or British shaft diameters up to 70mm). For largerinstallations, or where it is necessary to be able to “end for end” shafts with machinedtapers, flanged thrust bearing assemblies for connection to the propeller shaft half couplingcan be provided.

The thrust bearing housing is resiliently mounted onto a support plate constructedbetween the engine beds. This support plate must be strong and rigid enough to absorb themaximum loading that can be expected without any flexure or movement.

STRAIGHT INSTALLATION

Aquadrive shaftGearbox adapter

Joint angles subject to engine power and shaft RPM.

Thrust bearing support plate

Thrust bearing resilient mounts

Heavy duty Aquadrive thrust bearing

ANGLED INSTALLATION

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Aquadrive shafts without thrust bearingAquadrive 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.

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Torsional vibration analysisWhen 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 thedriveline is not available.

However, as with any shaft system being built into a new boat a T.V analysis is generallyrecommended. Normally the yacht or boat builder will arrange for this T.V.A to be carriedout since he has the full installation data required. On request we will be pleased to provideall necessary information and mass elastic data regarding our Aquadrive assemblies.

Your distributor can advise individual customers regarding the need for such analysisand can offer assistance when required.

Adapters for output and sterndrive input couplingsIt 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 manysterndrives, jets, “V” drives and “U” drives. Alternatively, we can supply adapters to suityour special requirements, machined to dimensions provided by the designer or installer.Aquadrive alloy steel adapters should be handled with care. Damages on the coating oflacquer 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 toface pilot fit. The piloting spigot should fit the recess neatly without movement, but on noaccount 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. Allbolts should be tightened to the settings tabled at the back of these instructions and securedwith thread locking liquid where appropriate.

M16 cap headed bolts require a heavy duty allen key adapter to enable them to be tighte-ned to the proper setting.

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Dimensions of the thrust bearing support plateAquadrive 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 materialused will depend on the hull structure material. Preferably, it should be made of blasted anddry-galvanized steel. This gives an excellent durability and adherence if the plate is glassed-in 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 propellerthrust with adequate safety margins for shock loading and must be rigid enough not to flexat full power.

mm

inch

mm

inch

inch

mm

Model A B C D EHDL680 210 275 60 95 60

HDL680 8 17/64” 10 13/16” 2 3/8” 33/4” 2 3/8”HDL700 210 275 60 95 60

HDL700 8 17/64” 10 13/16” 2 3/8” 33/4” 2 3/8”

Model A B C D EHDL780 270 360 50 95 50

HDL780 10 5/8” 143/16” 131/32” 3 3/4” 131/32”

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Positioning the thrust bearing support plateThis 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 goodalignment before assembling the thrust bearing unit.

When positioning the thrust bearing and supporting plate, it’s critical to ensure that theavailable space for the CV shaft corresponds to the correct “V” length, allowing for therequired “plunge” movement within the constant velocity joints. (See section on measuringthe “V” lengths of the Aquadrive).

The thrust bearing unit fits behind the supporting plate and pushes against it with thethrust 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 isrecommended to replace the rubber bushings with solid steel alignment bushings to preventthe unit or assembly from moving or sagging. On completion of the work, the steel bushingsare replaced with the original resilient rubber mounts.

The way that the thrust bearing support plate is positioned and mounted into the vesselwill depend on the type and construction of the craft. It will also depend on whether it isbeing assembled into a new build installation or being retrofitted into an existing boat. Thefollowing methods of positioning the supporting plate are suggested for guidance only.

Laser alignmentThe support plate can be positioned very accurately using laser alignment equipment.

The technique would require two rigid extension brackets to be bolted transversely to thefaces either side of the support plate. Each bracket would hold a laser “target”. The laserwould be fired through targets supported in the “P” brackets and/or stern tube and the sup-port plate adjusted until the computerized readout indicate that all ”targets” were inline.The extension brackets on the support plate are required to give sufficient separationbetween the two targets.

If you wish to use this method of positioning the support plate, we recommend youemploy the services of a specialist laser alignment company.

Ensure the propeller shaft is straightFor 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 ordial indicator at the coupling position. It’s also advisable to check just forward of the pro-peller taper, particularly with an existing shaft, to ensure the shaft is running true and soavoid vibration due to a bent shaft.

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Installation of the bearing assemblies HDL 680, HDL 700 & HDL 780These 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 atback of instructions). After tightening, check that the bushings compress equally.

Installation angles of Aquadrive CV shaftsCV 42 (HDL 600) & CV 60 (HDL 700)

Aquadrive can be installed straight “in line” or with the constant velocity joints runningat angles within certain permitted limits. Max recommended angles are dependent on thepower being transmitted and the maximum shaft speed. It is important that neither jointexceeds its maximum permitted angle. While there is no need to run the two joints at equalangles, 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 itallows 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 beingtransmitted and the shaft speed. The following information is provided as a guide for equalangle installations. For applications with data beyond the table below, please contact yourdistributor for advice. The r.p.m. values below refer to shaft speed after given gearboxreduction and not the engine speed.

Aquadrive CV shaftsRPM / Max deflection per joint.

CV 42 (HDL 600) CV60 (HDL 700)

0-1000 rpm 8.0 degrees 4.0 degrees

1000-1500 rpm 6.0 degrees 3.5 degrees

1500-1750 rpm 5.0 degrees 3.0 degrees

1750-2250 rpm 4.0 degrees 2.5 degrees

2250-3000 rpm 3.0 degrees 2.0 degrees

The Aquadrive CV shafts can also run with a compound angle where the joint angle arein a different plane to one another. i.e. the gearbox output flange and shaft are misalignedhorizontally as well as vertically. The above table of joint angles still applies providing thatthe effective compound angle is used.

The effective compound angle can be calculated from the following graph when the in-stallation is misaligned both vertically and horizontally. The accurate formula forcalculating the compound angle is:

ßcomp

= arc tan[ tan2(ßhor

) + tan2(ßver

)]

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Compound angle graph

EXAMPLE:

Vertical angle = 6 degrees Horizontal angle = 4 degrees

Effective Compound angle of joint = approx. 7 degrees.

Aquadrive CV shaft V-lengthAquadrive 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 CVshafts 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 spotwelded onto the side of the main shaft tube. It is important that this balancing plate is notremoved or disturbed.

The V- length, (“V” is for vital). Whether the CV shaft is one of our standard lengths, orcustom made to suit your requirements, it is vital that they have sufficient plunge movementwithin the joints and installed in the center of this movement. This plunge movement is toallow the engine to vibrate backwards and forwards on its soft mounts and for the thrustbearing to move forward on its resilient bushings.

The V- length is the measurements from the adapter face coupled to the output flange ofthe gearbox and the input flange of the thrust bearing (alternatively sterndrive / jet / V-driveetc., 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”

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Measuring the CV shaft installation lengthsOn a perfectly “true” inline installation, it would be possible to take the one simple di-

mension between adapter and thrust bearing, or adapter and adapter. However, in practice itis always best to take four length dimensions at 0-90-180-270 degrees around the flangesand then divide the sum of these dimensions by four. This calculated intallation V-lengthdimension allows for angular misalignment of the flanges and has to meet the CV shaftV-length (within the ±3 mm (±1/8”) tolerance).

Aquadrive CV joint pivot pointsThe Aquadrive CV joints pivot as shown below.

The pivot point distance for: CV 42 (HDL 600)=28,4mm (11/8”)

CV 60 (HDL 700) =40 mm (1 37/64”).

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 takenbetween flange faces excluding pilot recesses.

V length= A+B+C+D4

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Checking the Aquadrive CV joint anglesFor 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 thatthe crossing point is approximately equal between the two joints. The joint angle can bechecked with a bevel gauge.

For the larger angles it is good working practice to use a jig to accurately determine theangles of each joint. We will be pleased to advise if a jig is recommended dependent uponparameters of the particular installation.

Fixed jig

A fixed jig is generally used with a new build installation where the engine/gearbox posi-tion 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 flatand spirit level. The engine/gearbox output coupling adapter face is then aligned accuratelywith the jigs forward flange, as if it where a conventional shaft coupling. The jig ismanufactured at the correct V-length and the Aquadrive CV joints will run precisely at thesame angles as the jig. Removing the locating bolt allows the jig to contract to enable theflanges to be lifted clear of the spigots or piloting recesses.

Do not exceed angle limits for a single joint

CAUTION!

Even distribution= optimum lifeUneven distribution= reduced life

Fabricated at correct V length.

Remove T bar and jigcan be compressed to lift off spigots.

Jig faces set up at correct angles measured at the pivot point position.

Flat on flange for spirit level.

Spigots to suit thrust bearing input flange or adapter.

(Note! angles are exaggerated.)

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Variable angle jig

A variable jig can be used when fitting an Aquadrive into an existing vessel where theexact joint angles cannot be pre-determined. In this instance, the variable jig ensures thatthe joints do not exceed their maximum permitted angles. Again, the jig is manufactured tosuit the correct V-length for the CV shaft. Depending upon the particular pivot distance, itis sometimes better to manufacture the jig to fit between the two flanges without theadapters. 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 alignmentadjusted until suitable angles are achieved at both joints. The jig is then removed and theadapters mounted before the CV shaft is installed.

Installing the Aquadrive CV shaftInstall 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 lockliquid provided (or equivalent) on the securing bolts and tighten to the torque setting for thebolt diameter as the standard table on the back page.

With the Aquadrive installed, it is essential to ensure that each joint has an equal plungemovement.

With the Aquadrive CV 42 (HDL 600) and CV60 (HDL 700) series CV shafts, the jointsare normally supplied without end caps and fit directly onto the adapters which are suppliedwith grease reservoirs. When installing CV shafts with no end caps, each joint should beapplied with the self-adhesive gasket and packed with the special high-temperature greasesupplied. Cleanliness is of utmost importance and the quantity of grease is critical to avoidover filling the joint. (Your local distributor will advise).

Like smaller CV-shaft models, Aquadrive CV42 (HDL 600) series CV shaft is alsoavailable as a pre-assembled unit, already packed with special high temperature grease.

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Thrust bearing units with clamp coupling - Installation of thepropeller shaft.

Measure the bored depth of the clamp coupling and mark off this measurement onto thepropeller shaft. The shaft must be put into the full depth of the coupling. It is always goodpractice to slightly chamfer the shaft leading edge if the shaft and remove any burs. Theshaft should be a “neat fit” and if the alignment is correct will slide straight into thecoupling.

Good alignment of the propeller shaft into the clamp coupling is vital importance for theperformance and life of the thrust bearing.

If the coupling clamp has been closed up, there may be some difficulty in getting the shaftto enter the bore of the coupling. (Provided of course that the correct coupling has beenselected for the shaft diameter – some metric and imperial sizes are very close to one an-other but are not a direct match). The bolts can be removed and the bore of the couplingexpanded slightly by screwing the two rear bolts in from the threaded side against a smallsteel plate in the clamping slot.

Tightening the clamp coupling bolts

Corrosion protectionOn completion of the installation, we recommend that the whole exterior of the

Aquadrive assembly, including CV shaft, thrust bearing unit and adapter, is protected withtwo coats of an anti-corrosion paint.

Service and MaintenanceThe 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 maintenancerequired to the Aquadrive CV joints. (Usually, joint maintenance is only required oncommercial craft with high annual service hours).

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“RUNNING IN” Aquadrive installations - sea trailsAs with all new mechanical components it is necessary to “run in” a new Aquadrive in-

stallation for a short period before using maximum revolutions. We recommend running atidle for 30 minutes, 50% of max RPM for 30 minutes and building up to maximum RPMafter 2 hours. High power and / or high-speed installations may require extended “runningin”. In such cases, the Aquadrive CV shaft can be “run in” prior to final installation in amachine shop to avoid long sea trials. Your local distributor will advise.

Other than checking that bolts remain proper tightened, the only concern is the operatingtemperatures of the CV joints and thrust bearings. Joints and bearing may run a little hot tostart with, the temperature dropping as the component “bed in”. Your local distributor willadvise on these matters prior to the craft running initial sea trials.

Torque settings for high tensile stainless bolts

Torque settings for stainless bolts in rubber mounts

Thrust bearing – Max RPM / Max static torque

IN THE EVENT OF ANY QUESTIONS, PLEASE CONTACT:

Local distributor:

Svenska Uni-Cardan AB, P O box 3100, SE 12703 Skärholmen SWEDENe-mail: info@unicardan.se

Bolt diameter Torque (Nm) Torque(lbft)

M 12 115 85

M 16 250 184

M 20 480 353

Bolt diameter Torque (Nm) Torque(lbft)

M 16 187 138

Thrust bearing Max. rpm Max. cont. torque Max. static torqueHDL 680 / HDL 700 1700 rpm 4 900 Nm 12240 Nm

HDL 780 1400 rpm 10 000 Nm 25000 Nm