Technical Manual Type Exj Seal

Deep Sea Seals Ltd.
TECHNICAL MANUAL
FOR
TYPE EXJ SEAL
ManeGuard EXJ O.D. Pressurised - Inboard Seal
for Water Jet Applications
Based on G.A. Drawing:

H76833-01
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.
1998, Deep Sea Seals Limited. All Rights Reserved.
TM-EXJ-02 81080 ISSUE A Issue Date: 06 July 2006

CONTENTS
SECTION SUBJECT PAGE
1. SPECIFICATIONS / TECHNICAL DATA ......................................................................... 3
2. INTRODUCTION .............................................................................................................. 4
3. DESCRIPTION OF THE EQUIPMENT............................................................................. 5
4. STORAGE AND HANDLING ........................................................................................... 7
5. PREPARATION................................................................................................................ 8
6. SUPPLY CONNECTIONS................................................................................................ 9
7. SPECIAL INTERFACING REQUIREMENTS................................................................. 10
8. INSTALLATION ............................................................................................................. 12
9. TESTING. ....................................................................................................................... 28
10. NORMAL OPERATION.................................................................................................. 29
11. LUBRICATION SYSTEM ............................................................................................... 30
12. RECOMMENDED LUBRICANT LIST ............................................................................ 31
13. PROBLEM SOLVING - Level 'a'.................................................................................... 32
14. MAINTENANCE ............................................................................................................. 39
15. SPARE PARTS AND THEIR STORAGE ....................................................................... 68
16. ATTACHMENTS ............................................................................................................ 69
TM-EXJ-02 81080 ISSUE A Page 2 of 69

1. SPECIFICATIONS / TECHNICAL DATA
WORKS ORDER NO. : 12000587 (4500228107-MP00096.M1J1 & M2J1).

OWNER : Istanbul Deniz Otobusleri.
VESSEL NAME :
YARD : Austal.
YARD No. : 294 & 295.
STERNTUBE/SHAFT SEALS
Forward/Inboard Seal(s)
Type: EXJ + Inflatable.
Size:# 258mm.
Drawing No.: H76833-01.
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.

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 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: 1 757 558 3625

Fax: 44 (0) 2392 492470 Fax: 1 757 558 3627
NETHERLANDS JAPAN
Wärtsilä Propulsion Netherlands BV Japan Marine Technologies Ltd.

Lipsstraat 52 5th Floor, NTC Building,
5151 RP Drunen 1-11-2 Kyobashi, Chuo-ku
Tokyo, 104-0031
Tel: 31 416 388115 Tel: 81 (0) 3 5159 8700

Fax: 31 416 374853 Fax:
81 (0) 3 5159 8710

3. DESCRIPTION OF THE EQUIPMENT
3.1. ManeGuard EXJ seals are high performance Elastomer Rubber Bodied Radial
Face Type seals.
3.2. The EXJ, seal described in this Technical Manual is a Partially Split, O.D.
Pressurised, Inboard unit for use with Water Jet input drive shaft applications.
3.3. Designed for High Speed, operating in shallow or dirty waters, the EXJ seal
offers a robust, reliable, "fit and forget" sternseal.
3.4. The EXJ advanced computer optimised design provides: A statically mounted
O.D. pressurised elastomer body capable of accepting large amounts of axial
and radial movements, misalignment and vibration. Hard wearing long life
Silicon Carbide Face and Seat components plus Bronze and Stainless Steel
metal components offer High Corrosion resistance.
3.5. The provision of Housing and End Cap assemblies allow the EXJ seal to be
O.D. pressurised which means that it will accept a more demanding operational
environment than an I.D. pressurised seal, as well as providing an enhanced
sealing performance.

3.6. The high performance materials used plus the resilient mounting of both the
face and seat - which have "lapped" surfaces - provides the following
"Benefits".
Reliable.
Accommodates misalignment, vibration and high axial and radial shaft

movement.
No liner required.
High Abrasion resistance of Face and Seat.
No Galvanic corrosion.
Extended life expectancy and service intervals.
Low through life costs.
Fit and Forget.
3.7. This combination provides a simple but very effective sealing arrangement
capable of accommodating both radial and axial shaft movements, resulting in a
"High Performance - Low Maintenance" sealing solution.

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 Ltd 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, (copy to DSS).
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 Silicon Carbide running/sealing surfaces of the face and seat.

5. PREPARATION
5.1. Remove all burrs and sharp edges from the shaft in the area the seal will be
fitted. 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 and the shaft are machined to the following parameters:
6.3 Jm Ra or finer (Sterntube/Housing)
# Surface Finish 0.8 Jm Ra or finer (Shaft area of O-cord and Drive
Clamp Ring)
# Flatness 0.08 mm.
# Perpendicularity 0.35 mm FIM (Measure outside of the bolting P.C.D.)
The forward end of the Sterntube/Housing must be machined to accept the

Centralising plate M12 securing studs and insulated centralising dowels as
detailed on the G.A. Drawing.
The 10 off M-12 studs (6-7) require 20mm equispaced clearance holes
through the sterntube flange on a 390mm p.c.d., positioned as shown on the
G.A. drawing.
The 2 bushed centralizing dowels (6-8/6-9) require 14mm equispaced holes

on a 390mm p.c.d., as shown on the G.A. drawing. However, these can only
be machined after the centralizing plate has been centralised to the shaft – see
Section 8 Installation.
5.3. All mating surfaces should be clean with no debris or old joint material, etc.
present.
5.4. It is essential that the running surfaces 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.

6. SUPPLY CONNECTIONS
The flush water for the seal will be provided from a pumped system.
Details should be as per the following:

7. SPECIAL INTERFACING REQUIREMENTS
When installed the EXJ Inboard seal interfaces with various elements and components
around it.
Ensuring that the interfacing requirements are met is essential to the successful
installation, operation and performance of the seal.
Four areas of interfacing are important.
7.1. The Bore/I.D. of the seat and drive clamp ring assemblies to the shaft -
The seal will be supplied with the bore of the Seat Housing and the D.C.R.
sized to suit the stated shaft diameter.
The shaft must be of the stated diameter(s) as detailed in the G.A. Drawing.
7.2. The Centralizing Plate interface -

The surface of the Sterntube/Housing to which the Centralizing plate is to be
fitted must comply with the requirements of Section 5 (Preparation).
The mounting surface must be prepared in accordance with the G.A. drawing
with regard to clearance holes etc. for mounting the Centralizing Plate and EXJ
seal to it.

7.3. Axial Space.
Though the Inboard EXJ seal does not require a "specific" Axial Space into
which to fit, the space must be sufficient.
Check that inboard of the surface to which the seal is to be fitted, there is
sufficient clear and unobstructed shaft available to fit the seal.
The length required is the Approx (imate) Overall length of the seal (as shown
on the G.A. Drawing) plus a 1.0 mm joint, plus the drain pipe length, plus the
compression to be applied to achieve the Working length.
The compression will not normally be shown on the Drawing but it is usually
about 9 mm across all seal sizes.
Thus the "Axial Space" required to install the seal is the Approximate Overall
Length plus 1.0 mm + 22.0 mm + 9 mm to allow for the un-compressed state of
the seal.
7.4. The connection of services.

All connections and services (flush water, drain and air supply) as detailed on
the G.A. Drawing must be provided, ready for connection.
(Section 6 and Section 8.10. also make reference to the service connections).

8. INSTALLATION
Refer to Drawing H76833-01 - see Attachments - Section 16
Note: The numbers in brackets in the following text, refer to the position numbers of
items and assemblies on the drawing.
8.1. General Advice.

The EXJ seal is designed to be installed only during the assembly of the
water jet unit as the seal contains some non-split components.
The Installation procedure is based upon fitting the seal with the Waterjet
drive shaft being able to be disconnected/de-coupled.
As referenced in "Preparation" and "Interfacing" (Sections 5. & 7.), the

components that the EXJ seal will interface with, must be arranged/prepared
as described in these Sections.
8.2. Warning.
The Silicon Carbide Interface components must be handled with extreme
care. Be careful not to chip any sharp edges, especially at the edge of the
running surfaces.

8.3. Installation Procedure.
8.3.1. The complete installation sequence is described below.

In the following sections, only those procedures that relate specifically
to the EXJ seal are described in detail.
Those assembly stages relating to the Waterjet/drive shaft should be

described in detail in the waterjet manual.
8.3.2. Installation Sequence:-

Insert the Waterjet drive shaft.
Install all non-split seal assemblies/components over the shaft.
Align the shaft.
Centralise the centralising plate to the shaft.
Check and confirm Perpendicularity of centralising plate.
If necessary, detach, remove and re-machine the centralising
plate to compensate for sterntube flange, then re-fit.
Fit Inflatable seal housing with Inflatable seal installed.
Fit the drive clamp ring at the “setting dimension”.
Fit the seat/seat housing assembly.
Fit the EXJ Face, Body, Housing and End Cap assemblies.
Install service connections the EXJ seal.
8.4. Waterjet drive shaft.
8.4.1. Insert the drive shaft assembly and enter it into the thrust bearing
block.
8.4.2. Ensure that before it becomes impossible to do so, the non-split

components and cartridges of the EXJ seal assembly are correctly
orientated and fitted over the shaft.

8.5. Centralising Plate Assembly.
8.5.1. Ensure that the centralising plate (6-1) and its joint (6-6) have been
correctly orientated and fitted over the aligned Waterjet drive shaft.
8.5.2. Lightly grease both sides of the joint (6-6) and fit it to the centralising
plate (6-1) with the holes in the joint aligned with those in the plate.
8.5.3. Apply a suitable liquid threadlocker (supplied) to the longer of the

threaded section of each of the M12 retaining studs (6-7) and screw
them into the centralising plate from the aft (non-spigotted) side.
Ensure that the studs do not protrude from the forward surface of the
centralising plate.
8.5.4. Align the centralising plate (6-1) with TDC (TDC is stamped on the
O.D. of the plate), and then enter the studs through the clearance
holes machined in the sterntube.
8.5.5. Apply a suitable liquid threadlocker (supplied) to the exposed threads

of the M12 studs (6-7), and then fit the insulating washers (6-4), the
bronze washers (6-3) and nuts (6-5) as shown on the G.A. Drawing.
8.5.6. Tighten the nuts (6-5) to hold the centralising plate to the sterntube and
centralise the I.D. of the plate to the surface of the shaft to within 0.5 mm.

8.5.7. Check the Perpendicularity of the forward (spigotted) surface of the
centralising plate (outside of the studs PCD) to the shaft. It should be
within 0.35 mm as per the G.A. Drawing and referenced in Section 5.2.
If the Perpendicularity is outside the stated tolerance, the shaft must

be de-coupled, the centralising plate (6-1) removed from the shaft and
the studs (6-7) removed from the plate so that the aft surface (the non-
spigotted surface) of the centralising plate can be machined so that
when re-fitted, the Perpendicularity of the forward surface will now be
within tolerance.
8.5.8. If the centralising plate (5-1) was removed for re-machining, refit it and
re-centralise it as described in 8.5.2. onwards. Now tighten the nuts
(6-5) using an even, progressive and diagonal sequence to the torque
indicated on the G.A. Drawing.
8.5.9. Re- check and re-confirm the plate (6-1) centralisation, then using the
two 6 mm pilot holes in the centralising plate, drill/machine holes
through the centralising plate and the sterntube flange to suit the two
centralising dowels (6-8). The dowels are nominally 10.0 mm , and
the holes through the centralising plate (not the sterntube flange)
should be reamed to suit the actual diameter but the dowels must not
yet be fitted.

8.5.10. From the aft side of the sterntube flange, open out the two c. 10mm
holes machined in the sterntube flange to accept the two insulating
bushes (6-9). These composite bushes have an O.D. of 14.0 mm. and
are 25.0 mm long. Machine/open out the two holes in the sterntube to
accept the two insulating bushes (6-9) then thoroughly clean and de-
burr the holes for the dowels and bushes from both sides.
8.5.11. Fit the two insulating bushes (6-9) from the aft surface of the sterntube
flange using Araldite adhesive so that the bushes are flush with the
flange surface.
8.5.12. When the adhesive used on the bushes is set, tap the bronze
centralising dowels through the bushes from the aft surface of the
sterntube flange and into the machined holes in the centralising plate
(6-1).

8.6. Inflatable Seal Assembly.
The Inflatable seal assembly (5) is non-split and as such should already be in
position over the now installed shaft, orientated correctly as shown in G.A.
Drawing.
The inflatable seal (5-2) should already be installed in the recess at the back of
the housing with the inflation tube/valve held in place with a nut and washer as
shown on the G.A. Drawing.
8.6.1. Apply grease to the o-cord (5-4) and fit it into the groove in the back of
the housing assembly. Butt the ends of the o-cord together and work it
into the groove until fully entered and fitted in place.
8.6.2. Move the inflatable seal housing aft, ensuring that the counter bored
holes for the securing screws (6-2) are aligned with the M12 tapped
holes in the centralising ring.
Note: The top of the housing is stamped TDC to aid alignment.
8.6.3. Apply a suitable liquid threadlocker to the inflatable seal housing

securing screws (6-2) and fit them through the counter bored holes in
the housing. Slowly and evenly tighten the housing screws (6-2) so
that the inflatable housing (5-1) is evenly drawn into its spigot location
with the centralising ring (6-1).
When the inflatable housing is fully engaged with the centralising ring,
fully tighten the securing screws (6-2) to the torque specified on the
G.A. Drawing, again using a progressive diagonal sequence.

8.6.4. With the Emergency Inflatable seal and housing fitted and centralized
(via its tight spigot location with the centralising ring), it should be
tested at this stage.
Connect a suitable foot pump or other satisfactory means of inflation to
the air supply connection on the I.S. housing and pressurize to 4 Bar.
The Emergency seal should blow down fully and evenly to tightly
contact the shaft all round.
This test is to determine that the Inflatable Seal activates. Next

conduct a pressure test on the Inflatable seal as described in Testing,
Section 9.
When the Inflatable seal has been successfully tested, remove the
pressure and/or the pump and confirm that the Inflatable Seal retracts
into the housing recess.
8.6.5. With the Emergency Inflatable seal fitted and tested, re-check the
torque of the lock nut on the inflation tube (it should only be 1Nm as
per the G.A. Drawing) and lock it in place by applying a drop or two of
a suitable liquid threadlocker to it.

8.7. Drive Clamp Ring Assembly.
8.7.1. The drive clamp ring (4-1) as a split component did not require
installation over the shaft prior to the shaft being coupled up and
aligned.
The two halves may have been joined together and secured to the
seat housing (1-3) for transit purposes. If so, carefully detach them
from the seat housing and undo the butt screws (4-2) allowing the two
halves to be separated.
Inspect the butt surfaces and the forward face of the drive clamp ring
(4-1) halves and ensure that they are free of any nicks or burrs.
8.7.2. Install one half of the drive clamp ring (4-1) on the top of the shaft, at
the indicated setting dimension, shown in the G.A. Drawing.
8.7.3. Place the other half of the drive clamp ring (4-1) underneath the shaft
and lift it up, ensuring that the setting dimension remains as indicated.
Install the butt screws (4-2) with a suitable liquid threadlocker applied
and carefully and evenly torque to the value shown in the G.A.
Drawing.
8.7.4. The drive clamp ring may be fitted either way round.

8.8. Seat Assembly.
8.8.1. The seat housing (1-3), as a split component did not require
installation over the shaft prior to the shaft being coupled up and
aligned.
The two halves of the seat housing may have been joined together
and secured to the drive clamp ring (4-1) with the silicon carbide
seat (1-1) fitted for transit purposes.
With the DCR (4-1) already separated and installed around the
shaft, carefully undo the seat housing butt screws (1-4) – if fitted -
allowing the two halves to be separated.
8.8.2. Clean the butt ends, o-cord recess, sealing strip and seat installation
areas of the seat housing (1-3) and ensure that there are no nicks,
burrs or signs of damage.
8.8.3. Apply a thin and even coat of RTV silicon sealant to the butt
surfaces of one half of the seat housing.
If not already fitted, fit the two small dowel pins (1-6) into the closed
hole in each butt (one in either half on opposing sides).
8.8.4. Orientate the two halves of the seat housing as shown on the G.A.
Drawing (recess for o-cord aft – seat/sealing strip recess forward)
and bring them together around the shaft.
Lightly secure them in place by applying a suitable liquid
threadlocker to the two seat housing butt screws (1-4) and carefully
engaging both screws by a few threads.
8.8.5. Carefully and evenly tighten both butt screws (1-4) ensuring that the
two small dowel pins (1-6) are perfectly aligned with and engaging in
the open holes in the opposing butt surfaces.
Continue tightening both butt screws to the torque specified on the
G.A. Drawing, so that the two halves of the seat housing are joined
together with no detectable step at the butts, especially in the seat
or the sealing strip areas.
8.8.6. Ensure that the O-cord recess is clean and clear of any dried
on/extruded butt sealant, and then generously grease the recess.
8.8.7. Fit the O-cord (1-5) around the shaft between the drive clamp ring
(4-1) and the seat housing. Butt the two ends of the O-cord together
(do not bond or otherwise join the end of the O-cord). Arrange the
join in the O-cord so that it is at 90° to the butt joins in the seat
housing, then fit the O-cord into the recess in the seat housing.
Ensure that the O-cord is fully entered into the recess and that the
two ends remain firmly and squarely butted together.
Note: O-cords are supplied (apparently) overlength to ensure that

when fitted in a groove or recess, the end press hard together and
form a good seal.
Do not cut or shorten the O-cord and do not bond its ends together.
8.8.8. Slide the joined seat housing (1-3) aft so that it contacts the drive
clamp ring (4-1). Align the seat housing with the drive clamp ring so
that the holes for the hex head drive screws (1-7) are in line.
Apply a suitable liquid threadlocker to the drive screw threads (1-7),

then insert and tighten the screws in an even, progressive and
diagonal sequence to the torque value as shown in the G.A.
Drawing.

8.8.9. Clean and apply a coating of a weak soapy water solution to the
recess in the Seat Housing (1-3) where the Sealing Strip (1-2) will fit.
8.8.10. Insert the Sealing Strip (1-2) into the recess ensuring that the
radiused edge of the strip is outboard and on the inner diameter.
8.8.11. The Sealing Strip is provided overlength (see below). To overcome

the “apparent” excess length, the strip ends should be butted
together in the recess (not glued or bonded) and the excess rubber
slowly worked around whilst exerting light pressure on the loop.
NOTE: As above, the Sealing Strip is supplied overlength to ensure that the
ends butt hard together and that the strip fully supports the seat.
The Sealing Strip must not be cut or shortened.
8.8.12. Before fitting the Seat (1-1) into the Sealing Strip (1-2), apply a weak
soapy water solution to the exposed surfaces of the Sealing Strip.

8.8.13. Carefully position the non-split Silicon Carbide Seat (1-1) and insert
it into the Sealing Strip (1-2). Ensure that the Seat (1-1) is fully
inserted into the Sealing Strip (1-2).
It is very important that the seat is fully inserted into the sealing strip
and is perfectly flat.

8.9. Face, Body, Housing and End Cap Assembly.
8.9.1. This part of the seal assembly comprises the static part of the seal
(apart from the already installed centralising plate and inflatable seal
assemblies).
It has already been fitted over the shaft prior to its coupling up and
alignment.
The fitting of this assembly to the inflatable seal housing will set the
compression on the seal and complete its installation.
8.9.2. Lightly grease both sides of the joint (3-6) and fit it over the spigot
location at the aft end of the housing (3-1) if it is not already in
position. Align the joint so that all the securing screw holes are
clear, and then fit the screws (5-3) (with a suitable liquid
threadlocker applied) through the holes in the housing flange (3-1).
8.9.3. Very carefully move the housing (which contains the bellows and
face assemblies) aft along the shaft, towards the inflatable seal
housing and the seat/dcr assemblies.
Ensure that the housing is aligned re. TDC (one half of the housing
(3-1) is stamped TDC in line with one of the water flush
connections).
This should position the drain pipe in the already assembled end
cap (3-2) at BDC.

8.9.4. Slowly engage the spigot location of the housing (3-1) into the spigot
recess in the inflatable seal housing (5-1).
8.9.5. Use the screws (5-3) to evenly engage and draw in the housing
spigot location into the inflatable seal housing.
Evenly tighten all the securing screws (5-3) using a progressive and
diagonal sequence to achieve the torque figure given on the G.A.
Drawing.
8.9.6. With the rotating element of the seal assembly (the seat and dcr)
locked to the shaft at their setting dimension, this fitting of the
stationary bellows/face assemblies as part of the housing sets the
correct operating compression on the seal.

8.10. Service Connections.
8.10.1. Both flush water connections plus the air supply and drain pipe should
now be connected to appropriate supply/drain lines and services using
flexible connections as close to the seal as is possible.
Note: The inflatable seal has a flexible connector supplied with it
which fits to the steel inflation tube.
8.10.2. Referring to the G.A. Drawing, connect an appropriate flush water

supply to the two ½” BSPT flush connection positions which should
now be at TDC and BDC on the seal housing (3-1).
The single air connection to the Inflatable seal; is positioned in the
inflatable seal housing (5-1) as shown on the G.A. Drawing and will be
at 27° off TDC.
The single drain pipe (6 mm ) is to be found in the end-cap (3-2)
positioned at BDC.

8.10.3. Before connection, ensure that all service pipelines are clean and clear
of debris such as internal scale etc.
8.10.4. It is important that Water and Air are provided to the seal “in the
quantities and pressures as defined by the G.A. Drawing”.
Further, the water supply to the seal should be filtered to 200 micron or
better.
8.10.5. The single inflatable seal connection must be vented to atmosphere

when not in use.
8.10.6. It is important that water is provided to the seal "in the quantity,
pressure, temperature and of the cleanliness as defined by the G.A.
Drawing".

9. TESTING.
After the Seal has been fitted and compressed and with the Flush connections made as per
Section 8.10, it is possible to test the Seal.
9.1. Emergency Inflatable Seal.

The emergency seal is normally operated using compressed air or alternatively
CO2. Air (or CO2) should be available and used during routine testing and
when overhauling the EXJ seal afloat. In an emergency, should air or CO2 not
be available, then a suitable pressurised fluid such as fresh water or sea water
can be used to activate the inflatable seal.
Refer to Section 8.10, (Service Connections) regarding piping connections.
Test the inflatable using pressure to a maximum figure on the G.A. Drawing.
Refer to Section 8.6.4, when testing the inflatable and check that the seal is
hard against the shaft all round.
After the function test of the inflatable referenced in Section 8.6.4, carry out a
pressure drop test by increasing the pressure on the inflatable seal to 6.0 Bar
and closing the supply valve.
Isolate the supply for 10 minutes there should be a zero pressure drop over this
period of time.
9.2. Main Seal.

After the Seal has been fitted and compressed, and with the flush connection
made as per Section 8.10, proceed to test the Main Seal as follows:
With the air supply to the inflatable seal on, at the activation pressure as stated
on the G.A. Drawing, apply water pressure to the main seal via the water flush
(filtered to 200 micron or better) connection. A small leakage of c. 60ml/hour
between the face and seat is acceptable on static test.

10. NORMAL OPERATION
During Normal Operation with the EXJ seal functioning within parameters, all
conditions should be stable.
10.1. Stable Operating Conditions.
10.1.1. Water ingress within acceptable limits.
10.1.2. No noticeable signs of the seal overheating
10.2. Routine checks that should be conducted.
10.2.1. Check for leakage routinely.
10.2.2. Check for signs of overheating routinely.
10.2.3. Check for flush water flow rate to the seal routinely.
10.2.4. Check the position (open/closed) of the flush water supply valve(s)
routinely (if not locked in position).
10.2.5. Check the operation of any flush supply pumps, filters etc. (if fitted) on
a routinely basis.
10.2.6. Check the flush water flow alarm (if fitted) - monthly for correct
operation.

11. LUBRICATION SYSTEM
For an EXJ-Inboard, O.D. pressurised, Water Lubricated seal, see below:
Refer also to the G.A. Drawing which similarly defines the requirements of the system
with respect to pressures and required differentials as well as flow rates.
Note: The flush water supply rate of 258 litres per hour is based on the EXJ
standard requirement of 1 Litre/mm of shaft diameter/Hour.
This flush rate represents the "minimum" recommended cooling water flow
rate.

12. RECOMMENDED LUBRICANT LIST
For an EXJ-Inboard seal used in an "Open Water" lubrication system there are
obviously no recommended lubricants.
The EXJ-Inboard, O.D. Pressurised, Water lubricated seal is designed to work equally
well on Seawater or Fresh (River or Lake) Water or on a mixture (Estuarine) of these.
What is important is that the flow rate stated on the G.A. Drawing (which is a minimum
figure) is maintained "whenever" the shaft is dynamic.
Further: The flush must be filtered and of a temperature not exceeding the limit
figures stated on the G.A. Drawing.
Note: The reference to a “minimum” filter requirement on the G.A. drawing means
the minimum quality level that is acceptable, not the minimum mesh size.
The required level of filtration is that stated on the G.A. Drawing (i.e. 200Jm)
– “or better”.

13. PROBLEM SOLVING - Level 'a'
13.1. Any problems with the EXJ (Open Water) Inboard seal will normally show
themselves in one of two ways:
a) Water leakage from the seal.
b) Over heating of the seal.
(Refer to the associated causes and corrective actions in Section 13.4 and
13.5).
13.2. Evidence that either 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) Excessive Water leakage during routine inspection of the seal (Flow chart
13.3.2.)
ii) A high level alarm warning from the Bilge Alarm (Flow chart 13.3.3.)
iii) A low flow in the Flush Supply activating the Low Flow alarm if one is fitted
(Flow chart 13.3.4.)
iv) A high seal (Housing or Water Drain) temperature, during routine

inspection of the seal temperature. (Flow chart 13.3.5).
13.3. "Flow Charts".

Explanations of the above, including cause, effect and corrective actions now
follow:
13.3.1. Normal Operation

For Normal Operating Conditions, refer to Section 10.

13.3.2. WATER LEAKAGE
WATER LEAKAGE
OPERATE BILGE
PUMP TO REDUCE
BILGE LEVEL
CHECK WATER CHECK

SYSTEM 1
PRESSURE/FLOW
HIGH YES CORRECT TO

PRESSURE/ MEET SYSTEM
FLOW REQUIREMENTS
NO
WORN OR
DAMAGED YES REPLACE
COMPONENTS COMPONENTS
?
RESET BILGE PUMP

OPERATION TO NORMAL

13.3.3. BILGE HIGH LEVEL ALARM
HIGH BILGE
LEVEL ALARM
CHECK CHECK BILGE

1
LEVEL
IS
LEVEL NO REPAIR/RELACE FAULTY
HIGH LEVEL SWITCH
?
YES
OPERATE BILGE PUMP

TO REDUCE LEVEL
CHECK CHECK BILGE

2
LEVEL
IS
LEVEL
HIGH
?
NO YES
CHECK FOR OTHER REFER TO

REASON (S) FOR CHART 2 – CHECK 1
HIGH BILGE LEVEL (SECTION 13.3.2)
ONWARDS

13.3.4. LOW FLUSH SUPPLY FLOW ALARM
LOW FLUSH
FLOW ALARM
CHECK VISUALLY CHECK

1 FOR WATER FLOW
THROUGH METER
IS YES REPAIR / REPLACE

WATER FLOW FAULTY FLOW
RATE OK LEVEL ALARM
NO
CHECK CHECK FLUSH

2 SUPPLY VALVES ARE
CORRECTLY POSITIONED
ARE
NO RESET TO
VALVES ALL
RE-ESTABLISH
SET OK
CORRECT FLOW
?
YES
CHECK CHECK FLUSH SYSTEM

3 SUPPLY PUMP(S)
AND FILTERS
ARE
PUMP(S), FILTERS NO RESET, REPAIR, CLEAN
ETC. FUNCTIONING OR REPLACE
CORRECTLY DEFECTIVE COMPONENTS
?
YES
CHECK FOR BLOCKAGE /

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

13.3.5. HIGH SEAL TEMPERATURE
HIGH SEAL
TEMPERATURE
CHECK CHECK FLUSH SUPPLY

1
TO SEAL
REFER TO
IS YES CHART 4 – CHECK 2
FLUSH FLOW
(SECTION 13.3.4)
LOW?
ONWARDS
NO
CHECK OPERATING SPEED (RPM) AND

CHECK
2 WATER PRESSURE ARE WITHIN
PARAMETERS ON G.A. DRAWING
IS NO BRING OPERATIONAL
OPERATION PARAMETER WITHIN
O.K.? STATED LIMITS
YES
CHECK WATER FLUSH

CHECK TEMPERATURE WITHIN THE
3
MAXIMUM LIMIT DEFINED ON
THE G.A. DRAWING
IS WATER REDUCE TEMPERATURE

NO
TEMPERATURE OF FLUSH WATER IS
OK? REQUIRED
YES
CONSULT DEEP SEA SEALS

13.4. SECTION "A" - WATER LEAKAGE FROM THE SEAL.
Water leakage from the Inboard seal may be due to one or more causes. For
each, a suggested course of corrective actions follow:
CAUSE CORRECTIVE ACTION
A1 Water pressure/flow too high a Reduce to that stated on the G.A.

Drawing and in the Technical
Manual.
A2 Loss of seal compression due to a Strip down the seal.

age or wear Replace the component(s)
responsible for the loss of
compression.
A3 Insufficient compression due to a Strip down the seal.

installation or axial shaft Establish the correct compression by
movement resetting the seat housing.
b Determine and rectify the causes of

excessive shaft movement.
A4 Debris between the Face and a Strip down the seal.

Seat. Carefully remove any debris. If no
damage has occurred a good seal
should be re-established. If damage
has occurred - refer to "A5".
A5 Damage to the seal. a If the seal is damaged and is leaking

then it must be stripped down.
Replace damaged components as
soon as is possible.

13.5. SECTION "B" - EVIDENCE OF OVERHEATING OF THE SEAL
As for Water Leakage, Overheating may be due to one or more causes.
For each, a suggested course of corrective actions follow:
CAUSE CORRECTIVE ACTION
B1 Water pressure/flow too low. a Increase to that stated on the G.A.

drawing and in the Technical Manual.
B2 Loss of Water Flush. a Check and re-set all flush supply

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.
B3 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
to allow continued operation 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 Introduction (Section 2) of the Technical Manual.

14. MAINTENANCE
(Refer to relevant Drawing(s) – see Attachments - Section 16)
14.1. The need for "Maintenance"
This may be determined by several factors which are performance related.

Alternatively, though the performance of the seal 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 an
assembly that is itself needing or due for maintenance!
14.2. Factors that normally determine the need for Maintenance are:
14.2.1. Performance :-
Water leakage through the seal.
14.2.2. Wear:-
Wear is normally associated with the "face" and "seat" in a radial face
type seal.
However due to the extreme Durability and resistance to abrasion of
Silicon Carbide materials used for these components in the EXJ seal,
wear will not normally be a factor.
Normally a water lubricated seal operating "deep sea" experiences low
levels of wear, however, operation in abrasive conditions, may lead to
higher wear rates than when operating in clean water.
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.
Further, the materials used in the seal are specifically chosen to prevent
and resist corrosion caused by exposure to seawater.
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 EXJ elastomer components, the Seat
cup, O-cords, Body and Insert is 10 years (elapsed time - not just
operation) and renewal must be carried out every 2nd 4/5 year docking.
However, it is good practice to replace all elastomer components on a

4/5-year basis co-incident with a major overhaul/docking of the vessel.
Periodic replacement of the EXJ Body is necessary because on
assembly the Body is compressed in order to provide the necessary
closing force between the face and seat. Elastomers lose "elasticity"
over a period of time and the Bellows will develop a "permanent set"
with a subsequent loss of closing force.

14.3. Refurbishment.
None of the EXJ seal components or assemblies are considered to be

refurbishable as such.
Repair or Maintenance is by component replacement.
A new seal face or seat should not be run against a previously used seat or
face that exhibits any evidence of wear or grooving. One or both interfaces
should be replaced where any signs of wear are evident.
All elastomers should, as referenced above, be replaced every 4/5 years during
routine overhaul/Dry - docking.
Also, if any elastomer is disturbed, it should be replaced.
14.4. EXJ seal dismantling/maintenance procedures.
These cover 2 levels of overhaul.
(a) Shaft in-situ:

T Face and seat assemblies - replacement.
(b) Shaft decoupled or removed:
T Removal of the complete EXJ seal to a workshop for disassembly,
complete overhaul and re-build.
Note: When working on the seal with the shaft in-situ, the shaft must be stopped
and locked - to prevent accidental rotation.
Note: If the shaft is to be moved or removed – the EXJ seal must be
disassembled first – to prevent damage to the seal.

14.5. Level (a) In-Situ Seal Overhaul Procedure: - Disassembly.
A level (a) overhaul is conducted either afloat (with the inflatable seal activated
to isolate the sterntube), or with the vessel out of the water and “dry”.
Overhaul is limited to the replacement of the primary sealing elements, the

silicon carbide face and seat with split spares, their associated seat sealing
strip and seat housing o-cord plus a split housing joint.
These level (a) split spares are contained in “Service Kit A” (7) as detailed on
the G.A. Drawing.
Access is effected by disconnecting the housing (3-1) from the inflatable seal
housing (5-1) and then splitting and removing the seal housing (3-1) to gain
access to the face and seat assemblies.
14.5.1. With the shaft stopped and locked, ensure that the system supplying
water to the seal is either shut down or isolated.
Disconnect all flush water and drain pipe connections to the EXJ seal.
14.5.2. If the in-situ overhaul is being conducted in water, the inflatable seal
must be activated and kept inflated for the duration of the overhaul.
Refer to Section 9.1., close the vent to the inflatable seal and apply 4
Bar pressure to isolate the sterntube during the overhaul.
Only increase the pressure (in stages) up to the 6.0 Bar maximum if
necessary.
14.5.3. As stated in Section 14.3, none of the components of the EXJ Seal are
"refurbishable" as such. A level (a) overhaul comprises opening up the
seal and replacing components with those contained in service kit A.
14.5.4. When removing any elastomer (rubber) component, ensure that

replacement spares are available.
All non-elastomer components should be re-usable as long as they
exhibit no signs of wear or damage though a level (a) overhaul
presumes the replacement of the face and seat.
Proceed as follows:

14.5.5. Detach the non-split end cap (3-2) from the housing (3-1) by undoing
and removing the 10 off cap head screws (3-3) and pulling the end cap
(3-3) forward along the shaft and clear of the seal assembly.
Four off M6 jacking positions are provided in the end plate to assist in
its removal should they be required.
14.5.6. Support the housing (3-1), then undo and remove 10 off cap head
screws (5-3) that secure the housing (3-1) to the inflatable seal
housing (5-1).
14.5.7. The flange from which the securing screws (5-3) have just been
removed has 2 off M12 jacking positions in each half.
Use these jacking positions to carefully and evenly disengage the
housing spigot from the spigot recess in the inflatable seal housing.
14.5.8. With the housing (3-1) still supported and now disengaged from the
I.S. housing, carefully move the housing forward along the shaft to
clear the seat assembly which is still fixed to the shaft.

14.5.9. Carefully remove the two bronze alignment dowels (3-7) from the butts
of the housing by knocking them through. Then undo and remove the
housing butt screws (3-4) which will allow the two halves of the
housing (3-1) to be separated and removed from around the seal
bellows (2-1) and the shaft.
Note: On assembly, the two halves of the housing were jointed using
a butt jointing compound.
14.5.10. Carefully slide the bellows assembly (2) forward to separate the face
from the seat.
14.5.11. Examine the now exposed face (2-2). Unless it is in perfect condition,
exhibiting no visible signs of wear or damage, it should be replaced.
Before removing the face, ensure that a replacement split face (7-1) is
available.
14.5.12. Evenly undo and remove the two pairs of butt screws (2-4) holding
together the two halves of the split face clamp (2-3). Remove the two
halves of the face clamp from around the end of the bellows.

14.5.13. Having confirmed that a new split face (7-1) is available, crack or cut the
old silicon carbide face (assuming an un-split face is currently fitted) and
remove it from the shaft.
14.5.14. As for the face, check that a new split seat is available (7-2) and also a
new sealing strip (7-3), before attempting to remove the old seat. Then
ease the silicon carbide seat out of its sealing strip, and if non-split, cut or
crack it to remove it from the shaft. Remove and discard the old sealing
strip (1-2).
14.5.15. Undo and remove the hex head drive screws (1-7) that secure the seat
housing (1-3) to the drive clamp ring (4-1). Pull the seat housing (1-3)
forward to separate it from the drive clamp ring – there should be no
need to disturb the d.c.r. which should be at its setting dimension.

14.5.16. Undo and remove the seat housing butt screws (1-4) and carefully
separate the two halves of the seat housing.
Note: The seat housing was joined on installation using butt jointing
compound and has two small alignment dowels (1-6), one in each butt.
Remove and discard the old seat housing o-cord (1-5).
14.5.17. Thoroughly clean all removed and newly exposed items/surfaces that
are to be re-used. Ensure that the requisite split spares (contained in
service kit A (7) are available for the reassembly.
The EXJ seal is now ready to be re-built as follows:

14.6. Level (a) In-Situ Seal Overhaul Procedure: - Re-assembly.
14.6.1. Ensure that all components/items remaining in situ around the shaft
are perfectly clean and fit for re-use. All split items removed from
the shaft that are to be re-used should also be perfectly clean and fit
for re-use. Thoroughly clean all exposed areas of the shaft.
Ensure that the appropriate split spares as contained in service kit A

are available for the re-build of the seal.
14.6.2. Confirm that the drive clamp ring (4-1) is at its setting dimension and
the d.c.r. butt screws (4-2) are torqued to the figure as stated on the
G.A. Drawing.
14.6.3. Clean the butt ends, o-cord recess, sealing strip and seat installation
areas of the seat housing (1-3) and ensure that there are no nicks,
burrs or signs of damage.
14.6.4. Apply a thin and even coat of RTV silicon sealant to the butt
surfaces of one half of the seat housing.
If not already fitted, fit the two small dowel pins (1-6) into the closed
hole in each butt (one in either half on opposing sides).

14.6.5. Orientate the two halves of the seat housing as shown on the G.A.
Drawing (recess for o-cord aft – seat/sealing strip recess forward)
and bring them together around the shaft.
Lightly secure them in place by applying a suitable liquid
threadlocker to the two seat housing butt screws (1-4) and carefully
engaging both screws by a few threads.
14.6.6. Carefully and evenly tighten both butt screws (1-4) ensuring that the
two small dowel pins (1-6) are perfectly aligned with and engaging in
the open holes in the opposing butt surfaces.
Continue tightening both butt screws to the torque specified on the
G.A. Drawing, so that the two halves of the seat housing are joined
together with no detectable step at the butts, especially in the seat
or the sealing strip areas.
14.6.7. Ensure that the O-cord recess is clean and clear of any dried on or
extruded butt sealant, and then generously grease the recess.

14.6.8. Fit the O-cord (7-4) around the shaft between the drive clamp ring (4-1)
and the seat housing. Butt the two ends of the O-cord together (do not
bond or otherwise join the end of the O-cord). Arrange the join in the O-
cord so that it is at 90° to the butt joins in the seat housing, then fit the O-
cord into the recess in the seat housing.
Ensure that the O-cord is fully entered into the recess and that the two
ends remain firmly and squarely butted together.
Note: O-cords are supplied (apparently) overlength to ensure that when

fitted in a groove or recess, the end press hard together and form a good
seal.
Do not cut or shorten the O-cord and do not bond its ends together.
14.6.9. Slide the joined seat housing (1-3) aft so that it contacts the drive clamp
ring (4-1). Align the seat housing with the drive clamp ring so that the
holes for the hex head drive screws (1-7) are in line.
Apply a suitable liquid threadlocker to the drive screw threads (1-7), then
insert and tighten the screws in an even, progressive and diagonal
sequence to the torque value as shown in the G.A. Drawing.
14.6.10. Clean and apply a coating of a weak soapy water solution to the recess in
the seat housing (1-3) where the sealing strip (7-3) will fit.

14.6.11. Insert the sealing strip (7-3) into the recess ensuring that the
radiused edge of the strip is outboard and on the inner diameter.
14.6.12. The sealing strip is provided overlength (see below). To overcome

the “apparent” excess length, the strip ends should be butted
together in the recess (not glued or bonded) and the excess rubber
slowly worked around whilst exerting light pressure on the loop.
NOTE: As above, the sealing strip is supplied overlength to ensure that the
ends butt hard together and that the strip fully supports the seat.
The sealing strip must not be cut or shortened.
14.6.13. Before fitting the seat (7-2) into the sealing strip (7-3), apply a weak
soapy water solution to the exposed surfaces of the sealing strip.

14.6.14. Carefully place the two halves of the (spare-split) Silicon Carbide seat
(7-2) around the shaft, orientated as shown on the G.A. Drawing.
Ensure that the “cracked” butts of the seat halves perfectly match,
then carefully position the split Silicon Carbide seat (7-2) and insert it
into the sealing strip (7-3).
Ensure that the seat (7-2) is fully inserted into the sealing strip (7-3).
It is very important that the seat is fully inserted into the sealing strip and
is perfectly flat.
14.6.15. Carefully place the two halves of the (spare-split) Silicon Carbide face
(7-1) around the shaft, orientated as shown on the G.A. Drawing.
Ensure that the “cracked” butts of the face halves perfectly match.
14.6.16. Carefully push the face (7-1) into the recess of the front of the bellows
(2-1).
Ensure that the face is fully entered into the recess and it contacting
the bellows on its O.D. and back surfaces as shown in the G.A.
Drawing.

14.6.17. Place both halves of the face clamp (2-3) around the bellows
assembly (orientate the clamp ring as shown on the G.A. Drawing).
14.6.18. Apply liquid threadlock (supplied by DSS) to the threads of the face
clamp butt screws (2-4) and lightly tighten them.
14.6.19. Re-check the face. It is very important to ensure that no step is

detectable at the butt joins.
14.6.20. Tighten the face clamp butt screws (2-4) evenly and progressively
(maintaining an even gap at the butts) to the torque value shown on
the G.A. Drawing.
14.6.21. The housing (3-1) must now be re-joined around the bellows
assembly, taking particular care not to damage or displace the
newly fitted spare silicon carbide face and seat.
14.6.22. Apply the supplied butt jointing compound to the butt surfaces of one
half of the casing (3-1). Join the two halves of the casing (3-1)
together (correctly orientated as shown on the G.A. Drawing) so that
the feature on the inside of the housing engages in the groove
behind the flange of the bellows (2-1). The casing must be
supported while it is not joined to the inflatable seal housing.

14.6.23. Apply a suitable liquid threadlocker to the housing butt screws (3-4)
and lightly tighten them to hold the two halves of the casing (3-1)
together. Fit the two bronze dowels (3-7) – one through each butt
flange – to ensure perfect alignment of the two halves. Then fully
tighten the butt screws (3-4) to the torque specified on the G.A.
Drawing.
14.6.24. Locate the TDC position stamped on the casing (3-1) flange, and
then orientate the non-split end cap (3-2) so that the drain pipe will
be positioned at BDC.
Fit the end-cap (3-2) using the cap screws (3-3) having first applied
a suitable liquid threadlocker, and then tighten them using an even,
progressive and diagonal sequence to the torque specified on the
G.A. Drawing.
14.6.25. Lightly grease both sides of the spare split joint (7-5) and fit it over
the spigot location at the aft end of the housing (3-1). Align the joint
so that all the securing screw holes are clear, and then fit the screws
(5-3) (with a suitable liquid threadlocker applied) through the holes in
the housing flange (3-1).

14.6.26. Very carefully move the housing (which contains the bellows and face
assemblies) aft along the shaft, towards the inflatable seal housing and
the seat/dcr assemblies.
Ensure that the housing is aligned re. TDC (one half of the housing (3-
1) is stamped TDC in line with one of the water flush connections).
This should position the drain pipe in the already assembled end cap
(3-2) at BDC.
14.6.27. Slowly engage the spigot location of the housing (3-1) into the spigot
recess in the inflatable seal housing (5-1).
14.6.28. Use the screws (5-3) to evenly engage and draw in the housing spigot
location into the inflatable seal housing.
Evenly tighten all the securing screws (5-3) using a progressive and
diagonal sequence to achieve the torque figure given on the G.A.
Drawing.
14.6.29. With the rotating element of the seal assembly (the seat and dcr)
locked to the shaft at their setting dimension, this fitting of the
stationary bellows/face assemblies as part of the housing sets the
correct operating compression on the seal.
14.6.30. Complete the re-installation of the EXJ seal by re-connecting the

service connections as described in Installation Section 8.10, and then
testing the seal as described in Section 9.

14.7. Level (b) Workshop Overhaul Procedure: - Disassembly from shaft.
14.7.1. In order to remove the EXJ seal to a workshop in order to effect a

complete strip down and re-build, the vessel must be dry (i.e. out of the
water or in a dry-dock) and either the seal is removed forward from a de-
coupled shaft, or the shaft is withdrawn outboard after the seal has been
freed from where it is fitted to the shaft.
It is important that if the shaft is being withdrawn or moved, for any

reason whatsoever, that the EXJ seal is disconnected from the shaft and
ideally removed.
The following disassembly procedure is written based on the shaft

remaining in position but disconnected/de-coupled forward of the EXJ
seal allowing removal via this route.
14.7.2. Ensure that all necessary spares are available to conduct a workshop
overhaul and re-build – reference service kit B (8).
14.7.3. Support the housing (3-1), then undo and remove 10 off cap head screws
(5-3) that secure the housing (3-1) to the inflatable seal housing (5-1).
14.7.4. The flange from which the securing screws (5-3) have just been removed
has 2 off M12 jacking positions in each half.
Use these jacking positions to carefully and evenly disengage the
housing spigot from the spigot recess in the inflatable seal housing.
14.7.5. With the housing (3-1) still supported and now disengaged from the I.S.
housing, carefully move the housing forward along the shaft to clear the
seat assembly which is still fixed to the shaft. Remove the whole housing
and end-cap assembly with the bellows assembly still inside it to a
workshop for further disassembly.

14.7.6. Ease the silicon carbide seat out of its sealing strip, and remove it from
the shaft. Remove and discard the old sealing strip (1-2).
14.7.7. Undo and remove the hex head drive screws (1-7) that secure the seat
housing (1-3) to the drive clamp ring (4-1). Pull the seat housing (1-3)
forward to separate it from the drive clamp ring.
14.7.8. Undo and remove the seat housing butt screws (1-4) and carefully
separate the two halves of the seat housing.
Note: The seat housing was joined on installation using butt jointing
compound and has two small alignment dowels (1-6), one in each butt.
Remove and discard the old seat housing o-cord (1-5).

14.7.9. Undo and remove the drive clamp ring butt screws (4-2) and separate
the two halves of the d.c.r. and remove them from the shaft.
14.7.10. Separate and remove the inflatable seal assembly (5) from the
centralising plate (6-1) by undoing and removing the cap head screws
(6-2). With the retaining screws removed, pull the I.S. housing forward
to disengage it from its spigot location with the centralising plate and
remove it from the shaft.

14.7.11. Finally remove the centralising plate only if it is necessary to replace
the joint (6-6). Unless it is known that this joint has deteriorated, the
centralising plate should be left in position ready for the re-building of
the seal.
The insulating washers ((6-4) can be renewed by undoing the securing

nuts (6.5) and replacing the composite washers one at a time.
14.7.12. The following assumes that the centralising plate assembly (6) remains
in place while the rest of the EXJ seal is overhauled.

14.8. Level (b) Workshop Overhaul Procedure: - Workshop strip-down.
14.8.1. Following the disassembly described in Section 14.7, the following

components and assemblies will be in the workshop requiring in some
cases further disassembly. They are:
The inflatable seal assembly – requiring further disassembly.
The drive clamp ring assembly –already disassembled.
The seat assembly – already disassembled, and:
The housing and bellows assemblies – requiring further
disassembly.
14.8.2. Place the inflatable seal housing on a clean work-surface with the
inflatable seal uppermost.
Undo the nut and remove it and the washer from the inflation tube.
Withdraw the old inflatable seal (5-2) from the recess in the housing (5-
1) and the tube from the hole in the housing.
14.8.3. Remove the o-cord (5-4) if it is still fitted in the o-cord groove and
remove any traces of the joint (3-6) from the other side of the housing.
Thoroughly clean all surfaces of the inflatable seal housing (5-1)
especially the o-cord groove and the inflatable seal recess and tube
hole.
Ensure that the inflatable seal housing is ready for re-use and re-
assembly.
14.8.4. Thoroughly clean the drive clamp ring assembly components and
ensure that they are ready for re-use and re-assembly.

14.8.5. Mount the housing and bellows assembly on a clean work-surface with
the end-cap (3-1) uppermost.
14.8.6. Undo and remove the securing screws (3-3) from the end-cap and
then remove the end-cap from its spigot location in the housing (3-1).
Note: The end cap has 4 off M6 jacking holes provided to assist in
removal should it be necessary.

14.8.7. Reverse the housing/bellows assembly on the work-surface so that it is
now sat on the end from which the end-cap has just been removed.
14.8.8. Locate the two bronze alignment dowels (one in each butt flange) and
tap them through to remove them.
Undo and remove the cap head screws (3-4) holding the two halves of
the housing (3-1) together.
14.8.9. Separate the two halves of the housing (3-1) from around the bellows
assembly – the two halves were jointed using a butt jointing compound
on assembly.
Remove the two halves of the now split housing.

14.8.10. Undo and remove the cap-head screws (2-4) holding the two halves of
the split face clamp (2-3) together.
Separate the two halves of the face clamp and remove them from
around the bellows (2-1).
14.8.11. Remaining on the work-surface should be the bellows (2-1) with insert
(2-5) and bonded in support ring (2-6) plus the old face (2-2).
In a level (b) overhaul all these items should be replaced using new
spare parts from the service kit B. Confirm that all the components
necessary for a level (b) overhaul are available and in perfect
condition, then discard the old components remaining on the work-
surface.
14.8.12. All removed components that are being re-used should be perfectly
clean and fit for purpose.

14.9. Level (b) Workshop Overhaul Procedure: - Workshop re-build.
14.9.1. The workshop re-build is conducted using non-split spares as

contained in service kit B.
The following procedure assumes that all components are supplied
as individual items (i.e. not already built up into assemblies or partial
assemblies).
14.9.2. Place a new bellows (8-5) flange at the bottom on a clean work
surface.
14.9.3. Fit a new rubber insert (8-10) into the inside of the bulge in the
bellows (8-5) as shown on the G.A. Drawing.
Note: the insert is not bonded into the bellows.

14.9.4. Apply a suitable adhesive (e.g. Araldite) to the notch in the inside of
the bellows (8-5) where the bellows support ring (8-11) will fit.
Carefully insert the support ring into the bellows so that the key
feature on the ring (8-11) engages in the notch to which the
adhesive has been applied.
Ensure that the support ring is fully and evenly engaged in the
bellows, and then allow the adhesive to set.
14.9.5. Carefully push the new non-split face (8-1) into the recess of the
front of the bellows (8-5).
Ensure that the face is fully entered into the recess and it contacting the
bellows on its O.D. and back surfaces as shown in the G.A. Drawing.

14.9.6. Place both halves of the face clamp (2-3) around the bellows
assembly (orientate the clamp ring as shown on the G.A. Drawing).
14.9.7. Apply liquid threadlock (supplied by DSS) to the threads of the face
clamp butt screws (2-4) and lightly tighten them.
14.9.8. Re-check the face. It is very important to ensure that it is flat

and fully and evenly entered into the bellows.
14.9.9. Tighten the face clamp butt screws (2-4) evenly and progressively
(maintaining an even gap at the butts) to the torque value shown on
the G.A. Drawing.
14.9.10. The housing (3-1) must now be re-joined around the bellows
assembly, taking particular care not to damage or displace the
newly fitted spare silicon carbide face.

14.9.11. Apply the supplied butt jointing compound to the butt surfaces of one
half of the casing (3-1). Join the two halves of the casing (3-1)
together (correctly orientated as shown on the G.A. Drawing) so that
the feature on the inside of the housing engages in the groove
behind the flange of the bellows (2-1).
14.9.12. Apply a suitable liquid threadlocker to the housing butt screws (3-4)
and lightly tighten them to hold the two halves of the casing (3-1)
together. Fit the two bronze dowels (3-7) – one through each butt
flange – to ensure perfect alignment of the two halves. Then fully
tighten the butt screws (3-4) to the torque specified on the G.A.
Drawing.

14.9.13. Very carefully reverse the position of the assembly so far, so that the
bellows flange end is now at the top.
14.9.14. Locate the TDC position stamped on the casing (3-1) flange, and
then orientate the non-split end cap (3-2) so that the drain pipe will
be positioned at BDC.
14.9.15. Fit the end-cap (3-2) using the cap screws (3-3) having first applied
a suitable liquid threadlocker, and then tighten them using an even,
progressive and diagonal sequence to the torque specified on the
G.A. Drawing.
14.9.16. Lightly grease both sides of the spare joint (8-8) and fit it over the
spigot location at the aft end of the housing (3-1). Align the joint so
that all the securing screw holes are clear.
This completes the assembly of the housing and bellows assemblies
which are now ready for re-fitting.

14.9.17. The drive clamp ring and seat assemblies are not assembled before
installation which leaves only the inflatable seal assembly to prepare.
14.9.18. Place the inflatable seal housing on a clean work-surface with the
recess for the inflatable seal uppermost.
14.9.19. Carefully fit the new inflatable seal (8-6) into the recess passing the
inflation tube through the hole in the inflatable seal housing.
14.9.20. Fit the washer and nut supplied and very lightly tighten the nut. Check
that the inflatable seal is fully and evenly entered into its recess in the
housing, then tighten the securing nut to the torque specified on the
G.A. Drawing (1 Nm MAX).
14.9.21. Apply grease to the o-cord (8-7) and fit it into the groove in the back of
the housing assembly. Butt the ends of the o-cord together and work it
into the groove until fully entered and fitted in place.
14.9.22. The prepared assemblies and the individual components are now
ready to be re-installed as described in Installation – Section
8.6.onwards.

15. SPARE PARTS AND THEIR STORAGE
15.1. For the EXJ seal, as it is basically only a 6 component assembly (Seat,
Bellows, Housing, Drive Clamp Ring, Inflatable Seal and Centralising plate), the
requirement for “Spare Parts” is limited.
15.2. As referenced in Section 14 (Maintenance) none of the components are

considered to be refurbishable items.
15.3. All non-elastomer components that are undamaged and unworn are considered
re-usable.
15.4. Considering the practicalities and likelihood of replacement requirement we

suggest that spares held should be:
• Service Kit-A – Face/Seat Change Out.

• Service Kit-B – Major Overhaul
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 Section 4.6.

16. ATTACHMENTS
The following Drawings are covered by this Technical Manual (TM-EXJ-02-81080).
• H76833-01
Note: This manual is written based on the General Arrangement Drawing listed on
the front cover.
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
relevant Works Order.
The attachments identified above, now follow:

Technical Manual Type Exj Seal

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Deep Sea Seals Ltd.

TYPE EXJ SEAL

ManeGuard EXJ O.D. Pressurised - Inboard Seal

for Water Jet Applications

Based on G.A. Drawing:

1998, Deep Sea Seals Limited. All Rights Reserved.

TM-EXJ-02 81080 ISSUE A Issue Date: 06 July 2006

SECTION SUBJECT PAGE

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

3. DESCRIPTION OF THE EQUIPMENT............................................................................. 5

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

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

10. NORMAL OPERATION.................................................................................................. 29

11. LUBRICATION SYSTEM ............................................................................................... 30

12. RECOMMENDED LUBRICANT LIST ............................................................................ 31

13. PROBLEM SOLVING - Level 'a'.................................................................................... 32

14. MAINTENANCE ............................................................................................................. 39

15. SPARE PARTS AND THEIR STORAGE ....................................................................... 68

16. ATTACHMENTS ............................................................................................................ 69

TM-EXJ-02 81080 ISSUE A Page 2 of 69

WORKS ORDER NO. : 12000587 (4500228107-MP00096.M1J1 & M2J1).

TM-EXJ-02 81080 ISSUE A Page 3 of 69

UNITED KINGDOM USA

Deep Sea Seals Ltd. Wärtsilä Lips Inc.

Tel: 44 (0) 2392 492123 Tel: 1 757 558 3625

Wärtsilä Propulsion Netherlands BV Japan Marine Technologies Ltd.

Tel: 31 416 388115 Tel: 81 (0) 3 5159 8700

TM-EXJ-02 81080 ISSUE A Page 4 of 69

TM-EXJ-02 81080 ISSUE A Page 5 of 69

Accommodates misalignment, vibration and high axial and radial shaft

High Abrasion resistance of Face and Seat.

Extended life expectancy and service intervals.

Low through life costs.

Fit and Forget.

TM-EXJ-02 81080 ISSUE A Page 6 of 69

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

TM-EXJ-02 81080 ISSUE A Page 7 of 69

# Flatness 0.08 mm.

# Perpendicularity 0.35 mm FIM (Measure outside of the bolting P.C.D.)

The forward end of the Sterntube/Housing must be machined to accept the

The 2 bushed centralizing dowels (6-8/6-9) require 14mm equispaced holes

TM-EXJ-02 81080 ISSUE A Page 8 of 69

Details should be as per the following:

TM-EXJ-02 81080 ISSUE A Page 9 of 69

Four areas of interfacing are important.

7.2. The Centralizing Plate interface -

TM-EXJ-02 81080 ISSUE A Page 10 of 69

7.4. The connection of services.

TM-EXJ-02 81080 ISSUE A Page 11 of 69

8.1. General Advice.

As referenced in "Preparation" and "Interfacing" (Sections 5. & 7.), the

TM-EXJ-02 81080 ISSUE A Page 12 of 69

8.3.1. The complete installation sequence is described below.

Those assembly stages relating to the Waterjet/drive shaft should be

8.3.2. Installation Sequence:-

8.4. Waterjet drive shaft.

8.4.2. Ensure that before it becomes impossible to do so, the non-split

TM-EXJ-02 81080 ISSUE A Page 13 of 69

8.5.3. Apply a suitable liquid threadlocker (supplied) to the longer of the

8.5.5. Apply a suitable liquid threadlocker (supplied) to the exposed threads

TM-EXJ-02 81080 ISSUE A Page 14 of 69

If the Perpendicularity is outside the stated tolerance, the shaft must

TM-EXJ-02 81080 ISSUE A Page 15 of 69

TM-EXJ-02 81080 ISSUE A Page 16 of 69