ShipsPropulsion shaft and power generation solutions for Ship Owners, Ship Managers, Ship Designers and Shipyards

SCHAAF Solutions – A peace of mind technology!

Innovative solutionsfor the ship industryShaft and drive connections, oil press fits, assembly tools for engine and gear construction in up to 4000 bar hydraulic high-pressure technology

Hydraulic pretensioning since 1954 SCHAAF GmbH & Co. KG deals with the

development and manufacturing of hydraulic

high-pressure tools and hydraulic

high-pressure components, specifically

constructed to meet the requirements of the

ship industry and further application areas.

Due to our “in house” product development

department and onsite three shift manufacture,

we operate an almost 100 % vertical business

structure.

Thanks to a comprehensive and detailed

quality policy we are able to meet exacting

product requirements expressed by our

customers.

Examples of certificates

Internationally / multilingual for you.

Staff:

Internet:

Presentations:

Animations:

DVD-Interactive:

Represent. countries:

SCHAAF TaicangSince 2011, SCHAAF operations have included an additional 1500 sqm

manufacturing facility located in Taicang (close to Shanghai). Initially

starting with a Shanghai sales office in 2007, SCHAAF Taicang is now a fully

functional sales and manufacturing part of SCHAAF in China, to the same

exacting quality policies as held in Erkelenz, Germany. Product design and

development will continue to remain at the Erkelenz head office whilst both

sites operate in accordance with DIN ISO 9001 quality standards. A further

extension of the production area and distribution network is again in the

planning stage.

SCHAAF worldwideInternational production and installation

Quality ManagementTechnical SalesResearch & DevelopmentProductionCommercial departmentPurchasingITElectrical constructionAssembly

Germany China Global

100% positive locking in the flange bores plus frictional connection between flanges with guaranteed dismounting and remounting

ExpaTen

ExpaTen – Safety and cost reductionDue to patented technology within the ExpaTen design, the

radial expansion and axial pretensioning achieved, guarantees

a 100% form and friction fit. High torque values can then

be transferred via the coupling whilst remaining completely

free from backlash. ExpaTen Bolts have revolutionised the

removable flange connection of drive shafts, as a result of high

pressure hydraulic technology, improving safety and giving

recognised time and cost reductions. ExpaTen installation and

removal is guaranteed and can be done within 10 – 15 minutes

per bolt.

Reusable after removal, again and again – no sparebolts required

No delays to docking schedule, due the bolts seized in flange holes

Zero damage after removal, thereforce fully reusable for life of vessel

100% positive locking and frictional connection after installation, no slipping between the flanges

Simple and quick installation and removal of ExpaTen even after years of use

Ensures torsionally and structurally rigid connection even with sudden changes in the rotational speed or

direction of the propulsion shaft

High torque transmission, completely free from backlash

Tolerance for mounting is 0.05 to 0.2 % of the bore diameter – Increased clearance conditions for bolt installations

Simple machining of the flange holes is sufficient

Additional standard bolts can be tightened with the same Bolt Tensioner

Meets all Classification requirements

Following sea trials with shaft misalignment can be quickly and safely corrected without damage

Consistent radial and axial loads retained for all bolts on entire coupling, ensuring

no coupling slippage or bolt fatigue

No freezing required to achieve a shrink fit, improving worker safety and saving installation time

Easy installation at couplings incorporating a ‘spacer’ or additional flanges

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Traditional reamer bolts almost always

require re-working of the holes, therefore

the sleeve of the ExpaTen assembly can

be supplied in an oversize condition. The

oversize can be machined on site to give the

correct clearance condition.

Expa = Expansion = 100% positive locking in the flange boreTen = Tension = frictional connection for the joint

ExpaTen 2

ExpaTen ExpaTen with SCHAAF Bolt

Tensioner (SSV) up to 4000 bar

hydraulic pressure

Simple and quick installation and

removal of ExpaTen even after years

of use

Reusable after removal, again and

again – no sparebolts required

ExpaTen 2Ideal flange connection for misaligned flange

bores and / or unequal bore diameters

Inner bores which are exactly centric

to another

Maximum misalignment of 2 mm

Different bore diameters in the flanges

Different diameters and misalignment of the

bores in the flanges

ExpaBoltExpaBolt for flange-component-connection

Full expansion for press fitting

Free from backlash

OvermetalProviding +2mm of oversized

outer diameter of the sleeve

Allows the sleeve to be re-worked on site

to fit with the rebored hole diameters of the

flange connection holes

Overmetal

SCHAAF ExpaTen Bolts provide 5 times higher safety

than standard “friction” bolts.

Shaft and axle connection with removable, two-piece Hydraulic Nut and two-piece SafeLoc element

GripLoc

GripLoc – Powerful and safeThe GripLoc coupling system is capable of safely transferring

high forces (torque and axial) yet requiring minimal space for

installation or withdrawal, without the need of forged flanges

on the shafts. The system is as quick and easy to install as it

is to disassemble, even after longterm use. GripLoc operates

according to the principle of a radial shrinkage connection,

however overcoming the many technical challenges where

non-SCHAAF products often fail.

Made of high strength steel GripLoc, consists of an inner ‘Grip’

sleeve with conical ‘Outer Diameter’ and an outer ‘Loc’ sleeve

with a conical ‘Inner Diameter’. Using a split or integrated

hydraulic nut, the outer sleeve passes over the inner sleeve’s

conical ‘OD’ supported by oil injection channels. At the correct

position, guided by a SafeLoc element, the outer sleeve is

allowed to contract onto the inner sleeve ‘gripping and locking’

both connecting shafts together making the shaft ready for

operation.

Patented GripLoc sliding-on procedures for damage-free interference fit assembly

GripLoc can be removed simply and quickly even after years of use – again and again free from damage

High torque transmission, completely free from backlash

Time saving on assembly and disassembly

Removability is always ensured if replacement of defective Hydraulic Nut seal is ever required

Separate, removable Hydraulic Nut – that is used as a transferable tool for all same coupling types (PG 35, PG 36)

Maximum torque transfer even in minimum installation space thanks to SCHAAF friction increase design engineering

Torsionally and structurally rigid connection even with

sudden changes in the rotational speed, torque or direction of rotation

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Due to shrinkage and expansion of the conical sleeves the following advantages are given:

Can utilise a two piece hydraulic nut as a transferable tool for both cost and weight saving.

Removes coupling hole alignment issues.

Leaves the shaft free from damage and surface wear after removal.

Offers easy and flexibility of shaft removal for bearing inspection or tailshaft removal.

Easy operation and activation using one source of hydraulic pressure.

Consistent radial clamping force over entire coupling due to outer sleeve design profile.

A lifetime solution to known coupling bolt issues with a performance guarantee.

Patented GripLoc sliding-on procedures for damage-free interference fit assembly

GripLoc can be removed simply and quickly even after years of use – again and again free from damage

High torque transmission, completely free from backlash

Time saving on assembly and disassembly

Removability is always ensured if replacement of defective Hydraulic Nut seal is ever required

Separate, removable Hydraulic Nut – that is used as a transferable tool for all same coupling types (PG 35, PG 36)

Maximum torque transfer even in minimum installation space thanks to SCHAAF friction increase design engineering

Torsionally and structurally rigid connection even with

sudden changes in the rotational speed, torque or direction of rotation

PG 35 - 39 for individual solutions

GripLoc The different GripLoc characteristics and advantages of each design can be

combined with each other. So for example GripLoc can be built integrated

together with the SafeLoc mechanism in a removable Hydraulic Nut. An optimal

solution is therefore guaranteed for each application.

GripLoc PG 35 Shaft and axle connection with

removable, two-piece Hydraulic Nut

and two-piece SafeLoc element

GripLoc PG 36Shaft and axle connection with

removable, two-piece Hydraulic Nut

and flow caps

GripLoc PG 37Solidly fixed Hydraulic Nut for fast

clamping connection with SafeLoc

element screwed on

GripLoc PG 38Solidly fixed Hydraulic Nut for fast

clamping connection with SafeLoc

integrated in the Hydraulic Nut

Removable Hydraulic Nut

Removable SafeLoc

Removable Hydraulic Nut

Flow caps

Solidly fixed SafeLoc

Solidly fixed Hydraulic Nut

Solidly fixed SafeLoc

Solidly fixed Hydraulic Nut

SafeLoc in the Hydraulic Nut

Combining possibilitiesAll type of GripLoc coupling are

also available with flange and

other application requirements.

Robust, durable and lightweight mode of construction

Ready for immediate use, fully assembled and oil filled

All parts sealed and leakage free from –30 °C to +100 °C

Purely axial pressure force, independent of stroke

Uniform distribution of pressure forces

No torsion under load (no thread wear)

Wide choice of Hydraulic Nut sizes and designs

Several Hydraulic Nuts can also be operated uniformly due to the pressure build-up

Repeat accuracy even after a long period of use

Simple and easy to maintain

Treated surfaces

Special designs of any type available upon request

The Hydraulic Nut for mounting and dismantling oil-pressure mountings and roller bearings

Oil press fit

During the oil press fitting of a propeller or rudder assembly on

a ship, the intelligent control module in the SCHAAF oil press

fit system, constantly monitors and controls both the axial and

radial pressure values for each circuit. Up to 4000 bar can be

developed and distributed for the radial pressure circuit to

expand the oil injection hub and up to 700 bar pressure is fed

to the hydraulic nut by the axial pressure circuit for the push up.

By accurately monitoring and intelligently managing to target

values of pressure, time, distance and displacement on both

hydraulic circuits the hub reaches the target push up position.

Whilst remaining in position, the control module manages

both circuit pressures again, so that the hub contracts onto

the stock, or shaft, giving a perfectly positioned ‘Press fit’. In

addition to the ease and time saving advantages of operating

a single complete system, the SCHAAF oil press fit, is robust,

compact, maintenance free and designed for industrial use.

Ultimately proving itself ‘over and over’ through quality and

reliability, giving a perfect propeller or rudder installation every

time.

SCHAAF raises the world standards for oil press fit equipment, by offering improved

technology to work with ultra high hydraulic pressures. The SCHAAF STG provides a

trouble free 100% system solution incorporating hydraulic nuts, pumps, hoses and other

accessories, for all fully automated and documented installation.

4000 bar reliable Hydraulic

pump for oil press fit.

Individual tool sets for mounting large 2- and 4-stroke engines, propellers, rudders and much more

Tool setsIn addition to a number of standardized Bolt Tensioners and Hydraulic Nuts, SCHAAF has already

delivered thousands of customized axial Bolt Tensioners. The Design on Demand CAD system allows

us to realize customer solutions very quickly. All Bolt Tensioners and Hydraulic Nuts represent a 100%

system solution with SCHAAF’s accessories such as high-pressure hoses and high-pressure generators.

Saving of timeBolt Tensioners (SSV) and Hydraulic Nuts (HM) will

dramatically save the time required for tensioning applications.

This effect increases for higher tensioning forces, larger bolt

thread diameters and also the installation of several SCHAAF

SSV or HM. It is no longer necessary to apply large torque

by hand. There is a number of handling features available,

designed to make work even more easier with SCHAAF SSV

and HM.

Construction

Single stage, “large” outer diameter, small installation height

Multi-stage, small outer diameter, “large” installation height

Threads to match all screws to be pre-tensioned

All thread types, all thread sizes, all standards

Stroke limiting device

Mechanical stop (up to full operating power)

Excess stroke valve (hydraulic limited stroke through internal

pressure bleeding)

Surface treatment

Gun metal finished, blackened, varnished, chemically nickel-plated,

as per customer’s specification

Connector variations

Various thread sizes and types, axial and / or radial connecting, screw-type

connector, quick coupling nipple, rotary connection, serial connections

4000 bar reliable Hydraulic

pump for oil press fit.

Hand Lever Pumps, High-pressure units and electro-hydraulic control systems up to 4000 bar

Pumps and units

HP 3000-HT Two-stage hand lever pump for pressures up to 3000 bar,

completely assembled and ready for immediate use

HDL 1000-4000Air-Hydraulic Pumps ready for immediate use

at hydraulic pressures up to 4000 bar

HDE 3000-BKElectrohydraulic high-pressure unit for up to 3000 bar

in compact design

STG 4000-2KElectro-hydraulic two-circuit high-pressure automatic

control system for fully automatic oil press fits

MDSMounting Documentation System for control and monitoring

of the axial, hydraulic bolt-tightening process

All pumps and power units available in various models.

HP 3000-HT HDL 1000-4000 HDE 3000-BK STG 4000-2K MDS

Geometric volume / Conveying performance:

Step 1 approx. up to 30 barStep 2 up to 3000 bar

1000 - 2500 bar1.0 cm³ / stroke

1600 - 4000 bar 2.0 cm³ / stroke

0 - 1600 bar 0 - 3000 bar< 700 bar – 0.43 l/min> 700 bar – 0.085 l/min

0 - 700 bar 0 - 4000 bar

0 - 4000 bar < 700 bar – 2.3 l/min> 700 bar – 0.5 l/min

Safety valve: Factory set approx. to max. hydraulic pressure

Factory set approx. to max. hydraulic pressure

Factory set approx. to max. hydraulic pressure

Factory set approx. to max. hydraulic pressure

Oil-level indicator: Readable on the outside Readable on the outside Inspection glasses / Float switch

Inspection glasses / Float switch

Pressure connection: According to type key Broadest range of variations

According to type keyBroadest range of variations

According to type key Broadest range of variations

According to type key Broadest range of variations

According to type key Broadest range of variations

Tank content: 2.1 litre 6 litre 2.5 litre 33 litre 33 litre

Useable volume: 2.0 litre 5 litre 1.5 litre 23 litre 23 litre

Pump body / Set-up: Burnished, high-strength tempered steel

Service-friendly construction in compact frame

Service-friendly construction in mobile frame

Service-friendly construction in mobile housing

Service-friendly construction in mobile housing

Weight 17 kg Approx. 34 kg (incl. distributor and pressure gauge)

60 kg Approx. 240 kg Approx. 240 kg

Quick-locking coupling nipple

Quick-locking coupling socket Adapter High-pressure

hoseadapterRotatable

elbow connectorBlanking plug

Thread: CVN15 G ¼“ IG CVK15 G ¼“ IG G ¼“ AG / G ¼“ AG G ¼“ AG / M14x1,5 AG 60° G  ¼“ AG / CVN16 G ¼“ with cutting edge 

Thread: CVN16 G ¼“ IG CVK16 G ¼“ IG G ¼“ AG / G ¼“ AG G ¼“ AG / M14x1,5 AG 60° G ¼“ AG / CVN16 G ¼“ with cutting edge

Thread: CVN25-2 G¼“ IG CVK25-2 G¼“ IG G¼“ AG BSP120° G¼“ BSP 120° / G¼“ AG 60° G ¼“ BSP 120° AG / CVN25-2 G ¼“ BSP 120°

Thread: SVN30/40 M16x1,5 IG SVK30/40 M16x1,5 IGM16x1,5 AG 58° / M16x1,5 AG 58°

M16x1,5 AG 58° / G¼“ AG 60°

M16x1,5 AG / SVN30 M16x1,5 with cone 58°

Hydraulic High Pressure Accessories which are customized to each application

Accessories

SCHAAF offers all hydraulic high pressure accessories which are required

for the operating and handling of hydraulic devices.

Gauges

Scale: 0 - 1000 bar, Double (bar / MPa) 0-1600 bar, Double (bar / MPa) 0-2500 bar, Double (bar / MPa) 0-3000 bar, Double (bar / MPa)

Class / Filling: 1,0 / Glycerine 1,0 /Glycerine 86,5 %

Hoses A0562 A0654 A0647

High pressure hoses and tubesAll items are available individually.

Max. / Test / Bursting pressure for item 1: 1800 bar / 2700 bar / 4500 bar 3000 bar / 4650 bar / 6200 bar 3000 bar / 3750 bar / 6250 bar

Inner tube: POM

Pressure jacket: 4 spiralled layers of corrosion-proof high tensile steel

6 spiralled layers of corrosion-proof high tensile steel

Outer sheath / Protective hose: PA, Nylon / PVC

In- /Outside diam. (incl. protective hose) 5.0 mm / 11.6 mm (18.0 mm) 5.0 mm / 13.0 mm (22.0 mm)

Weight: 0.29 kg/m 0.43 kg/m

Item 1: High-pressure hose

Item 2: Adapter G¼“ AG / M14x1.5 AG 60° Adapter G¼“ BSP 120° AG / G¼“ AG 60° Adapter M16x1.5 AG 58° DK / G¼“ AG 60°

Item 3: Quick-release coupling sleeve CVK16 G¼“ IG Quick-release coupling sleeve CVK25-2 G¼“ IG Quick-release coupling sleeve SVK30 M16x1.5 IG

Item 4: Quick-release coupling nipple CVN16 G¼“ IG Quick-release coupling nipple CVN25-2 G¼“ IG Quick-release coupling nipple SVN30 M16x1.5 IG

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... and state of Asian test equipment, replicas...

When saving money and no quality philosophy...

In Asia and many other countries we regularly see examples

of low quality steel and materials being used which would

definitely fail the German DIN standards that we use. We

see examples of materials which have no bursting strength,

cracks & faults present, low quality packaging, no corrosion

protection and often manufactured by workers with minimal

skill, training or engineering knowledge. When considering

price, you must also consider quality and total cost. The

failure and resulting costs caused by using low quality

products, does not justify the slight price saving seen by

the purchaser alone. Here are a few examples of competing

products, and the many resulting problems that will prove

expensive to your business if you ignore quality and safety.

When dismounting a drive train or shaft, poor design and

material weakness become clearly visible in terms of the

time loss, and the replacement products needed. The use

of heavy tools, damaged bolts and components destroyed

during removal make re-installation impossible. As a result

the costs associated with increased operational delays,

extended docking time, re-engineering and replacement

products cannot be ignored.

... and poor design failure the result.

Low quality = danger and high costsAt SCHAAF we offer ‘A peace of mind Technology’, helping you make low quality examples like these part of history… and not your future.

Low-cost transportation boxes.

... with inconsistant tensioning force.Tensioner failure...

Dismounting of standard bolts with heavy tools... ...causing additional expense.

Poor quality shielding of hoses are a danger for life!

When pre-tensioning forces are not reached due to poor quality equipment, failures occur leading to danger and

damage. To understand high pressure just consider a 30kg mass resting on a 1mm2 area (The tip of a writing pen)

You are now considering 300N of force or 3000 bar. Unsafe high pressure equipment can kill!

1mm2

Certificates Approval given by all

classification societies

Material test reports

Specific test reports

Certificates in accordance with

special customer requirements

SCHAAF ReferencesA small selection of our ExpaTen and GripLoc supply references

Cruise vessel

“Mein Schiff 3”

Cruise Vessel

“CARNIVAL FREEDOM”

Cutter Suction Dredger

“TIAN JING HAO”

Car Carrier

“VIKING SEA”

Cruise vessel

“CARNIVAL LIBERTY”

Container vessel

“PONA”

Cruise Ferry

“COASTAL RENAISSANCE”

Various Air Craft Carrier

Container vessel

“FESCO BAYKAL”

Best in TechnologyOut of more than 3000 suppliers SCHAAF

received the award “Best in Technology”

from MAN Diesel & Turbo SE. In the last 30

years over 10000 orders for the companies of

MAN Diesel & Turbo SE were executed.

Quality AssuranceAll SCHAAF products are checked for material

quality, dimensional accuracy, correct functioning

and load-resistance. During order execution, they are

subject to continuous quality assurance measures

and are supplied together with detailed technical

documentation.

Certificates Approval given by all

classification societies

Material test reports

Specific test reports

Certificates in accordance with

special customer requirements

ServicesAll SCHAAF products are, of course, supplied packaged,

ready for installation and use. SCHAAF equipment is

user-friendly, reliable, and manufactured in accordance

with the highest level of technical know-how. Our

highly-motivated staff would be pleased to train your

personnel, in situ or at our works, in mounting and

dismantling the bolts.

Container vessel

“KING ALFRED”

Crude and Oil Product Carrier

“MV PETRODVORETS”

Bulker

“HEROIC”

Container vessel

“MAERSK BOSTON”

RoRo Cargo Ship

“Ulusoy 14”

LNG Tanker “Taitar N°1“

Cruise Vessel

“ROYAL PRINCESS”

Cruise Vessel

“QUEEN ELIZABETH”

Cargo vessel

“MASUREN”

Various Navy

Patrols

SCHAAF GmbH & Co. KGBruesseler Allee 22

41812 Erkelenz - Germany

Telephone: +49 - 24 31 - 9 77 70-0

Fax: +49 - 24 31- 9 77 70-77

E-Mail: info@schaaf-gmbh.com

Internet: www.schaaf-gmbh.com

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SCHAAF (Taicang) Co. Ltd. 萨尔福超高压液压技术（太仓）有限公司

No.8 North Loujiang Road, Taicang 215400, Jiangsu Province, P.R. China

中国江苏省太仓市娄江北路8号. 邮编：215400

Phone / 电话: +86 (0)512 -81 60 80 60

Fax / 传真: +86 (0)512 -81 60 80 61

E-Mail: info@schaaf.cn

Internet: www.schaaf.cn