Formular-Nr.:51 Rev.-Nr.:10 01/18 - 1 -
Manual for the Feathering Propeller
DF-80 and DF-107
2-, 3- and 4 blade model
Installation on the shaft page 2
Installation on the Saildrive page 3
Operation page 4
Pitch adjustment LH ( left-hand rotation propeller ) page 5
Pitch adjustment RH ( right-hand rotation propeller) page 6
Defining and checking adjustments page 7
Removing from the shaft ( after one or two seasons ) page 8
Removing from the shaft ( after the 3rd season ) page 9
Servicing page 10
Torque settings prop-nut page 11
Formular-Nr.:51 Rev.-Nr.:10 01/18 - 2 -
INSTALLATION on the shaft
The VARIPROP is delivered assembled, greased and ready for installation.
He may not be disassembled, otherwise the warranty claim goes out!
MOUNTING:
First slide the prop on the shaft without key. Mark the shaft with a grease-pen at the prop end.
After tightening the shaft nut very strongly ( torque-setting see page 11 ) the mark must disappear. If not, the
key is binding and the top or the sides of the key must be filed down. Light must be shining through on the
top of the key when looking into the hub from astern. You may have to move your eye vertically to see it.
ATTACHING THE ZINC-CONE:
First, insert all three zinc-cone screws (1) loosely,then tighten securely in succession. Use LOCTITE low
(pink) and observe the little washers. They prevent the grease from squeezing out of the hub during
operation. Be sure to clean the screws and screw-holes from any grease before applying the loctite.
ENGINE DRY TEST:
Please consider that the dry test of the engine MUST NOT be done while the VARIPROP is fitted onto
the shaft! The VARIPROP needs water pressure on the blades, otherwise the prop could be
damaged!!
Before fitting the VARIPROP onto the shaft, check key
and keyway in the propeller hub. Take care that the
key is the proper dimension and that the hub slides
completely onto the shaft (see below). Remove the
zinc anode (2) and the nut (4). Fit the propeller onto
the shaft strongly. Tighten the nut (4) with LOCTITE
low (pink) onto the shaft ( torque-setting see page 11 )
and secure it with the lock pins (3). Fit the anode (2).
Make sure that the propeller is always protected from
electrolytic corrosion by changing the anode (2) latest
every year! May not be necessary in freshwater.
A
fter the VARIPROP has been fitted properly check
that the blades rotate freely from the forward stop to
the reverse stop. The shock absorber function can be
felt ! See servicing page 10.
Only two of the three lock-pin
holes can be used, depending on
the final position
of the shaft-nut
flange.
Carefully align the lock-pins (3) straight. They must go
in easily. If not, try first to tighten the propnut a little
further until they do. If impossible, back off the nut a
little. The lock-pins should be hand tightened only.
If overtightened they may strip.
Formular-Nr.:51 Rev.-Nr.:10 01/18 - 3 -
INSTALLATION on the SAILDRIVE
The VARIPROP is delivered assembled, greased and ready for installation.
ATTACHING THE ZINC-CONE:
First, insert all three zinc-cone screws ( 1 ) loosely, then tighten securely in succession. Use LOCTITE
low (pink) and observe the little washers. They prevent the grease from squeezing out of the hub
during operations. Be sure to clean the screws and screw-holes from any grease before applying the
loctite.
Only two of the three lock-pin holes can
be used, depending on the final position
of the shaft-nut flange.
Carefully align the lock-pins (3) straight. They must go
in easily. If not, try first to tighten the propnut a little
further until they do. If impossible, back off the nut a
little. The lock-pins should be hand tightened only.
If overtightened they may strip.
Before mounting the VARIPROP properly onto the saildrive spline, please check if the propeller hub gears
mate precisely with the saildrive spline grooves. Tolerances are very tight to avoid on-axis movement.
Some careful “wiggling” may be required to find the exact position where the hub slides unto the spline.
After removal ot the zinc cone (4) and the propeller nut (1) the propeller hub will slide completely unto the
spline. Tighten nut (1) strongly ( 60Nm / 45ft/lb; Yanmar SD 40/50 100Nm / 75ft/lb ) and use loctite low
(pink) . Observe the recommended torque settings of the saildrive manufacturer.
A
fter installation, check that there is only a little end clearance for the prop on the saildrive shaft. If it is too
high, fit one or more of the different spacer disc between the forward end of the prop and the saildrive to
reduce it. The spacer discs are delivered with the prop.
Secure the propeller nut (1) with the hexagonal socket cap screw ( 2 ( M8x45 DF-80 / M8x60 DF-107 /
15Nm / 10ft/lb) and two lock pins (3). Hand tighten only, and then mount the zinc cone ( see below ). Make
sure that the propeller is always protected from electrolytic corrosion by changing the zinc anode (2) latest
every year, less often in fresh water. After the VARIPROP has been fitted properly check that the blades
rotate freely from the forward stop to the reverse stop. The shock absorber function can be felt ! See
servicin
g pag
e 10.
Formular-Nr.:51 Rev.-Nr.:10 01/18 - 4 -
OPERATION
The VARIPROP feathers automatically when the shaft rotation is stopped. After engine start-up and shifting
into gear the blades will engage in either forward or reverse.
THE BEST WAY TO FEATHER THE PROPELLER IN THE SAILPOSITION IS:
VARIPROP sailposition with mechanical gear-box:
Power at 3 to 4 knots in forward.
Stop the engine and engage the transmission in reverse to stop the freewheeling of the shaft.
VARIPROP sailposition with hydraulic transmission:
Power at 3 to 4 knots in forward.
Stop the engine while still engaged in forward. The remaining oil pressure of the transmission will
stop spinning the shaft to feather the blades in the sailposition.
If the propeller is not feathered in the sailposition the shaft will freewheel like with a fixed propeller.
In that case start the engine again and repeat the steps above.
Once the prop is feathered , it is better to shift the transmission to neutral.
DO NOT stop the engine while it turns in reverse. In this case the blades will stay in the reverse position and
will not feather. You can actually use this feature to drive a shaft generator.
TROUBLE SHOOTING:
If the propeller does not work in forward or reverse go systematically through the
points below:
Check low idle of the engine. It should be 800 to 900 rpm in idle.
Check shifting movement of the transmission lever. Make sure that the shifting travel is
not too short. The amount of lever travel, as measured at the pivot point of the actuating
lever, between the neutral position and end positions for forward and reverse can be found
in the owners manual of your transmission. A larger amount of lever travel is in no
way detrimental.
Check the clutch discs of the transmission. They could be worn out.
WARNING:
It is important to follow the instructions below carefully so as to avoid excessive load and shock
to the gears, shortening their life.
When going from ahead to astern or the opposite, it is necessary to idle down and shift at low
rpm’s (max.1200rpm) between gears to allow smooth reversing of rotation without binding. This will
substantially lengthen the service life of your propeller gears.
When going from ahead to astern or the opposite, you can hear the turning-noise of the feathering
blades. This is normal and not a problem or a defect of your VARIPROP.
The propeller body must always be completely filled with a high viscosity grease. We recommend
synthetic grease typ TW.2 GEL or mineral multi-purpose grease EP/SAL 8 (see servicing page 10 )
The propeller must be protected from electrolytic corrosion by fitting the usual zinc anodes on the
shaft plus the prop anode. We recommend the replacement of the anode once a year.
If you want to protect your VARIPROP with Antifouling, use only Antifouling which needs a primer
first. Otherwise chemical interaction and decomposition could occur. Our recommendation is Velox
TF plus including a primer ( offers also protection against electrolyses ), available from your
VARIPROP distributor.
Never dismantle the VARIPROP yourselves !!
Disassembly and reassembly require special tools and technical know-how only available at the
factory or their approved service centres.
Formular-Nr.:51 Rev.-Nr.:10 01/18 - 5 -
PITCH ADJUSTMENT „LH“
GERNAL:
The pitch adjustment is very simple on the VARIPROP, and can be done in or out of the water in
a matter of few minutes, if there is enough space between propeller hub and strut to fit an allen
key into the set screws (1) & (3) at Fig.2 . If not, the propeller must first be pulled. (see removing
from the shaft)
Propeller in the drawing below (Fig.2) is for a left hand rotation VARIPROP
LH.
The following description refers to the view towards astern for a left hand VARIPROP.
A. Adjusting the forward pitch: B. Adjusting the reverse pitch:
1. Remove the set screw (1/ 4mm allen key). 1. Remove the set screw (3/ 4mm allen key).
Under water: only 3 turns loosen. Under water: only 3 turns loosen.
2. Turn the adjusting screw (2) which is marked as 2. Turn the adjusting screw (4) which is marked as
“AH” or “V” with the 5mm Allen-key as follows: “AS” or “R” with the 5mm Allen-key as follows:
2a. Increasing of pitch approx. 3“ max.:
2a. Increasing of pitch approx. 2“ max.:
- Turn the adjusting screw (2) clockwise. - Turn the adjusting screw (4) anti-clockwise.
( see “NOTE” and page 7) ( see “NOTE” and page 7)
- Secure set screw (1) with LOCTITE low (pink) - Secure set screw (3) with LOCTITE low (pink)
Lock set screw strongly. Lock set screw strongly.
2b. Reducing of pitch approx. 2“ max.:
2b. Reducing of pitch approx. 3“ max.:
- Turn the adjusting screw (2) anti-clockwise. - Turn the adjusting screw (4) clockwise.
( see “NOTE” and page 7). ( see “NOTE” and page 7).
- Secure set screw (1) with LOCTITE low (pink) - Secure set screw (3) with LOCTITE low (pink).
- Lock set screw strongly. - Lock set screw strongly.
NOTE:
It is quite possible to set the pitch continuously variable and independently for forward and reverse.
Turning of the adjusting screws (2) & (4) by half a revolution ( 180° ) changes the pitch approx. 1“. This will
change the engine revolution by approx.200.
.
R= AS(Astern) V= AH (Ahead
)
+ +
--
adjustment markings
Markings to check
and determine
degree of pitch
ad
j
ustment
adjusting screws
(2&4)
set screws (1&3)
Formular-Nr.:51 Rev.-Nr.:10 01/18 - 6 -
PITCH ADJUSTMENT „RH“
GERNAL: The pitch adjustment is very simple on the VARIPROP, and can be done in or out of the water in
a matter of few minutes, if there is enough space between propeller hub and strut to fit an Allen
key into the set screws (1) & (3) at Fig.3a. If not, the propeller must first be pulled. ( see removing
from the shaft )
Propeller in the drawing below (Fig.3a) is for a right hand rotation
RH.
Fig.3a
The following description refers to the view towards astern for a right hand VARIPROP.
A. Adjusting the forward pitch : B. Adjusting the reverse pitch :
1. Remove the set screw (1/ 4mm allen key). 1. Remove the set screw (3/ 4mm allen key).
Under water: only 3 turns loosen. Under water: only 3 turns loosen.
2. Turn the adjusting screw (2) which is marked as 2. Turn the adjusting screw (4) which is marked as
“AH” or “V” with the 5mm Allen-key as follows: “AS” or “R” with the 5mm Allen-key as follows:
2a. Increasing of pitch approx. 3“ max.:
2a. Increasing of pitch approx. 2“ max.:
- Turn the adjusting screw (2) clockwise. - Turn the adjusting screw (4) anti-clockwise.
( see “NOTE” and page 7) ( see “NOTE” note and page 7)
- Secure set screw (1) with LOCTITE low (pink). - Secure set screw (3) with LOCTITE low (pink).
- Lock set screw strongly. - Lock set screw strongly.
2b. Reducing of pitch approx. 2“ max.:
2b. Reducing of pitch approx. 3“ max.:
- Turn the adjusting screw (2) anti-clockwise. - Turn the adjusting screw (4) clockwise.
( see “NOTE” and page 7). ( see “NOTE” and page 7).
- Secure set screw (1) with LOCTITE low (pink). - Secure set screw (3) with LOCTITE low (pink).
- Lock set screw strongly. - Lock set screw strongly.
NOTE: It is quite possible to set the pitch continuously variable and independently for forward and reverse.
The turning of the adjusting screws (2) & (4) by half a revolution (180°) changes the pitch approx. 1“. This will
change the engine revolution by approx. 200.
R= AS(Astern) V= AH (Ahead
)
.
+ +
--
adjustment markings
Markings to check
and determine
degree of pitch
ad
j
ustment
adjusting screws
(2&4)
set screws (1&3)
Formular-Nr.:51 Rev.-Nr.:10 01/18 - 7 -
Defining and checking pitch adjustments
It is quite possible to set the pitch continuously variable and independently for forward and reverse. The
turning of the adjusting screws (2) & (4) in Figure 2 & 3a ( see pages 5&6 ) by half a revolution changes the
pitch approx. 1“.That means a quarter turn ( 90° ) changes the pitch by ½” and a one full turn by 2” etc..
For a check of pitch adjustments there are markings on the hub face under the zinc anode.
To return to original factory pitch settings, line up “AH” or “V” resp. “AS” or “R” markings on the hub face.
Example:
check adjustments ahead inner marking has moved
original factory pitch setting pitch has been increased ahead
ahead
check adjustments astern inner marking has moved
original factory pitch setting pitch has been decreased astern
astern
Note :
If the engine does not reach the desired RPM reduce the pitch.
If the engine exceeds the desired RPM increase the pitch.
1” of pitch reduction / increase results in approx. 200 engine revolutions increase / reduction.
p
lus
minus
markings
line up
markings
lined up
Formular-Nr.:51 Rev.-Nr.:10 01/18 - 8 -
VARIPROP REMOVAL
VARIPROP removal after 1 or 2 seasons.
1.) In order to remove the VARIPROP you must first remove the zinc anode (2).
2.) Remove both lock pins (3) and the prop nut (4)
3.) Fit the short hexagonal head screws (7) into the inner bolt circle diameter of the puller (6).Fit the
SPW puller (6) onto the aft of the rear boss and screw the short hexagonal head screws (7)
completely into the zinc screw holes (10). Take care that plate (6) will fit snugly and evenly to the
aft boss.
CAUTION: DO NOT OPEN THE HEXAGON SOCKET SCREWS (5) !
It would dismantle the two separate halves of the VARIPROP hub !!!
4.) Now turn the hexagonal head bolt (9) against the end of shaft until the VARIPROP comes off the
taper. Do not use excessive force to turn bolt (9). If prop does not come off, proceed to page 9 –
removal after the 3
rd
season. Never use a hammer to remove the prop from the taper !!!
necessary tools for removal see servicing page 10.
We highly recommend the use of above described special puller, available from your VARIPROP
dealer. Standard 3-prong pullers can easily slip and damage the rounded VARIPROP housing !
Formular-Nr.:51 Rev.-Nr.:10 01/18 - 9 -
VARIPROP REMOVAL
VARIPROP removal after 3 years or more.
1.) In order to remove the VARIPROP you must first remove the zinc anode (2).
2.) Remove both lock pins (3) and the prop nut (4)
3.) Then remove at first only two hexagonal socket screws (5). DO NOT OPEN ALL !
4.) Fit two of the long hexagonal head screws (7) into the outer bolt circle diameter of the puller (6).
Now fit the SPW puller (6) onto the aft of the rear boss and screw the long hexagonal head
screws (7) completely into the screw holes (11) of the front boss halve (10). Tighten the nut (8)
on the head screws (7) until the plate (6) is fitted snugly and evenly to the aft boss.
CAUTION: Do not dismantle the two separate halves of the VARIPROP hub !!!
In this mode remove the last hexagonal socket screw (5) as well and fit the third long hexagonal
head screw. Take care that plate (6) will fit snugly and evenly to the aft boss.
5.) Now turn the hexagon head bolt (9) against the end of shaft until the VARIPROP comes off the
taper. Never use a hammer to remove the prop from the taper !!!
6.) At the end remove the puller (6) carefully and secure the boss halves (10) with the socket screws
(5). Tighten strongly with LOCTITE blue ( medium ). Take care that the hub halves do not come
apart when removing the hexagonal head screws (7).
We highly recommend the use of above described special puller, available from your VARIPROP
dealer. Standard 3-prong pullers can easily slip and damage the rounded VARIPROP housing !
Formular-Nr.:51 Rev.-Nr.:10 01/18 - 10 -
SERVICING
The VARIPROP needs to be greased a minimum of once a year. The VARIPROP body should always be
completely filled with a high viscosity grease of a hydrophobic nature. Remove the cap screw (5) and screw
in the lubricating nipple which is supplied with the tools. Further remove the zinc anode! With each pump of
the grease gun rotate the propeller from forward stop to reverse stop to allow the grease to work through the
propeller. Stop to pump when enough grease comes out of the anode drill holes on top of the prop (Fig.1A).
Fig.1A
Factory supplied special grease EP/SAL is recommended and available from your VARIPROP distributor.
Avoid regular white grease (sterntube-grease ) !
Shock-absorber:
The integrated shock-absorber reduces unpleasant operating noises. The pitch stops are
substantially protected against wear. At rotating the blades by hand, you can feel the shock-absorber
function. This “heavy” turning at the absorber area is normal and necessary for the function !
Make sure that you always keep the zinc anode in good condition. The VARIPROP must be protected by a
lot of zinc, so also use a zinc anode onto the shaft if possible. Use fine sandpaper to clean the aft of the end
boss and the forward face of the VARIPROP-anode to give the zinc good contact with the propeller.
Lubrication nipple
5mm
Cap-screw (5
)
Stop greasing if
grease squeeze
out here!
Tools supplied with each VARIPROP ( Fig.1 ):
1x small plastic bottle with Loctite low (pink)
1x grease nipple 5mm
1x allen key 2mm ( DF80 ) or 3mm ( DF107 )
1x allen key 4mm
1x allen key 5mm
necessary tools for removing the prop
after 1 or 2 seasons ( page 8 )
1 open-end- / box spanner 8mm 1 allen key 2mm DF- 80
1 open-end- / box spanner 24mm 1 allen key 3mm DF-107
1 open-end- / box spanner 36mm 1 allen key 4mm
necessary tools for removing the prop
after years ( page 9 )
1 open-end- / box spanner 10mm DF -80 1 allen key 2mm DF- 80
1 open-end- / box spanner 13mm DF-107 1 allen key 3mm DF-107
1 open-end- / box spanner 24mm 1 allen key 4mm
1 open-end- / box spanner 36mm 1 allen key 5mm DF- 80
1 allen ke
y
6mm DF-107
Formular-Nr.:51 Rev.-Nr.:10 01/18 - 11 -
Torque settings for the prop-nut
( page 2, Fig.1, part-no.4 )
Standard – thread
Fine – thread
SUBJECT TO TECHNICAL ALTERATIONS; ERRORS and MISPRINTS
M 16 x 2
BSW 5 / 8 “ – 11 60 Nm / 45 ft/lb
UNC 5 / 8 “ - 11
M 14 x 2
UNC 1/2 “-13 40 Nm / 30 ft/lb
M 20 x 2,5
BSW 3 / 4 “ – 10 125 Nm / 95 ft/lb
UNC 3 / 4 “ - 10
M 24 x 3
BSW 1 “ - 8 210 Nm / 155 ft/lb
UNC 1 “ - 8
M 14 x 1,5
BSF 1/2 “- 16 40 Nm / 30 ft/lb
M 16 x 1,5
BSF 5 / 8 “ – 14 70 Nm / 50 ft/lb
UNC 5 / 8 “ - 18
M 20 x 1,5
BSF 3 / 4 “ – 12 135 Nm / 100 ft/lb
UNC 3 / 4 “ - 16
M 24 x 2
BSF 1 “ - 10 225 Nm / 165 ft/lb
UNF 1 “ - 12
M 27 x 3 315Nm / 230 ft/lb
UNC 7 / 8 “-9 160 Nm / 115 ft/lb
M 30 x 2 430 Nm / 315 ft/lb
M 30 x 3,5
UNC 1 1/8” - 7 350 Nm / 255 ft/lb
M 20 x 2
Yanmar Saildrive 100 Nm / 75 ft/lb
SD 40 & SD 50
M 16 x 2
Yanmar Saildrive 60 Nm / 45 ft/lb
SD 20 & SD 31
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