6.11 Connection to Engine
Conditions for connection to engine:
The gearbox is aligned with the propeller shaft.
The gearbox is firmly fixed on the foundation.
The engine is aligned axially to the gearbox. The space between gearbox and engine must correspond to the mounting length of the flexible coupling. The axial reaction forces of the flexible coupling on engine and gearbox shall be as low as possible.Observe the initial values of engine and flexible coupling manufacturer.
Operational steps for connection to engine
Align the engine with the adjusting screws, horizontally in longitudinal and transverse directions, and vertically in front of the input flange of the gearbox, according to the specified data.
With approved methods (gauges, laser), measure the horizontal and vertical gap and sag values.
Permissible tolerances:
Radial misalignment 0.05 mm (centreline run-out 0.025 mm) - sag Angular misalignment 0.05 mm related to 300 mm flange diameter - gap
Document your gap and sag values.
Consider the thermal expansion of the engine, gearbox and foundation at operating temperature.
Note that the resilient mounting elements of the engine will settle later.
Consider that displacement of the engine and gearbox can occur and that the working forces can have an impact on the foundation.
Consider the maximum permissible reaction forces exerted by the flexible coupling on the gearbox input shaft.
During all operations, observe the instructions of the engine and coupling manufacturers.
When the engine alignment and the alignment check are finished, the engine foundation can be cast.
Connect gearbox and engine with the flexible coupling according to the manufacturer's instructions.
Variables for determining the reaction forces of the flexible coupling
Determine the radial reaction force of the coupling FR due to radial misalignment.
FR = r x Cr dyn
r - radial shaft misalignment;
Cr dyn - radial stiffness of the flexible coupling
Determine the corresponding bending moment MB due to angular misalignment.
MB=0.5 x Cax x D x X1
Cax - axial stiffness of the flexible coupling;
D - diameter of the connection between the flange and the flexible coupling/flywheel X1 - measured angular misalignment (GAP)
Inform REINTJES of the reaction force FR, the bending moment MB and the distance L for approval.
L = S + X = distance from point of application FR to big cone diameter of gearbox input shaft
6.12 Connection to the gearbox PTO
Pre-conditions for connection to the PTO:
The gearbox is aligned with the propeller shaft.
The gearbox is aligned with the engine.
The gearbox is firmly fixed on the foundation.Operational steps for connection to PTO
Align the auxiliary unit driven by the PTO (e. g. generator) with the adjusting screws, horizontally in longitudinal and transverse directions, and vertically in front of the PTO shaft of the gearbox, according to the specified data.
With approved methods (gauges, laser), measure the horizontal and vertical gap and sag values.
Permissible tolerances:
Radial misalignment 0.05 mm (centreline run-out 0.025 mm) - SAG Angular misalignment 0.05 mm related to 300 mm flange diameter - GAP
Document your GAP and SAG values.
Consider the thermal expansion of the gearbox, auxiliary unit and foundation at operating temperature.
Consider that displacement of the auxiliary unit and gearbox can occur and that the working forces can have an impact on the foundation.
Consider the maximum permissible reaction forces exerted by the flexible coupling on the gearbox PTO shaft.
During all operations, observe the instructions of the auxiliary unit and coupling manufacturers. Fix the auxiliary unit on the foundation according to the supplier's instructions.
Determine the reaction forces of the flexible coupling (as described in point 6.11).
Connect PTO and auxiliary unit with the flexible coupling, according to the manufacturer's instructions.
!
The alignment will only be recognised as complete by REINTJES, if you completely documented the alignment of propeller shaft - gearbox, gearbox - engine and gearbox PTO - auxiliary unit!6.13 Alignment Check
6.13.1 Alignment Check on Engine Side
Check the gearbox foundation bolts for tightness.
Remove the flexible coupling on the engine.
Finally, check the gap and sag values and compare them with the data specified by the coupling manufacturer. In case of deviations, please contact REINTJES.
6.13.2 Alignment Check on Propeller Side
Check the gearbox foundation bolts for tightness.
Remove the flange mounting screws on the propeller side.
Finally, check the gap and sag values and compare them with the specified data.
In case of deviations, please contact REINTJES.
6.13.3 Alignment Check PTO
Check the gearbox foundation bolts for tightness.
Remove the flexible coupling.
Finally, check the gap and sag values and compare them with the data specified by the coupling manufacturer. In case of deviations, please contact REINTJES.
6.14 Connection of Gearbox Components
6.14.1 Connection of valve control and supervision system
Lay the cables for the control and supervision system to the gearbox junction box and connect them in compliance with the supervision drawing.
On the gearbox itself, the cables for the control and supervision system are completely connected.
Check the functioning of the valve control and the gearbox supervision system according to the commissioning instructions.
6.14.2 Connection of Shaft Brake
Lay the compressed air line to the brake control valve.
The connection is indicated in the installation drawing.
Install a dehumidifier in the compressed air system.
The initial pneumatic pressure must be 5 - 7 bar.
6.14.3 Connection of Heat Exchanger
Install the pipes on the water side of the heat exchanger with SAE counterflanges (see installation drawing). They must be laid vibration-free. We recommend using rubber/steel-wire compensators.
Seawater cooling
The parts flown through by water of the heat exchanger consist of seawater-proof materials. Nevertheless, for proper functioning the following has to be observed:
Install a filter in the seawater circuit.
Ensure that there is sufficient anodic protection in the water pipes.
Freshwater cooling
Inform REINTJES, if an anticorrosion additive is admixed to the freshwater circuit.
The additive can reduce the cooling capacity of the heat exchanger.
!
Note that the cross section at the entry to the heat exchanger on the water side must not be reduced!6.14.4 Connection of Electric Standby Oil Pump
If the stand-by pump is mounted on the gearbox, the pump is supplied complete with all required pipes.
Lay the electric supply line to the standby oil pump.
Connect the motor according to the enclosed circuit diagram. You will find the circuit diagram in the junction box of the pump motor.
During commissioning the pump must start running in the indicated sense of rotation. Check the sense of rotation with an induction instrument and make the proper terminal connections.
If the electric standby oil pump of your gearbox is supplied separately, you must also lay and connect the suction and pressure pipes between the pump and the gearbox.
When connecting the pump pipes, pay attention to the indicated sense of rotation of the pump.
Clean the pipes installed on board or changed during installation, e.g. by subjecting them to acid treatment. The pipes must be free of dirt.
Observe the connection instructions (pipe cross section, length of pipe and number of pipe bends).
CAUTION!
If the pump direction is reversed, there is danger that excessive pressure builds up in the pipes
Danger of injury from bursting pipes
When connecting the pump motor electric supply line, pay attention to the indicated sense of rotation of the pump.
DANGER!
of electric shock!
Do not connect/disconnect or service this device until power supply has been disconnected!
Index
A
Alignment 48 Alignment Check 65
B
Brief product description 19
C
Characteristics of the gearboxes 22 Connection of Gearbox Components 65 Connection to Engine 61
Connection to Propeller Shaft 48 Connection to the gearbox PTO 64 Corrosion protection 28
Interruptions in operation 31 Protective measures 31 Corrosion protection oils 33
D
Demands on the installation personnel 46 Directional valves 39, 43
E
Electrical lubrication oil pump 67 Electrical stand-by pump 39
F
Fixing the gearbox to the foundation 50
G
Gearbox type 35
Gearbox with shaft brake 43
H
Heat exchanger 38 Hydraulic system 43
I
Illustration of the gearbox 19 Initial preservation 28 Installation 45 Introduction 17
L
Long interruptions in operation 31
O
Oil filter 38 Oil pump 38
Operation delay system 39, 44
P
Packaging inspection intervals 29 Path of drive 35
Place of installation requirements 46 Preservation 28
Opening the gearbox 31 Preservation oil
Volume to be filled 30 Preservation oils 33 PTO K41 40 PTO K51 41
R
Requirements for assembly personnel 13 Responsibility 45
S
Safety 11
Screwed Connections 58 Seat Chocks 57
Setting up the gearbox 46 Set-up 45
Shaft brake 44 Storage 26
T
Technical Data 21 Transport and Storage 25 Types of Documentation 17
V
valves
Directional 39, 43 Pressure limiting 38 VCI preservation oil 28
LAF 2346 – 4575
© 2013 REINTJES GmbH
All Rights Reserved.
Table of Contents
1 Safety
... 5 1.1 Meaning of Warnings and Notes ... 5 1.2 Basic measures of caution ... 6 1.3 Requirements for operating and maintenance personnel ... 7 1.4 Safety information for assembly ... 8 1.5 Protective measures against fire and danger of explosion ... 92 Putting the unit into operation
... 11 2.1 Note this safety information before putting the unit into operation the first time ... 11 2.2 Installation check ... 12 2.3 Fill with operating oil (initial filling) ... 12 2.4 Handling the checklists for putting the unit into operation ... 15 2.5 Checklist before initially putting the unit into operation ... 16 2.6 Checklist before starting the engine ... 19 2.7 Checklist for gearbox after engine start ... 20 2.8 Notes on the checklists for putting the unit into operation ... 213 Operation
... 23 3.1 Engaging procedures for standard gearboxes ... 23 3.2 Power Take Off PTO K51 ... 23 3.3 Shaft brake ... 24 3.4 Special operating modes ... 25 3.5 Emergency operation ... 27 3.6 Setting the pressure limiting valve ... 304 Maintenance
... 31 4.1 Maintenance plan ... 33 4.2 Maintenance job cards ... 35 4.3 Check of tube bundle contamination in the heat exchanger ... 54 4.4 Replacement of the mechanical gearbox oil pump ... 59 4.5 Conversion factors and screw tightening torque values ... 68 4.6 Screw Locking ... 69 4.7 Maintenance performed ... 705 Trouble-shooting
... 716 Spare and replacement parts
... 75 6.1 Gearbox oil pump A001.00, Type KF2/.., KF3/.., KF4/.. ... 77 6.2 Heat exchanger A002.00, Type P ... ... 796.3 Duplex filter A003.00, Type RFLD ...81 6.4 Control valve V1 (4/2-way-valve), electrical ...83 6.5 Control valve V114 (4/2-way-valve), electrical, for PTO ...85 6.6 Control valve V189 (4/2 way-valve), pneumatical, for shaft brake ...87 6.7 Operation Delay Pot H426.00 ...89 6.8 Operation Delay Pot H401.00 ...91 6.9 Operation Delay Pot H417.00 ...93 6.10 Control block V006.00, type HB4 D 0327 A ...95 6.11 Control block V006.00, type HB 4 A 0328 B ...97 6.12 Control block, type HB 4 B 0320A + DKF4O30 ...99
Index
...1011 Safety
1.1 Meaning of Warnings and Notes
Warnings and notes indicating various levels of danger or importance are used within this documentation.
The signal word indicates the danger level in each case. Important notes to be observed for problem-free, safe operation are indicated with an exclamation mark in front of them. These are the individual danger levels:
1.1.1 Warnings
1.1.2 Notes DANGER!
Imminent danger!
Death or serious injury will occur!
Human lives are acutely endangered
WARNING!
Possibly imminent danger
Death or serious injury may occur
Human lives are possibly endangered
CAUTION!
Possibly imminent danger Light injury may occur
Danger of personal injury
!
NOTICE!Important information for safe and problem-free operation.Possibly imminent danger of damage to the gearbox
!
Note without signal word:... Here you will find notes on working effectively and safely.
Additional information and recommendations
1.2 Basic measures of caution
Frequently, accidents occur as a result of not observing general safety regulations or cautionary measures.
The individual chapters of these operating instructions contain specific safety notes.
Accidents may often be avoided by recognizing potential hazard situations in advance.
Dangerous places on the gearbox
Symbol Meaning Symbol Meaning
General Warning Sign These warnings must be observed!
Smoking and open fires prohibited!
Danger of being drawn or caught in by rotating components
Wear tightly fitting protective clothing e.g. coverall
Danger of electric shock!
Do not disconnect or service this device until power supply has been disconnected!
Wear ear protectors
1 Caution, hot components Read instructions carefully!
Output side Input side
1.3 Requirements for operating and maintenance personnel
Maintenance personnel must be trained in the operation and maintenance of marine gearboxes and have a mastery of the tasks required in safely carrying out maintenance.
This includes knowledge of procedures required in the event of failures or in cases of emergency as well as professional skills required for using the tools.
In order to maintain safety during operation, and to avoid any damage to the gearbox, it is necessary for you to carefully read and to understand the chapters
“Putting the unit into operation” from page 11, “Operation” from page 23 and
“Maintenance” from page 31.
In order to ensure your safety and the safety of others during assembly, utilise only tools, procedures, and methods of working in line with the most recent technology.
If the gearbox appears to require work not described in the documentation, please consult the REINTJES service department or a REINTJES representative.
General protective measures and personal protection in the engine room
The gearbox may be operated and maintained only by qualified staff knowledgeable in its operation and maintenance. Immediately repair any faults that pose a safety hazard!
Ensure that no foreign objects enter the inside of the gearbox during assembly.
Wear protective eyewear when cleaning with compressed air.
Danger of eye injuries due to dirt particles.
While the engine is running, wear ear protectors to prevent hearing impairments.
Do not wear long hair loosely or any loose clothing or jewelry, including rings, when near the gearbox while in operation.
Danger of injury due to getting caught or drawn in!
Do not touch the gearbox while it is warm from operation.
Danger of burns!
!
In addition to this documentation, please observe and follow applicable laws and any other binding regulations governing accident prevention and environmental protection!DANGER!
Rotating Parts!
Danger of accidents due to getting caught or drawn in!
Prior to trial run mount covers to all rotating parts to prevent being caught or drawn in.
1.4 Safety information for assembly
The gearbox has been built in accordance with the most recent technology and with recognized safety regulation standards. Yet, even when the gearbox is used appropriately, due to its manner of functioning and depending on how it is installed, a danger of personal injury or death to the user or other individuals may arise.
Observe the following procedures!
Safety prior to working on the gearbox
Before performing adjustments or repairs on the gearbox or on systems powered by the gearbox, shut down the engine.
Secure the propeller and drive shafts against unchecked rotation.
Before loosening or dismantling any tubes or accessory parts in air, oil or water circulating systems, first reduce the pressure.
WARNING!
When working on the gearbox, prevent the engine from being switched on!
Danger of death due to rotating components!
Shut down the compressed air feed and bleed the air tubes.
Prior to any assembly work on the gearbox, place a sign reading "OUT OF ORDER" or a similar warning sign on the start-up switch or starter button and on the remote starter.
Make sure that the remote starter of the drive motor on the bridge is also disabled and not functioning.
WARNING!
Oil pipes on the gearbox are under pressure when in operation!
Any oil escaping as a result of cracks or other leakage can result in serious injury.
Avoid damaging piping during assembly.
Perform a daily sight check of the piping in order to recognize any leakage at any early stage.
1.5 Protective measures against fire and danger of explosion
General information
Immediately remove any oil residues completely.
Do not leave on the gearbox any rags or cloths used to wipe oil residues.
Pipes and tubes
Check all tubes and oil pipes daily for wear or damage.
Check to see that these have been laid, supported and fastened in accordance with professional standards.
Tighten bolt joints only to the required torque.
Note that lubricants are flammable.
Never weld pipes or tubes carrying lubricants.
Do not straighten or bend any pipes or tubes under pressure during operation.
Immediately replace any bent or damaged pipes or tubes.
Do not replace steel pipes with copper ones.
Hoses
Do not damage hoses by subjecting them to mechanical force.
Check all hoses daily for any cracks forming or any mechanical damage.
Keep flames, acids and other corrosive or caustic liquids away from hoses.
Replace hoses no later than after 5 years.
Drained oil
Collect drained oil in a used oil collector.
Collect any rags soiled with oil in containers intended for this purpose.
!
Store all lubricants in appropriately labelled containers. Dispose of filter elements and used oil either as recyclable substances or as hazardous wastes.Cables connected to the gearbox
Make sure that all cables are maintained in an undamaged condition.
Check to see that all cables are laid properly and cannot be damaged by abrasion.
Immediately after connecting any cables to the gearbox, remove any leftover pieces of cable or refuse.
Use only wires and cables having the required diameter and type of insulation.
Protect cabling on the board side by means of fuses in front of them in circuits.
Foreign substances near to the gearbox
Ensure that no used parts, dirt or foreign substances are near the gearbox.
2 Putting the unit into operation
2.1 Note this safety information before putting the unit into operation the first time
Please take note of the following before putting the unit into operation:
Before putting the gearbox into operation, remove all tools and any other loose objects from it.
Make sure that all protective devices and covers have been mounted once again.
Inspect the gearbox for any possible hazards (i.e. sharp edges, loose cables, loose screw connections)
DANGER!
If a warning sign has been mounted:
Danger of death due to open drive parts and gears!
Do not start the engine under any circumstances!
Do not operate the control unit!
Every time prior to putting the engine or gearbox into operation, carefully ensure that no work is being done on these components or in the vicinity of them.
WARNING!
Rotating parts!
Danger of accidents due to getting caught or drawn in!
Prior to operation mount covers to all rotating parts to prevent being caught or drawn in.
Do not wear long hair loosely or any loose clothing or jewellery, including rings, when near the gearbox while in operation.
2.2 Installation check
2.2.1 Check of documents
2.2.2 Check of the gearbox
When performing a final check before putting the gearbox into operation, make sure that all necessary cables, tubes and pipes (e.g. electricity, water and air) have been connected.
Check to make sure that all of the bolts holding the gearbox and the connected elements are well seated.
2.3 Fill with operating oil (initial filling)
The inside of the gearbox is preserved with preservation oil when delivered. (refer to installation instructions, chapter “Preservation” on page 22)
!
Check to make sure you have most recent versions of these documents pertaining to the gearbox:
Installation instructions (part of this documentation)
Operating instructions (this document)
Drawing of installation
Supervision plan
Alignment protocolCheck the alignment protocol to make sure all of the required details have been entered and signed (responsibility of the shipyard).
The documents listed above include descriptions, illustrations and values necessary for safely operating the unit.
!
Attention!Remove the v-rings marked with label before commissioning. Before filling with oil, take a fresh oil sample.
Have the fresh oil sample analysed by a laboratory authorised to perform oil analyses. Include the analysis results among the gearbox documents.
Loosen and remove the oil drain screw.
Drain the preservation oil.
Dispose of the preservation oil in accordance with legal requirements for used oil disposal.
Any small amount of preservation oil remaining may be mixed
Any small amount of preservation oil remaining may be mixed