Operating Instruction ASL 94

COVER SHEET WITH TABLE OF CONTENTS
Operating Instruction
for
RENK-Marine
gear unit
ASL 94
Manufacturer: RENK AG
Gögginger Straße 73, 86159 Augsburg, Germany
(PO) box 10 23 07, 86013 Augsburg, Germany
Telex: 83781
Telephone Fax e-Mail
Service department: +49821 5700-219 -532 marine.augsburg@renk.biz
Design department: +49821 5700-269 -235 marine.augsburg@renk.biz
Sales department: +49821 5700-270 -559 marine.augsburg@renk.biz
Homepage: www.renk.de
RENK AG has been granted approval under DIN-EN ISO 9001.

Refer to protection notice ISO 16016.
This operating instruction including all data and drawings remain our exclusive
property. They are entrusted only for the agreed purpose. Copies or any other
reproductions, including storage, treatment and dissemination by use of electronic
systems must not be made for any other than the agreed purpose. Neither originals
nor reproductions must be forwarded or otherwise made accessible to third parties.
Issue: 2005-10-28 - MT/Hu/Erh Type: ASL 94 Revision: 2007-01-12 6955073/4 C 1 /6

Gear unit type: ASL 94
Customer: Schelde Naval Shipbuilding
Project:: Ynr 397/398
Shipyard: Schelde Naval Shipbuilding
Yard no: 397, 398, 399, 400
Ship: Indonesian Corvette
RENK order no.: 80124652 (yard no. 397, 398)

80130939 (yard no. 399, 400)
RENK gear unit product no: port 6461053

starboard 6461054
Board spare parts product no: 6461055
Serial no.: see type plates
Year of manufacture of the gear unit 2005, 2006, 2007

Issue of the Operating Instruction:
Issue Customer address + RENK Number and Issue data Employee

language responsible
Dept./Name
First issue Schelde Naval Shipbuilding 15x English 2005-10-28 MT/Erhard

attn. Mr. Adriaan Coppoolse 2x CD-rom 1. ship
Glacisstraat 165
P.O. Box 15x English 2006-04-07
4380 AN Vlissingen 2xCD-rom 2. ship
The Netherlands
15x English 2007-01-12
2xCD-rom 3. ship
15x English 2007-01-12

2xCD-rom 4. ship
Department MT 1x English 2005-10-28 MT/Erhard

1x CD-rom
Department MS 2x English
2x CD-rom
1st amendment See first issue See above 2005-12-09 MT/Erhard
2nd amendment See first issue See above 2006-04-07 MT/Erhard
3rd amendment See first issue See above 2007-01-12 MT/Erhard

Documents modified (3rd amendment):

Note: In case of a modification all modified documents will be provided with a new
revision date and the document number will obtain an index letter starting
with „A“. The modifications carried out will be marked with a black stroke in the
documents on the left side. The active modifications will be marked only.
The following modifications were made in the Operating Instructions available at your hand.
cons. Invalid (to be deleted) Replace by/Newly added
no. Designation Sheet Issue Designation Sheet Issue
1 Cover sheet Cover sheet

• 6955073/4 b 1 to 6 2006-04-07 • 6955073/4 C 1 to 6 2007-01-12
2 Part 1 Part 1
• 6954079/4 b 1 to 8 2004-09-27 • 6954079/4 C 1 to 8 2006-06-06
3 Part 5 Part 5
• 6955077/4 1 to 17 2005-10-14 • 6955077/4 A 1 to 17 2007-01-04
4 Part 9 Part 9
• 6817549/4 1 to 19 25. Mai 05 • 6817549/4 1 to 19 17. Jul. 06
5 Part 10 Part 10
• 6460900/0 G 1 to 2 11/05 • 6460900/0 I 1 to 2 03/06
• 6461243/0 D 1 to 2 09/05 • 6461243/0 H 1 to 2 01/07
• 6817565/0 B 1 to 2 09/05 • 6817565/0 C 1 to 2 02/06

TABLE OF CONTENTS
Part 1 General operating and safety information........................................ 6954079/4

• General operating information
• General safety information
Part 2 Technical data ................................................................................. 6955074/4

• Gear unit main data
• Technical data hydraulic
• Function sequences
Part 3 General description.......................................................................... 6955075/4

• Mechanic description
• Description of the hydraulic system
Part 4 Putting into service, Operation......................................................... 6955076/4

• Safety information
• Operating and display elements
• Putting into service
• Operation
• Longer stop periods
Part 5 Maintenance .................................................................................... 6955077/4

• General maintenance note
• Maintenance work
• Lubricant specification
• Routine maintenance work
Part 6 Operational failures, Repairs ........................................................... 6955078/4

• Operational failures
• Repairs
• Adjustment work
Part 7 Supply, Installation and installation check ....................................... 6955027/4

• Supply
• Preservation at delivery
• Installation and installation check
• Sea-water system

Part 8 Main parts list .................................................................................. 6955079/4

• Introduction
• Port gear unit
• Starboard gear unit
• On board spare parts list
Part 9 Additional documents ...................................................................... 6955080/4

• Hydraulic components
Part 10 Drawing appendix ............................................................................ 6955081/4

• Drawings mechanic
• Drawings hydraulic
Note: All four-digit item numbers listed and described in these operating instructions
can be identified by means of the parts lists and on the corresponding
drawings. The allotment of the instrument numbers of the Technical Data
(chap. 2.2) is carried out by using the main parts list (part 8), the connection
schemes and the different hydraulic schemes (part 10). The instrument
numbers are shown in hexagons on the hydraulic schemes. The instrument
numbers are written on rectangular number plates made of brass which are
glued on the corresponding instruments.

GENERAL OPERATING
AND SAFETY INFORMATION PART 1
TABLE OF CONTENTS
1 GENERAL OPERATING AND SAFETY INFORMATION .................................2
1.1 General operating information.......................................................................2

1.1.1 Introduction ................................................................................................2
1.1.2 Proper use .................................................................................................2
1.2 General safety information ............................................................................3
1.2.1 Symbols and explanation of notice ............................................................3
1.2.2 Notes and explanation of notice.................................................................5
1.2.3 Safety instructions for the operator, for maintenance and inspection ........5
1.2.4 Improper operation ....................................................................................6
1.2.5 Hazard potential where safety instructions are ignored .............................7
1.2.6 Safety data sheet .......................................................................................7
1.2.7 Remaining dangers for the user and protective measures.........................8
Issue: 1999-10-29 - MT/Hu/Erh Revision: 2006-06-06 6954079/4 C 1 /8

GENERAL OPERATING
1 General operating and safety information
1.1 General operating information
1.1.1 Introduction
• This operating manual shall have to be strictly respected in order to avoid any
damage to and thus downtimes of the gear unit.
• Any non-respect of the present operating manual shall imply a loss of guarantee
performances.
• Additional operating instructions beyond this manual for instruments/units not being
part of the RENK system shall also have to be adhered to.
• In particular the operating instructions for the entire propulsion system shall have to
be respected.
• Attention has to be paid to the safety regulations and accident prevention
instructions.
• Any person responsible for assembly, putting into operation, service, maintenance or
disassembly of the gear unit shall have read and understood the entire operating
manual, in particular chapter 1.2 „General Safety Information“.
• For the performance of special repair work on the gear unit, specialists of RENK,
Augsburg shall have to be consulted.
• This operating manual fulfils the requirements of laws, decrees, instructions,
technical standards, guidelines and agreements as to the relevant product and its
application.
1.1.2 Proper use
• The gear unit is state-of-the-art, and is operationally safe.
• The gear unit must only be used for the intended purpose built, and as indicated in
the technical data. Use for any other purpose is deemed to be improper. The
manufacturer shall not be responsible for damage caused by such improper use; the
risk shall be borne by the user.
• Proper use also embraces adherence to the manufacturer's installation, dismantling,
commissioning, operating and maintenance instructions.
• No changes of any kind may be made to the gear unit without the express approval
of RENK. Adding and removing parts in particular is forbidden.
• Only original manufacturer's parts may be used for repairs. Using components of
other manufacturers is permissible only with the express consent of the
manufacturer.

GENERAL OPERATING
1.2 General safety information
ALL SAFETY INSTRUCTIONS OF THIS OPERATING MANUAL SHALL HAVE TO BE

STRICTLY ADHERED TO
for transport, installation, putting into operation, service, maintenance and repair!
1.2.1 Symbols and explanation of notice
• Safety symbol
You will find this symbol in all safety instructions in this operating
manual and on the gear unit where there is danger to life and limb.
Please observe the safety instructions, and take particular care in
these cases. Please also pass on all safety instructions to all other
users as well. In addition to the instructions in this operating
manual, all applicable national safety and accident prevention
regulations of the host country must also be observed. These
regulations must be available to the operator.
• Danger of explosion!
This symbol means that in case of maloperation there is an
0 increased risk to life and limb. Handling instructions given in this
manual have to be strictly respected!
• Caution – Danger due to electrical current!

Authorised electricians are only allowed to work on the
electrical equipment.
Components of the plant on which inspections, maintenance or repair
works have to be carried out, have to be de-energised. Devices used
tor this purpose have to be secured against uninterntional or self-
acting switching-on (lock away fuses, bock circuit breakers, etc.).
Voltageless components have to be checked whether they are dead,
then have to be earthed and short-circuited. Neighbouring parts that
are still alive have to be insulated.
The definition of the denomination specialist electrician is given in the
Standards DIN VDE 0105 and IEC 364.
• Caution – Warning of Over-Pressure!

Severe injuries are possible due to hot fuel oil spraying out
under high pressure.
• The lube oil system has to be de-pressurised before any work

is carried out at the piping or components of the lube oil
system.

GENERAL OPERATING
• Danger – Warning of Hot Surface!

Burning of hands and arms is possible
• at all accessible housing parts,

• at the piping and vessels of the hydraulic system and
• through the lube oil itself.
Higher ambient temperatures also lead to increased temperatures on

the housing surface of the gearbox.
• Wear safety gloves while working on the gearbox.
• Protective gloves!
Wear protective gloves!

At all sides of access to the gearbox.
• Pay attention to manual!
Before starting the plant user's information (operating instruction)

has to be read in any case.

GENERAL OPERATING
1.2.2 Notes and explanation of notice

• Warning Notice!
This notice indicates those passages in these operating
instructions which are of particular importance for ensuring that the
ATTENTION guidelines, regulations, instructions and the correct method of
working are adhered to, and that damage to the gear unit and/or
other items of the plant is prevented.
• Note!
This refers to a procedure or to a circumstance of special interest or
importance. Within the interest of the proper application of the
Note
gearbox as intended, all the stated measures and notes shall be
carefully fulfilled and observed.
1.2.3 Safety instructions for the operator, for maintenance and inspection
• All local safety and accident prevention regulations which apply in the host country
must be observed.
• Parts of the gear unit (casing, pipes, etc.) can become hot in continuous operation.
WARNING: when touching! (Wear safety gloves)
• There must be no fire or open flame near the gear unit.
• At all exposed shaft outlets, ensure that no rotating parts are touched.
WARNING: The safety guard must not be removed when the gear unit is running.
• Inspection hole covers in the gear unit casing must not be opened when the unit is
running.
WARNING: It is forbidden to reach into the running gear unit, and to insert objects.
• No screwed pipe joints or flanged joints may be slackened while the unit is running.
WARNING: Danger from escaping oil.
• The manufacturer's switch-point settings for monitoring and control instruments such
as pressure switches, valves, throttles etc. must not be changed.
• The gear unit must be operated, serviced an maintained only by suitably trained and
instructed personnel.
• Any action which impairs the safety of the gear unit is forbidden.
• Rotating and moving parts must be guarded as required by machine guarding
legislation. All rotating input and output elements those are not protected by RENK,
must with running plant by means of safety device be protected.
WARNING: Guards must be fitted when the plant is running.
• Normal protective clothing such as safety helmet, safety glasses, safety gloves and
safety shoes must be worn when working on the gear unit.
• All operating, servicing and repair work must be carried out only by suitably trained
and instructed personnel.

GENERAL OPERATING
• Work on the electrical system of the gear unit must only be carried out by trained
personnel. Electrical components, especially terminal boxes, must not be opened
when power is connected.
WARNING: Danger of electric shock!
• Before carrying out any work on the gear unit which involves complete or partial
opening of the unit, the person responsible for the unit must positively ensure that it
is impossible for the gear unit to start up. Work on the gear unit (main and auxiliary
gear units) must without exception be carried out only when the unit is at rest.
• No alterations must be made to the gear unit. In particular, the addition and removal
of parts is forbidden.
• Only original manufacturer's parts may be used when carrying out repairs.
Components of other manufacturers which are not expressly approved by the gear
unit manufacturer may not be used.
• Before starting work on the gear unit, the drive units and ancillary equipment must
be prevented from being switched on unintentionally.
• Guards may be removed only when the gear unit is at rest and has been positively
secured. All electrical components must be disconnected before disassembly.
• Before switching the gear unit back on after maintenance or inspection work, check
that all guards are in place.
• When carrying out repair work, before removing any part from the gear unit, it must
be suspended or supported.
• Do not walk under suspended loads during transport.
• The load-bearing capacity of the lifting equipment installed must at least equal the
heaviest individual load.
• Environmental regulations must be observed when draining off oil.
• Manufacturer's instructions must be observed when using solvents and other
aggressive materials.
1.2.4 Improper operation
• Operation outside the performance figures indicated is not permitted.
• Any change in the gear unit which impairs safety (increased noise level, higher
temperatures than normal, etc.) must be immediately investigated, the cause sought
or the fault rectified. Any such change must also be reported to the management of
the plant, and operating personnel must be similarly required to report any change.
• The gear unit must only be operated when functioning correctly in accordance with
the technical data (see part 2).
• Operating without safety guards is not permitted.
• Proper functioning of the oil unit needed for lubricating the gear unit must be
ensured at all times.

GENERAL OPERATING
1.2.5 Hazard potential where safety instructions are ignored

• There is a danger to life and limb for untrained personnel if they operate the gear
unit incorrectly or improperly.
• Rotating parts and the energy released when they suddenly stop can cause serious
damage to people and equipment.
• Extended downtime and high repair costs with damaged gear parts.
• Remaining danger for the operator see chapter 1.2.7.
1.2.6 Safety data sheet
• Responsibility for safety must be clearly assigned and binding guidelines established
by the user. Responsibility for the various aspects of installation, commissioning,
operating, maintenance and repair and dismantling must be clearly determined and
discharged.
• The management must exercise proper supervision and control of the installation
site of the transmission to ensure clean and orderly housekeeping.

GENERAL OPERATING
1.2.7 Remaining dangers for the user and protective measures
• Steps must be taken to ensure that no moving parts can be touched at any shaft
outlet.
WARNING: Safety guard may not be removed when the gear unit is running.
• Parts of the gear unit (case, pipes, etc.) can become hot in places with prolonged
operation.
WARNING: when touching! (Wear safety gloves).
• When working on the gear unit and parts fitted to it, it is necessary to wear the usual
protective clothing such as safety helmet, safety glasses, safety gloves and safety
shoes.
• Do not walk under suspended load during transport.
• There must be no fire or naked flame.
• Work on the electrical system must only be carried out by trained personnel.
Electrical components, especially terminal boxes, motor starters, etc. must be
disconnected before being opened.
WARNING: Danger of electric shock.
• The manufacturer's switch-point settings for monitoring and control instruments such
as pressure switches, valves throttle, etc. must not be changed.
• No screwed pipe joints or flanged joints may be slackened while the unit is running.
There is a particular danger in the case of high pressure hydraulics.
WARNING: Danger from escaping oil.
• Inspection hole covers in the gear unit case must not be opened when the unit is
running.
WARNING: It is forbidden to reach or insert objects into the running gear unit.
Before any work which requires complete or partial opening of the unit it is necessary to
ensure that the gear unit cannot be started up from the plant side.

TECHNICAL DATA PART 2
TABLE OF CONTENTS
2 TECHNICAL DATA ...........................................................................................2
2.1 Gear unit main data.......................................................................................2

2.1.1 Input diesel engine (DE) ............................................................................2
2.1.2 Output gear unit .........................................................................................2
2.1.3 Auxiliary devices ........................................................................................2
2.1.4 Hydraulic data............................................................................................2
2.1.5 Plain bearing data ......................................................................................3
2.2 Technical data with lubricating oil pressure diagram

6817651/4 to connection scheme ........................................................1 to 35
2.3 Function sequences 6817239/4 ...........................................................1 to 11
Issue: 2005-08-04 - MT/Hu/Erh Type: ASL 94 Revision: 6955074/4 1 /3

2 Technical data
2.1 Gear unit main data

ASL 94
Design type
Port Starboard
Dimensions in mm (LxBxH) 2550x2625x2640
Weight gear unit app. 14000 kg
Classification society Llyods Register of Shipping (LRS)
2.1.1 Input diesel engine (DE)

Power 8900 kW
Input speed 1084 rpm
Multi-disc clutch
- max. DE speed for engagement 405 - 500 rpm
Direction of rotation (see from aft) cw ccw
2.1.2 Output gear unit

Power 8775 kW
Output speed 245.3 rpm
Direction of rotation (see from aft) ccw cw
Propeller thrust
- nominal ±420 kN
- maximal ±715 kN
2.1.3 Auxiliary devices
OD-box connection Dimension see installation drawing
2.1.4 Hydraulic data
Oil viscosity (details see chap. 5.4) SAE 30 / ISO VG 100

Oil quantity per gear unit 600 litre

2.1.5 Plain bearing data

The resistance temperature sensors PT 100 installed into the plain bearings (see fig. 1)
are transmitting signals to the ships control system for monitoring purposes.
As soon as the adjusted alarm temperature has been reached, an alarm will be triggered
in the control room. After the test run and/or putting into operation alarm values can be
corrected as follows:
Alarm temperature = max. measured operating temperature + 5°C
For adjusted alarm temperatures refer to Technical Data, chapter 2.2.
fig. 1 - output shaft cpl.
111/1
112
113
111/2

Technical data Type: ASL 94
to: Connection scheme Drawing no. 6817650/0
General Instructions
1. When the ship control system is activated while gear unit is standing still, the stand-by pump switches on automatically.
Until the lube and control oil pressure has built up, the control curves of lube and control oil are to be delayed for approx. 30 sec.
Attention! The temperatur range for the operation of the gearbox is +5°C to +48°C.
Cold start at air temperature range 0°C to +5°C, the oil must to be warmed up at least to +5°C by operating of
the electric control oil stand-by pump.
The temperatur is not controlled by RENK.
2. For multi-disc clutch OFF the transmitter item 93, 102, 104 are to be deactivated.
3. Transmitter / switches items 100, 101, 103, 105 at engaging of multi-disc clutch delay of 15 sec.
4. Transmitter / switches items 100, 101, 103, 105 with rotating output shaft delay of 5 sec.
5. Oil level tester 99 delay 60 sec.
6. Delay relays for all are not Renk supply
7. At start diesel engine signal to operating valve item 20: multi-disc clutch OFF
8. Control of operating valves item 50 connection number 920/921 only with continuous current 24 VDC
9. Control of operating valve item 51 connection number 925 only with continuous 24 VDC
Drawing no: 6817651/4d
Order number: 80124652
2005 -01-25/ Aumüller Product number: 6461053
Page 1/35 refer to protection notice ISO 16016 6461054
Description of "START - STOP Control"

for electric control oil stand-by pump item 3 further to the lube oil diagram
1. Normal operation as a function of speed
1.1 Start-up of the plant: Start of the electric control oil stand-by pump for prelubrication of the gear unit.
Stop of the plant: stop of the stand-by pump at standstill of the propeller (n=0) and stop of all diesel engines.
1.2 The start and stop of the electric control oil stand-by pump is controlled as a function of the output shaft speed.
After the start of the entire gear unit installation, the electric control oil stand-by pump has to be stopped
at npropeller = 113 rpm increasing
When the propeller speed drops (multi disc clutch engaged) the electric control oil stand-by pump has to be started again
at npropeller = 92 rpm decreasing
1.3 Test run Diesel engine (multi disc clutch disengaged):

The electric control oil stand-by pump has to be operated over the whole speed range
nDE = 0 to 1084 rpm
2. Emergency operation - as a function of oil pressure and speed
2.1 Lube oil pressure min.

Start of the electric control oil stand-by pump as per control curve "A"
2.2 Control oil pressure min .

Start of the electric control oil stand-by pump at control oil pressure < 14 bar
Attention! After a start of the stand-by pump accordingly to item 2.1 and 2.2 there is no stop of the stand-by pump
permitted!

Oil pump
Item Quantity Material Flow quantity Pump Suction

(for each Type Speed Remarks
no. gear unit) no. +10% / -5% pressure height
[r.p.m.] [l/min] [bar] [m]

Port gear unit
Built-on 20
1 1 6817247 1990,8 112 2 primary running
control oil pump (max.-)
direction of rotation CCW (view onto the pump shaft)
Starboard gear unit
Built-on 20
1 1 6817241 1990,8 112 2 primary running
control oil pump (max.-)
direction of rotation CW (view onto the pump shaft)
Port gear unit
Built-on 6
2 1 6817248 2253,6 267 3 secondary running
lube oil pump (max.-)
direction of rotation CW (view onto the pump shaft)
Starboard gear unit
Built-on 6
2 1 6817240 2253,6 267 3 secondary running
lube oil pump (max.-)
direction of rotation CCW (view onto the pump shaft)
Electric 20 Control oil pump, electrically driven
3 1 6817242 1765 163 2,3
control oil pump (max.-) direction of rotation CW (view onto the pump shaft)

Electric motor
Thermistor
Rated Standstill heating
protection
Vol- Type
Protec- Insula-
Item Quantity Material tage / Starting of Vol- Rated Release
(for each Type Power Speed Current Design tion tion Remarks
no. gear unit) no. fre- current connec- tage power temperature
type class
quency tion
[V] /
[kW] [r.p.m.] [A] [A] Code [V] [W] [° C]
[Hz]
Electric control oil
pump item 3
Electric 440 /
4 1 6817242 13,2 1760 23,5 167 B5 IP 55 F direct 230 50 145 direction of rotation
oil pump 60
CCW (view onto the
motor shaft)

Filter
Item Quantity Filter Mesh Flow Operating Pressure loss

(for each gear Make Type Remarks
no. unit) surface width quantity pressure at 66°C
[cm²] [mm] [l/min] [bar] [bar]
Line strainer in the suction line of built-on control oil pump item
6 1 6811517 - 1,25 - 0,3 -
DN 50, PN 16 1
Line strainer
7 1 1105915 - 1,25 - 0,3 - in the suction line of built-on lube oil pump item 2
DN 65, PN 16
Line strainer in the suction line of electric control oil pump item
8 1 1105915 - 1,25 - 0,3 -
DN 65, PN 16 3
Line strainer
10 1 6811517 - 1,25 - 0,3 - gear oil filling
DN 50, PN 16
max. max. Control oil double filter
11 1 6815266 Double filter 2x2780 0,025 0,3
300 20 manual change over
max. max. Lube oil double filter
12 1 6815266 Double filter 2x2780 0,025 0,25
300 5 manual change over

Oil cooler for lube oil, Sea water design
Oil
Quantity Operating Pressure Water Water Operating Pressure
Item Cooling Oil flow tempera-
(for each Make Type pressure loss flow temperature pressure loss Remarks
no. gear unit) capacity quantity ture
Oil Oil at 50°C quantity IN / OUT Water Water
IN / OUT
[kW] [l/min] [° C] [bar] [bar] [m³/h] [° C] [bar] [bar]
max. max. max. Mesh width for sea water
13 1 6817243 Oil cooler 125 66 / 50 0,3 18 32 / 38 0,2 strainer max. 4.0 mm
300 16 10

Temperatur controller
Item Quantity Regulating Oil flow Operating Regulated

(for each gear Make Type Remarks
no. unit) insert quantity pressure temperature
Code [l/min] [bar] [° C]
2012 A - max. max.
14 1 6817656 DN 50 35 bis 45
105/41 300 10

Pressure relief valve for lube oil
Item Quantity
(for each Make Type Remarks
no. gear unit)
6817677 STB Pressure valve Valve producing the control oil pressure for all multi-disc clutches,
45 1
6817678 BB DBV 40 (40) - So consisting of item 45/1 to 45/4
Main valve
45/1 1 piloted by item 45/2
DBV 40 (40) - So
Lube oil pressure ps = 3,5 bar adjusted at:
- Diesel engine - nominal speed
- multi-disc clutch engaged
Pilot control valve
45/2 1 - built-on control oil pump item 1 ON
DB 9 So
- stand-by electric control oil pump item 3 OFF
- Oil pressure indication see pressure gauge item 71
- Operating temperature 50°C, see thermometer item 81
Filter
45/3 1 Mesh width: 0.5 mm
HF1
45/4 1 Control oil throttle Bore diameter: 1.5 mm

Pressure accumulating valve (control oil pressure multi-disc clutch)
Item Quantity
no. gear unit)
6817677 STB Pressure valve Valve producing the control oil pressure for all multi-disc clutches,
46 1
6817678 BB DBV 40 (40) - So consisting of item 46/1 to 46/4
Main valve
DBV 40 (40) - So
Main operating pressure: pk = 18,0 bar for the multi-disc clutches of the Diesel engines
adjusted at:
- Diesel engine - rated speed
Pilot control valve - multi-disc clutch engaged
46/2 1
DB 9 So - built-on control oil pump item 1 ON
- Oil pressure indication see pressure gauge item 72
- Operating temperature 50°C, see thermometer item 81
Filter
HF1

Pressure accumulating valve (control oil pressure multi-disc clutch)
Item Quantity
no. gear unit)
6817677 STB Pressure valve

47 1 consisting of item 47/1 to 47/4 and 51
6817678 BB DBV 40 (25 ) -So
Control valve
DBV 40 (25 ) -So
Reduced operating pressure: pkv = 5,0 bar for the multi-disc clutches of the Diesel engines
adjusted at:
- Diesel engine - rated speed
pilot valve for reduced - multi-disc clutch engaged
47/2 1
control oil pressure - Built-on control oil pump item 1 ON
- Oil pressure indication see pressure gauges item 73
- Operating temperature 50°C, see thermometers item 81
Filter
HF1

Operating valve
Quantity Nominal
Item Flow Oil
(for each Make Type diameter Control Power input Remarks
no. gear unit) medium pressure
DN
mm [bar] [bar] [V] [W]
4/2-way valve electric
control valve for multi-disc clutch of the
EWEDE-42- Control impuls/
50 1 6815308 10 0 - 30 24 36 main propulsion with manual emergency
C-10-3 oil continuous
operation
24VDC-S483N current
4/2-way valve Operating valve for pressure accumulating
VL B6 FZ AO Control valve item 47
51 1 6815309 6 0 - 30 electric 24 36
E5 WO 10 oil with manual emergency operation
0 810 091 254 for switching between pk and pkv

Pressure relief valve for control oil
Quantity Nominal
Item
(for each Make Type diameter Adjustment of oil pressure Remarks
no. gear unit)
DN
reduced control Control oil lube oil
mm oil pressure pressure pressure
[bar] [bar] [bar]
6817677 STB
48 1 RPIS-LNN 40 - 32
6817678 BB

Check valve
Quantity Nominal Nominal

Item Opening
(for each Make Type diameter pressure Remarks
no. gear unit) pressure
DN PN
[mm] [bar] [bar]
40 1 6721008650 RK 86 50 40 0,1 in the pressure line downstream of built-on control oil pump item 1
41 1 6721008665 RK 86 65 40 0,1 in the pressure line downstream of stand-by electric control oil pump 2
42 1 6818796 RK 86 40 40 0,1 in the pressure line upstream of built-on control oil pump item 1
43 1 6721008650 RK 86 50 40 0,1 in the pressure line upstream of built-on lube oil pump item 2
44 1 6721008650 RK 86 50 40 0,1 in the pressure line upstream of stand-by electric control oil pump 2
66 1 6812541 RVSAE3DS 50 210 0,2 in the pressure line upstream of lube oil filter item 12
67 1 RKVE-40 40 350 0,2 in the connection line between valve item 45 and 46 (control block)
68 2 1100754 RHD38 S 32 250 1 in the suction pipe feeding of the built-on control oil pump 1

Throttle
Pressure
Item Quantity Bore Flow
(for each loss Remarks
no. gear unit) diameter quantity
at 50° C
[mm] [bar] [l/min]
max.
52 1 2,0 4,5 Relief throttle, built-on lube oil pump item 2
6
max.
53 1 9,0 56,3 Suction pipe feeding for built-on control oil pump 1
2
max.
54 2 4,5 20 Throttle for thrust bearing, ahead and astern
3
max.
55 1 4,5 20 Throttle for plain bearing astern
3
max.
56 1 1,2 2,8 Relief throttle, built-on control oil pump item 1
20
max.
57 1 2,0 8 Relief throttle, stand-by electric control oil pump item 3
20
max.
84 1 5,4 54,4 Throttle for operating valve item 50 (multi disc clutch)
18

Measuring point
Item Quantity
(for each Make Type Connection Remarks
no. gear unit)
G 1/4
60 1 - - Control oil pressure downstream of operating valve item 50
Inner thread
G 1/4
61 1 - - Control oil pressure upstream of operating valve item 50
Inner thread
G 1/2
62 3 - -
Inner thread
G 1/2
63 1 - -
Inner thread
G 1/2
64 1 - -
Inner thread
G 1/4
65 9 1101807 EMA 3 1/4 Measuring connection with screwed coupling M 16
Inner thread

Pressure gauge
Item Quantity Casing Thread Indicating Normal

(for each Make Type Alarm range Remarks
no. gear unit) diameter connection range range
[mm] [bar] [bar] [bar]
70 RCHG 0 bis 0,7 Lube oil pressure

1 6815617 100 G 1/2 A 0 bis 10 0,7 bis 5,0
(502) 100-1, rFR 5,0 bis 10 downstream of the double oil filter item 12
71 RCHG 0 bis 0,7 Lube oil pressure

1 6815338 100 G 1/2 A 0 bis 10 0,7 bis 4,5
(505) 100-1, rFR 4,5 bis 10 at gear unit inlet
Control oil pressure for multi-disc clutches main
72 RCHG 0 bis 14
1 6815618 100 G 1/2 A 0 bis 25 14 bis 20 propulsion
(608) 100-1, rFR 20 bis 25
at gear unit inlet
73 RCHG 0 bis 14 Control oil pressure for multi-disc clutches

1 6815618 100 G 1/2 A 0 bis 25 14 bis 20
(609) 100-1, rFR 20 bis 25 main propulsion operating indication

Thermometer
Sensor length /
Item Quantity Casing Thread Indicating Normal ran- Alarm range
(for each Make Type Capillary line Remarks
no. gear unit) diameter connection range ge (green) (red)
length
[mm] [° C] [° C] [° C] [mm]
80 TFCHG 0 bis 5 110/ Lube oil temperature

1 6815619 100 G 1/2 A 0 bis 100 5 bis 75
(520) 100, rmFR 75 bis 100 3000 upstream of the oil cooler item 13
81 TFCHG 0 bis 5 110/ Lube oil temperature

1 6815623 100 G 1/2 A 0 bis 100 5 bis 58
(521) 100, rmFR 58 bis 100 3000 at gear unit inlet

Pressure switch
Circuit
Item Quantity Setting Voltage Contact Control
(for each Make Type breaking Remarks
no. gear unit) range DC type point
capacity
[bar] [V] [W] [bar]
Control indicator
90 MBC 5100 - 12
1 6813958 5 bis 20 24 12 Changer Multi-disc clutch main propulsion
(609) 3231 - 2 DB04 increasing
ENGAGED / DISENGAGED
91 MBC 5100 - 10
1 6813958 5 bis 20 24 12 Changer Valve item 51 locked
(609) 3231 - 2 DB04 increasing
92/1 MBC 5100 - 0,8 Lube oil pressure at gear unit inlet
1 6807668 -0,2 bis 4 24 12 Changer
(505) 1211 - 2 DB04 increasing Start release of Diesel engine
93 MBC 5100 - 14 Control oil pressure min. at gear unit inlet

1 6813958 5 bis 20 24 12 Changer
(609) 3231 - 2 DB04 decreasing start of stand-by electric control oil pump item 3

Differential pressure switch
Quantity Circuit
Item Setting Voltage Contact Control
capacity
[bar] [V] [W] [bar]
97 2,5 Differential pressure
1 AE.80.2,5 - 24 12 Changer
(506, 507) increasing Alarm; installed in the control oil double filter item 11
98 2,5 Differential pressure
1 AE.80.2,5 - 24 12 Changer
(503, 504) increasing Alarm; installed in the lube oil double filter item 12

Level switch
Quantity Circuit
Item Setting Voltage Contact Control
capacity
[bar] [V] [A] [bar]
Oil level
99 1 6811210 PLCA-50 - 24 0,08 Opener -
Alarm; installed in the gear unit casing bottom part

Pressure transmitter
Supply
Item Quantity Pressure Output control
(for each Make Type voltage Remarks
no. gear unit) range signal point
DC
[bar] [V] [mA] [bar]
100 MBS 5150 - 1811 - as per Lube oil pressure min. at gear unit inlet
1 6813720 0 bis 6 12 bis 34 4 bis 20
(505) 2 DB04 diagramm Alarm and indication - see lubricating oil pressure diagram
101 MBS 5150 - 2411 - 15,0 Control oil pressure min. at gear unit inlet
1 6813959 0 bis 25 12 bis 34 4 bis 20
(608) 2 DB04 decreasing
Alarm and indication
102 MBS 5150 - 2411 - 15,0 Control oil pressure min. multi-disc clutch inlet
1 6813959 0 bis 25 12 bis 34 4 bis 20
Alarm and indication
103 MBS 5150 - 1811 - as per Lube oil pressure min. at gear unit inlet
1 6813720 0 bis 6 12 bis 34 4 bis 20
(505) 2 DB04 diagramm for emergency stop - see lubricating oil pressure diagram
104 MBS 5150 - 2411 - 13,0 Control oil pressure min. at gear unit inlet
1 6813959 0 bis 25 12 bis 34 4 bis 20
for emergency stop
Lube oil pressure min. at gear unit inlet
105 MBS 5150 - 1811 - as per
1 6813720 0 bis 6 12 bis 34 4 bis 20 Start of stand-by electric control oil pump -
(505) 2 DB04 diagramm
see lubricating oil pressure diagram

Resistance thermometer
Item Quantity Measuring Measuring Sensor Thread control

no. gear unit) element range length connection point
Ohm / 0° C [° C] [mm] [° C]
Lube oil temperature at gear unit inlet
110 55
1 6810854 MBT 5250 1 x PT 100 0 bis 120 120 G 1/2 A Alarm and indication
(522) increasing
downstream of the temperature regulating valve item 14
111/1 80 Plain bearing temperature at gear unit inlet
1 6813261 MBT 5253 2 x PT 100 0 bis 120 G 1/2 A
(523/1) increasing Alarm and indication; input shaft, engine side
111/2 80 Plain bearing temperature at gear unit inlet
1 6813261 MBT 5253 2 x PT 100 0 bis 120 G 1/2 A
(523/2) increasing Alarm and indication; output shaft, propeller side
112 80 Thrust bearing temperature
1 6813261 MBT 5253 2 x PT 100 0 bis 120 G 1/2 A
(524) increasing Alarm and indication, ahead
113 80 Thrust bearing temperature
1 6813261 MBT 5253 2 x PT 100 0 bis 120 G 1/2 A
(525) increasing Alarm and indication, astern

Proximity switch
Quantity Voltage
Item Load Contact Switch
(for each Make Type range
no. gear unit) current type distance
DC
[V] [mA] [mm]
BES 516-300-S290- Multi-disc clutch for main propulsion
115 1 6807333 BO-D-PU05 10 to 30 130 Closer 0 to 1,1 Control indicator: signal "ON"
(650)
(NPN-design) installed in the operating valve item 50
BES 516-300-S290- Multi-disc clutch for main propulsion
116 1 6807333 BO-D-PU05 10 to 30 130 Closer 0 to 1,1 Control indicator: signal "OFF"
(651)
(NPN-design) installed in the operating valve item 50

Speed transmitter
Sensor
Working wheel
Item Quantity
(for each Make Type Output signal voltage Number of Remarks
no. gear unit)
DC ( V ) teeth
Impulse frequence f = 560 Hz at:

square wave -Diesel engine speed n = 1084 rpm
voltage z = 137 -output shaft speed n = 245,3 rpm
125/1 1 6817869 FA1H-4C-125 24
m = 11 (Output shaft speed = transmitter wheel speed)
Distance of transmitter 0,8 - 1,0 mm
(Transmitter thread M 18x1 = 1,0 revolution of kead of tooth)
Impulse frequence f = 560 Hz at:
square wave -Diesel engine speed n = 1084 rpm
voltage z = 137 -output shaft speed n = 245,3 rpm
125/2 1 6817869 FA1H-4C-125 24
m = 11 (Output shaft speed = transmitter wheel speed)
Distance of transmitter 0,8 - 1,0 mm
(Transmitter thread M 18x1 = 1,0 revolution of kead of tooth)

Time relay
Working Circuit
Item Quantity Contact
(for each Make Type voltage breaking Remarks
no. gear unit) type
DC capacity
[V] [A]
24 connection Operating valve item 51 locked the the multi-disc clutches

130 1 6810531 Z-REL1-W/4-RT 10
(18 bis 36) wiping Switch over time for the operating valve item 51 adjusted to 10 seconds

Relay
Working Circuit
no. gear unit) type
DC capacity
[V] [A]
EMG17-REL/ 24
131 3 6808151 8 changer
KSR 24/21 (18 bis 36)
EMG17-REL/ 24 double
132 2 6810067 8
KSR 24/21-21-LC (18 bis 36) changer

Amplifier
Working
Item Quantity Load Output
(for each Make Type Measuring range voltage Remarks
no. gear unit) current signal
DC
[V] [mA] [mA]
24
140 5 6817867 VP51-I2 0 to 120 °C 50 4 bis 20 Amplifier for PT100 item 110 to 113
(18 bis 36)
24
141 2 6817868 VF501-I2-646 20 to 646 Hz 50 4 bis 20 Amplifier for speed transmitter item 125/1 to 125/2
(18 bis 36)

Starter for electric motor
Item Quantity Operating Operating Control

no. gear unit) voltage frequency voltage
[V] [Hz] [V]
for the electric motor item 4 of the electric control oil pump item 3
150 1 - 440 60 - After a pump start caused by item 93/1 and item 106 there is no pump stop
permitted!
for the standstill heating of the electric motor item 4
151 1 - 230 60 -

Tripping unit for thermistor motor protection
Item Quantity Response

(for each Make Type Voltage Remarks
no. gear unit) temperature
[° C] [V]
160 1 - - 140 for the electric motor item 4 of the electric control oil pump item 3

Safety Relay
Working Circuit
no. gear unit) type
DC capacity
[V] [A]
24
165 1 - 3TK2822--1CB30 5 interruptor for the electric motor item 4 of the electric control oil pump item 3
(18 bis 36)

Customer`s connections at the gear unit (to be rooted by the shipyard): Oil connections
Item Quantity
(for each Connection size Remarks
no. gear unit)
901 1 G 1 1/2 Gear unit - oil drain

EN 1092-1-DN50
902 1 Gear unit - oil filling
PN6
EN 1092-1-DN50
903 1 Gear unit - air vent
PN6

Customer`s connections at the gear unit (to be rooted by the shipyard): Sea water connections
Item Quantity
no. gear unit)
DIN 2501-DN50
910 1 Sea water supply line to the gear unit oil cooler item 13 (cooler "INLET")
PN16
DIN 2501-DN50
911 1 Sea water return line from the gear unit oil cooler item 13 (cooler "OUTLET")
PN16

Customer`s connections at the gear unit (to be rooted by the shipyard): Electrical connections (not from the gear unit terminal box)
Item Quantity
no. gear unit)
Control magnet M 2 from operating valve item 50 with continous current 24 V DC

920 1 Shipyard
Multi-disc clutch, diesel engine "DISENGAGED"
Control magnet M 1 from operating valve item 50 with continous current 24 V DC
921 1 Shipyard
Multi-disc clutch, diesel engine "ENGAGED"
925 1 Shipyard Main circuit connection 24 V DC
Main circuit connection 440 V, 60 Hz
930 1 Shipyard
1 x starter item 150
Main circuit connection 230 V, 60 Hz
940 1 Shipyard
1 x standstill heating item 151
Connection
945 1 Shipyard Starterbox item 150 to ship control system
impulse signal start - stop (control voltage 24 V.D.C.)
Connection
946 1 Shipyard Safety relay item 165 to yard
emergency stop standby pump

Date:
Operating range standby pump + prim. built-on pump
15,0 Alarm - Transmitter
20,0
no. 101 and 102
25.01.05
18,0
14,0 Standby pump
16,0 start
14,0 13,0 Opening
Name:
multi-disc clutch
Control oil pressure

12,0
Monitoring curve
- Connection scheme
Transmitter 104
Miehle
100 200 300 400 500 600 700 800 900 1000 1100 n DE (rpm)
p bar 0 n propeller (rpm)
Checked:
4,5 Standby-pump stop Operating range sec. + prim. built-
on pump at multi disc clutch
Aumüller
4,0
6817650/0
Operating range stand-by pump +

prim. built-on pump + sec. built-on
3,5
Technical data for the connection scheme
Idling speed
3,0 Operating range stand-by
Drawing-no.:
Alarm
pump + prim. built-on pump Transmitter
2,5 2,5 no. 100
2,1 Start standby-
Lube oil
2,0 pump
6817651/4
1,7 Transmitter
1,5 no. 105
Standby-pump start A Emergency
stop
Monitoring curve
1,0
Transmitter
0,7 no. 103
0,5
0,3
Index:
d
DE (rpm)
Lubricating oil pressure diagram
0 50 100 150 200 250 300 350 400 450 500 550 600 650 700 750 800 850 900 950 1000 1050 1084 n
11 23 34 45 57 68 79 92 102 113 124 136 147 158 169 181 192 204 215 226 238 245,3 n propeller (rpm)
Alarm
Transmitter
Sheet:
no. 100 405 - 500 Speed range for engagement + multi disc clutch
Type:
Start standby-pump
Transmitter no. 105
34/35
Emergency stop
Transmitter no. 103 Refer to protection notice ISO 16016
ASL 94
Modifications
Item- Item-
Date Index Page Description Date Index Page Description
no. no.
02.03.2005 a 1 - 1. changed 25 125/2 added
4 4 standstill heating power added 27 140 added
5 9/10 added 27 141 added
8 45 complete added 28 151 operating voltage changed
9 46 item no.15 into 46 and typ changed 30 165 added
10 47 item no.16 into 47 changed 33 920 remarks changed
11 50/51 item no. 20 into 50 and 21 into 51 changed 33 920 remarks changed
12 48 added 33 940 remarks changed
13 66/67 added 33 946 added
13 68 item 45 into 68 changed 25.10.2005 c 5 9 removed
14 56/57 item 50/51 into 56/57 changed 10 47/2 remarks changed
14 84 item 55 into 84 changed 11 51 remarks changed
15 60/61 remarks changed 13 42 make changed
15 65 quantity changed 13 66 complete changed
16 73 added 14 55 added
27 151 added 14 56 bore, pressure loss and flow quantity changed
29 901 connection size changed 24 125/1 make added
31 940 remarks changed 24 125/2 make added
31 945 added 27 141 measuring range changed
15.06.2005 b 1 - 3., 4. 8., 9. changed 23.03.2006 d 24 125/1 type rectified
4 4 power, speed, current, start. current, volt. changed 24 125/2 type rectified
6 13 oil quantity, oil temp., press. loss water changed
7 14 make added
14 53 bore diameter, flow quantity changed
17 81 make changed
18 92/2 removed
23 115 remarks changed
23 116 remarks changed
25 125/1 typ, signal and remarks changed

Function sequences Type: ASL 94
1. General
1.1 Preliminary remark
The function sequences are just a guide for the gear unit functions.
Operating scheme drawing no. 6817650/0 and Technical Data Drawing no. 6817651/4
are applicable to the functions with priority.
The shipyard or the control system manufacturer is responsible for the complete
function sequences including all components for machine installation.
The instrument numbers of the indication instruments, sensors, etc. indicated in the function sequences refer to
operating scheme no. 6817650/1 and Technical Data Drawing no. 6817651/4.
1.2 Genereal Conditions for all operating conditions

1.2.1 Normal operation
- Control system in normal function
- All components (pumps, etc.) in function
1.2.2 Emergency operation

- Partial failure of individual components
- Control partly with hand emergency actuation of control components and via local instruments.
Drawing no: 6817239/4c

29.06.2005 / Aumüller refer to protection notice ISO 16016 Product number: 6461053
Page 1/11 6461054
2. Normal operation
2.1 Activation of propulsion system
No. Description Action REMOTE AT SITE Remark

1 Diesel engine standstill
2 Monitoring plant activate not from RENK
3 Engine room temperature check t < 0°C Operation of the plant not possible
the oil must to be warmed up at least to +5°C
by operating of the electric control oil stand-
4 Engine room temperature check 0°C < t < 5°C
by pump.
Temperature is not monitored by RENK.
5 Engine room temperature check t ≥ 5°C Plant is in defined temperature range
Delay monitoring curve approx. 30 sec.

START of electric control oil after pump start (not from RENK).
6 start 150 150
stand-by pump item 3 Risk of damage when starting the gear unit
without sufficient lube oil pressure.
Propulsion system is ready for
7
operation

Page 2/11 6461054
2.2 Start diesel engine

check if there are
1 Complete system Start in case of alarm signals not admissible
alarm signals
YES - continue
2 Lube oil pressure ok check 92/1 (72)* - 608
NO - Start of DE not admissible!
Multi-disk clutch DE propulsion - Disconnection of el. signal el. signal to valve 50 with
3 actuate M2
OFF shifting valve 50 connection 920 continuous current 24 VDC
Multi-disk clutch DE propoulsion - YES - continue
4 OFF ? check 116 (73)* - 609 NO - start of DE not admissible!
Risk of damage !
YES - continue
93, 100, 101,
Deactivate alarm and emergency stop NO - Start of DE not admissible!
5 deactivate 102, 103, 104,
curves and/or points for transmitter Emergency stop and/or alarm signals
105
possible! Not from RENK!
6 START Diesel engine start Not from RENK!
YES - continue
Activate alarm and emergency stop 100, 101, 103, NO - Start of DE not admissible!
7 activate
curves and/or points for transmitter 105 Emergency stop and/or alarm signals
possible! Not from RENK!

Page 3/11 6461054
2.3 Connecting of diesel engine

check YES - continue
Diesel engine speed in required speed
1 405 < nDM < 500 rpm NO - Adjust speed DE!
window ?
Not from RENK
YES - continue
2 Control oil pressure ok check 101 (72)* - 608
NO - Coupling of DE not admissible!
Multi-disk clutch DE propulsion - Connect el. signal el. signal to valve 50 with
3 actuate M1
ON shifting valve 50 connection 921 continuous current 24 VDC
Operating valve 50 multi-disk clutch YES - continue
4 check 115 (73)* - 609
DE propulsion - ON ? NO - check operating valve 50 !
JA - continue
Activate alarm and emergency stop
5 activate 93, 102, 104 NO - Operation not admissible !
curves and/or points for transmitters
Risk of damage! Not from RENK!
after signal "multi-disk clutch ON"
Release signal with
6 Lube oil pressure delay 100, 103, 105 - input shaft at rest 15 sec.
- rotating input shaft 5 sec.
delay (not from RENK) .
after signal "multi-disk clutch ON"
Release signal with
93, 101, 102,
7 Control oil pressure delay - input shaft at rest 15 sec.
104
- rotating input shaft 5 sec.
delay (not from RENK) .
YES - continue
8 Coupling DE propulsion ON ? check 90 (73)* - 609
NO - check coupling !
9 DE propulsion ON 90 (73)* - 609

Page 4/11 6461054
2.4 Disconnecting diesel engine

Multi-disk clutch DE propulsion - disconnect el. signal el. signal to valve 50 with continuous current
1 activate M2
OFF shifting valve 50 connection 920 24 VDC
Shifting valve 50 multi-disk clutch YES - continue
2 check 116 (73)* - 609
DE propulsion - OFF ? NO - check operating valve 50!
YES - continue
Deactivate alarm and emergency stop NO - Operation not admissible !
3 deactivate 93, 102, 104
curves and/or points for transmitter Emergency stop and/or alarm signals
possible!
YES - continue
4 Coupling DE propulsion OFF ? check 90 (73)* - 609
NO - check coupling !
5 DE propulsion OFF

Page 5/11 6461054
2.5 Control of electric control oil stand-by pump

1 Activation of propulsion system see item 2.1
YES - continue
2 Coupling DE propulsion ON ? check 90 (73)* - 609
NO - continue with cons. no. 7 and 8
YES - continue
check
NO - hold electric control oil
3 Output shaft speed increasing 113 < npropeller rpm 125
stand-by pump ON!
Not from RENK!
STOP of electric control oil
4 stop Not from RENK!
stand-by pump item 3
YES - continue
check
NO - hold electric control oil
5 Output shaft speed decreasing npropeller ≤ 92 rpm 125
stand-by pump OFF!
Not from RENK!
Risk of damage when operating the gear unit
START of electric control oil
6 start without sufficient lube oil pressure.
Not from RENK!
check Hold electric control oil
7 Diesel engine speed range 0 < nDM < 500 rpm stand-by pump ON!
Not from RENK!
check Hold electric control oil
Test run diesel engine
8 0 < nDM < 1084 rpm stand-by pump ON!
Diesel engine speed range
Not from RENK!

Page 6/11 6461054
2.6 Emergency operation stand-by pump

YES - continue with cons. no. 5
1 Lube oil pressure ok ? check 100 (71)* - 505
NO - Alarm! Continue
YES - Continue with cons. no. 4
NO - continue
3 start without sufficient lube oil pressure.
Not from RENK!
check what is the
4 Check the reason for alarm lube oil
reason for the alarm
(72)* - 608 YES - continue with cons. no. 9
5 Control oil pressure ok ? check 101
(73)* - 609 NO - Alarm! Continue
(72)* - 608 YES - continue with cons. no. 8
6 Control oil pressure ok ? check 93
(73)* - 609 NO - continue
7 start without sufficient control oil pressure.
Not from RENK!
check what is the
8 Check the reason for alarm lube oil
reason for the alarm
9 Plant is running properly

Page 7/11 6461054
2.7 Emergency stop for gear units

1 Control oil pressure ok ? check 104 (73)* - 609
NO - continue
el. signal to valve 50 with continuous current
disconnect el. signal
2 Disengage multi-disk clutch actuate M2 24 VDC
operating valve 50 connection 920
Check plant !
NO - continue
el. signal to valve 50 with continuous current

24 VDC.
Normal stop diesel engine with a
disconnect
Disengage multi-disk clutches, el.signal disconnection time of approx. 5 to 10 sec.
4 operating valve 50 actuate M2
immediately stop diesel engine connection 920 admissible.
Stop diesel engine
Risk of damage in case of operation without
sufficient lube oil pressure.
Check plant !
5 Plant is running properly

Page 8/11 6461054
2.8 Deactivation of propulsion plant

1 Diesel engine disconnect not from RENK
YES - continue
2 Diesel engine OFF ? check NO - check !
Not from RENK!
3 Monitoring plant deactivate not from RENK

Page 9/11 6461054
3. Emergency handling/Emergency operation
Failure of control electronics
Manually check starting conditions.

Hand emergency activation of the valves in all functions concerned.
Function sequence in conformity with normal operation.
Exception:
Engaging of multi-disk clutch DE operation ON:

First actuate operating valve item 51, then connect corresponding clutch shifting valve item 50.
Disconnect operating valve item 51 approx. 10 sec. after actuation of clutch shifting valve (release).

Page 10/11 6461054
Modifications
Date Index Sheet Cons. No. Description
03.03.2005 a 2 3+4 added

21.06.2005 b 3 2/3/4 2 added; 3 action + remark; 4 at site + remark
4 2/4/6/8/9 2 remote + at site; 4 at site; 6 remote; 8+9 at site
5 1/2/4 1 remark; 2 at site + remark; 4 at site
6 2 at site
7 5/6 at site
8 1/2/4 1 at site; 2/4 action + remark
10 exception
29.06.2005 c 3 2/3 3 description; 2 action+ remark
4 1/4 1 action; 4 description
5 2 description
6 3/5/7/8 action

Page 11/11 6461054
GENERAL DESCRIPTION PART 3
TABLE OF CONTENTS
3 GENERAL DESCRIPTION ...............................................................................2
3.1 Mechanic description.....................................................................................2

3.1.1 Intended use ............................................................................................2
3.1.2 Main groups gear unit ..............................................................................3
3.1.3 Gear unit description ................................................................................3
3.1.3.1 Toothing............................................................................................3
3.1.3.2 Casing ..............................................................................................3
3.1.3.3 Bearing .............................................................................................4
3.1.3.4 Multi-disc clutch ................................................................................4
3.2 Description of the hydraulic system...............................................................4
3.2.1 General ....................................................................................................4
3.2.1.1 Assembly of the hydraulic system ....................................................4
3.2.1.2 Primary built-on control oil pump ......................................................5
3.2.1.3 Secondary built-on lube oil pump .....................................................5
3.2.1.4 Electrically driven control oil pump ...................................................5
3.2.1.5 Oil cooler ..........................................................................................5
3.2.1.6 Lube oil pressure control ..................................................................6
3.2.1.7 Control block for the multi-disc clutch ...............................................6
3.2.1.8 Double filters for lube and control oil ................................................6
3.2.1.9 Temperature control of the gear unit oil............................................7
3.2.2 Monitoring and control system .................................................................7
3.2.2.1 Monitoring gear unit..........................................................................7
3.2.2.2 Local operating panel .......................................................................8

3 General description
3.1 Mechanic description
3.1.1 Intended use

The gear unit have the following main functions (see fig. 1):
• Transmission of the input power supplied by Diesel Engine with speed reduction
to the propeller shaft;
• Drive of the built-on control oil pump primary running;
• Drive of the built-on lube oil pump secondary running;
• Connection of the OD-box (not RENK supply);
fig. 1 – starboard gear unit
input
DE
1
11
10
2
5
7
4 9 8
3
Note:
port gear mirror inverted
output
shaft

3.1.2 Main groups gear unit

Each gear unit comprise the following main components (see fig. 1):
• Integrated multi-disc clutch
• Built-on control oil pump, primary running
• Built-on lube oil pump, secondary running
• Electric control oil pump
• Oil cooler (sea water) for lube oil
• Change over double oil filter for lube oil
• Change over double oil filter for control oil
• Temperature controller
• Control block with pressure/operating valves for multi-disc clutch and lube oil
• Local operating panel (LOP)
• Connection for OD-box (not RENK supply)
3.1.3 Gear unit description
Note: All mechanical parts and components are depicted in the assembly drawing
6461243/0 identified by item no (see part 10).
3.1.3.1 Toothing
The main gears (item 2400 and 3011) are of single helical tooth design, all main gears are
case harden and ground. Tooth depth, inclination angle and module are selected such that
optimum noise behaviour is achieved.
The toothing of the pump wheels (item 2115 and 2404) are gas nitrided. The toothing of
the pump pinions (item 8523 and 8542) are temper-hardening. The teeth of the pump
stage are of straight design and noise optimized.
3.1.3.2 Casing
The casing is steel-welded and of vibration-resistant design. The casing bottom part is
equipped with an oil collecting tank.
The casing is oil and water-tight.
The casing top parts are provided with inspection covers which allow the inspection of all
teeth, without having to remove the casing top part.

3.1.3.3 Bearing
The input and pinion shaft are accommodated in large sized antifriction bearings, which
are all lubricated by pressurized oil. The output shaft is running in plain bearings (see
chap. 2.1.5). The output shaft has integrated the propeller thrust bearing; the thrust pads
are of RENK design. The plain bearing temperatures are measured by resistance
thermometers (PT100) and monitored in the LOP.
3.1.3.4 Multi-disc clutch

The pressure oil controlled multi-disc clutch can be engaged during operation
(engagement speed see technical data part 2). The clutch plates which feature the
material pairing steel/sinter bronze are compressed by pressure oil. The clutch shift energy
converted into heat is dissipated by the cooling oil which passes through the clutch.
3.2 Description of the hydraulic system
3.2.1 General
Note:
• Items nos. with up to 3 digits refers to the technical data 6817651/4 (part 2) and
the connection scheme 6817650/0 (see part 10).
• Item nos. with asterisk (*) identify such parts which are not included in the
RENK scope of supply.
• Different frames in the connection scheme identify assembly groups being built
on the gear unit and others which are arranged separately or which are mounted
to the monitoring panel or fitted by the customer.
Depending on the operating condition, lube oil is supplied by the
• primary built-on control oil pump (1) and the
• secondary built-on lube oil pump (2)
The control oil for engagement of the multi-disc-clutch is supplied by the
• primary built-on control oil pump (1) and/or the
• electrically driven control oil pump (3)
3.2.1.1 Assembly of the hydraulic system

All main units, operating elements and monitoring instruments of the hydraulic system are
attached or mounted on the gear unit port side and starboard each.

3.2.1.2 Primary built-on control oil pump

The primary built-on control pump (1) which is driven by a spur gear stage is flanged to the
gear unit casing at the input side. It ensures the operating oil supply when the diesel
engine is in operation. Except of a small amount of leakage oil in the multi-disc clutch the
entire oil of the primary pump is fed into the lube oil system.
Detailed description, drawings and parts

identification see part 9!
3.2.1.3 Secondary built-on lube oil pump

The secondary built-on lube oil pump (2) which is driven by a spur gear stage is flanged to
the gear unit casing at the output side. Under normal operation, this pump supports the
lube oil supply to the gear unit.

3.2.1.4 Electrically driven control oil pump

The electrically driven control oil pump (3) is mounted on top of the gear unit.
The electrically driven control oil pump (3) is driven by electric motor (4) which can either
be controlled manually or automatically by mean of starter (150).

3.2.1.5 Oil cooler
The tubular oil cooler (13) is mounted on top of the gear unit. During operation of the unit
seawater (910) passes through the oil cooler in which the power loss of the gear unit is
transmitted to the cooling medium (sea water).
Note: Recommendations for installation, putting-into service and operation of the

gearbox sea-water cooler see part 4, 5 and 7.


3.2.1.6 Lube oil pressure control

The lube oil pressure relief valve (45) protects the gear unit oil system against
overpressure. From the consumption points the oil is fed back into the oil collecting tank in
the bottom part of the gear unit.
The pressure relief valve is installed upstream of the filter.

3.2.1.7 Control block for the multi-disc clutch

The multi-disc clutch is engaged and/or disengaged via the 4/2-way control valve (50). The
control valve (50) is supplied with impulse or continuous current.
After engagement of the multi-disc clutch the control oil pressure is increased in two steps
by means of the pressure accumulating valve (47) thus providing for a smooth
engagement process. In this way, an impermissible speed reduction of the diesel engine
during engagement is avoided.
A manual emergency actuation (in case of a current failure) is possible at the operating
valves (50, 51). In the case of a current failure the operating valves (50, 51) remain in their
momentary position.
The multi-disc clutch must only be operated while the diesel engine is running (refer to
technical data, part 2).

3.2.1.8 Double filters for lube and control oil

The double filters (11, 12) are mounted on top of the gear unit. Before the lube or control
oil enters the gear unit solid matters and metallic abrasion is retained by the double filter.
Only one of the filter halves is operating. Once the filter element is soiled, the oil is
deviated to the other side by turning the hand lever (position I or II).
The soiled filter element can be cleaned during operation.
The plug on the cover is provided for deaeration of the relevant filter chamber.
The pollution indicator on the filter is furnished with a micro switch responding to
differential pressure which signals strong soiling of the filters. In the pollution indicator the
green LED signals the normal operating state, while the red LED signals that the filter
element needs to be changed.


3.2.1.9 Temperature control of the gear unit oil

The temperature regulating valve (14) is installed downstream of the oil cooler. Thanks to
the regulating insert in the valve depending on the temperature, the oil quantity is divided
up such by the oil cooler "3" and by the by-pass line "2" around the oil cooler (14) that a
gear unit inlet temperature within the control range is achieved in outlet "1". For the
temperature control range refer to Technical Data, Part 2.
The temperature regulating valve (12) is equipped with a manual actuation device by
means of which the entire oil quantity is led through the cooler.

3.2.2 Monitoring and control system

A series of sensors and switches for monitoring of lube oil pressure, oil level, control oil
pressure etc. are integrated in the lube oil and control oil system.
Note: All adjusting values (pressure, alarm temperatures and so on) for the control
system are finally fixed after sea trial.
Detailed information to the control system (description,

arrangement, adjusting values and so on) are shown and
described in the Technical data (see part 2), in the Connecting
scheme and in the Piping scheme (see part 10).
3.2.2.1 Monitoring gear unit

- Local monitoring by a light-emitting at the double oil filters (11+12);
- Remote pressure switch (90) is used to indicate operating multi-disc clutch
“ENGAGED or DISENGAGED” for control indicator;
- Remote pressure switch (92/1) is used to indicate start release of DE;
- Remote pressure switch (93) is used to indicate start of electrically
control oil pump (3);
- Differential pressure switch (97+98) installed in double oil filter (11+12) for indicating
instruments and alarm transmitter;
- Level switch (99) installed in the gear unit casing bottom part for indicating
instruments and alarm transmitter ;
- Remote pressure transmitter (100) is used to indicate lube oil pressure alarm at
gear unit INLET for indicating instruments and alarm transmitter;
- Remote pressure transmitter (101) is used to indicate control oil pressure alarm at
gear unit INLET for indicating instruments and alarm transmitter ;

- Remote pressure transmitter (102) is used to indicate control oil pressure alarm at
multi-disc clutch INLET for indicating instruments and alarm transmitter;
- Remote pressure transducer (103) is used to indicate minimum lube oil pressure
gear unit INLET for emergency stop DE;
- Remote pressure transducer (104) is used to indicate minimum control oil pressure
multi-disc clutch INLET for disengagement multi-disc clutch;
- Remote pressure transducer (105) is used to indicate minimum lube oil pressure
gear unit INLET for automatic pump start of electrically control oil pump (3);
- Remote resistance thermometer (110) is used to indicate lube oil temperature at
gear unit INLET for indicating instruments and alarm transmitter;
- Remote resistance thermometers (111-113) are used to indicate bearing
temperature for indicating instruments and alarm transmitter;
- Several inductive proximity switches (115, 116) are used to indicate multi-disc clutch
“ENGAGED or DISENGAGED” for control indicator;
- Speed transmitter (125) is used to indicate output shaft speed, gear unit monitoring
and pump control depending on pressure and speed;
3.2.2.2 Local operating panel

The optical displays, pressure gauges and thermometers are installed into the local
operating panel (LOP see part 10 and chap. 5.2.1). The panel is installed at the gear unit.
The following operating parameters are read and evaluated at the operating panel:
- Pressure gauge 70
lube oil pressure upstream of double filter → connection no. 502
- Pressure gauge 71
lube oil pressure gear unit INLET → connection no. 505
- Pressure gauge 72
control oil pressure at gear unit INLET → connection no. 608
- Pressure gauge 73
control oil pressure multi-disc clutch main propulsion ON → connection no. 609
- Thermometer 80
lube oil temperature upstream of the oil cooler → connection no. 520
- Thermometer 81
lube oil temperature gear unit INLET → connection no. 521

PUTTING INTO SERVICE
OPERATION PART 4
TABLE OF CONTENTS
4 PUTTING INTO SERVICE

OPERATION.....................................................................................................2
4.1 Safety Information...........................................................................................2

4.2 Operating and display elements......................................................................3
4.2.1 Manual operating elements.......................................................................3
4.2.2 Local indication .........................................................................................4
4.3 Putting into service..........................................................................................5
4.3.1 Preparation ...............................................................................................5
4.3.2 Flushing ....................................................................................................5
4.3.3 Seawater cooling system ..........................................................................6
4.3.4 lnitial operation ..........................................................................................6
4.3.5 After putting into service............................................................................7
4.4 Operation ........................................................................................................8
4.4.1 General notes ...........................................................................................8
4.4.2 Normal Operation/Emergency Operation ..................................................8
4.4.3 Hints for electrically driven control oil pump ............................................10
4.4.4 Normal DE operation – Remote control ..................................................10
4.4.4.1 Requirements for Start of Diesel Engine ..........................................10
4.4.4.2 Engagement of multi-disc clutch (MDC) ...........................................11
4.4.4.3 Disengagement of multi-disc clutch..................................................12
4.4.5 Test of Diesel Engine ..............................................................................12
4.4.6 Operation with trailed propeller (DE is stopped)
(the other gear unit is in normal operation or the propeller
is driven by water flow)............................................................................14
4.4.7 Emergency Operation DE – Local control ...............................................15
4.4.7.1 Case I - electrically driven control oil pump still available.................15
4.4.7.1.1 Preparations before DE start .....................................................16
4.4.7.1.2 Start of the DE ...........................................................................16
4.4.7.1.3 Engagement of the multi-disc clutch..........................................17
4.4.7.1.4 Disengagement of the multi-disc clutch .....................................17
4.4.8 Case II - electrically driven control oil pump not available.......................18
4.4.8.1 Preparations and operation in this condition ....................................18
4.4.9 Action at alarm ........................................................................................19
4.5 Longer stop periods gear unit .......................................................................21
4.5.1 General ...................................................................................................21
4.5.2 Procedures at the oil cooler ....................................................................21
Issue: 2005-10-13 - MT/Hu/Erh Type: ASL 94 Revision: 6955076/4 1/21

OPERATION PART 4
4 Putting into service, Operation
Note:
• The manufacturer should be immediately informed of any shutdown, or resale to
a third party of the new or used gear unit.
• The date of initial commissioning must be communicated to the manufacturer
immediately.
• This Part of the Operating instructions only refers to the gear units and such
parts which are included in the RENK scope of supply.
4.1 Safety Information

lt is absolutely essential to observe the following safety instructions when commissioning
and operating the gear system.
- The gear unit shall only be used for its intended purpose.
- The system shall not be operated outside its given performance limits.
- Any change in the complete drive system or the performance data must be
submitted to the manufacturer for approval.
- Local accident prevention regulations must be observed.
- There must be no fire or naked flame near the drive unit.
- Switch points set by the manufacturer on monitoring and control instruments such
as pressure switches, valves, restrictors etc. must not be changed.
- When the plant is running no threaded pipe connections or flanged connections
shall be slackened.
- When the system is running, inspection hole covers must not be opened. Reaching
into the running gear unit is dangerous, even with a tool.
- Take care at all rotating shaft outlets and do not touch any rotating parts.
Protections of all rotating parts must be provided by the shipyard.
- Parts of the gear unit may locally become hot after extended operation.
ATTENTION when touching!

OPERATION PART 4
4.2 Operating and display elements
Note: Items nos. with up to 3 digits refers to the technical data (see part 2) and the
connection scheme (see part 10). The item nos. with 4 numbers refers to
assembly drawing (see part 10).
4.2.1 Manual operating elements (see fig. 1)

- Manual emergency actuation on temperature valve (14)
- Manual emergency actuation on operating valve (50) for multi-disc clutch
- Manual emergency actuation on operating valve (51) for pressure
accumulating valve (47)
- Operating lever (change over lever) for double oil filters (11+12)
fig. 1 – details see piping scheme part 10
top view gear unit

(starboard)
manual emergency at the

temperature valve (14)
connection no. 902
operating lever at the

double oil filters (11+12)
M2
action at the valve (50)
M3
manual emergency
manual emergency
at the valve (51)
M1

OPERATION PART 4
4.2.2 Local indication

The following operating parameters are read and evaluated at the instrument panel:
- Pressure gauge 70
lube oil pressure upstream of double filter → connection no. 502
- Pressure gauge 71
lube oil pressure gear unit INLET → connection no. 505
- Pressure gauge 72
control oil pressure at gear unit INLET → connection no. 608
- Pressure gauge 73
control oil pressure multi-disc clutch main propulsion ON → connection no. 609
- Thermometer 80
lube oil temperature upstream of the oil cooler → connection no. 520
- Thermometer 81
lube oil temperature gear unit INLET → connection no. 521
fig. 2 - LOP gear unit
71
70
80
72
81
73

OPERATION PART 4
4.3 Putting into service
Note: Consider part 1 and chapter 4.1!
4.3.1 Preparation
The gear unit with the hydraulic system (RENK supply) is delivered completely flushed and
prepared for operation. All connections between gear unit (connection nos. see technical
data part 2) and all ship equipment must be connected by yard.
Before starting the plant, the prescribed gear unit oil (see chap. 5.5.8) must be filled in
through the filling device (connection 902, see fig. 1) until the proper oil level has been
reached. The gear unit oil must have a purity degree of 18/15/12 by ISO 4406.
4.3.2 Flushing
Note: For the flushing the original oil shall be used.

Then the entire oil system must be cleaned by flushing as follows:
- Flushing of the gear unit by operating the electrically control oil pump (3).
Alternatively flushing can be carried out by operating an external electric pump. For
that purpose the suction pipe line is connected to the fitting (connection 901-G11/2)
and the feed line is connected to the fitting (connection 501, G1) which are provided
for flushing (connection nos. see technical data and piping scheme).
- The pipe system must be flushed until all dirty particles are retained in the oil filters.
The flushing must be continued at least 2 hours after the filter shows no more
contamination. After 1 hour the duplex filter must be switched over to the second
chamber. Cleaning of the first filter chamber can be carried out while the flushing
procedure is taking place.
Note:
♦ The oil system must be flushed until the same degree of the oil purity has
been achieved, as it is desired by new oil.
♦ The degree of the oil purity can be ascertained by an appropriate oil
analyses. For this purpose a probe of the oil must be taken from the ground
of the tank.
♦ Furthermore it is recommended to check the oil for water contamination and
the oil purifying, if necessary. lf the water content exceeds 0,2% the oil must
be separated.
After the flushing procedure the filter elements and the solenoid insert of the duplex filter
must be inspected and cleaned. In case of strong contamination of the filter elements the
flushing procedure should be repeated.

OPERATION PART 4
4.3.3 Seawater cooling system

- if a continuous ventilation is not provided by a by-pass pipe, the cooler (13) must be
de-aerated during first start of the plant with the special plugs (see chap. 9.1.5 -
instruction manual);
- an internal cooler protection layer in the sea water pipes will be build-up in the first
time of operation; thus the most critical time is the initial operation period, especially
in dirty harbour water; frequently checks of the anode-conditions are recommended
during this time, at least before and after dock and sea trials;
- check the anode conditions; re-new the anodes if 60% or more is wasted;
4.3.4 lnitial operation

For initial putting into operation, all modes of operation shall be tested (see chap. 4.4).
During these sea trials (SAT), all parameters of the gear unit control system must be
observed and compared with the nominal values (see tech. data part 2). Any abnormal
measurement must be checked and RENK must be informed.
During the trials with the Diesel engines, the engagement characteristic of the multi-disc
clutch must be recorded by oscillograph or equivalent instrumentation. At least the
following signals have to be recorded:
• Diesel engine speed
• Propeller speed
• clutch control oil pressure (before multi-disc clutch)
The records of the control oil pressure curve vs. time in the clutches must be handed over
to RENK for approval. A slipping time of app. 10 sec. is required until slip-free
synchronous speed in the clutch. lf necessary the parameters synchronising
pressure/-time must be optimised after consulting RENK.
The gear unit must only be operated with the sense of rotation indicated on the pertinent
plate. During testing the tooth contact pattern is to be checked during gear unit operation
as a function of load and time.
lt is mandatory for operating mode propeller drive to start at partial load and to rev up to
full load step by step.
The following load stages are recommended:
Minimum operating Load stages DE
time (min)
60 at 1/3 load
120 at 2/3 load
240 at full load

OPERATION PART 4
Note: The load must be increased gradually within each load stage. RENK
recommends increasing the propeller speed in steps of 20 rpm. If the load
stages need to be changed to provide for an adaptation to the overall test
schedule of the ship, RENK has to be consulted.
After the full load operation, the pattern of the toothing must show an even contact over
face width and tooth depth on the load flank. Non-contact areas at the tooth tip and tooth
root are still admissible.
Note: Based on the execution of proper alignment and final tooth contact check with
the ship in water it is very unlikely that the tooth contact after load operation
during sea trials will not correspond to the requirements.
Anyhow in case of insufficient tooth contact which may harm the performance of the gear
unit the cause has to be analyzed and corresponding counter-measurements must be
taken.
4.3.5 After putting into service

• After putting the ship into normal service it is recommended to check the anodes
of the oil cooler (13) more frequently in the first time; according to the results of
this checks the time interval can be prolonged up to the normal recommended
check intervals (see part 5);

OPERATION PART 4
4.4 Operation
4.4.1 General notes

These gear unit control descriptions are including only the gear unit relevant criteria’s. The
responsibility for the complete control of the whole propulsion plant is not covered by
RENK.
The sensors and instrument nos. indicated for “REMOTE” or “LOCAL” control, refer to
drawing „Connection Scheme“ (see part 10) and „Technical Data“ (see part 2).
Additionally the “Lubricating pressure diagram” has to be considered (see technical data
part 2, sheet 34/35).
ATTENTION: For operation with the DE and engaged multi-disc-clutch the

propeller shaft must be connected. Operation with not connected
propeller shaft (which means completely unloaded gear) is not
permitted.
4.4.2 Normal Operation/Emergency Operation

1) Conditions for Normal Operation – Remote Control:
• Electric energy is available;
• Ship control system is available;
• Electrically driven control oil pump (3) is available;
Check: Main switch (see fig. 2) at starter box (150) in position “ON” and switch
for electrically driven pump in position “REMOTE”. In this case START
or STOP is activated by the ship control system acc. to the conditions
as indicated in the “Lubricating pressure diagram” (see technical data
part 2, sheet 34/35).
ATTENTION: A start of the gear unit without electrically driven control oil pump
(3) is only admissible in case of emergency operation!
RISK OF DAMAGE!
2) Conditions for Emergency Operation – Local Control:

• If the ship controls system fails all necessary actuations on the gear unit can be
executed manually;
• All important operational indications can be read off on the local instruments (see
chap. 4.2.2);
Case I:
• Electric energy still available;
• Ship control system not available;

OPERATION PART 4
• Electrically driven control oil pump (3) still available;

Switch (see fig. 3) at starter for electrically driven control oil pump (3) in
position “LOCAL” (=continuously running);
ATTENTION: A start of the gear unit without electrically driven control oil pump
(3) is only admissible in case of emergency operation if the
stand-by pump is not available!
Case II:
• Electric energy not available;
• Ship control system not available;
• Starting and stand-by pump (3) not available;
ATTENTION: A start of the gear unit without running stand-by pump (3) is only
admissible in case of emergency operation if the stand-by pump
is not available!
fig. 3 – starter box (150)
indication lamps
switch stand-by switch turning

pump (3) gear
main switch

OPERATION PART 4
4.4.3 Hints for electrically driven control oil pump

• Before start of the plant pre-lubrication with the electrically driven control oil
pump (3) for some minutes;
• Switch (see fig. 3) at starter box for electrically driven control oil pump (3) always
in position “REMOTE”;
• If the ship control system fails the switch for electrically driven control oil pump
(3) has to be switched over to position “LOCAL”;
• After a complete stop of the plant the electrically driven control oil pump shall
operate app. 3 minutes longer in order to cool-down the plant;
4.4.4 Normal DE operation – Remote control

Conditions for normal operation:
• Ship control system in function
• Electric energy available
4.4.4.1 Requirements for Start of Diesel Engine

Description Action REMOTE LOCAL Remark
control control
complete system energise system - - (not by RENK)
diesel engines (DE) stand-still - - (not by RENK)
engine room check if engine - yes ⇒ go on
room no ⇒ check following
temperature conditions: if < 0°C =
respective lube operation not possible;
oil sump if >0°C to <5°C = warm-up at
temperature is least to +5°C by electrically
5°C minimum pump (3); (temperature is not
monitored by RENK)
starter (150) main switch in - visually yes ⇒ go on
position “ON” no ⇒ switch over to ON
switch for - visually yes ⇒ go on
electrically pump no ⇒ switch over to
(3) in position REMOTE
“REMOTE”
electrically pump automatic start 150 - delay (not by RENK)
(3) monitoring curve 30 sec. after
pump start;
RISC of DAMAGE, if gear is
started without sufficient lube
oil pressure;

OPERATION PART 4

control control
complete system check if there are - - start in case of alarm signals
alarm signals not admissible;
lube oil pressure check oil 100 71 yes ⇒ go on
pressure no ⇒ start DE not
admissible!
multi-disc clutch check, if 116 73 yes ⇒ go on
(MDC) operating valve no ⇒ start DE not
(50) “OFF” admissible;
electric signal to valve (50-
M2) "OFF"
diesel engine (DE) START release 92/1 - yes ⇒ go on
DE no ⇒ start DE not
admissible;
START DE - - (not by RENK)
4.4.4.2 Engagement of multi-disc clutch (MDC)

control control
preparation for set DE speed to - - (not by RENK)
engagement engagement
speed
(see chap. 2.1.1)
control oil pressure check control oil 101 72 yes ⇒ go on
pressure no ⇒ connecting of MDC not
admissible; check oil system;
lube oil pressure check lube oil 100 71 yes ⇒ go on
pressure no ⇒ check oil system
(MDC) operating valve no ⇒ operation not possible;
(50) in position electric signal to operating
"ON" valve (50-M1) “ON”
DE operation admissible in full (125/1 - (DE max. speed 1084 rpm)
speed range 125/2)

OPERATION PART 4
4.4.4.3 Disengagement of multi-disc clutch

control control
disengage multi- electric signal 116 73 yes ⇒ go on
disc clutch (MDC) from control no ⇒ operation not possible;
system to electric signal to valve (50-M2)
operating valve “OFF”
(50) "OFF"
speed DE limit idling speed 125/1 - (not by RENK)
125/2
electrically pump automatic stop 93, 105 - (not by RENK)
(3) (depending oil
pressure and
speed)
diesel engine STOP - - (not by RENK)
4.4.5 Test of Diesel Engine

Diesel engine can be tested if the multi-disc clutch is “OFF” and the following indications
are available:
control control
monitored by RENK)
electrically pump no ⇒ switch over to
(3) in position REMOTE
“REMOTE”

OPERATION PART 4

control control
electrically pump automatic start 150 - delay (not by RENK)
(3) monitoring curve 30 sec. after
pump start;
RISC of DAMAGE, if gear is
started without sufficient lube
oil pressure;
complete system check if there are - - start in case of alarm signals
alarm signals not admissible;
lube oil pressure check oil 100 71 yes ⇒ go on
admissible!
(50) “OFF” admissible;
M2) "OFF"
diesel engine (DE) START release 92/1 - yes ⇒ go on
DE no ⇒ start DE not
admissible;
START DE for - - (not by RENK)
testing admissible in full DE speed
range!

OPERATION PART 4
4.4.6 Operation with trailed propeller (DE is stopped)

(the other gear unit is in normal operation or the propeller is driven by
water flow)
Note: Trailing of the propeller shaft is admitted in normal sense of rotation only!
RISK of DAMAGE!
control control
operating valve no ⇒ start trailed operation is
(50) “OFF” not admissible;
M2) "OFF";
electrically pump no ⇒ switch over to LOCAL
(3) in position (=continuous running);
“LOCAL”
lube oil pressure check oil 100 71 delay 5 sec. (not RENK) after
pressure pump start;
RISK OF DAMAGE, if the
propeller shaft is trailed
without lube oil pressure
available!
operation with admissible in - - -
trailed propeller 50% speed
range
Note: If ALARM is triggered by control system if propeller turns, adjust propeller pitch
and stop shaft!

OPERATION PART 4
4.4.7 Emergency Operation DE – Local control

If the ship control system is not available the multi-disc clutch can be controlled also locally
by hand.
4.4.7.1 Case I - electrically driven control oil pump still available

Conditions for emergency operation:
• Ship control system not available
• Electric energy still available
• Electrically driven control oil pump (3) still available
Note: In the case I normal start of the plant with running starting and stand-by pump
and actuating the manual emergency hand engagement of the multi-disc
clutch with valves (50, 51) is possible.
fig. 4
manual emergency
top view gear unit at the valve (51)
(starboard) M2
action at the valve (50)
M3
manual emergency
M1
sign at gear unit

OPERATION PART 4
4.4.7.1.1 Preparations before DE start

control control
monitored by RENK)
electrically pump no ⇒ switch over to “LOCAL”
(3) in position
“LOCAL”
lube oil pressure check oil - 71 yes ⇒ go on
admissible! RISC of
DAMAGE, if gear is started
without sufficient lube oil
pressure;
multi-disc clutch check, if - 73 yes ⇒ go on
(50) admissible;
“DISENGAGED” change over valve (50/M2-
see sign gear unit or fig. 4) to
position DISENGAGED
4.4.7.1.2 Start of the DE

control control
diesel engine (DE) start DE - - (not by RENK)
DE speed idling speed (at DE - (not by RENK)
(DE with panel, if
disengaged still
multi-disc clutch) available)

OPERATION PART 4
4.4.7.1.3 Engagement of the multi-disc clutch

control control
control oil check control oil - 72 yes ⇒ go on
pressure pressure no ⇒ check oil system
(failures see part 6)
engaged multi- shift valves (50, 51 - 73 yes ⇒ go on
disc clutch = - see fig. 4 or sign no ⇒ operation not possible;
“ENGAGED” at gear unit) to change over valves (50, 51)
position to position "ENGAGED"
"ENGAGED"
lube oil pressure check if electrically - 71 check oil system (failures see
low pump is running if part 6)
the pressure drops
below 3.0 bar
lube oil pressure emergency stop of - 71 stop DE
low/low DE is required if the (not by RENK)
pressure drops
below 2.5 bar
4.4.7.1.4 Disengagement of the multi-disc clutch

control control
speed DE reduce DE speed - - (not by RENK)
and load
disengage multi- shift control valve - 73 shift valve (50 - see sign
disc clutch = (50, see fig. 4) (no gear unit or see fig. 4) to
“DISENGAGED” to position indication position "DISENGAGED"
"DISENGAGED" = no
pressure)
DE stop DE if - - (not by RENK)
required

OPERATION PART 4
4.4.8 Case II - electrically driven control oil pump not available

Conditions for emergency operation – case II:
• Ship control system not available
• Electric energy not available
• Starting and stand-by pump (3) not available
In case II, engagement of multi-disc clutch is executed directly on the control
valves (50, 51 – see fig. 4 and sign at gear unit)
WARNING:
In the case II the plant must be started without support of the electrically driven control oil
pump (3). During this start and engagement the lube oil pressure and flow is reduced to a
minimum; therefore this procedure should be limited to really emergency cases and not for
training purpose. RISK OF DAMAGE!
4.4.8.1 Preparations and operation in this condition

control control
multi-disc clutch check, if operating - 73 yes ⇒ go on
(MDC) valve (50) (no no ⇒ start DE not
“DISENGAGED” indication admissible;
= no change over valve (50/M2-
pressure) see sign gear unit or fig. 4)
to position DISENGAGED
diesel engine (DE) start DE - - (not by RENK)
DE speed idling speed (at DE - (not by RENK)
(DE with panel, if
disengaged multi- still
disc clutch) available)
control oil check control oil - 72 yes ⇒ go on
pressure pressure no ⇒ operation not
possible!
engaged multi- shift valves (50, 51 - 73 yes ⇒ go on
disc clutch = - see fig. 4 or sign no ⇒ operation not
“ENGAGED” at gear unit) to possible;
position change over valves (50, 51)
"ENGAGED" to position "ENGAGED"
lube oil pressure emergency stop of - 71 stop DE
low/low DE is required if (not by RENK)
the pressure drops
below 2.0 bar

OPERATION PART 4

control control
Disconnect gear unit and stop DE
speed DE reduce DE speed - - (not by RENK)
and load
disengage multi- shift control valve - 73 shift valve (50/M2-see sign
disc clutch = (50, see fig. 4) (no gear unit or fig. 4) to
“DISENGAGED” to position indication position "DISENGAGED"
"DISENGAGED" = no
pressure)
DE stop DE if required - - (not by RENK)
4.4.9 Action at alarm

• Limit values see “Technical Data 6817651/4 and pressure diagram sheet 34/35”
(see part 2).
• All conditions and values can be read on the instrument panel at the instruments
(see chap. 4.2.2).
control control
lube oil pressure ALARM 100 71 If ALARM is triggered
LOW (monitoring by ship control
system) reduce load to
idling;
check plant
lube oil pressure EMERGENCY 103 71 If EMERGENCY STOP is
LOW/LOW STOP triggered (monitoring by
ship control system) stop
plant;
check plant
lube oil pressure ALARM 100 71 If pressure exceeds 6 bar,
HIGH reduce load to idling; check
plant (not automatically)
lube oil temperature ALARM 110 81 If ALARM is triggered (by
HIGH ship control system) reduce
load to idling; check plant;
ALARM +5°C: stop plant
and check

OPERATION PART 4

control control
lube oil temperature ALARM 110 81 If the permissible cold start
LOW temperature of 5°C
undercut, the DE must not
be started
plain and thrust ALARM 111-113 - If ALARM is triggered (by
bearing temperature ship control system) reduce
HIGH load to idling; check plant;
ALARM +5°C: stop plant
and check
control oil pressure ALARM 101, 102 72, 73 If ALARM is triggered (by
DROPPING ship control system) open
multi-disc clutch, check plant
control oil pressure DISENGAGED 104 73 If DISENGAGED MULTI-
MINIMUM MULTI-DISC DISC CLUTCH is triggered
CLUTCH (by ship control system)
reduce DE speed to idling;
check plant
lube and control oil ALARM 97, 98 70/71 If ALARM is triggered
filter plugged difference immediately change-over
between the filter to the clean filter
connection side; the plugged filter insert
no. 503/ must be changed;
504 and admissible during operation
506/507
oil level LOW ALARM 99 oil dip If ALARM is triggered (by
stick (item ship control system) reduce
1096) load to idling and stop plant
(recommended delay 60
seconds);
check for oil leaks

OPERATION PART 4
4.5 Longer stop periods gear unit
4.5.1 General
The following procedures have to be performed if standstill periods or discontinuations of
the gear units exceed 1 month:
• the gear unit has to be operated with running at external electrically pump (see
chap. 4.4.3) for at least 30 min.;
• the multi-disc clutch has to be operated with local manual emergency
(see chap. 4.4.7);
ATTENTION: Only at standstill propeller shaft!
Note: These procedures have to be repeated monthly!
4.5.2 Procedures at the oil cooler

Stand still up to 2 days:
• if possible, keep the water flow through the cooler in circulation (within the
indicated flow limits);
Stand still up to 2 weeks:
• drain the cooler and flush it with fresh water for a minimum period of 1 hour;
Longer stand still periods than 2 weeks:
• drain the cooler and flush it with fresh water for a minimum period of 1 hour; than
fill it with fresh water plus corrosion inhibitors;

MAINTENANCE PART 5
TABLE OF CONTENTS
5 MAINTENANCE ................................................................................................2
5.1 Safety Information .........................................................................................2
5.2 General maintenance note ............................................................................3

5.2.1 Local monitoring instruments on LOP ......................................................3
5.3 Maintenance work .........................................................................................4
5.3.1 Timetable for routine maintenance work ..................................................4
5.3.2 Maintenance points ..................................................................................6
5.4 Lubricant specification...................................................................................7
5.4.1 Field of application ...................................................................................7
5.4.2 Lubricant requirements ............................................................................7
5.4.3 Oil Brand List............................................................................................7
5.4.4 Lubricants, operating auxiliary material and filling capacities ...................8
5.5 Routine maintenance work............................................................................9
5.5.1 General note ............................................................................................9
5.5.2 Visual check duplex oil filter ...................................................................10
5.5.3 Drain off oil and clean double oil filters (11 or 12) ..................................10
5.5.4 Re-grease on input and output shaft ......................................................12
5.5.5 Check or change anode of oil cooler......................................................13
5.5.6 Clean filter at pressure relief valve (45) and
accumulating valve (46+47) ...................................................................13
5.5.7 Inspection of toothing .............................................................................14
5.5.8 Oil level check and oil filling ...................................................................16
5.5.9 Initial oil change .....................................................................................17
5.5.10 Oil analysis.............................................................................................17
5.5.11 Oil change ..............................................................................................17
Issue: 2005-10-14 - MT/Hu/Erh Type: ASL 94 Revision: 2007-01-04 6955077/4 A 1/17

MAINTENANCE PART 5
5 Maintenance
5.1 Safety Information
When working on the gear system and with housekeeping maintenance work the following
safety regulations must always be observed:
- All operating and maintenance work must be carried out only by suitably trained
personnel.
- The gear unit must not be altered in any way. Adding or removing parts is
forbidden in particular.
- Repairs shall be carried out only using original manufacturer's parts. Any use of
components of other manufacturers not expressly approved by the gear unit
manufacturer is forbidden.
- Before parts are removed from the gear unit for repair work they have to be
suspended or supported
- When working on the gear unit it is necessary to wear the usual protective
clothing such as safety helmet, safety glasses, safety gloves and safety shoes.
- When equipment is being moved, never stand under a suspended load.
- Observe local accident prevention regulations.
- There must be no fire or naked flame near the gear unit.
- Work on the electrical equipment of the gear unit must only be carried out by
trained personnel. Electric components, especially terminal boxes, must only be
opened when the power is disconnected.
ATTENTION: Danger of Electric Shock

- Switch settings on monitoring and control instruments such as pressure switches,
valves, throttles etc must not be changed.
- When the system is running, the inspection covers must not be opened.
Reaching into the machine, even with a tool, is dangerous.
- Before starting any work on the gear unit which requires them to be fully or partly
opened, it must be ensured from the system side that the gear unit cannot be
switched on.
- At all free shaft outlets it must be ensured that no rotating parts are touched.
- Parts of the gear unit can become hot with continuous running.

MAINTENANCE PART 5
5.2 General maintenance note
Even if the reduction gear is provided with instruments for remote indication and alarm
devices for monitoring the most important operating values, continual, direct observation of
the reduction gear is recommended.
The periodic maintenance work must be recorded. The reason for any abnormal situation
like abnormal noises, vibrations, abnormal temperatures, smoke etc. must be immediately
analysed.
ATTENTION: Don’t operate the gear unit if an abnormal
situation is indicated.
5.2.1 Local monitoring instruments on LOP

The following values can be read at the measuring instruments of the reduction gear and
be compared with the theoretical values (see tech. data chap. 2.2).
- Lube oil pressure upstream of the double oil filter ⇒ pressure gauge (70)
- Lube oil pressure at gear unit INLET ⇒ pressure gauge (71)
- Control oil pressure at gear unit INLET ⇒ pressure gauge (72)
- Control oil pressure for multi-disk clutch main propulsion ON
⇒ pressure gauge (73)
- Lube oil temperature upstream of the oil cooler ⇒ thermometer (80)
- Lube oil temperature at gear unit INLET ⇒ thermometer (81)
71
70
80
72
81
73

MAINTENANCE PART 5
5.3 Maintenance work
5.3.1 Timetable for routine maintenance work
Note: Instrument nos. up to 3 digits refers to Technical Data (see chap. 2.2) and
connection scheme or piping scheme (see part 10).
Picture overviews for all maintenance points see chap. 5.3.2.
Point
Maintenance item Work to be carried out Frequency
no.
1 Double oil filter (11+12) Visual check the light-emitting

(LED see chap. 5.5.2)
Note: If the light-emitting diode (LED)
daily
light up red, the filter must be switched
over and the contaminated filter side
must be cleaned (see chap. 5.5.3).
2 Oil lines and water Visual check pipes and flanges for
connections leaks
3 Electric wiring Visual check for condition
4 Seals on input and Press in grease (see chap. 5.5.4) 500 hours
output shaft Visual check for leaks or
1 month
5 Double oil filter (11+12) Switched over to other filter side and
check filter insert (see chap. 5.5.3);
Note: If metal chips or abrasion in the
filter insert are determined, is
immediately set RENK to inform.
6 Oil cooler (13) Check condition of anode

(see chap. 5.5.5) 3 month
Inspect the tubeside (see chap. 9.1.5)
7 Pressure relief valve (45) Clean dirty oil filter 1) 1)

(500 hours
and pressure (see chap. 5.5.6 and chap. 9.1.7.1 to after initial
accumulating valves 9.1.7.3) putting into
(46+47) operation)
8 Oil cooler (13) Inspect the shellside (see chap. 9.1.5) 2 500 hours
or
9 Gear oil First oil change (see chap. 5.5.9) 6 month
Check oil level (see chap. 5.5.8)
Analyse oil quality (see chap. 5.5.10)

MAINTENANCE PART 5
Point
Maintenance item Work to be carried out Frequency
no.
10 Oil cooler (13) Clean oil cooler (see chap. 9.1.5) 5 000 hours
or
11 Toothing Check of toothing by means of
1 year
inspection cover (see chap. 5.5.7)
12 Gear oil Change oil (see chap. 5.5.11) 10 000 hours

or
13 All equipment gear unit Check fixing and tighten all equipment 2 years
14 Pressure relief valve (45) Check valve seats and piston guide for
and pressure wear (see chap. 9.1.7.1 to 9.1.7.3)
accumulating valves 15 000 hours
(46+47) or
3 years
15 Built-on pumps (1+2) Check condition and/or replace for a
and electrical driven general overhaul (see chap. 9.1.1, 9.1.2
pump (3) and 9.1.3)
16 Basic overhaul 1. Check bearings

For this maintenance a
suitable workshop and a 2. Visual inspection of all gears
specialist of RENK is rotating elements
required; 30 000 hours
necessary spare parts to 3. Check disks and clutch parts or
be available (by (replacement only if necessary)
6 years
customer)
4. Change grease at electric motor
(4, see chap. 9.1.3.2)
5. Inspection of the hydraulic system
Note: No other routine maintenance work is performed on the gear unit.

To carry out maintenance work for routine interim a RENK specialist
should be demanded.

MAINTENANCE PART 5
5.3.2 Maintenance points
4 = point no.
902
4 = connection no.
= Oil dip stick
15
6
8
5 1 10
9 15 11 7 902
14
5 1 9
15

MAINTENANCE PART 5
5.4 Lubricant specification
5.4.1 Field of application

This recommendation applies to pressure-lubricated marine reduction gears.
5.4.2 Lubricant requirements

Non-ageing, non-foaming, mildly alloyed mineral oils as per DIN 51517 part 3, hydraulics
oils as per DIN 51525 part 2 or HD-lubricating oils with efficient anticorrosive behaviour
must be used. Behaviour against the shaft sealing varnish and masses normally used in
the gearbox construction must be neutral. FZG load stage ≥ 12 as per DIN 51354.
Additives must not aggravate the frictional-and the engagement/disengagement behaviour
of the built-in multi-disc clutches.
5.4.3 Oil Brand List

Circulation oils like CLP, HLP as per DIN 51502 of the Viscosity Class ISO VG 100 as per
DIN 51519 or diesel engine oils of the Viscosity Class SAE 30 as per DIN 51511, as
present in the main- or auxiliary diesel have to be applied.
Table for oils ISO VG 100/SAE 30:
Producer Oil type Producer Oil type
Agip Blasia 100 Chevron Gear Compound EP100

Agip Blasia SX Chevron Ultra Gear Lubriant
Agip Diesel SIGMA S ISO 100
Agip Diesel SIGMA FS Chevron Delo Motor Oil SAE 30
Mobilgear 600 XP 100
Degol BG 100
Mobil Delvac 1230
Vitam GF 100
Mobil Delvac 1630
Shell Omala 100

Energol GR-XP 100 Tellus 100
Enersyn HTX 100 Sirius FB Oel 30
Vanellus C3 Mono SAE 30 Gadinia Oel 30
Rimula X 30
Caltex Meropa EP 100 Texaco Meropa EP 100

Caltex Pinnacle EP 100 Texaco Pinnacle EP 100
Caltex Delo 300 SAE 30 Texaco Ursa Super LA SAE 30

MAINTENANCE PART 5
Producer Oil type Producer Oil type
Alpha SP 100
Carter EP 100
Alphasyn T 100
Epona Z 100
Alpha ZN 100
Atlanta Marine D 3005
Tribol 1100/100
Disola M 3015
Optigear BM 100
Disola M 3020
Assuron T Plus SAE 30
5.4.4 Lubricants, operating auxiliary material and filling capacities
Cons. Subassembly/ Lubricant Lubricant Application

Note
no. Part lubricated specification quantity method
1 Gear unit Lube oil app. Filling in Volume per gear

(see chap. 5.3.2) 600 litre unit!
2 Seal on input Grease 1) app. 1 kg Re-grease Volume per gear

and output Shell Alvania unit!
shaft EP(LF)1
3 E-motor (4) for Grease 1) 0,14 kg Change Pay attention to the

control oil Shell Alvania R3 grease operating manual
pump (3) (see chap. 9.1.3.2)!
4 Sealing faces Sealing - - For housing face

compound sealing!
Hylomar SQ32/M
5 Screws Fixation - - For internal screws

compound connections!
Loctite 243
(see chap. 6.3)
6 Cleaning Weral 560 - - For cleaning from

(or petroleum- dirt and grease
based solvent) parts at the repair
works!
7 Cleaning oil - - - Products for

cooler chemical cleaning
(see chap. 9.1.5) or
www.ashchem.com!
1)
Other grease brands with identical qualities are admissible.

MAINTENANCE PART 5
5.5 Routine maintenance work
5.5.1 General note
ATTENTION: Part 1 and chapter 5.1 must always be observed when carrying
out all work.
Before the maintenance work:
• Ensure the unit or equipment cannot be switched on.

• Fix prohibiting sign „ATTENTION: Out of operation ....“ at the ship control
stand.
• Never carry out any work at energised lines.
• Possibly stop the installation when carrying out work on the gear unit oil system or
the seawater system. Relieve pressure and discharge the piping at the work place
by closing all pertinent slides/valves.
Note:
- When working on the gear unit or on peripheral units, observe the instructions
given for such units/components which are not part of the RENK system.
- Adhere to the operating manual for the entire propulsion system!
- Consider drawings and detail description for the components see part 9!
After the maintenance work:

• Perform a functional check.
• Remove tools, instruments and cleaning cloth from place of installation.
• Remove prohibiting signs and release installation for operation again.

MAINTENANCE PART 5
5.5.2 Visual check double oil filter

- Consider chap. 5.5.1 and detail description chap. 9.1.4!
- Visual check the clogging indicator on the top side duplex oil filter (see
maintenance point no. 4, chap. 5.3.2)
- If the light-emitting diode (LED) light up red, the filter must be switched over
- The contaminated filter side filter insert must be cleaned
ATTENTION: If any abnormal abrasives are found in the filter by

exchanging of filter element, please inform RENK service!
top
i
LED`s light red

or green
(only
example)
5.5.3 Drain off oil and clean double oil filters (11 or 12)
- Consider chap. 5.5.1
- Open pressure balance valve (A, filter 11 or 12)
- Change over the contaminated filter side or for testing function switching
armature (B)
- Closed pressure balance valve (A)
view form aft A

MAINTENANCE PART 5
Note: Detail descriptions see chap. 9.1.4!

- Remove the plug screw (D1 to D4) and hold container under the drain
- Change over the stop valve (C, one each filter side) from the contaminated filter
side and drain off the dirty oil
- Reassembly takes place in opposite sequence
- Afterwards clean the dirt filter side
view form aft

D1 D2 D3 D4
D1 = Control oil filter (11) left side
D2 = Lube oil filter (12) left side
D3 = Lube oil filter (12) right side
D4 = Control oil filter (11) right side

MAINTENANCE PART 5
5.5.4 Re-grease on input and output shaft

- Consider chap. 5.5.1 and maintenance point 4 (see chap. 5.3.2)!
- The lubrication nipples (item 1046 and 1066) are be located on bottom cover side
(see figures output and input shaft);
- Press grease on lubrication nipple by means of a grease press (not supplied by
RENK) until grease leaves on the pipe (item 1116) at the opposite side;
Note: Use grease according to chap. 5.4.4!
T T
U U
1116
Input shaft Output shaft
1116
section T-T section U-U
1046
lubrication nipple 1066
lubrication nipple

MAINTENANCE PART 5
5.5.5 Check or change anode of oil cooler

- Consider chap. 5.5.1 and maintenance point 6 (see chap. 5.3.2)
- Always drain the tube side circuit (drain screws N5 and N8) before removing the
anodes
- Remove the anodes N7 (3x) and check or change provided destroy the anode
top view oil cooler N8

= 3x anode N7
N5
N5
N8
5.5.6 Clean filter at pressure relief valve (45) and accumulating valve (46+47)
- Consider chap. 5.5.1, maintenance point 7 (see chap. 5.3.2) and detail
description chap. 9.1.7!
- Remove and loosen the screw with seal (10+23)
- Remove the snap ring (13), filter (8) and clean (cleaning agent see chap. 5.4.4)
view Z
filter

MAINTENANCE PART 5
5.5.7 Inspection of toothing

- Consider chap. 5.5.1
- Item nos. to description see fig. 2 and assembly drawing (see part 10).
X Inspection of the main toothing

- Loosen screws (item 1092) and remove the inspection cover (item 1090)
- Check pinion toothing (item 2400) and output wheel (item 3011)
o Inspection of the toothing of primary built-on pump

- Loosen plug screw (item 1041)
- Introduce endoscope and check wheels (item 2115 and 8523)
p Inspection of the toothing of secondary built-on pump

- Loosen plug screws (item 1059)
- Introduce endoscope and check wheels (item 2404 and 8542)
Note:
• Make sure that no foreign matter enters the gear unit during the inspection of the
toothing.
• Check the toothing for an even contact over the entire face width and depth.
• Check the toothing for pittings, sliding wear, striae, etc.
• On the head of several teeth of each gear small areas (see fig. 1) are grinded a
little bit; this is not damage; it was needed for workshop hardness test.
ATTENTION: When detecting any damage to the toothing or a bad tooth
contact pattern, immediately demand for a RENK AG specialist.
• Check seal (item 1091) for damage and replace them if necessary.
• Reassembly takes place in opposite position.
fig. 1

MAINTENANCE PART 5
fig. 2
top view starboard gear
1041
902
6754
1096
1059 1090
1092

MAINTENANCE PART 5
5.5.8 Oil level check and oil filling
a) Oil level check:
The oil level is checked by means of the dipstick (item 1096, see fig. 3) which is located in
the lower casing part. The oil level must be between the min and max markings of the
dipstick with the gear unit at standstill (see fig. 3). If the oil level drops under the min.
marking, the level switch (99) triggers alarm.
b) Oil filling:
- The lower gear unit part has been conceived as oil collecting tank.
- The gear unit must be filled with gear oil according to table of lubricants
(chap. 5.4). Remove the flange (see fig. 2, item 6754, connection no. 902) at the
casing upper part and mounting the oil filling in device (not RENK supply).
Note: The inserted filter (line strainer 10) with mesh size 1.25 is intended only for the
rough dirt filtering.
- The oil is to be filled in via a filter with a mesh width of approx. 0.01 mm.
- The oil quantity has been rated so that the oil level is between the two dip stick
markings (see fig. 3) when the gear unit and the electrically pump (3) are at
standstill.
- Close after filling with flange (item 6754).
fig. 3
max.
Oil level
markings
min.

MAINTENANCE PART 5
5.5.9 Initial oil change

The first oil change must be performed after the first 2500 operating hours or six months,
whichever occurs first.
5.5.10 Oil analysis

Analyse the oil after 2500 operating hours or six months at the latest. The oil sample
should be taken immediately after a shutdown (oil at normal operating temperature).
Observe the lubricant specification (refer to chap. 5.4).
The result of the examination must be assessed by the manufacturer.
If the oil quality does not correspond to the specification, the oil must be changed before
an expiry of the normal oil change interval.
If the water content exceeds 0.2 % the oil must be separated.
Taken oil analysis:
- The gear unit is at standstill;
- Hold recipient under the drain on the duplex oil filter (11 or 12, see chap. 5.3.2);
- Remove the drain screw (6) at activity filter side and drain oil quantity for oil
analyses;
- Assembly plug screw (6)
picture only for example
5.5.11 Oil change

Further oil changes after every 10000 operating hours or every 2 years.
If the oil analysis (chap. 5.5.10) has negative results, the oil must also be changed.

OPERATIONAL FAILURES
REPAIRS PART 6
TABLE OF CONTENTS
6 OPERATIONAL FAILURES, REPAIRS ............................................................2
6.1 Safety information .............................................................................................2
6.2 Operational failures...........................................................................................3

6.2.1 Failure removal list.....................................................................................3
6.3 Repairs .............................................................................................................5
6.3.1 General note ..............................................................................................5
6.3.2 Repair information......................................................................................5
6.3.3 Screws tightening torque’s.........................................................................6
6.3.4 Securing of screws with Loctite..................................................................7
6.4 Adjustment work ...............................................................................................8
6.4.1 Adjust lube oil pressure at pressure relief valve (45) .................................8
6.4.2 Adjust main operating pressure at
pressure accumulating valve (46) ..............................................................9
6.4.3 Adjust reduced operating pressure at
pressure accumulating valve (47) ............................................................10
6.4.4 Adjust time relay (130) for accumulating valve ........................................11

REPAIRS PART 6
6 Operational failures, Repairs
6.1 Safety information

When working on the gear system and with housekeeping maintenance work the following
safety regulations must be observed.
- All operating and maintenance work must be carried out only by suitably trained
personnel.
- The gear unit must not be altered in any way. Adding or removing parts is
forbidden in particular.
- Repairs shall be carried out only using original manufacturer's parts. Any use of
components of other manufacturers not expressly approved by the gear unit
manufacturer is forbidden.
- Before parts are removed from the gear unit for repair work they have to be
suspended or supported
- When working on the gear unit it is necessary to wear the usual protective
clothing such as safety helmet, safety glasses, safety gloves and safety shoes.
- When equipment is being moved, never stand under a suspended load.
- Observe local accident prevention regulations.
- There must be no fire or naked flame near the gear unit.
- Work on the electrical equipment of the gear unit must only be carried out by
trained personnel. Electric components, especially terminal boxes, must only be
opened when the power is disconnected.
ATTENTION! Danger of Electric Shock
- Switch settings on monitoring and control instruments such as pressure switches,
valves, throttles etc must not be changed.
- When the system is running, the inspection covers must not be opened.
Reaching into the machine, even with a tool, is dangerous.
- Before starting any work on the gear unit which requires them to be fully or partly
opened, it must be ensured from the system side that the gear unit can not be
switched on.
- At all free shaft outlets it must be ensured that no rotating parts are touched.
- Parts of the gear unit can become hot with continuous running.

REPAIRS PART 6
6.2 Operational failures
Proceed as described in table „Failure removal list“ in case of any failures. All important
instruments are directly monitored in the ship’s control room.
For further information about Operational failures see components part 9, (mechanic and
hydraulic components part).
Note: Check all instruments/sensors at regular intervals and compare the values
determined with those listed in the Technical Data, part 2.
For further important instructions refer to chapter 6.3.1.
6.2.1 Failure removal list
cons.
Failure Cause Rectification
no.
1 Excessive oil Leakage at flange joints or Make tight or exchange flange
consumption pipework joints or pipe work
Leakage at oil discharge Remove oil discharge screw
screw and replace seal
Leakage on gearshaft seal Check for tightness or exchange
seals
2 Lube oil Leakage’s in the piping Check for piping or exchange
pressure too system
low or too Double filter (12) strongly Change over double filter and
high contaminated clean dirty filter side (see chap.
5.5.3 and 9.1.4)
Primary built-on lube oil Repair or overhaul pump
pump (1) or secondary pump
(2) deficient
Clogged tooth sprays Remove tooth sprays and clean
Check oil viscosity Oil change (see chap. 5.5.11)
Pressure relief valve (45) Readjust (see chap. 6.4.1 and
wrongly adjusted or deficient chap. 9.1.7.1) or replace pressure
relief valve (45)
3 Lube oil Oil cooler (13) contaminated Check cooling water inlet and
temperature outlet temperature;
too high Check cooling water supply;
Clean oil cooler (see chap. 9.1.5)
Temperature regulating valve Replace regulating elements (see
(14) does not operate chap. 9.1.6)
Note: Change over by means of
manual emergency actuation (see
chap. 9.1.6)

REPAIRS PART 6
cons.
Failure Cause Rectification
no.
4 Gear unit Roller bearing damaged; ATTENTION!
noises Plain bearing damaged; Reduce power and/or put plant out
Toothing damaged; of operation, demand for a RENK
Propeller alignment bad; AG specialist.
5 Multi-disc 4/2-way valve (50) blocked Check voltage supply connection;
clutch does Change over by means of manual
not open or emergency actuation (see chap.
close 4.4.7 and chap. 9.1.7.5)
4/2-way valve (50) defective Replace 4/2-way valve
Multi-disc clutch plates worn Replace clutch plates
Control oil pressure too low see cons. no. 6
6 Control oil Leakage in the piping system Check piping or exchange
pressure too control oil
low or too high Double filter (11) strongly Change over double filter and
contaminated clean dirty filter side (see chap.
5.5.3 and 9.1.4)
Electrically driven control oil Repair or overhaul pump
pump (3) deficient
Primary built-on control oil Repair or overhaul pump
pump (1) deficient
Pressure accumulating valve Adjust (see chap. 6.4.2), check
(46) wrongly adjusted or filter (see chap. 5.5.5) or replace
deficient pilot valve (see chap. 9.1.7.2)
7 Shifting Inductive proximity switches Check connection
position of (115, 116) deficient Check or change inductive
multi-disc proximity switch
clutch does
not indicated
8 Electric motor Electric connection Check terminals, lines and fuses
(4) of pump interrupted
(3) does not Thermistor safety switch Reconnect after a certain cooling
start provided for disconnection period

REPAIRS PART 6
6.3 Repairs
6.3.1 General note
IMPORTANT!
Part 1 and chapter 6.1 must always be observed when carrying out all work.
Before the repair work:
• Ensure the unit or equipment cannot be switched on.
• Fix prohibiting sign „ATTENTION: Out of operation ......“ at the ship control
stand.
• Never carry out any work at energised lines.
• Possibly stop the installation when carrying out work on the gear unit oil system or
the seawater system. Relieve pressure and discharge the piping at the work place
by closing all pertinent slides/valves.
Note: When working on the gear unit or on peripheral units, observe the instructions
given for such units/components which are not part of the RENK system.
Adhere to the operating manual for the entire propulsion system!
After the repair work:
• Perform a functional check.
• Remove tools, instruments and cleaning cloth from place of installation.
• Remove prohibiting signs and release installation for operation again.
6.3.2 Repair information

• Repair work shall only be performed by skilled personnel. In the event of major
repairs, it is suggested asking RENK AG to send a specialist to supervise the
work.
• Prior to the disassembly of casing components, any hindering pipelines are to be
removed. The piping apertures must be plugged to avoid the penetration of any
dirt; otherwise the pipelines will have to be flushed prior to reassembly.
• Make sure to keep dirt and foreign matter away from the gear unit while it is open
for inspection or work.
• We would recommend attaching the required tools at the wrist by means of a
string.
• Thoroughly clean all parts with a good cleaning agent, prior to reassembly.
• Renew all bolts, screw and other fastening or locking elements that have become
damaged in the process of dismounting.
• Before reassembling parts of the gear housing, remove old sealing compound
from the joints and coat them with new compound.
• Change oil after major repairs. Check the alignment of the gearbox.

REPAIRS PART 6
6.3.3 Screws tightening torque’s

Preloading forces and tightening torques for bolts with metric threads and head-contact
dimensions as specified in EN ISO 4014 and 4017, EN ISO 4762 and EN ISO 4032,
screws oiled (no Molykote).
Table: Metric coarse-pitch thread DIN 13, Part 1.
Thread Preloading force Fv (kN) Tightening torque TA (Nm)

µ total = 0.125 8.8 10.9 12.9 8.8 10.9 12.9
M5 6.55 9.2 11.1 5.5 8 9.5

M6 9.25 13 15.6 9.5 13 16
M8 17 23.9 13.9 23 32 39
M10 27.1 38 45.7 46 64 77
M12 39.5 55.5 66.7 80 110 135
M14 54 76 91.3 125 180 215
M16 75 105 126 195 275 330
M18 90.5 127 156 270 390 455
M20 117 164 197 385 540 650
M22 145 205 245 510 720 870
M24 169 237 284 660 930 1100
M27 221 311 374 980 1400 1650
M30 269 379 454 1350 1850 2250
M33 325 457 - 1800 2500 -
M36 382 537 - 2300 3200 -
M39 459 645 - 2950 4150 -
M42 525 738 - 3650 5100 -
M48 692 - - 5500 - -

REPAIRS PART 6
6.3.4 Securing of screws with Loctite
Screw connections within the gear casing and separately marked screw connections
outside the gear are to be secured with Loctite. Only use the Loctite type indicated on the
assembly drawing.
Hints for assembly:
Cleaning: Dirty and greasy screws, nuts, and thread bores
are to be cleaned. Cleaning means is alkali free
neutral, P3-T 5125, Per.
Applying of product: Put sufficient Loctite for filling the gap along the
total thread length onto the screw thread. For
larger threads from abt. M16 on and generally for
sag holes it is necessary to add wetting of thread
bores.
Tightening of screw connections: Tighten screw by the required torque only as long
as it can be turned by hand. The friction coefficient
when using Loctite corresponds to the one of oiled
screws (µ = 0.125).
Putting into service: Putting into service (loading of connection) must
not take place before the product is stable for
functioning.
New use of items: When using again items which have been
dismantled and secured with Loctite before, the
old Loctite remainders on screws have to be
removed mechanically, e.g. by means of a wire
brush. The thread bores must be cleaned and
Loctite remainders removed and blown with
greaseless compressed air.
Loctite type 243
suitable for threads ≤ M36
manually turntable 15-30 min.
stable for functioning about 1 hours
final stability 3 hours
temperature resistance -55°C up to 150°C

REPAIRS PART 6
6.4 Adjustment work
6.4.1 Adjust lube oil pressure at pressure relief valve (45)
Note: Consider chap. 6.3.1, see fig. 1 and chap. 9.1.7.1!

- Remove cap nut (item 13, wrench opening 32)
- Loosen the counter nut (item 12, wrench opening 17)
- Turn pressure regulating spindle (item 4, square key □6):
♦ Pressure increase: turn to the right
♦ Pressure reduction: turn to the left
- Mount cap nut (item 13)
Note: For adjusting data refer to chap. 2.2, sheet 8/35!
fig. 1
top view starboard gear unit
valve block cpl.
section A-
1
A
A
4 1

REPAIRS PART 6
6.4.2 Adjust main operating pressure at pressure accumulating valve (46)

fig. 2
top view starboard gear unit
valve block cpl.
section A-
1 4
4 1
A

REPAIRS PART 6
6.4.3 Adjust reduced operating pressure at pressure accumulating valve (47)

fig. 3
top view starboard gear unit section A-
2
1
A A
valve block cpl.

4

REPAIRS PART 6
6.4.4 Adjust time relay (130) for accumulating valve
Note: Consider chap. 5.5.1!

For adjustment work of pressure accumulating valve (47) see chap. 6.4.3.
For adjustment work of time relay (130) time setting on the relay (installed in
terminal box K1, see scheme gear wiring part 10) must be regulated.
- Remove cover of potentiometer
- Setting range is marked on the nameplate
- Adjust operating time new by using screw driver
potentiometer

SUPPLY
INSTALLATION AND INSTALLATION CHECK PART 7
TABLE OF CONTENTS
7 SUPPLY
INSTALLATION AND INSTALLATION CHECK ....................................................2
7.1 Supply ...........................................................................................................2

7.1.1 Volume of supply .......................................................................................2
7.1.1.1 Loose parts ........................................................................................2
7.1.2 Transportation............................................................................................3
7.1.2.1 Shackle selection ...............................................................................4
7.2 Preservation at delivery.................................................................................5
7.2.1 General ......................................................................................................5
7.2.2 Interior preservation ...................................................................................5
7.2.3 Exterior preservation..................................................................................5
7.2.4 Period of corrosion protection ....................................................................6
7.2.5 Renewal of gear unit preservation .............................................................6
7.2.5.1 Renewal of interior preservation.........................................................6
7.2.5.2 Renewal of exterior preservation........................................................7
7.2.6 Removal of gear unit preservation .............................................................7
7.2.6.1 Removal of the exterior preservation..................................................7
7.2.6.2 Removal of the interior preservation...................................................7
7.2.7 Supply sources ..........................................................................................7
7.3 Installation and Installation check..................................................................8
7.3.1 Foundation design .....................................................................................8
7.3.2 Preparation ................................................................................................8
7.3.3 Alignment of the gear unit towards the propeller shaft ...............................9
7.3.3.1 Load on the output shaft bearings at full load...................................12
7.3.3.2 Radial displacement .........................................................................14
7.3.3.3 Axial displacement ...........................................................................14
7.3.3.4 Measurement of the gear shaft bearing loads ..................................15
7.3.3.5 Inner alignment ................................................................................16
7.3.3.6 Fitting of chocks ...............................................................................17
7.3.4 Alignment of the diesel engine towards the gear unit...............................18
7.3.4.1 Displacement input...........................................................................19
7.3.4.2 Axial displacement ...........................................................................19
7.3.5 Final jobs after alignment.........................................................................19
7.4 Sea-water system .......................................................................................20
7.4.1 General ....................................................................................................20
7.4.2 Installation................................................................................................20
7.4.3 Sea water flow .........................................................................................20
Issue: 2005-02-07 MT/Hu/Erh Type: ASL 94 Revision: 2005-02-21 6955027/4 b 1/20

SUPPLY
7 Supply
Installation and Installation Check
7.1 Supply
7.1.1 Volume of supply

The gear unit is delivered in a completely assembled state. The oil supply unit, control units
and electrical wiring shall likewise be mounted.
Item Parts Weight

QTY Denomination Dimension
no. identification kg
1 1 Port gear unit ASL 94 6461053 see drawing 6460900/0 14.000
2 1 Starboard gear unit ASL 94 6461054 (see part 10) 14.000
7.1.1.1 Loose parts

Following equipment is supplied as loose part:
Item Weight
QTY Denomination Parts identification Dimension mm
no. kg
7750 1 Level switch (see fig. 1) 6811210 46x51x124 0,2

SUPPLY
7.1.2 Transportation
For shipping the gear unit is screwed on a wooden stand so that it can be placed on an even
support.
When the gear unit is transported by means of a crane, the ropes must be hung in the seats
envisaged at the gear unit casing to this end (see fig. 1 and fig. 2).
As for the rest, the instructions and rules of the freight carries must be adhered to.
fig. 1 – view from aft starboard gear unit
traverse
Loose
part
frame

SUPPLY
fig. 2 – top view starboard gear unit
= traverse
for balance
= hanging point
Weight gear unit without frame 14.000 kg
CG
10
min. 2800 mm min. 1000 mm
7.1.2.1 Shackle selection
Note: The following lifting shackles are recommended by RENK in order to transport
and lift the gear units. The lifting shackles are not included in the scope of
supply of RENK. Different lifting tools with the same admissible load can also be
used.
Hanging tool QTY Part max. load Weight Dimension
identification
Shackle 4 DIN 82101-A12 each 125 kN 13 kg
∅50
(= hanging 73
234
points)
158
∅52
ball 104
167

SUPPLY
7.2 Preservation at delivery
7.2.1 General
On the outside a paint coat in accordance with the order specification is applied. Parts
which, for functional reasons, must not be painted, have been left unpainted. Before
dispatch of the finish-assembled gear unit the latter is preserved both inside and out. Unless
otherwise specified by the ordering party the following preservation is applied to the gear
unit:
Interior preservation: ARAL Konit ISO VG 100 (see chap. 7.2.7)
Exterior preservation: VALVOLINE Tectyl 506 (see chap. 7.2.7)
For detailed information as to preservation, duration of preservation, renewal of preservation
and supply sources refer to the next chapter.
7.2.2 Interior preservation

For the test run of the gear unit RENK use the fuel-soluble preservation oil ARAL Konit of
viscosity class ISO VG 100. In doing so all gear unit components are wetted with
anticorrosion oil during the test run.
After the rest run all gear unit apertures are plugged. Oil feed and oil drain is sealed by
flanges.
The anticorrosion oil ARAL Konit will fully dissolve during putting into operation provided the
operating oil in accordance with the lubricants chart (see chapter 5.4) is used.
7.2.3 Exterior preservation

The exterior preservation of blank parts is carried out independently from the interior
preservation.
First all blank exterior parts and single parts are cleaned from dirt and grease by means of
Weral 560; afterwards, the parts have to be drying-out.
A rich amount of VALVOLINE Tectyl 506 is sprayed or brushed on. This preservation agent
guarantees a long period of corrosion protection provided the protection film is not
damaged. The duration of corrosion protection is decisive for the interior preservation.

SUPPLY
7.2.4 Period of corrosion protection

The gear must be stored inside a room spanned by a roof. The ambient temperature in
stock must not exceed 50°C. Furthermore, the storage conditions must be such as to
prevent foreign bodies (water, dust) entering the gear.
If the gear is stored for a period exceeding one year upon supply ex works, interior and
exterior preservation must be checked every 6 months and renewed if necessary. If the gear
is stored, however, in an outdoor area under cover or a tropical country, preservation must
be checked every 6 months and renewed if necessary.
For renewal of preservation, the instructions of the chapter 7.2.5 must be adhered to.
7.2.5 Renewal of gear unit preservation

A renewal of the preservation is required, if the following conditions occur:
• The delays set forth in chapter 7.2.4 have expired or the relevant storage
instructions are not respected.
• If any standstill periods or downtimes are to be expected after the sea trial exceeding
6 to 8 weeks (home and European countries) and/or 2 weeks (overseas and tropical
climates).
7.2.5.1 Renewal of interior preservation

As a first step, remove all condensed water that might have entered the gear.
Case 1:
Gear units installed at machine room and all connections connected:
For this purpose the electrically driven control oil pump (3) is to be used. Flush the gear
units with preservation oil for approx. 10 minutes.
Case 2:
Electrically driven control oil pump (3) not available and all connections not connected:
For this purpose a separately smaller pump is permissible. Supply line connected at gear
unit connection G 1 (connection no. 501). For this case flush the gear unit approx. 20
minutes.
Note: The preservation oil has to be drained via the drain screw (connection no. 901)
after or during the preservation.
Use the same preservation oil if possible. Other compounds may be used if equivalent to or
compatible with the original compound (see chap. 7.2.1).

SUPPLY
7.2.5.2 Renewal of exterior preservation

Remove the oiled paper and wash off the existing preservative from all polished parts, using
a Weral 560 (or petroleum-based solvent). Then apply an even layer of the new compound
on all polished parts and replace oiled paper.
If possible, use the same preservative. Other compounds may only be used if equivalent to
and compatible with the original one (see chap. 7.2.1).
7.2.6 Removal of gear unit preservation

Prior to each putting into operation of the gear unit (and to the test run) the preservation
agent has to be removed inside and out.
7.2.6.1 Removal of the exterior preservation

The anticorrosion agent VALVOLINE Tectyl 506 is removed from exterior gear unit
components. For this purpose, the oil paper is removed and the old preservation agent is
washed off by means of Weral 560 (trichlorethylene or a similar solvent).
7.2.6.2 Removal of the interior preservation

The anticorrosion oil ARAL Konit will fully dissolve during putting into operation provided the
operating oil as per the lubricants chart (see chap. 5.4) is used.
7.2.7 Supply sources

a) ARAL AG
Export Lubricants
Wittener Str. 45
44776 Bochum
b) VALVOLINE OEL GmbH & Co.

Überseering
22297 Hamburg 60
c) WERA INDUSTRIE-CHEMIE GmbH

Riesstraße 82
80993 München 50

SUPPLY
7.3 Installation and Installation check
IMPORTANT!
The "General Safety Instructions" set forth in Part 1 has to be strictly adhered
to during the performance of installation work.
7.3.1 Foundation design

The gear unit foundation must be sufficiently stiff so that under all operating conditions no
misalignments will occur which deteriorate the tooth contact of the gear unit. Besides the
individual operating conditions (loaded and unloaded) and in particular the forces result from
the propeller thrust must be considered.
Between the top plate and the gear unit, plates from steel or cast iron are fitted at each
screw. Depending on the gear unit, the height of the chocks ranges between 30 and 50 mm.
Normally, the foundation is designed such that the chocks can be mounted with an
inclination of 1:50 to 1:200.
7.3.2 Preparation
When installing the gear unit into the ship, put it provisionally on the jacking screws.
Before the actual alignment work at the gear unit, the propeller shaft over the entire length
must be brought into its final position considering the special alignment instructions of the
yard.
If the coupling provided between diesel engine and gear unit is not yet rigidly connected with
the gear unit input shaft, it must be flange-connected to the gear unit shaft.
Attention must be paid that the weight of the engine side part of the coupling will not load the
gear unit (support the engine side part of the coupling).
Note:
The thermal growth calculations during alignment in this chapter refer to a machine
room temperature of 20°C and an operating temperature of 50°C (temperature
difference = 30°C). If the machine room temperature deviates by more than ± 3°C,
the alignment values have to be corrected as follows:
50 − amt
AV = IV ×
30
AV = current alignment value

IV = indicated alignment value
amt = current machine room temperature

SUPPLY
ATTENTION! If the gear unit is turned during the alignment process the plain
bearings must be lubricated. To this effect the electrically driven
control oil pump (3) must operate constantly. It must be started 5
minutes before the turning drive is connected. If not lubricated
during the turning process, the bearings may suffer damage.
7.3.3 Alignment of the gear unit towards the propeller shaft

The gear unit must be approached to the ∆r and for the gap ∆w and/or the propeller shaft
such that in accordance with fig. 3 the prescribed values for the radial offset angular offset α
are attained. The pertinent theoretical values result from the propeller shaft calculation
which is carried out by the yard.
All influences on the propeller shaft bending line have to be considered (as ship
deformations, thermal growth, influences of the propeller etc.).
The supporting forces resulting at both gear unit output shaft bearings should almost be
acting in the same direction under all operating conditions. These forces are a consequence
of other forces which originate in the gear unit and the weight shares of the propeller shaft in
accordance with the propeller shaft calculation. The forces resulting from the gear unit itself
(from tooth forces and the weight of the gear unit output shaft) are explained in the following
pages for the different full-load operating conditions and for the unloaded condition (only
weight).
The additional forces resulting from the propeller shaft calculation have to be indicated to
RENK.
The definitely attained values for the radial shaft offset ∆r, the clearance ∆w and/or the
angular offset can be drawn from the values measured by dial gauge or sensor gauge in
accordance with the formulas of the following figure. The values determined are to be
recorded. The differences between the theoretical and actual values must not exceed 0.05
mm for the radial shaft offset (0.1 mm deflection of the dial gauge) and/or for the clearance
0.01 mm per 100 mm flange diameter difference of the indication values of the dial gauge
(i.e. 0.0001 rad).
In axial direction the gear unit must be approached to the propeller shaft leaving a gap of
approx. 0.5 mm. In doing so, the gear unit output shaft must be aligned axially considering
the reference dimensions mentioned in the installation drawing.
The final alignment values towards the propeller shaft must be recorded (see Table 1).

SUPPLY
Table 1
Gear unit - Propeller shaft Port gear / Starboard gear

Actual values
seen from propeller shaft to gear Required values
unit acc. to propeller Alignment Final
shaft calculation shipyard alignment
(shipyard)
mm mm mm
Radial run out: r1 top ........................ ........................ ........................

Dial gauge values r2 port ........................ ........................ ........................
r3 below ........................ .......... .............. ........................
r4 starboard ........................ ........................ ........................
Angular run-out: a1 top ........................ ........................ ........................
Gap of plane
surface measuring a2 port ........................ ........................ ........................
diameter a3 below ........................ ........................ ........................
= ..................... mm
a4 starboard ........................ ........................ ........................

SUPPLY
fig. 3
r4 − r2 ∆Wh a 4 − a 2
On the horizontal plane: ∆rh = α h= = (in rad)
2 dp dp
r3 − r1 ∆Wv a3 − a1
On the vertical plane: ∆rv = αv = = (in rad)
2 dp dp

SUPPLY
7.3.3.1 Load on the output shaft bearings at full load

Forces seen from aft.
S= Centre of gravity
F= Bearing load consisting of weight and tooth force
G= Weight output wheel
G = 4600 kg
A B

SUPPLY
Port gear unit Starboard gear unit
FRA=263,6 FRA=263,6
36,98 36,98
Bearing A Bearing A
FRA=196,6 FRA=196,6
2,96 2,96
Bearing B Bearing B
• Maximum permissible static load from shaft line calculation for:

bearing A = 56 kN
bearing B = 123 kN
• External bearing load only in down direction
• Maximum bearing load difference:
at cold static condition: 50%
at warm full load: 30%

SUPPLY
7.3.3.2 Radial displacement

Radial displacement of the gear unit output shaft by heat dilatation at temperature difference
∆t =30°C and bearing clearance (see from aft).
Bearing clearance sm = 0.365 mm
Port gear Starboard gear
0.12 0.12
K K
0.45
0.45
M M
M: Position of the shaft at cold condition without transmission of power

K: Position of the shaft at warm condition under full load
7.3.3.3 Axial displacement

For axial alignment the gear unit output shaft must be adjacent with the axial bearing in
forward travel mode.
The axial therminal growth the gear output shaft by heat dilatation at temperature
difference ∆t = 30°C:
0.24 mm (growth into aft direction)

SUPPLY
7.3.3.4 Measurement of the gear shaft bearing loads

After completion of the inner alignment the gear unit is connected to the propeller shaft. In
doing so, the bearing forces for cold and load-free condition will become effective in
accordance with the propeller shaft calculation.
These bearing loads are to be checked. To this effect, the shaft train is lifted at the output
shaft bearings until the output shaft is slightly in contact with the upper half of the bearing
shell.
The force required for this and the deflection of the shaft are to be compared with the
reference values contained in the propeller shaft calculation and to be recorded.
The load check of the forecastle bearing is to be carried out in accordance with the following
sketch.

SUPPLY
7.3.3.5 Inner alignment

• A RENK specialist must be demanded to carry out the alignment. This specialist will
bring along the required tooth contact documents.
• The inner alignment of the gear unit and the check of the tooth contact patterns of the
individual meshes is done by using the reference tooth contact patterns.
• The tooth contact patterns are subject to acceptance test and documented at RENK.
• To ascertain the contact patterns contrast compound must be applied carefully at
least 3x over circumference and over 2-5 teeth of the pinion test flanks. For contact
patterns without load we recommend to use bluing ink "LUKAS BLAU" for contact
patterns under load testing lacquer "Dykem RED” or equivalent products.
• After alignment of the gear unit towards propeller shaft and prior to mounting the
remaining fitted plates the contact pattern of the bull gear / pinion mesh must be
checked. The shaft must be turned by means of the turning device as long as a print
of the contrast compound, which can be assessed, is recognisable on the tooth flanks
of the bull gear.
• The thus obtained tooth contact pattern must correspond to the reference tooth
contact pattern. In case of tooth contact pattern deviations the gear unit must be
positioned anew by means of the remaining setting screws of the casing until a
coincidence is achieved.
• The final tooth contact patterns of all pairings must be documented.
Note: On the head of several teeth of each gear small areas (see fig. 4) are grinded
a little bit; this is not damage; it was needed for workshop hardness test;
fig. 4

SUPPLY
7.3.3.6 Fitting of chocks

After alignment of the gear unit towards the propeller shaft, the chocks must be fitted at first
without clearance and directly next to the jacking screws on which the gear unit was placed.
The jacking screws are then removed.
In order to avoid that the gear unit is displaced in the course of further alignment work, the
foundation bolts and/or chocks must be positioned directly next to the setting screws.
ATTENTION:
Prior to fitting the remaining chocks without clearance the inner alignment
(tooth contact pattern) is to be checked.
For the tightening torques of the foundation bolts refer to the installation
drawing (see part 10)!

SUPPLY
7.3.4 Alignment of the diesel engine towards the gear unit

When aligning the diesel engines towards the gear unit input shaft, attention has to be paid
to the axial, radial and angular position. The correct axial position results from the assembly
reference dimension of the elastic couplings.
This reference dimension must be adhered to in warm condition during ahead travel.
In order not to exhaust the displacement capability of the elastic couplings by circumstances
which can be exactly calculated, one should adequately consider the displacements due to
heat dilatation and bearing clearances of the engines and the gear unit for radial alignment.
The alignment in cold and unloaded condition is then not done to zero but to that value
which results from the difference between the mentioned displacement of engine shaft and
the gear unit shaft.
Special attention is to be paid to the fact that in any case both influences must be known.
The consideration of only one of these influences (engine or gear unit displacement) is not
admissible. The displacements of the gear unit input shafts as a consequence of thermal
growth and the bearing clearances have been summed up on the following pages.
The instructions of the manufacturer of the elastic coupling must also be adhered to.
The check for a correct radial and angular alignment between engine and gear unit input
shaft is normally done by means of dial gauges (see fig. 5). To this effect, a special
measuring bracket is used and the radial offset (radial runout) and the angular offset (axial
runout) between the primary-side coupling part and the input shaft are measured. The
differences between the theoretical and actual values must not exceed 0.1 mm for the radial
offset (0.2 mm indication of dial gauge) and/or for the clearance 0.2 mm per 100 mm flange
diameter difference of the indication of the dial gauge (i.e. 0.002 rad).
fig. 5
elastic coupling
GEAR UNIT DIESEL ENGINE
For the axial runout measurement two dial gauges are to be used which are arranged offset
by 180°.
The final values are to be recorded after completion of alignment and to be checked at a
later moment in warm condition (50°C).

SUPPLY
7.3.4.1 Displacement input

Radial displacement of the gear unit input shaft by heat dilatation at temperature
difference ∆t =30°C (see from aft).
Port gear unit Starboard gear unit
0.17 0.1
K K
0.18
0.1
M M
M: Position of the shaft at cold condition without transmission of power

K: Position of the shaft at warm condition under full load
Note: No displacement from mechanical influences
7.3.4.2 Axial displacement

The axial thermal growth the gear input shaft by heat dilatation at temperature
difference ∆t = 30°C:
0.55 mm (growth into ahead direction)
Note: No displacement from mechanical influences
7.3.5 Final jobs after alignment

• Subsequently all interfaces (hydraulic and electric system) between gear unit and ship
must be connected.

SUPPLY
7.4 Sea-water system
7.4.1 General
• the gearbox sea-water-cooler tube package is made of copper-nickel 90/10 tubes; this
material is sea water resistant, but special conditions may harm the resistance
capacity; thus it is strongly recommended to follow the given instructions.
• it must be noted that any corrosion / erosion damages of the cooler tube package are
not be covered by the guarantee of the cooler maker.
• for further instructions refer to the full instruction manual of the cooler, added in the
chapter of sub-suppliers documentation.
7.4.2 Installation
• turbulent sea water flow into the cooler must be avoided (no sharp bends before the
sea water inlet).
• adjustment of the sea water flow by orifice behind the cooler; orifices before the cooler
may cause bad filling conditions of the cooler.
• sea water piping-system fitted in that way that the cooler will be drained automatically
in stand-still conditions.
• installation of a small by-pass pipe behind the cooler directly connected to the sea
water drain for automatic ventilation (de-aeration) of the cooler during start-up and
operation.
• in the ship sea water system anodes have to be provided in the necessary amount.
The anodes in the gearbox-cooler are only designed to protect the cooler itself. If
there are not enough additionally anodes in the complete system, the cooler anodes
will be destroyed in a very short time.
• an additional good corrosion protection is provided if the last part of the cooler
connection pipe at the sea water inlet is made of simple thick-walled carbon steel.
• sea water supply to be passed through a strainer with filter mesh of max. 3 mm.
7.4.3 Sea water flow

• too low or too high sea water flow velocity in the cooler is causing corrosion respective
erosion; thus minimum / maximum sea water flow through the cooler must be kept
within the limits during all operating conditions (full speed range, operation with
attached pump or electric pump etc., flow/pressure characteristic of the complete sea-
water system and the sea-water pump); the flow limits are indicated in the technical
data sheets.

MAIN PARTS LIST PART 8
TABLE OF CONTENTS
8 MAIN PARTS LIST ...........................................................................................2
8.1 Introduction ...................................................................................................2

8.1.1 Division ......................................................................................................2
8.1.2 Spare parts order.......................................................................................2
8.2 Port gear unit ................................................................................................3
8.2.1 Mechanic parts list .....................................................................................3
8.2.2 Hydraulic parts list .....................................................................................5
8.3 Starboard gear unit .......................................................................................8
8.3.1 Mechanic parts list .....................................................................................8
8.3.2 Hydraulic parts list ...................................................................................10
8.4 On board spare parts list.............................................................................13

8 Main parts list
8.1 Introduction
8.1.1 Division
The main parts list is divided in:
• Port gear unit parts list see chap. 8.2
• Starboard gear unit parts list see chap. 8.3
• On board spare parts list see chap. 8.4
The main components list is provided with subsequent item nos. The number of the parts is
always stated for one gear. The assembly drawing and/or the piping scheme required for
identification of single parts is contained in part 10.
8.1.2 Spare parts order

Always state the following details when ordering for spares:
- Order no.:
- Product no.:
- Gear unit serial no.:
- Item no.:
- Denomination
- Parts identification
- Quantity
Order example:
- Order no: 80124652
- Product no: see type plates gear unit
- Gear unit serial no: see type plates gear unit
- Item no: 2401
- Denomination Inner disc carrier
- Parts identification 6460950
- Quantity 1

8.2 Port gear unit
8.2.1 Mechanic parts list

Product no.: 6461053
Assembly drawing: 6461243/0 sheet 1 to 2
Parts identification
Item no. Denomination QTY Weight1)
RENK
1042 Sealing ring 6562000713 1
1043 Vent 2442381 1
1044 Sealing ring 6562000717 1
1048 Rotary shaft seal 6461419 2
1060 Sealing ring 6561900736 1
1061 Oil supply bushing 1045303 1
1091 Gasket 1043190 1
1096 Dip stick 6461427 1
1100 Gasket 1001970 1
2104 Cylinder roller bearing 1100864 1 20,7
2112 Grooved ball bearings 1102012 1 14,5
2115 Pump wheel 6460923 1 31,5
2117 Cylinder roller bearing 1101678 2 109
2129 4-point bearing 6314903983 1
2200 Input flange 6460890 1 214,2
2201 Input shaft 6460919 1 286
2203 Pin 6222401709 12
2206 External disc carrier 6460946 1 240
2207 Clutch carrier 6456433 1 51
2302 Rectangular ring 6420478 1
2304 Piston 6438237 1 67

RENK
2309 Compression spring 6438258 36
2313 Outer clutch disc 1002853 12 6,5
2314 Inner clutch disc 1000330 11 5
2400 Pinion shaft 6460916 1 688
2401 Inner disc carrier 6460950 1 100
2402 Fitting key 6456867 2
2404 Pump wheel 6460928 1 7
3002 Plain bearing 6461432 1 112
3003 Plain bearing 6461429 1 112
3010 Output shaft 6460892 1 2.434
3011 Spur gear 6460893 1 2.074
3020 Thrust pad 1100011 22
3021 Thrust pad 6461369 2
3023 Wire ring 6461456 2
3025 Splash ring 6461439 1
3026 Worm spring 6461440 1
8523 Pinion 6460937 1 6,8
8542 Pinion 6460938 1
1) Information single weight in kg, only if >5 kg

8.2.2 Hydraulic parts list

Piping scheme: 6817565/0 sheet 1 to 2
Instrument panel: 6817977/1 (see items 7040 to 7212)
RENK
6101 Line strainer (6) 6811517 1
6110 Check valve (40) 6721008650 1
6141 Line strainer (7) 1105915 1
6170 Line strainer (8) 1105915 1
6171 Check valve (41) 6721008665 1
6210 Check valve (42) 6721008632 1
6240 Check valve (44) 6721008650 1
6310 Check valve (43) 6721008650 1
6340 Check valve (68/1) 1100754 1
6342 Check valve (68/2) 1100754 1
6361 Check valve (66) 6812541 1
6703 Ball cock 6816329 4
6752 Line strainer (10) 6811517 1
6960 Temperature controller (14) 6817656 1 18
7040 Vibration element 6808824 2
7101 Thermometer (80) 6815619 1
7102 Thermometer (81) 6815623 1
7126 Pressure gauge (70) 6815617 1
7127 Pressure gauge (71) 6815338 1
7128 Pressure gauge (72, 73) 6815618 2
7152 Pressure transmitter (100, 103, 105) 6813720 3
7153 Pressure switch (92/1) 6807668 1
7161 Pressure transmitter (101) 6813959 1
7171 Pressure transmitter (102, 104) 6813959 2
7172 Pressure switch (90) 6813958 1

RENK
7191 Pressure control valve 6891954 1
7212 Ball cock 6805530 4
7541 Varistior 6813932 3
7546 Time relay (130) 6810531 1
7547 Relay (131) 6808151 3
7548 Relay (132) 6810067 2
7549 Amplifier (140) 6817867 5
7550 Amplifier (141) 6817868 2
7600 Starter box (150, 151) 6817648 1
7651 Resistance thermometer cpl. (110) 6810854 1
7656 Resistance thermometer cpl. (111/1) 6813261 1
7656/1 Resistance thermometer 2xPT100 6813167 1
7671 Resistance thermometer (112) 6813261 1
7750 Level switch (99) 6811210 1
7780 Speed transmitter (125/1, 125/2) 6817869 2
7781 Plug 6817870 2
8521 Built-on control oil pump (1) 6817247 1 30
8540 Built-on lube oil pump (2) 6817248 1 48
8560 Electrically driven control 6817242 1 414
oil pump, cpl.
8562 Oil pump (3) to electrically pump 6818168 1 47
8563 E-Motor (4) to electrically pump 6818169 1 108

RENK
8564 Coupling to electrically pump 6818170 1
8600 Double filter control oil (11) 6815266 1 40
8620 Double filter lube oil (12) 6815266 1 40
8640 Oil cooler (13) 6817243 1 77
8660 Control block cpl. 6817678 1 95
8661 4/2-way valve (50) to control block 6815308 1 7,6
8662 4/2-way valve (51) to control block 6815309 1
8663 Proximity switch (115, 116) to control 6807333 2
block
8664 Pressure relief valve (45) to control 6818171 1 11
block
8665 Pressure accumulating valve (46) to 6818172 1 11
control block
8666 Pressure accumulating valve (47) to 6818173 1 12,5
control block
8667 Pressure relief valve (48) to control 6818174 1
block

8.3 Starboard gear unit
8.3.1 Mechanic parts list

Assembly drawing: 6461243/0 sheet 1 to 2
RENK
1042 Sealing ring 6562000713 1
1043 Vent 2442381 1
1044 Sealing ring 6562000717 1
1060 Sealing ring 6561900736 1
1091 Gasket 1043190 1
1096 Dip stick 6461427 1
1100 Gasket 1001970 1
2104 Cylinder roller bearing 1100864 1 20,7
2112 Grooved ball bearings 1102012 1 14,5
2115 Pump wheel 6460923 1 31,5
2117 Cylinder roller bearing 1101678 2 109
2129 4-point bearing 6314903983 1
2200 Input flange 6460890 1 214,2
2201 Input shaft 6460919 1 286
2203 Pin 6222401709 12
2206 External disc carrier 6460946 1 240
2207 Clutch carrier 6456433 1 51
2304 Piston 6438237 1 67

RENK
2309 Compression spring 6438258 36
2313 Outer clutch disc 1002853 12 6,5
2314 Inner clutch disc 1000330 11 5
2400 Pinion shaft 6460949 1 688
2401 Inner disc carrier 6460950 1 100
2402 Fitting key 6456867 2
2404 Pump wheel 6460928 1 7
3002 Plain bearing 6461433 1 112
3003 Plain bearing 6461430 1 112
3010 Output shaft 6460892 1 2.434
3011 Spur gear 6460894 1 2.074
3020 Thrust pad 1100011 22
3021 Thrust pad 6461369 2
3023 Wire ring 6461456 2
3025 Splash ring 6461439 1
3026 Worm spring 6461440 1
8523 Pinion 6460937 1 6,8
8542 Pinion 6460938 1

8.3.2 Hydraulic parts list

Piping scheme: 6817565/0 sheet 1 to 2
Instrument panel: 6817977/1 (see items 7040 to 7212)
RENK
6101 Line strainer (6) 6811517 1
6110 Check valve (40) 6721008650 1
6141 Line strainer (7) 1105915 1
6170 Line strainer (8) 1105915 1
6171 Check valve (41) 6721008665 1
6210 Check valve (42) 6721008632 1
6240 Check valve (44) 6721008650 1
6310 Check valve (43) 6721008650 1
6340 Check valve (68/1) 1100754 1
6342 Check valve (68/2) 1100754 1
6361 Check valve (66) 6812541 1
6703 Ball cock 6816329 4
6752 Line strainer (10) 6811517 1
6960 Temperature controller (14) 6817656 1 18
7101 Thermometer (80) 6815619 1
7102 Thermometer (81) 6815623 1
7126 Pressure gauge (70) 6815617 1
7127 Pressure gauge (71) 6815338 1
7128 Pressure gauge (72, 73) 6815618 2
7152 Pressure transmitter (100, 103, 105) 6813720 3
7153 Pressure switch (92/1) 6807668 1
7161 Pressure transmitter (101) 6813959 1
7171 Pressure transmitter (102, 104) 6813959 2

RENK
7212 Ball cock 6805530 4
7541 Varistior 6813932 3
7546 Time relay (130) 6810531 1
7547 Relay (131) 6808151 3
7548 Relay (132) 6810067 2
7549 Amplifier (140) 6817867 5
7550 Amplifier (141) 6817868 2
7600 Starter box (150, 151) 6817648 1
7671 Resistance thermometer (112) 6813261 1
7750 Level switch (99) 6811210 1
7780 Speed transmitter (125/1, 125/2) 6817869 2
7781 Plug 6817870 2
8521 Built-on control oil pump (1) 6817241 1 30
8540 Built-on lube oil pump (2) 6817240 1 48
8560 Electrically driven control 6817242 1 414
oil pump, cpl.
8562 Oil pump (3) to electrically pump 6818168 1 47
8563 E-Motor (4) to electrically pump 6818169 1 108

RENK
8564 Coupling to electrically pump 6818170 1
8600 Double filter control oil (11) 6815266 1 40
8620 Double filter lube oil (12) 6815266 1 40
8640 Oil cooler (13) 6817243 1 77
8660 Control block cpl. 6817677 1 95
8661 4/2-way valve (50) to control block 6815308 1 7,6
8662 4/2-way valve (51) to control block 6815309 1
8663 Proximity switch (115, 116) to control 6807333 2
block
8664 Pressure relief valve (45) to control 6818171 1 11
block
8665 Pressure accumulating valve (46) to 6818172 1 11
control block
8666 Pressure accumulating valve (47) to 6818173 1 12,5
control block
8667 Pressure relief valve (48) to control 6818174 1
block

8.4 On board spare parts list

RENK
0001 Seal set for built-on lube oil pump (2) 6818196 1 -
0002 Seal set for built-on control oil pump (1) 6818197 1 -
0003 Seal set for electrically driven control oil 6818198 1 -
pump (3)
0004 Anode for oil cooler (13) 6815781 2 set -
(each 3)
0005 Thermometer (80) 6815619 1 -
0006 Thermometer (81) 6815623 1 -
0007 Pressure transmitter 6813720 1 -
0008 Pressure transmitter 6813959 1 -
0009 Pressure switch 6807668 1 -
0010 Pressure switch 6813958 1 -

ADDITIONAL DOCUMENTS PART 9
TABLE OF CONTENTS
Note: In case of spare part orders from the additional documents the denomination,
the item number and the RENK part number (see main parts list, part 8) of the
instruments must be indicated as reference. In addition, the designation and
the item number of the spare part must be stated (see order example).
Order example:
• Order no: 80124652
• Product no: see type plates gear unit
• Gear unit serial no: see type plates gear unit
• RENK Denomination: Built-on control oil pump
• RENK Item no: 8521
• RENK Part no: 6817247
Additional information:
• Reference drawing no. 6955087/4
• Description: Spherial roller bearing
• Item no: 170
• Quantity: 1
Chap. Denomination Item no. Tool no. Drawing no. Sheet
9.1 Hydraulic components

9.1.1 Built-on control oil pump, primary 8521 1
• Technical Documentation 6955083/4 1 to 15
• Installation drawing 6955086/4 1 to 1
• Assembly drawing with parts list 6955087/4 1 to 1
9.1.2 Built-on lube oil pump, secondary 8540 2
• Technical Documentation see chap. 9.1.1
9.1.3 Electrical driven control oil pump 8560 3+4
9.1.3.1 Oil pump 8562 3
• Technical Documentation see chap. 9.1.1
9.1.3.2 E-Motor 8563 4
• Operating Instructions 6955090/4 1 to 28

ADDITIONAL DOCUMENTS PART 9
Chap. Denomination Item no. Tool no. Drawing no. Sheet
9.1.4 Double filter control/lube oil 8600, 8620 11, 12

• Manual and maintenance instructions 6955091/4 1 to 3
• Assembly drawing with spare parts 6955044/4 1 to 2
• Clogging indicator 6955051/4 1 to 2
9.1.5 Oil cooler 8640 13
• Instructions for installation start up and …. 6955039/4 1 to 17
• Recommendations for Installation 6954234/4 1 to 2
9.1.6 Temperature regulating valve 6960 14
• General information 6955038/4 1 to 4
• Removal and replacement of manual override 6955043/4 1 to 2
9.1.7 Control block, cpl. 8660 -
• Description for pressure valves 45 to 47 6955045/4 1 to 4
9.1.7.1 Pressure relief valve 8664 45
• Assembly drawings with parts list 6955097/4 1 to 4
9.1.7.2 Pressure accumulating valve 8665 46
9.1.7.5 4/2-way valve 8661 50
• Installation drawing with spare part list
and technical data 6955101/4 1 to 2
9.2 Electric documents
9.2.1 Starter box 7600 150

• Description 6817549/4 1 to 19

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Safety and commissioning instructions
1. Safety and commissioning instructions

1.1 Warning symbols in these instructions
The symbols are used in these operating instructions to point out to particular dangers.
This symbol refers to a dangerous situation which can cause fatal or serious injuries or
considerable damage to property.
Danger
This symbol refers to a possibly dangerous situation which can cause injuries and damage to
property if it is not avoided.
1.2 General
Low voltage motors have dangerous, live and rotating parts, and probably hot surfaces. All work for transport,
connection, commissioning and maintenance is to be made by qualified, responsible specialists (EN
50110–1/VDE 0105 Part 1, IEC 60364 must be observed). An inadequate behaviour can cause severe dam-
ages to persons and property.
1.3 Specified use

These low voltage motors are meant for use in industrial plants. They are in accordance with the standards of
the series EN 60034 (VDE 0530).
Air–cooled types are suitable for ambient temperatures from –20°C (–4°F) to +40°C (+104°F) as well as alti-
tudes ≤ 1000 m above sea level. It is imperative to observe differing data on the rating plate. The conditions at
the site of application must comply with all indicated data on the rating plate.
Low voltage motors are components to be installed into machines in accordance with
Directive 89/392/EEC.
Commissioning is not allowed as long as the conformity of the end product with this directive is not estab-
lished (EN 60204–1 has also to be observed).
1.4 Transport, storage

The carrier is immediately to be informed on damages found upon delivery; commissioning must not be
admitted, if required. Screwed–in eye bolts are to be tightened. They are suitable for the weight of the low volt-
age motor, no additional loads are allowed to be attached. If required, sufficiently dimensioned means of trans-
port (e.g. rope guides) are to be used. Prior to commissioning the transport locking devices are to be re-
moved. Reuse for further transports. For storage of low voltage motors, take care of a dry, dustfree and
low–vibration (veff v 0.2 mm/s) ambience (bearing damages with motor at standstill).
Before commissioning the insulation resistance is to be measured. In case of values v 1kΩ per Volt of the
rated voltage the winding must be dried. Observe the ”Storage instructions”.
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1.5 Installation
Take care of an even ground, suitable fastening of feet or flange and an exact alignment for direct coupling.
Avoid that structure–dependent natural frequencies occur within the rotary frequency and the double mains fre-
quency. Turn rotor by hand, listen to abnormal frictioning noises. Check direction of rotation before coupling
(Observe section ”Electrical connection”).
Pulleys and couplings are only allowed to be installed or removed with suitable devices (Heating!) and to be
covered with protection against accidental contact. Avoid inadmissible belt tensions (Tech. List). The bal-
ance of the low voltage motor is indicated on the shaft end face or on the rating plate (H = half key, F = full
key). In case of a half key (H), the coupling must also be balanced with a half key. In case of any protruding
and visible part of the key take care of the mass balancing.
If required, make the necessary pipe connections. Mounting types with the shaft end facing upwards are to be
provided with a cover by the customer, avoiding that foreign bodies fall into the fan.
Ventilation must not be hindered and the

outgoing air – also from adjacent units – must
not be directly sucked in again.
1.6 Electrical connection

All work is only allowed to be done by qualified personnel with the low voltage motor and driven machine at
standstill, electrically dead and locked against restart.
This is also applicable to auxiliary circuits (e.g. space heater).
Check de–energizing!
A non–observance of the tolerances indicated in EN 60034–1/VDE 0530, part 1 – voltage " 5%, frequency "
2%, curvature, symmetry – will result in an excessive heating and is influencing the electromagnetic compatibil-
ity. Observe data on the rating plate as well as wiring diagram in the terminal box.
Observe connection and differing data on the rating plate as well as the wiring data in the terminal box.
Connection is to be made in such a way that a durably safe, electrical connection is maintained (no uncovered
wire ends); especially provided cable end equipment is to be used. A safe earthing is to be made.
The minimum air gaps between uninsulated and live parts themselves and to earth must not be lower than the
following values: 8 mm at UN v 550 V, 10 mm at UN v 750 V, 14 mm at UN v 1000 V.
The terminal box must be free of foreign bodies, dirt as well as humidity. Unused cable entries and the box it-
self are to be sealed against dust and water. For trial operation without driving elements the key is to be se-
cured. For low voltage motors with brake it is to be checked before putting into operation, if the brake is per-
fectly functioning.
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1.7 Operation
Vibration severities veff ≤ 3.5 mm/s (PN ≤ 15 kW) and 4.5 mm/s (PN > 15 kW) are not critical in coupled oper-
ation. In case of changes compared with normal operation – e.g. higher temperatures, noises, vibrations –
the cause is to be found, if required, consult the manufacturer. Even for trial operation the safety devices are
not allowed to be put out of function. In case of doubt switch off the low voltage motor.
In case of heavy dirt accumulation, the air ducts must be cleaned at regular intervals.
Bearings with regreasing devices are to be regreased with low voltage motor running. Risk of accidents! Pay
attention to rotating parts. Observe saponification class! If grease drainholes are sealed with a plug, remove
these plugs before putting into operation. Boreholes have to be sealed with grease. Replacement of bearings
in case of permanent lubrication see Appendix 1 or motor documentation.
1.8 Warranty
The Warranty is only applicable if all of these instructions for safety and putting into operation as well as the
following paragraphs of the operating instructions and the directions for possible additional units are strictly ob-
served.
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Description
2. Description
2.1 Overall construction and design

Mounting arrangement acc. to EN 60034–7: see dimension drawing or rating plate
Mounting dimensions for surface cooling (TEFC) up to frame size 315 M acc. to
DIN 42 673 (foot mounted)
DIN 42 677(flange mounted)
from frame size 315 L acc. to dimension drawing,
all frame sizes acc. to IEC 60072–1 or IEC 60072–2: see dimension drawing
Mounting dimensions for internal cooling (ODP) up to frame size 315 M acc. to
DIN 42 672 (foot mounted)
DIN 42 676 (flange mounted)
from frame size 315 L acc. to dimension drawing,
all frame sizes acc. to IEC 60072–1 or IEC 60072–2: see dimension drawing
Connection designations acc. to

DIN VDE 530 part 8
IEC 60034 – 8: see wiring diagram
Enclosure acc. to
EN 60034 – 5: see rating plate
Cooling acc. to EN 60034–6:

IC 411 surface cooling or hollow–fin cooling
IC 511 tube cooling
IC 01 internal cooling
IC 611 internal cooling with mounted–on air–to–air heat exchanger
IC 81 W internal cooling with air–water circuit cooler
IC 71 W water jacket cooling
Details of the motor design are indicated in the valid technical catalogues.
2.2 Bearings
The motors are equipped with grease–lubricated antifriction bearings. The standard version of the
bearings in surface–cooled motors up to frame size 280 and in internally cooled motors up to frame
size 225 is permanently lubricated.
The bearings of totally enclosed fan–cooled (TEFC) motors from frame size 315 and the internally
cooled open–drip proof (ODP) motors from frame size 250 are equipped with regreasing devices
and automatic grease quantity control.
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Description
2.5 Stator winding

The stator winding is executed in insulation class (see rating plate) acc. to EN 60034–1. High–qual-
ity enamelled wires, suitable surface insulating materials and the type of insulation provide a high
level of mechanical and electrical stability with a high utilization factor and a long service life.
If required, the winding heads are sealed with a silicon–rubber compound. This sealing offers
special advantages in combination with the insulation classes F and H, when the motors are oper-
ated under severe starting– and braking conditions. Furthermore, the sealing provides an in-
creased mechanical short circuit resistance and the motor inside (in case of surface cooling) is pro-
tected against condensed water.
2.6 Rotor
The rotor in motors of small frame sizes is equipped with a squirrel cage made of aluminium die
cast, in case of larger frame sizes and for special starting– and braking conditions a brazed rotor
version is also available. The rotor is dynamically balanced.
The balance is indicated on the shaft end or the rating plate, see Paragraph 4.1 ”Installation”.
The motors in standard design meet the requirements of vibration level N
acc. to DIN EN 60034–14 / IEC 60034–14, in special cases level R (reduced) or S (special).
2.7 Terminal boxes

If required, additional terminals for the monitoring devices are available inside the
terminal box. On special order an additional terminal box will be installed for larger motors (see
dimension drawing).
The number of available terminals is indicated in the wiring diagrams.
2.8 Monitoring devices

Monitoring devices are only available on special request. See wiring diagram.
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Installation and commissioning
4. Installation and commissioning
A most careful mounting and alignment of the motors on an absolutely even surface is impera-
tive to avoid distortions when the screws are being tightened. For machines which are to be
coupled it must be paid attention to a careful alignment. See Appendix 2 for alignment check.
As elastic as possible couplings should be used.
The motors with surface cooling (TEFC), hollow–fin cooling or tube cooling , internal
cooling or internal cooling with air–to–air heat exchanger
(for all indicated types except Type A.WA.–... and JNWA–...)
Maximum permissible coolant temperature (ambient temperature on site) acc. to EN 60034–1/IEC
60034–1 is 40°C (104°F) and a permissible altitude up to 1000 m above mean sea level (other va-
lues see rating plate).
Care must be taken that the cooling air can flow without hindrance into the air inlet openings and
freely pass through the air outlet openings and cannot be directly sucked in again. Suction and
outlet openings must be protected from obstructions and coarse dust.
The motors with water jacket cooling (Type A.WA.–132..–.. to A.WA–560..–..)

Before commissioning of water–cooled motors, the troublefree function of the cooling–water circuit
must be guaranteed. It must be ensured that the motor will only be switched on when the cooling–
water circuit is in operation. It must be kept functioning until the motor comes to standstill after
switching–off. Inlet and outlet openings are found on the motor housing.
The cooling water circuit is to be monitored. Normally, the motor is equipped with PTC thermistor
sensors, which switch off the motor if the cooling–water circuit fails. If the housing is provided with
vent plugs for the water chamber, venting is to be made for the first filling and thereafter at regular
intervals.
Only clean, non–aggressive cooling water is to be used. Admissible content of suspended solids
is max. 10mg/l
A most careful mounting and alignment of the motors on an absolutely even surface is impera-
tive to avoid distortions when the screws are being tightened. For machines which are to be
coupled it must be paid attention to a careful alignment. See Appendix 2 for alignment check.
As elastic as possible couplings should be used.
The inlet temperature of the cooling water should be at least 20 °C (68 °F).
Temperatures below 20 °C (68 °F) result in higher formation of condensation water and motor fail-
ure. Admissible inlet and outlet temperature, maximum pressure and the required amount of cool-
ing water are indicated on the motor plates.
The motors are only allowed to be operated at a coolant temperature over 0 °C (32 °F). For lower
temperatures it is required to add an antifreeze due to reduced cooling effect. Consultation with
the motor manufacturer is required.
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The motors with mounted–on air–water heat exchanger for the Type JNWA–..
Before commissioning of the motors, the troublefree function of the cooling–water circuit must be
guaranteed. It must be ensured that the motor will only be switched on when the cooling–water
circuit is in operation. It must be kept functioning until the motor comes to standstill after switching–
off.
Admissible inlet and outlet temperature, maximum pressure and the required amount of cooling
water are indicated on the motor plates.
4.1 Mounting
Fitting of pulleys or couplings.
First the shaft end should be cleaned (not with emery cloth) and then greased. Pulley or coupling
should be fitted only with the aid of a fitting device. For this purpose the threaded centering hole
in the shaft end can be used. Insert a threaded bolt into the threaded hole. Then place the steel
washer, the diameter of which is large enough to cover the hub borehole of the pulley or coupling.
The pulley and coupling is to be fitted onto the shaft end by means of a nut or a suitable hydraulic
device.
The fitting of the drive elements by means of hammer blows is not permitted because of
the risk of bearing damages.
When replacing the bearings those must only be removed and reinstalled by means of suit-
able devices using the shaft centering. Only original spare parts must be used.
The rotor of the motor is dynamically balanced. Balance is indicated on the shaft end face or the
rating plate (H = half key, F = full key). Take care of the balance for installation of the driving el-
ement!
The balancing of the transmission elements to be fitted must be adapted to the rotor balancing.
In case of half key balancing any protruding and visible part of the key has to be removed.
The motor must only be mounted and operated according to the specified mounting arrangement
(see rating plate).
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4.3.2 Change of rotational direction:

For DOL (direct on–line) starting and in pole–changing motors with separate windings the di-
rection of rotation can be reversed by exchanging two mains conductors on the terminal board
of the motor.
For motors with star/delta starting and pole–changing motors with Dahlander winding, 2 (two)
mains conductors at the input to the motor switch have to be exchanged.
For a machine with one shaft end only or with two shaft ends of different diameters, that rota-
tional direction of the rotor is considered as the direction of rotation, being noticed by anybody
when looking at the front end or thicker shaft end.
4.3.3 With forced ventilation the direction of rotation is separately marked by an arrow on the forced
ventilation itself.
4.4 Air–water heat exchanger

(motors with air–water heat exchanger of the type JNWA–...)
For connection and commissioning the instructions for air–water heat exchangers must be con-
sidered.
Admissible inlet and outlet temperature, maximum pressure and the required amount of cooling
water are indicated on the motor plates.
4.5 Check before commissioning

– Check whether the bearing lock has been removed!
See Paragraph 3.2 ”Bearing lock”!
– Observe data on the rating plate!
– Check whether voltage and frequency of the motor comply with the mains data!
– Check whether the rotational direction is correct and for inverter operation, that the
limit speed is not exceeded!
– Check whether the motor is protected as specified in the regulations!
– Check and make sure that in case of star/delta–starting, because of the risk of
inadmissible operational loads, the switching from star to delta can only be
executed after fading of starting current of the star step!
– Check whether the electrical connections are securely tightened and whether the
monitoring devices are correctly connected and adjusted!
– Check coolant temperature!
– Check whether the additional equipment – if any – is functioning.
– In case of water–cooled motors, check whether the cooling water circuit is in operation!
– Check whether the cooling air inlet openings and cooling surfaces are clean!
– Check whether protective measures have been taken: earthing!
– Check whether the motor is securely fixed!
– In case of a belt drive, check the belt tension!
– Check whether the cover of the terminal box is closed and whether the cable
entries are properly sealed.
– For forced–ventilated motors it is to be checked, whether the forced ventilation is
functioning and in operation when the main motor is in operation.
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4.6 Tightening torques for screwed joints

4.6.1 General
If no other data are indicated the following torque limits (screw and nut) are applicable.
Note: Screws which become unusable have to be replaced by
new ones of the same strength class and type.
4.6.2 Screwed joints for electrical connections
Thread Tightening torque [Nm] Thread Tightening torque [Nm]

M4 1.2 M 12 15.5
M5 2 M 16 30
M6 3 M 20 52
M8 6 M 24 80
M10 10 M 30 150
4.6.3 Screwed joints strength class 8.8 and A4–70

Tightening torques for screws of the strength class 8.8 and A4–70 (A4–80) only in components
with higher strength (e.g. grey cast iron, steel).

M4 2.3 M 14 105
M5 4.6 M 16 160
M6 7.9 M 20 330
M8 19 M 24 560
M10 38 M 30 1100
M 12 66 M 36 1900
4.6.4 Screwed joints strength class 5.6

Tightening torques for screws of the strength class 5.6, 4.6, A2 or for screws in components
with lower strength (e.g. aluminium).

M4 1.1 M 14 49
M5 2.1 M 16 75
M6 3.7 M 20 150
M8 8.9 M 24 260
M10 18 M 30 520
M 12 30 M 36 920
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Maintenance
5. Maintenance
The responsible for the facility must ensure that the specified maintenance work
is made adequately.
5.1 Bearings and greasing
5.1.1 The bearings in totally enclosed fan–cooled (TEFC) motors up to frame size 280 and of inter-
nally cooled open drip–proof (ODP) motors up to frame size 225 are permanently lubricated. In
case of differences this is marked by indication plates on the motor.
For normal coolant temperatures (see EN 60034–1 or page 2 of these instructions) motors
are greased in our plant, which under normal operating conditions must only be replaced after
several years (see Appendix 1).
5.1.2 Bearings of totally enclosed fan–cooled (TEFC) motors from frame size 315 (upon customer
request also for the range from frame size 160 to 280) and of internally cooled open drip–proof
(ODP) motors from frame size 250 as well as the water–cooled motor with air–water circuit
cooler are equipped with regreasing devices and automatic grease quantity control. The re-
greasing of the bearings is done by means of a grease gun through the nipples provided on the
end shields.
Overfilling of the bearing chambers is not possible since in case of an extended regreasing the
used grease will be thrown off by a rotating disk in the outer grease chamber through an aper-
ture in the end shield (or into a grease collecting chamber).
Regreasing during operation only!

Regreasing intervals, grease quantity and grease quality are indicated on the instruction plates at
the motor. Regreasing, however, is to be made at least once a year.
If the motor is equipped with grease removal rams, the used grease must be removed after re-
greasing by pulling the ram at the bearing several times to the stop, with the motor in operation.
If the motor is equipped with grease collecting chambers, these chambers are to be dismounted
at motor standstill acc. to the intervals on the instruction plate and the used bearing grease is to
be removed. If this is not done, the grease piles up and the bearings are overheated.
Extending the regreasing intervals endangers the bearing and might risk a deterioration of the
sealing provided by the grease and thus the ingress of dust into the bearing. If the motors have
not been operated for a longer period we recommend even for new motors to regrease the bearings
before putting into operation, especially if due to congealing grease in the bearing there are noises
which are caused by vibrations of the bearing cage. In the course of running–in increased bearing
noises might occur for a short period. The bearing noise is not critical as long as the operating tem-
perature of the bearing is not yet reached and if the noise is caused by the dynamic viscosity of
the bearing grease.
The temperature of the bearings is continuously to be checked. Up to an ambient temperature of

40 °C/104 °F a heating–up of 80 K is acceptable if the recommended grease quality is used.
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Maintenance
We would like to point out that the grease quantity regulation can only work properly if the grease
types specified by us are used. Decisive is the plate fixed on the motor!
Only use antifriction bearing grease as specified for regreasing on the motor plate, i.e. for the ambi-
ent temperature range from –25°C (–13°F) to +70°C (+158°F) lithium based grease (e.g Shell Al-
vania RL3), for the ambient temperature range from –60°C (–76°F) to +80°C (+176°F) special
grease (e.g. Klüber Isoflex Alltime SL2). Admissible ambient temperature for the motors: See
Paragraph 1.3.
Motors for special operating conditions are supplied with a separate greasing plate stating the
grease quality to be used as well as the regreasing intervals.
Relubrication with grease of a different saponification basis. e.g. sodium saponified grease,
might cause a deterioration and elimination of the grease effect and thus a total damage of the
bearings.
In case of 2 and 4 pole motors it might happen that by the use of unsuitable grease the grease
quantity regulation fails and when pressing new grease into the bearings they get abnormally hot
due to overfilling. In such cases the bearings have to be cleaned thoroughly by using cold–degreas-
ing agent, and be refilled with suitable grease.
5.1.3 Avoidance of mechanical damages (bearing damages)

All machines have to be checked at regular intervals for mechanical damages.
Special attention must be paid that the intervals for bearing replacement and regreasing inter-
vals or grease change intervals as well as oil change intervals to be specified by the user are
observed.
When the rated service life is reached the bearings should either be replaced or it is to be
proven by an inspection that there are no mechanical damages.
– For bearings which are not regreasable it is ensured that the rated service life will only be
reached clearly after achieving the grease service life of the bearings.
– The calculated rated service life of the bearings can be seen in the data sheet of the ma-
chine, if it was specified particularly or for structural reasons specified for an individual case.
– For machines which are exposed to forces applied externally (e.g. belt force or axial load
from the driven machine) the bearing service life is a minimum of 20.000 hours for the full load
indicated in the technical list.
– All of the other machines have a rated bearing service life of at least 40.000 hours.
– For bearings with separate oil supply the user is to watch suitably that the lubrication is main-
tained.
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Maintenance
5.2 Terminal locations, terminals, ventilating passages

Depending on the operating conditions, the following should be done at certain intervals
checking the cleanliness of terminal locations and terminals
– checking of the electrical connections with regard to tightness
– cleaning of the ventilating passages.
Both the cooling air inlets and the cooling surfaces must be protected against obstruction and
contamination.
– If required, the water chambers are to be flushed and cleaned from deposits.
Never use sharp–edged tools for cleaning.
5.3 Air–water heat exchanger

(Motors with air–water heat exchanger of the Type JNWA–...)
For maintenance please consider the instructions for the air–water heat exchangers.
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Additional equipment
6. Additional equipment
On special order only.
6.1 Temperature monitoring *)

The temperature sensors for monitoring e.g. of the stator winding temperature, the bearings, the
coolant must be connected to the additional terminals in the main terminal box or by one or several
terminal boxes.
The temperature sensors have to be connected according to the relevant connection diagram. For
connection the specifications and instructions acc. to Paragraph 4.2 ”Connection” are applicable.
6.2 Electronic speed monitoring *)

This one is essentially consisting of the slot–type initiator and the control segment. The electronic
speed monitoring is maintenance–free.
6.3 Space heater *)

Heating capacity and connection voltage: See special plate on the motor. The space heater has
to be connected to the terminals provided in the main terminal box or by an additional terminal box
acc. to the relevant connection diagram.
For connection the specifications and instructions acc. to Paragraph 4.2 ”Connection” are appli-
cable.
An operation of the space heater is only allowed when the motor is switched off. The space heater
must never be switched on during motor operation.
6.4 Forced ventilation *)

Observe direction of rotation! (see arrow for directional rotation.)
Forced ventilation is to be connected acc. to the wiring diagram inside the terminal box.
During operation of the main motor the forced ventilation must be switched on!
The forced ventilation is dissipating the heat loss during operation of the main motor. When switch-
ing off the main motor a temperature–dependant follow–up run of the forced ventilation is required.
6.4.1 To be checked when commissioning the main motor:

Check whether the forced ventilation works and is in operation when the main motor is
switched on!
*) On special order only
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Three–phase motors as centrifugal drive
for heavy starting
7. Three–phase motors as centrifugal drive for heavy starting

Special requirements for a safe application (Type AW.A–...–..)
For mounting and removal of the motor the corresponding operating instructions of the centrifuge
must be observed.
Starting– and braking conditions of the motor in accordance with the corresponding operating in-
structions must be observed.
Even for trial operation the control and safety devices as well as the motor monitoring (thermal
motor protection, speed monitoring and others) are not allowed to be put out of function.
The motor must only be mounted and operated according to the specified mounting arrangement.
Any other application is prohibited.
It has to be secured that the servicing personnel is informed at once or the electrical machine is
immediately stopped to find the causes, if contrary to the rated operation higher temperatures, no-
ises, vibrations etc. occur.
Direction of rotation:
The centrifuge is only suitable for one direction of rotation. The relating arrow on the centrifuge
must be observed.
Bearing and greasing:
For permanently lubricated motors (also see bearing and greasing data sheet on request) the
grease life, grease quantities and grease qualities as indicated in Appendix 1 of these operating
instructions are applicable. Motors with regreasing device are equipped with an automatic grease
quantity control. Regreasing intervals, grease quantity, grease quality and the exact bearing type
are indicated on the motor plate or in the bearing– and greasing data sheet to be requested.
A lack of regreasing, an extension of the regreasing intervals or the use of a wrong grease quality
might endanger the bearing. This can result in a deterioration of the bearing and the motor shaft,
also entailing consequential damages on the centrifuge.
For this reason it is recommendable to maintain an inspection– and maintenance plan where re-
greasing and possible bearing replacements are documented.
Replacement of bearing:
See safety instructions, section ”Operation”.
The service life of the bearings depends on many influences. Therefore, the operation of the low–
voltage motor has continuously to be checked and the intervals for bearing replacement to be de-
termined accordingly.
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Spare parts
8. Spare parts
When ordering spare parts or components please state the type, serial number of the motor.
Both data can be taken from the rating plate.
Standard version:
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Storage instructions
9. Storage specifications
9.1 For motors which have to be stored for a period of up to 2 years, the fol-
lowing is to be observed:
9.1.1 Storage
9.1.1.1 The motors are to be stored dry, dustfree and at room temperature. In this case no special
packing is required. Otherwise the motors must be packed into plastic foil with humidity–ab-
sorbing substances (e.g. Branogel) or into an air–sealed foil. Protective cover against sun and
rain is to be provided.
9.1.1.2 In order to avoid secondary failures at the bearings caused by vibrations at standstill, for
example by adjacent running machines, the motors are only allowed to be stored in vibration-
less rooms.
9.1.1.3 For transport the TEFC, ODP and water–cooled motors with roller bearings have to be
equipped with a bearing lock at the driving end. It is to remain locked until commissioning resp.
to be reinstalled after an inspection or a trial operation. A locking device is not necessary and
not available, if the bearing is axially preloaded.
9.1.1.4 On motors with sealed condensation water drain holes it might be necessary to have the con-
densation water flow out. Afterwards the boreholes are to be sealed again.
9.1.2 Commissioning
9.1.2.1 Before commissioning the insulation resistance of the winding must be measured by qualified
personnel phase against phase and phase against mass. Damp windings may cause leakage
currents, arcing and ruptures. In case of values ≤ 1 kΩ per Volt of rated voltage measured at a
winding temperature of 20 °C (68 °F) the winding must be dried. Drying is possible by feeding
of the winding with single phase a.c. current. The voltage has to be adjusted in a way that the
recommended values of the heating current in accordance with Illustrations a) and b) are not
exceeded.
The temperature should reach approx. 80 °C (176 °F) and be active for several hours. Drying
is also possible in a drying kiln.
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9.1.3.2 Commissioning
Before commissioning the humidity–absorbing substance (e.g. Branogel) is to be removed from
the terminal boxes and the measures according to 9.1.2 are to be performed.
9.1.3.3 For outdoor storage it is additionally to be observed:

Protective cover against the influence of sun and rain is to be provided, exchange of air must
be possible to avoid condensation water.
After 2 months it must always be checked if the protective measures acc. to 9.1.3.1a are still
given and functioning.
9.2 For motors which are stored for more than 2 up to 4 years before com-
missioning additionally applies:
9.2.1 Storage
9.2.1.1 The manufacturer must be informed on the storage time in the purchase order.
9.2.1.2 Shaft opening and terminal box cover are to be provided with grease seals of antifriction bear-
ing grease. The motor shafts are not allowed to be rotated, as otherwise the protective grease
coating is destroyed. If a movement of rotating parts is unavoidable, the protective grease
coating has to be renewed.
9.2.1.3 A humidity–absorbing substance (e.g. Branogel) must be in the terminal boxes.
9.2.1.4 Due to the long standstill the antifriction bearings must be greased with the special grease
”Staburags NBU 8 EP”.
9.2.2 Commissioning
9.2.2.1 Before commissioning the humidity–absorbing substance (e.g. Branogel) is to be removed from
the terminal boxes and the measures according to 9.1.2 are to be performed.
9.2.2.2 Antifriction bearings, lubrication

Motors with regreasing device must be relubricated immediately after commissioning with
about the double grease quantity, until the used grease has been thrown out. Further greasing
can then be made with the bearing grease indicated on the lubrication plate. During the run-
ning–in period increased bearing noises may occur, which are not dangerous, when the operat-
ing temperature of the bearing has not been reached and is caused due to the dynamic viscos-
ity of the bearing grease.
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9.3 If motors (not Type A.WA–... and JNWA–...) are stored at temperatures till
–50°C (–58 °F) the following must be observed in addition to the instruc-
tions according to point 9.1. and 9.2:
9.3.1 The standard antifriction bearing grease for the motors as per catalogue is suitable for
operating temperatures between –30 °C (–22 °F) and +130 °C (+266 °F). Temperatures till –50
°C (–58 °F) are harmless for the antifriction bearing grease, when the motors are at standstill
or stored. (For an operation at –50 °C (–58 °F) a special grease, e.g. Klüber Isoflex Alltime
SL2, is available for the bearings).
9.3.2 Motors with regreasing device are to be relubricated with the double grease quantity when put
into operation.
9.4 If motors with direct water jacket cooling or with air–water cooler (Type
A.WA–... or JNWA–... )
are stored at temperatures up to –20 °C (–4 °F) the following must be ob-
served in addition to the instructions of point 9.1 and 9.2:
The water has to be removed completely from the air–water coolers.
In any case the coolers have to be dried completely with hot air of max. 60 °C (140 °F) and
then to be sealed.
Motors with coolers have to be stored in a dry and dustfree room.
At commissioning the motors with regreasing device have to be relubricated with the double
grease quantity.
9.5 Further to these storage instructions all data of these operating instruc-
tions are to be considered.
The manufacturer’s warranty is only applicable if all of the above men-
tioned items are strictly observed.
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Appendix 1
Grease life and grease quantities

for antifriction bearings of three–phase motors with squirrel cage for low voltage and permanent lubrication.
Grease life for permanent lubrication 1) Grease

operation hours at rated speed 1/min: quantities in g
per bearing for
Frame size Horizontal mounting (IM B) permanent
3600 3000 1800 1500 1200 v 1000 lubrication
63 4
71 5
33000
80 9
33000
90 11
100 15
112 24000 33000 25
33000
132 33000 33000 50
160 70
24000
180 80
200 17000 60
225 70
250 17000 90
24000
280 12000 24000 120
Vertical mounting (IM V)

3600 3000 1800 1500 1200 v 1000
63 4
33000
71 5
24000
80 33000 9
33000
90 24000 11
33000
100 15
17000 33000
112 25
132 17000 50
160 24000 70
180 12000 24000 80
200 60
12000
225 24000 70
250 17000 24000 90
9000 17000
280 9000 120
The indicated grease life is applicable for an ambient temperature of max. 40 °C (104 °F).
For a temperature rise of 10 °C (50 °F) each the grease life is to be reduced by factor 0.7 of the chart value
(max. 20 °C/68 °F = factor 0.5).
At an ambient temperature of 25 5C (77 5F) the double grease life can be expected, however, 33000
operating hours at a maximum.
1) Independently of the operation hours the antifriction bearing grease resp. the bearing (2Z bearings) have to
be replaced after 3–4 years at the latest.
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Sea-Water Cooling System
Recommendations for Installation and Putting-into-Service

and Operation of the Gearbox-Sea-Water-Cooler
1. General
• the gearbox sea-water-cooler tube package is made of copper-nickel 90/10 tubes;

this material is sea water resistant, but special conditions may harm the
resistance capacity; thus it is strongly recommended to follow the given
instructions.
• it must be noted that any corrosion / erosion damages of the cooler tube package
are not be covered by the guarantee of the cooler maker.
• for further instructions refer to the full instruction manual of the cooler, added in
the chapter of sub-suppliers documentation.
2. Installation
• turbulent sea water flow into the cooler must be avoided (no sharp bends before
the sea water inlet).
• adjustment of the sea water flow by orifice behind the cooler; orifices before the
cooler may cause bad filling conditions of the cooler.
• sea water piping-system fitted in that way that the cooler will be drained
automatically in stand-still conditions.
• installation of a small by-pass pipe behind the cooler directly connected to the sea
water drain for automatic ventilation (de-aeration) of the cooler during start-up and
operation.
• in the ship sea water system anodes have to be provided in the necessary
amount. The anodes in the gearbox-cooler are only designed to protect the cooler
itself. If there are not enough additionally anodes in the complete system, the
cooler anodes will be destroyed in a very short time.
• an additional good corrosion protection is provided if the last part of the cooler
connection pipe at the sea water inlet is made of simple thick-walled carbon steel.
• sea water supply to be passed through a strainer with filter mesh of max. 3 mm.
3. Sea water flow
• too low or too high sea water flow velocity in the cooler is causing corrosion
respective erosion; thus minimum / maximum sea water flow through the cooler
must be kept within the limits during all operating conditions (full speed range,
operation with attached pump or electric pump etc., flow/pressure characteristic of
the complete sea-water system and the sea-water pump); the flow limits are
indicated in the technical data sheets.
Issue: 2000-07-21 - GS/Hu 6954234/4 1 /2

Sea-Water Cooling System
4. Putting into operation
• if a continuous ventilation is not provided by a by-pass pipe, the cooler must be

de-aerated during first start of the plant with the special plugs (see instruction
manual).
• a internal cooler protection layer in the sea water pipes will be build-up in the first
time of operation; thus the most critical time is the initial operation period,
especially in dirty harbour water; frequently checks of the anode-conditions are
recommended during this time, at least before and after dock and sea trials.
• check the anodconditions; re-new the anodes if 60% or more is wasted.
5. Operation
• After putting the ship into normal service it is recommended to check the anodes
more frequently in the first time; according to the results of this checks the time
interval can be prolonged up to the normal recommended check intervals (every 3
months).
6. Stop periods
• stand still up to 2 days:

if possible, keep the water flow through the cooler in circulation (within the
indicated flow limits).
• stand still up to 2 weeks:
drain the cooler and flush it with fresh water for a minimum period of 1 hour.
• longer stand still periods than 2 weeks:
drain the cooler and flush it with fresh water for a minimum period of 1 hour; than
fill it with fresh water plus corrosion inhibitors.
Issue: 2000-07-21 - GS/Hu 6954234/4 2 /2

THERMOSTATIC VALVES
(SELF ACTUATED TYPES)
MVA SERIES ``M...... ´´ GENERAL INFORMATION
MVA Thermostatic Valves are used to provide reliable, automatic control of fluid temperatures in
turbines, compressors and engine water jacket and lubricating oil cooling systems. They are
also suitable for process control and industrial applications where fluids must be mixed or
diverted depending on their temperatures. They may also be applied to co-generation systems
to control temperatures in the heat recovery loop assuring proper engine cooling and
maximising heat recovery.
All MVA Thermostatic Valves are equipped with positive 3-way valve action in which the water
or lubricating oil is positively made to flow in the direction required. On jacket water applications
when the engine is started up and is cold, the MVA Thermostatic Valve causes all of the water
to be positively by-passed back into the engine, thus providing the quickest warm-up period
possible. After warm up, the correct amount of water is by-passed and automatically mixed with
the cold water returning from the heat exchanger or other cooling device to produce the desired
jacket water outlet temperature. If ever required, the MVA Thermostatic Valve will shut off
positively on the by-pass line for maximum cooling. The 3-way action of the MVA Thermostatic
Valve allows a constant volume of water through the pump and engine at all times with no pump
restriction when the engine is cold.
ADJUSTMENTS & MAINTENANCE
No adjustments are ever required on MVA Thermostatic Valves. Once installed a MVA
Thermostatic Valve will provide years of trouble-free service.
TEMPERATURE SETTINGS
Because MVA Thermostatic Valves are set to a predetermined temperature at the factory,
costly errors due to mistakes of operating personnel are eliminated. After a MVA Thermostatic
Valve has been installed, it is impossible for the operator to arbitrarily change the operating
temperature and run the engine too cold or too hot unless the temperature element assemblies
themselves are changed.
MVA Thermostatic Valves are temperature rated for the expected nominal operating
temperature in jacket water service. On lubricating oil applications the system operating
temperature may be slightly above the nominal rating, depending on the type of oil flow rate, oil
cooler capacity and other conditions of the system.
For long life, MVA Thermostatic Valves should not be operated continuously at temperatures
more than about 75°F (24°C) above their nominal ratings. If higher continuous over-
temperatures are expected, contact the factory for recommendations.
OPERATION
The power creating medium utilises the expansion of a special thermostatic wax material which
remains in a semi-solid form and which is highly sensitive to temperature changes.
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INSTRUCTIONS FOR MVA TEMPERATURE VALVE MODEL "M" WITH AND WITHOUT
MANUAL OVERRIDE
1) Maintenance
Properly applied and installed, MVA Thermostatic Valves require minimal maintenance. An
inspection at 2 or 3 year intervals is adequate to detect and make provision for manual wear.
Excessive temperatures, chemical, electrolytic attack or cavitation will shorten the life of the
element assemblies, seals and seats. These items are replaceable. Water additives may cause
swelling of the O-ring seals around the stem and the sliding valve to a point where they may
affect valve action and require replacement. Synthetic base lubricants will definitely attack the
O-ring seals which may be replaced by O-rings of alternate materials. Contact the MVA factory
for recommendations.
Carbonates, scale and other solids must not be permitted to build up on sliding valve or sensing
cup surfaces. The valve and element assemblies may be cleaned with mild acid or Oakite
solutions. Hard scale may require wire brush buffing.
2) Manual override
If for any reason "M"-Thermostatic valves with manual override should not work properly, each
element assembly is fitted with an infinitaly variable override which allows on accurate manual
temperature regulation.
Before the manual override is used we recommend, however, to check whether the cause of
trouble is not somewhere in the system, according to paragraph 3) "Trouble shooting". Manual
override should only be used in emergency case.
If a thermostatic valve with several element assemblies is installed (DN 65 - DN 125) it is
recommended to open one element assembly after the other against cooler by turning screw
until desired temperature is nearly reached. Final regulation is done with next element
assembly.
3) Trouble-Shooting
In the event that your cooling system does not operate close to the desired temperature, the
following check list may point to one or more causes for the problem.
2005-03-29 6955038/4 2/4

3.1 System Temperature too cold
a) Insufficient heat rejected to coolant to maintain the temperature
b) Wrong nominal temperature selected
c) Thermostatic valve is greatly oversized for the system flow rate or cooling
capacity of the system is much greater than is required
d) Thermostatic valve ist installed backwards, forces water to cooler and causes engine to
run cold under all conditions
e) Worn O-ring seal around the element assembly
f) Too great a pressure difference (in excess 1,7 bar) between ports 2 and 3
g) Foreign material is stuck between sliding valve and seat
h) Element assembly may have been over-temperated sufficiently to affect calibration or
rupture wax seal and does therefore not close "2"-port completely anymore. Requires
complete new element assembly.
3.2 System Temperature too hot

a) Cooling capacity of system not adequate
b) Thermostatic valve too small for flow rate (also causes high pressure drop and possibly
cavitation)
c) Valve installed backwards; as temperature increases, Port 2 closes, reducing flow to
cooler
d) Bypass will not close due to worn or pitted seats, sliding valve, O-ring seal, etc.
e) Worn O-ring seal around the element assembly
f) Element assembly may have been over temperated sufficiently to affect calibration or
rupture wax seal and does therefore not fully open "3"-port anymore. Requires complete
new element assembly.
g) Solids build up on sliding valve prevents proper action of element assembly
h) Foreign material stuck between sliding valve and seat
i) Excessive pressure differential between port (very low pressure through bypass leg, very
high pressure in cooler)
3.3 Additional Considerations

a) Thermometers: A thermometer that reads the same whether system is cold or hot needs
replacing
b) Location of thermometers: on horizontal pipe runs, these should be in the side of the pipe
when possible, particularly on oil systems. Also, pipes do not always run full so the
thermometer may not be immersed in the fluid
c) Thermometers should be as far as possible downstream from the confluence of two
streams of different temperature to allow complete mixing
d) Look for bypasses or "sneak circuits" which prevent thermostatic valve control of the
complete system
2005-03-29 6955038/4 3/4

2005-03-29 6955038/4 4/4
2005-03-29 6955043/4 1/2
2005-03-29 6955043/4 2/2
Control block, item 8660
Port control block
Issue: 2005-09-06 - MT/Hu/Erh Revision: 6955096/4 1 /3

Starboard control block

Parts list control block, port and starboard:

Weight: 95 kg
Item Piece Designation

10 1 Connecting block NG10
45 1 Pressure relief valve
46 1 Pressure accumulating valve
47 1 Pressure accumulating valve
50 1 4/2-way valve
55 2 Proximity switch
67 1 Non return valve
84 1 Nozzle
100 2 Sealing set for item 45-47 consists of:
4 O-ring seal
2 O-ring seal
110 1 Sealing set for item 50 consists of:
5 O-ring seal
120 1 O-ring seal
121 2 O-ring seal
122 3 O-ring seal
123 1 O-ring seal
130 18 Screw
131 4 Screw
140 3 Screw plug
141 3 Sealing ring
142 1 Screw plug
143 1 Sealing ring
144 1 Screw plug
145 1 Sealing ring

2005-03-30 6955045/4 1/4
2005-03-30 6955045/4 2/4
2005-03-30 6955045/4 3/4
2005-03-30 6955045/4 4/4
Pressure relief valve (45), item 8664

Parts list pressure relief valve (45):

Weight: 11 kg

1 1 Valve box (45/1)
2 1 Pilot valve (45/2)
7 1 Piston
8 1 Filter (45/3)
9 1 Compression spring
10 1 Adaptor
12 1 Grub screw
13 1 Snap ring
14 4 Cheese-head-screw
16 3 O-ring
18 1 O-ring
19 2 O-ring
21 1 Screw plug
22 1 Sealing ring
23 1 Sealing ring

Pilot valve (45/2)
Parts list
Weight: 2,4 kg
1 1 Valve cover
2 1 Pilot cartridge
5 1 Screw plug
6 2 Screw plug
10 1 Ball
11 1 Sealing ring
12 2 Sealing ring

Pilot cartridge (see sheet 3/4 - item 2)
Parts list
Weight: 0,6 kg
1 1 Screw connection
2 1 Piston
4 1 Spindle
6 1 Ball
8 1 Snap ring
9 1 Circlip
10 1 Snap ring
11 1 Washer
12 1 Hexagon nut
13 1 Cap nut
14 1 Sealing ring
15 1 Sealing ring



Weight: 11 kg

2 1 Pilot valve (46/2)
7 1 Piston
8 1 Filter (46/3)
10 1 Adaptor
12 1 Grub screw
13 1 Snap ring
16 3 O-ring
18 1 O-ring
19 2 O-ring
21 1 Screw plug
22 1 Sealing ring
23 1 Sealing ring

Pilot valve (46/2)
Parts list
Weight: 2,4 kg
1 1 Valve cover
2 1 Pilot cartridge
5 1 Screw plug
6 2 Screw plug
10 1 Ball
11 1 Sealing ring
12 2 Sealing ring
13 4 Washer

Parts list
Weight: 0,6 kg
1 1 Screw connection
2 1 Piston
4 1 Spindle
6 1 Ball
7 46 Plate spring
8 1 Snap ring
9 1 Circlip
12 1 Hexagon nut
13 1 Cap nut
14 1 Sealing ring
15 1 Sealing ring



Weight: 12,5 kg

2 1 Valve cover
3 1 Pressure relief valve (47/2)
4 1 4/2-way valve (51)
5 1 Manual override
6 1 Plug
7 1 Directional valve
8 1 Filter (47/3)
10 1 Adaptor
12 1 Circlip
13 1 Snap ring
16 3 O-ring
18 1 O-ring
19 2 O-ring
21 1 Screw plug
22 1 Sealing ring
23 1 Sealing ring
25 1 Screw plug
27 1 Ball
28 1 Sealing ring
29 4 Washer

Pilot valve (47/2, see item 3)
Parts list
Weight: 2,4 kg
1 1 Valve box
2 1 Pilot cartridge
3 4 O-ring

Parts list
Weight: 0,42 kg
1 1 Valve box
2 1 Spindle
3 1 Valve cone
4 1 Disc
5 1 Valve set
6 1 Ball
7 1 O-ring
8 1 Cup nut
10 1 Snap ring
11 1 Snap ring
12 1 Washer
13 1 Hexagon nut
14 1 Grub screw
15 1 Sealing ring

Parts list:
Weight: 4 kg

1 1 Valve block
3 1 O-ring

4/2-way valve (50), item 8661
Parts list:
Weight: 7,6 kg

10 2 Proximity switch assembly group
30 2 Coil LSK-D19-2014-32-24V DC
40 2 Core tube
50 2 Manual override
60 2 Plug
70 4 Cylindrical screw
80 1 Seal kit

4/2-way valve (50), item 8661
Technical data:

DRAWING APPENDIX PART 10
TABLE OF CONTENTS
10.1 Drawings mechanic
Drawing no.
Installation drawing 6460900/0 sheet 1 to 2
Assembly drawing 6461243/0 sheet 1 to 2
Mass scheme 6460901/3
10.2 Drawings hydraulic
Drawing no.
Piping scheme 6817565/0 sheet 1 to 2
Instrument panel 6817977/1
Connection scheme 6817650/0
Scheme gear wiring 6817652/0 sheet 1 to 2

Operating Instruction ASL 94

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Operating Instruction ASL 94

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COVER SHEET WITH TABLE OF CONTENTS

RENK AG has been granted approval under DIN-EN ISO 9001.

Issue: 2005-10-28 - MT/Hu/Erh Type: ASL 94 Revision: 2007-01-12 6955073/4 C 1 /6

Gear unit type: ASL 94

Customer: Schelde Naval Shipbuilding

Project:: Ynr 397/398

Shipyard: Schelde Naval Shipbuilding

Yard no: 397, 398, 399, 400

Ship: Indonesian Corvette

RENK order no.: 80124652 (yard no. 397, 398)

RENK gear unit product no: port 6461053

Serial no.: see type plates

Year of manufacture of the gear unit 2005, 2006, 2007

Issue: 2005-10-28 - MT/Hu/Erh Type: ASL 94 Revision: 2007-01-12 6955073/4 C 2 /6

Issue of the Operating Instruction:

Issue Customer address + RENK Number and Issue data Employee

First issue Schelde Naval Shipbuilding 15x English 2005-10-28 MT/Erhard

15x English 2007-01-12

Department MT 1x English 2005-10-28 MT/Erhard

1st amendment See first issue See above 2005-12-09 MT/Erhard

2nd amendment See first issue See above 2006-04-07 MT/Erhard

3rd amendment See first issue See above 2007-01-12 MT/Erhard

Issue: 2005-10-28 - MT/Hu/Erh Type: ASL 94 Revision: 2007-01-12 6955073/4 C 3 /6

Documents modified (3rd amendment):

cons. Invalid (to be deleted) Replace by/Newly added

no. Designation Sheet Issue Designation Sheet Issue

1 Cover sheet Cover sheet

Issue: 2005-10-28 - MT/Hu/Erh Type: ASL 94 Revision: 2007-01-12 6955073/4 C 4 /6

Part 1 General operating and safety information........................................ 6954079/4

Part 2 Technical data ................................................................................. 6955074/4

Part 3 General description.......................................................................... 6955075/4

Part 4 Putting into service, Operation......................................................... 6955076/4

Part 5 Maintenance .................................................................................... 6955077/4

Part 6 Operational failures, Repairs ........................................................... 6955078/4

Part 7 Supply, Installation and installation check ....................................... 6955027/4

Issue: 2005-10-28 - MT/Hu/Erh Type: ASL 94 Revision: 2007-01-12 6955073/4 C 5 /6

Part 8 Main parts list .................................................................................. 6955079/4

Part 9 Additional documents ...................................................................... 6955080/4

Part 10 Drawing appendix ............................................................................ 6955081/4

Issue: 2005-10-28 - MT/Hu/Erh Type: ASL 94 Revision: 2007-01-12 6955073/4 C 6 /6

1 GENERAL OPERATING AND SAFETY INFORMATION .................................2

1.1 General operating information.......................................................................2

Issue: 1999-10-29 - MT/Hu/Erh Revision: 2006-06-06 6954079/4 C 1 /8

1 General operating and safety information

1.1 General operating information

Issue: 1999-10-29 - MT/Hu/Erh Revision: 2006-06-06 6954079/4 C 2 /8

1.2 General safety information

ALL SAFETY INSTRUCTIONS OF THIS OPERATING MANUAL SHALL HAVE TO BE

1.2.1 Symbols and explanation of notice

• Caution – Danger due to electrical current!

• Caution – Warning of Over-Pressure!

• The lube oil system has to be de-pressurised before any work

Issue: 1999-10-29 - MT/Hu/Erh Revision: 2006-06-06 6954079/4 C 3 /8

• Danger – Warning of Hot Surface!

• at all accessible housing parts,

Higher ambient temperatures also lead to increased temperatures on

• Wear safety gloves while working on the gearbox.

Wear protective gloves!

• Pay attention to manual!

Before starting the plant user's information (operating instruction)

Issue: 1999-10-29 - MT/Hu/Erh Revision: 2006-06-06 6954079/4 C 4 /8

1.2.2 Notes and explanation of notice

Issue: 1999-10-29 - MT/Hu/Erh Revision: 2006-06-06 6954079/4 C 5 /8