Operating Instruction PWS 18-E (Gearbox) SEL 12 PDF

COVER SHEET WITH TABLE OF CONTENTS
Operating Instruction
for
RENK-Marine
gear unit
PWS 18-E
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
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: 2004-04-14 - MT/Hu/Erh Type: PWS 18-E Revision: 6954890/4 1 /5

Gear unit type: PWS 18-E
Customer: MTU Friedrichshafen GmbH
Contract no.: 740799
Code: HN Hunt Class
Shipyard: Vosper Thornycroft
RENK order no.: 80119109
RENK product no.: Gear unit port 6459252

Gear unit starboard 6459253
Serial no.: see type plates
Year of manufacture of the gear unit 2004

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

language responsible
Dept./Name
First issue MTU Friedrichshafen GmbH 10x English 2004-05-28 MT/Erhard

attn. Mr. Arndt von Drathen 2x CD-rom
Maybachplatz 1
88045 Friedrichshafen
Department MT 1x English 2004-05-28 MT/Erhard

1x CD-rom
Department MS 2x English
1x CD-rom
1st amendment

Documents modified (1st amendment):
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

TABLE OF CONTENTS
Part 1 General operating and safety information........................................ 6954079/4
• General operating information
• General safety information
Part 2 Technical data ................................................................................. 6954891/4
• Gear unit main data
• Technical data hydraulic
Part 3 General description.......................................................................... 6954892/4
• Mechanic description
• Description of the hydraulic system
Part 4 Putting into service, Operation......................................................... 6954899/4
• Safety information
• Operating and display elements
• Putting into service
• Operation
• Longer stop periods
Part 5 Maintenance .................................................................................... 6954883/4
• General maintenance note
• Maintenance work
• Lubricant specification
• Routine maintenance work
Part 6 Operational failures, Repairs ........................................................... 6954893/4
• Operational failures
• Repairs
• Adjustment work
• Instrument list
Part 7 Supply, Installation and installation check ....................................... 6954894/4
• Supply
• Preservation at delivery
• Installation and installation check
• Sea-water system
Part 8 Main parts list .................................................................................. 6954895/4
• Introduction
• Mechanic parts list
• Hydraulic parts list
Part 9 Components (Subcontractors) ......................................................... 6954896/4
• Mechanic components
• Hydraulic components
• Electric components
Part 10 Drawing appendix ............................................................................ 6954897/4

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.................................................................4
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 .............................6
1.2.6 Safety data sheet .......................................................................................6
1.2.7 Remaining dangers for the user and protective measures.........................7
Issue: 1999-10-29 - MT/Hu/Erh Revision: 2003-02-04 6954079/4 a 1 /7

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.
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.

GENERAL OPERATING
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.
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.
• 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.

GENERAL OPERATING
• 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.
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.
• The oil pressure in the lubricating oil line must not fall below 0.7 bar.

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 Input PTI ....................................................................................................2
2.1.3 Hydraulic data............................................................................................2
2.2 Technical data 6815538/4 to

connection scheme ..............................................................................1 to 31

TECHNICAL DATA PART 2
2 Technical data
2.1 Gear unit main data

PWS 18-E
Design type
Port Starboard
Dimensions in mm (LxBxH) 2070x1392x2366
Weight gear unit app. 2.620 kg
Paint external colour Silver grey (RAL 7001)
2.1.1 Input diesel engine (DE)

Ratio 9.068 9.119
Input power 805 kW
Input speed 1800 rpm
Output speed 198.5 rpm 197.4 rpm
Multi-disc clutch
- max. DE speed for engagement 700-1000 rpm
Direction of rotation (see from aft)
- input ccw ccw
- output forward ccw cw
- output revers cw ccw
2.1.2 Input PTI

Ratio 15.0
Input power 125 kW
Input speed 1500 rpm
Output speed 100 rpm
Multi-disc clutch
- max. PTI speed for engagement 75-450 rpm
Direction of rotation (see from aft)
- input forward cw ccw
- output forward ccw cw
- input revers ccw cw
- output revers cw ccw
2.1.3 Hydraulic data

Oil viscosity (details see chap. 5.4) ISO VG 150/SAE 40
Oil quantity per gear unit 160 litre

Technical data
to connection scheme drawing no. 6815519/0
Oil pump
Supply Supply Suction

Item Speed
Quantity Make Type quantity pressure height Remarks
no.
[rpm] [l/min] [bar] [m]
Built-on control oil pump

R45/80
1 1 Rickmeier 2146 158 28 2,5 primary running, diesel engine
FL-K-So
Pump direction of rotation left
Built-on lube oil pump

2 1 Rickmeier R6.0/100 1525 147 8 2,5 secundary running
Pump direction of rotation changed
Lube oil pump, electrical driven

R35/50
3 1 Rickmeier 1725 85 8 2,5 Pump direction of rotation right
FL-Z-So
(double pump item 3+4)
Control oil pump, electrical driven

R25/16
4 1 Rickmeier 1725 22 28 2,5 Pump direction of rotation right
FL-Z-So
(double pump item 3+4)
Order no: 80119109

2003-06-18 / Erh / Joas Type: PWS 18-E
Product no: 6459252 - port
Page 1/31 Drawing no. 6815538/4 c 6459253 - starboard
Technical data
Electric motor
Nominal Type of
Item Power Speed Start current Type of connection
Quantity Make Type Voltage current Design code protection Insulation
no.
[kW] [rpm] [A] [A]
Flender/ ANGA 440 V

5 1 4,8 1725 55,0 8,9 IM B 3/5 IP 55 F direct
Loher 112MB 04D 60 Hz
Order no: 80119109

Technical data
Electric motor
Thermistor protection
Item Standstill heating system
Release temperature Remarks
no.
Voltage Rated power [°C]
5 230 V / 60Hz 25 W 145 Electric egine for oil pump item no. 3+4
Order no: 80119109

Technical data
Filter
Filter Mesh Flow Operating

Item delta p
Quantity Make Type surface width quantity pressure Remarks
no.
2
[cm ] [mm] [l/min] [bar] [bar]
DU 251.25G
8 1 Internormen 30.E.P.-.FS.8 2x3000 0,025 180 8 0,45 Change-over duplex oil filter
AE 80.2,5.P.-.B.M.G
Order no: 80119109

Technical data
Oil cooler (sea water design)
Water Mash width

Cooling Oil Oil temp. Operating delta p Water max. press. delta p
Item temp. for sea water
Quantity Make Type capacity flow IN / OUT oil press. oil flow water water
no. IN / OUT filter
[kW] [l/min] [°C] [bar] [bar] [m3/h] [°C] [bar] [bar] [mm]
P13-2P
10 1 Bloksma 45 180 59/50 8 0,17 10 32/36 6 0,11 max. 3
L=600
Order no: 80119109

Technical data
Pressure relief valve (main operating pressure)
Item
Quantity Make Type Remarks
no.
15 1 Rickmeier pressure valve DBV 40 consisting of 15/1 to 15/5

control valve
15/1 1 Rickmeier piloted by item 15/2
DBV 40
Main operating pressure pk=27 bar adjusted at DE nominal speed:
(DE multi-disc clutch closed, electric pump not running)
pressure relief pilote
15/2 1 Rickmeier - Oil pressure indication see pressure gauge item no. 71 (514, 515)
valve
- Operating temperature 50°C see thermometer item no. 80 (511)
Non-return valve 15/5 opening pressure 40 bar
15/3 1 Rickmeier Filter Mesh width: 0,5 mm
15/4 1 Rickmeier Throttle Bore diameter 1,5 mm
maximum pressure
15/5 1 Rickmeier for item 15/2
relief valve
Order no: 80119109

Technical data
Control block (for multi-disc clutch DE + PTI)
Item
no.
16 1 Rickmeier pressure valve DBV 40 consisting of 16/1 to 16/5 and 21

control valve
DBV 40
Reduced operating pressure pkv=4,0 bar adjusted at DE operating speed:
(DE multi-disc clutch closed, electric pump not running)
16/2 1 Rickmeier - Valve item 21 with manual emergency engaged
valve
- Oil pressure indication see pressure gauge item no. 71 (514, 515)
maximum pressure
relief valve
Order no: 80119109

Technical data
Pressure relief valve (lubricating oil pressure)
Item
no.
17 1 Rickmeier pressure valve DBV 40 consisting of 17/1 to 17/5

control valve
DBV 40
Lube oil pressure ps=5,5 bar adjusted at DE nominal speed:
- Multi-disc clutch ENGAGED (propeller running)
17/2 1 Rickmeier - Electric pump item 3+4 "OFF"
valve
- Oil pressure indication see pressure gauge item no. 70 (504)
maximum pressure
relief valve
Order no: 80119109

Technical data
Operating valve for multi-disc clutch
Nominal
Power
Item diameter Flow Pressure Voltage
Quantity Make Type Control input Remarks
no. DN medium
[mm] [bar] [VDC] [W]
4/2 - way valve Electric

Rickmeier operating valve with manual emergency hand
20 3 EWEDE-42-C-10-1 10 Control oil 0 to 35 continous 24 36
HTF operated for multi-disc clutch
24VDC-S483N current
Electric operating valve for control block item 16 with

Rickmeier/ 4/2 - way valve
21 1 6 Control oil 0 to 30 continous 24 33 manual emergency operation for switching
Bosch 0810091254
current between pk and pkv
Order no: 80119109

Technical data
Backpressure valve
Nominal Nominal pressure

Item
Quantity Make Type diameter DN PN Remarks
no.
[mm] [bar]
40 1 GESTRA RK 86 32 40 Opening pressure 0,1 bar
43 2 ZAN 15342 RHD-30S 25 400 Opening pressure 1,0 bar
45 1 HT WRVCG-06 6 350 Installed in control block
46 3 HT RV20 20 250 Installed in control block
47 2 HT RV 6 6 350 Installed in control block
Order no: 80119109

Technical data
Throttle
Item Bore diameter delta p oil Oil flow

Quantity Remarks
no.
[mm] [bar] [l/min]
50 1 1,5 28 5,5 Relief throttle for built-on control oil pump item no. 1
51 1 1,5 28 5,5 Relief throttle for electric-control oil pump item no. 4
52 1 1,5 8 3,0 Relief throttle for built-on lube oil pump item no. 2, installed in pump
53 1 1,5 8 3,0 Relief throttle for electric lube oil pump item no. 3
54 1 7,0 5 49,0 Relief throttle for suction piping filling lines, control oil pump item no. 1
55 1 6,0 25 79,0 Relief throttle, installed in operating valve 20/1
56 1 2,5 25 13,7 Relief throttle, installed in operating valve 20/3
57 1 1,4 25 4,3 Relief throttle, installed on controlblock 20
Order no: 80119109

Technical data
Connection piece
Item
Quantity Make Type Connection Remarks
no.
G 1/4
60 7 - - Pressure gauge connection
inner thread
G 1/4
61 9 - - Pressure gauge connection
inner thread
SMK 20
65 4 Stauff G 1/4 / M16 Pressure gauge connection switch screw coupling
G 1/4-PC
66 2 Ermeto EMA3 G1/4 G 1/4 / M16 Pressure gauge connection switch screw coupling
67 2 SIKA 179.207.120 G 1/2 Thermometer connection with protective sleeve
Order no: 80119109

Technical data
Pressure gauge
Casing Indicating Normal range Alarm range

Item Thread
Quantity Make Type diameter range (green) (red) Remarks
no. connection
[mm] [bar] [bar] [bar]
0 - 0,6
Lube oil pressure upstream of the duplex oil filter
0,6 - 7,0
(connection no. 501)
7,0 - 10
70 1 Wika 213.40 63 G 1/4 0 to 10
0 - 0,6
Lube oil pressure at gear unit inlet
0,6 - 6,0
6,0 - 10
0 - 24 Control oil pressure multi-disc clutch at gear unit inlet,

24 - 29 Main propulsion
29 - 40 (connection no. 508)
Control oil pressure multi-disc clutch at operating indication, DE
0 - 24
drive
24 - 29
Main propulsion, equal rotating
29 - 40
71 1 Wika 213.40 63 G 1/4 0 to 40
Control oil pressure multi-disc clutch at operating indication, DE
0 - 24
drive
24 - 29
Main propulsion, contra rotating
29 - 40
Control oil pressure multi-disc clutch at operating indication, PTI
0 - 24
drive
24 - 29
Main propulsion
29 - 40
Order no: 80119109

Technical data
Thermometer
Casing Indicating Normal range Alarm range Sensor

Item Thread
Quantity Make Type diameter range (green) (red) length Remarks
no. connection
[mm] [° C] [° C] [° C] [mm]
0 to 10
Lube oil temperature upstream oil cooler
10 to 70 70
70 to 100
210-NR-
80 1 SIKA 63 G 1/2 0 to 100
21001
0 to 10
Lube oil temperature at gear unit inlet
10 to 58 70
58 to 100
Order no: 80119109

Technical data
Pressure switch
Permiss.
Setting
Item Voltage switch Switch point
Quantity Make Type range Contact type Remarks
no. capacity
[bar] [VDC] [A] [bar]
Operating indication main propulsion, equal rotating
MBC 5100- 21
90 1 Danfoss 5 to 30 24 2 Change-over ENGAGED
3421-2DB04 increasing
Multi-disc clutch DE drive
Operating indication main propulsion, contra rotating
MBC 5100- 21
91 1 Danfoss 5 to 30 24 2 Change-over ENGAGED
Multi-disc clutch DE drive
MBC 5100- 21 Operating indication main propulsion, ENGAGED
92 1 Danfoss 5 to 30 24 2 Change-over
3421-2DB04 increasing Multi-disc clutch PTI drive
MBC 5100- 15
93 1 Danfoss 5 to 30 24 2 Change-over Valve item 21 locked
Internorme
94 1 AE80.2,5.P.B - 24 1 Change-over 2,5 Differential pressure installed at the oil duplex filter item no. 8
n
MBC 5100- 15
95 1 Danfoss 5 to 30 24 2 Change-over STOP electric douple pump item no. 3+4
MBC 5100- 15
96 1 Danfoss 5 to 30 24 2 Change-over START electric douple pump item no. 3+4
3421-2DB04 decreasing
MBC 5100- 0,4 Lube oil pressure at gear unit inlet

97 1 Danfoss -0,2 to 4 24 2 Change-over
1211-2DB04 decreasing - for disengaging MDC and emergency engine stop
MBC 5100- 22 Control oil pressure at gear unit inlet

98 1 Danfoss 5 to 30 24 2 Change-over
3421-2DB04 decreasing - for disengaging multi-disc clutch (MDC)
Order no: 80119109

Technical data
Pressure transmitter
Pressure Supply Output

Item Alarm point
Quantity Make Type range voltage signal Remarks
no.
[bar] [VDC] [mA] [bar]
MBS 5150- as per Lube oil pressure at gear unit inlet

100 2 Danfoss 0 to 10 12 to 34 4 to 20
2011-2 DB04 diagram - for alarm and indication (as per lubricating oil pressure diagram)
MBS 5150- 24 Control oil pressure at gear unit inlet

103 2 Danfoss 0 to 40 12 to 34 4 to 20
2611-2 DB04 decreasing - for alarm and indication
Order no: 80119109

Technical data
Resistance thermometer
Measuring Measuring Sensor Switch

Item Thread
Quantity Make Type element range length point * Remarks
no. connection
Ohm / 0°C [° C] [mm] [° C]
MBT 58 Lube oil temperature at gear unit inlet

110 2 Danfoss 1x PT1000 0 to 100 120 G 1/2 A
5250 increasing - for indication and alarm
Order no: 80119109

Technical data
Inductive proximity switch
Load
Item Voltage range Switch distance
Quantity Make Type current Remarks
no.
[VDC] [mA] [mm]
BES 516-300-
Installed in control valve item no. 20/1
115 1 Balluff S290-BO-D-PU05 10 to 30 200 0 to 1,1
DE input/output - contra rotating ENGAGED
(NPN-model)
BES 516-300-
116 1 Balluff S290-BO-D-PU05 10 to 30 200 0 to 1,1 Installed in control valve item no. 20/1
(NPN-model)
BES 516-300-
DE input/output - equal rotating ENGAGED
(NPN-model)
BES 516-300- Installed in control valve item no. 20/2

118 1 Balluff S290-BO-D-PU05 10 to 30 200 0 to 1,1 Start release DE
(NPN-model) DE multi-disc clutch, equal and contra rotating DISENGAGED
BES 516-300-
PTI drive DISENGAGED
(NPN-model)
BES 516-300- Installed in control valve item no. 20/3

120 1 Balluff S290-BO-D-PU05 10 to 30 200 0 to 1,1 PTI drive ENGAGED
(NPN-model) (Valve item no. 20/1 and 20/2 DISENGAGED)
Niveau sensor
125 1 BEDIA PLCA-50 (NPN) 24 8 - installed in tank item no. 170
Low oil level alarm
Order no: 80119109

Technical data
Speed transmitter
Item OUTLET Type of current

no.
System 1 System 2 [VDC]
Speed and sense of rotation at max. propeller speed

Rectangle Rectangle n = 198 rpm
130 2 Deuta DF 22 24
U-B-3V U-B-3V Transmitter wheel z = 54 ; Frequenc max. = 557,7 Hz
Processing for sense of rotation identification
Order no: 80119109

Technical data
Time-delay relay
Permissible
Item Type of Voltage
Quantity Make Type switch capacity Remarks
no. contact
[A] [VDC]
connection DE + PTI Multi-disc clutch for main propulsion

135 1 Kleemann Z-Rel 1 W/4-RT 10 24
wiping Operating time for valve item no. 21 adjusted to: 10 sec.
EMG 17-REL/ Double-

136 10 Phöenix KSR 24/21-21- Change- 8 24
LC over
Order no: 80119109

Technical data
Starter for electric motor
Control
Item Operating
Quantity Make Type voltage Remarks
no. voltage
[VDC]
not RENK 440 V

140 1 - 24 - for electric motor douple oil pump item no. 3+4
supply 60 Hz
Order no: 80119109

Technical data
Tripping unit for thermistor motor protection
Response
Item Voltage
Quantity Make Type temperature Remarks
no.
[°C] [W]
145 1 145 for electric motor item no. 5
Order no: 80119109

Technical data
Compensator
Item Connection flange

no. DIN 2501
AFN 06
160 1 Witzenmann DN 200 - PN 6 oil drain gearbox to tank item no. 170
.0200.040.0
AFN06
161 1 Witzenmann DN 50 - PN 6 suction connection, pump item no. 1
.0050.020.0
AFN06
162 1 Witzenmann DN 50 - PN 6 suction connection, pump item no. 2
.0050.020.0
AFN06
163 1 Witzenmann DN 50 - PN 6 suction connection, electric pump item no. 3 and 4
.0050.020.0
AFN06
164 1 Witzenmann DN 40 - PN 6 ventilation connection tank item no. 170, to gearbox
.0040.016.0
Order no: 80119109

Technical data
Tank
Item Contents
no. m3
170 1 RENK 0,1 Lube oil bottom tank for gear
Order no: 80119109

Technical data
900 figures and customer´s connections (to be rooted by Yard) oil connections
Item
Quantity Connection size Remarks
no.
901 1 G1 1/4 with screw plug Tank oil drain and flushing sution connection
902 1 M42x1,5 Gear oil filling
903 1 G1" with screw plug Flushing connection for workshop test
Blind flange DIN 2527
904 1 Oil drain connection gearbox to tank item no.170
B 200 - PN6
905 1 Oil drain connection tank item no.170 to gearbox
B 200 - PN6
906 1 Suction connection, pump item no.1, to tank
B 50 - PN16
907 1 Suction connection, tank item no.170, for pump item no.1
B 50 - PN16
908 1 Suction connection, pump item no.2, to tank
B 50 - PN16
909 1 Suction connection, tank item no.170, for pump item no.2
B 50 - PN16
910 1 Suction connection, electric-pump item no.3 and 4, to tank
B 50 - PN16
911 1 Suction connection, tank item no.170, for electric-pump item no.3 and 4
B 50 - PN16
Order no: 80119109

Technical data
900 figures and customer´s connections (to be rooted by Yard) air connection
Item
no.
920 1 M42 x 1,5 Ventilation to gear

921 1 Ventilation connection gearbox to tank item no.170
B 40 - PN 16
922 1 Ventilation connection tank item no.170 to gearbox
B 40 - PN 16
Order no: 80119109

Technical data
900 figures and customer´s connections (to be rooted by Yard) seawater connections
Item
no.
DIN 2501 Oil cooler item no. 10 water inlet

925 1
DN50 - PN 16
DIN 2501
926 1 Oil cooler item no. 10 water outlet
DN50 - PN 16
Order no: 80119109

Technical data
900 figures and customer´s connections (to be rooted by Yard) electrical connections
Item
no.
930-935 1 according to yard standard Control of operating valves item 20/1, 20/2 and 20/3, with continuous courrent (24 VDC)
936 1 according to yard standard Main connection 24 VDC
937 1 according to yard standard Main connection at the starterbox item 140 (440 V, 60Hz)
938 1 according to yard standard Connection starterbox item 140 to E-motor item 5 ( electric pump)
939 1 according to yard standard Connection termistor motor protection to tripping unit item 145 ( electric pump)
940 1 according to yard standard Niveau sensor 125,installed in tank 170, to gear terminalbox
Order no: 80119109

DE-range
Data:
PTI-range
6,0 6,0
2003-06-18
LP oil pressure
5,5 DE mp 5,5
g adjusted
at in range uilt-on pu ed
b
Name:
ag
oper p + prim.
m h diseng
tc
idling speed
Erhard
E-pu -disc clu
5,0 lti 5,0
at m u
ed
Check:
p g ag 4,3
d E um ) en
ge
Joas
4,0 p a g e D on p DC
4,0
m ng an ilt- (M
TI n p u C) e t in g r . bu tch
m lu
P -o D era pri c c Alarm
nge built h (M op c. + i-dis 3,5 transmitter no. 100
ra c. lutc se mult
p bar
monitoring curve
at ing + se c c at
Drawing-no.:
er p dis
op pum ulti-
3,0 E- I m 3,0
PT
operating range
6815538/4
E-pump
2,0 2,0
Index:
c
Lubricating oil pressure diagram
PTI controll range for see description

1,0 engagement MDC 1,0
start-up, prop. at Start-Stop for E-pump
stand-still
Page:
0,6 PTI-DE controll range for engagement
MDC-change-over Stop diesel engine
0,4 0,4 or PTI
Type:
pressostat no. 97
DE controll range for engaged MDC
0
Order no.:
29/31
nprop. 5 30 50 66 77 100 110 154 198 n (rpm)
80119109
PWS 18-E
nDE 600 700 909 1000 1400 1800

nPTI 75 450 750 990 1500
Type:
Description of PWS 18-E
Order no.:
„START-STOP control“ 80119109
Description of „START-STOP control“

for electric pump
further to lube oil pressure diagram
1. Normal operation - Diesel engine
1.1 Start-up of the plant: prelubrication of the gear unit by electric pump
at standstill of the gear unit
1.2 The start of the electric pump is controlled

- by a signal of the pressure switch (control oil pressure) item 96,
„DE multi-disc clutch input disengaged“
1.3 The stop of the electric pump is controlled

- by a signal of the pressure switch (control oil pressure) item 95,
„DE multi-disc clutch input engaged“
1.4 Stop of electric pump only if complete gear plant is at standstill (speed 0 rmp)
2. Normal operation - PTI
2.1 Start-up of the plant: prelubrication of the gear unit by electric pump
at standstill of the gear unit
2.2 Attention!
Electric pump must always run at PTI-operation
2.3 Stop of electric pump only if complete gear plant is at standstill (speed 0 rmp)
Data: Name: Check: Drawing-no.: Index: Page:

2003-06-18 Erhard Joas 6815538/4 c 30/31
Technical data
Modifications
Date Index Page Item no. Description
2003-09-04 A 11 55,56 item added
15 97;98 item added
16 100,103 quantity corrected (1in 2)
16 101,104 item deleted
17 110 quantity corrected (1in 2)
19 130 quantity corrected (1in 2)
20 136 item added
23 160 connection DN 150 into DN 200 corrected
29 curve STOP diesel engine or PTI 3,0bar into 0,4 bar corrected
2004-04-07 B 11 54 Bore diameter 10,0 into 7,0; Oil flow 102 into 49
11 57 Item added
2004-04-20 C 8 17/2 ps=5,0 bar into ps=5,5 bar
11 55 Bore diameter 5,0 into 6,0; Oil flow 48,0 into 79,0;
6 15/2 indication see pressure gauge item no. 71 (508) into 71 (514,515)
29 LP oil pressure adjusted 5,0 into 5,5 bar
Order no: 80119109

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 General.............................................................................................3
3.1.3.2 Casing ..............................................................................................3
3.1.3.3 Gear stages ......................................................................................3
3.1.3.4 PTI gear stage ..................................................................................4
3.1.3.5 Bearings ...........................................................................................4
3.1.3.6 Multi-disc clutches (MDC) planetary gear .........................................4
3.1.3.7 Multi-disc clutch (MDC) PTI ..............................................................5
3.2 Hydraulic Description ....................................................................................5
3.2.1 General ....................................................................................................5
3.2.1.1 Primary built-on control oil pump ......................................................5
3.2.1.2 Secondary built-on lube oil pump .....................................................6
3.2.1.3 Electric lube and control oil pump (double pump).............................6
3.2.1.4 Duplex oil filter ..................................................................................6
3.2.1.5 Oil cooler ..........................................................................................7
3.2.1.6 Gear unit oil pressure regulation.......................................................7
3.2.1.7 Control block for multi-disc clutches .................................................7
3.2.2 Monitoring and control system .................................................................8
3.2.2.1 Remote monitoring display ...............................................................8
3.2.2.2 Local monitoring instruments............................................................9

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 (DE) with speed
reduction to the propeller shaft;
• Transmission of the input power supplied by PTI 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;
fig. 1 – top view gear unit
3 7
output 1
input
shaft DE
Input
PTI
4 5

3.1.2 Main groups gear unit

Each gear unit comprise the following main components (see fig. 1):
• Reduction gear unit PWS 18-E with integrated multi-disc clutches 1
• Built-on control oil pump, primary running 2
• Built-on lube oil pump, secondary running 3
• Electric lube oil pump 4
• Electric control oil pump 5
• Oil cooler (sea water) for lube oil 6
• Change over duplex oil filter 7
3.1.3 Gear unit description

Note: All mechanical parts and components are depicted in the assembly drawings
identified by item nos. (see part 10).
3.1.3.1 General
The gear unit concerned is an input gear stage with single helical tooth design and a
double planetary gear unit with straight teeth with integrated multi-disc clutches. The input
speed is reduced via the toothings of the input gear stage and the planet stages to the
output flange. The input shaft is vertical offset above the output shaft and they are coaxial
arrange. The PTI input is vertical and horizontal offset above output shaft (details see
installation drawing part 10).
3.1.3.2 Casing
The casing is of cast aluminium as used for navy gear unit and of vibration-resistant
design. The casing bottom part is designed as an oil collecting tank. The gear has a
separate tank additional arranged in the base frame area.
3.1.3.3 Gear stages

1. Description input gear stage
Via the input pinion (item 2050) the diesel engine power is transmitted to the spur gear
(item 2100). The gears are of CrNiMo-steel and are case-hardened. The teeth of the
pinion and wheel are of single helical design.
2. Description p-stage
Via the sun pinion (item 2211) and the 6 planets (item 2308) the diesel engine power is
transmitted to the output flange shaft. At input DE the annulus (item 2520) is held by the
integrated multi-disc clutch. The DE power is transmitted via the planetary carrier (item
2251) to the output shaft. When the multi-disc clutch is opened, all inner parts are rotating
while the output flange shaft is at a standstill. The input and output shaft are equal-rotating.

3. Description z-stage
Via the sun pinion (item 2210) and the 5 planets (item 2308) the diesel engine power is
transmitted to the output flange shaft. At input DE the planetary carrier (item 2330) is held
by the integrated multi-disc clutch. The DE power is transmitted via the annulus (item
2340) to the output shaft. When the multi-disc clutch is opened, all inner parts are rotating
while the output flange shaft is at a standstill. The input and output shaft are contra-
rotating.
3.1.3.4 PTI gear stage

Via the pinion (item 4010), the spur gear (item 4212), the engaged multi-disc clutch, the
pinion (item 4201), the spur gear (item 4301) and the annulus (item 2340) the PTI power is
transmitted to the output shaft. During PTI operation the multi-disc clutches of the
planetary stages are disengaged, hence the planetary stages are uncoupled.
All spur gear stages feature single helical teeth.
3.1.3.5 Bearings
All shafts and gear wheels are accommodated in large sized antifriction bearings, which
are all lubricated by pressurized oil.
3.1.3.6 Multi-disc clutches (MDC) planetary gear

Description p-stage:
The inner disc carrier (item 2601) is connected with the annulus (item 2520). The outer
disc carrier (item 2630) is connected with the casing.
Description z-stage:
The inner disc carrier (item 2333) is connected with the planet carrier (item 2330). The
outer disc carrier (item 2430) is above the cylindrical flange (item 2401) connected with the
casing.
The multi-disc clutch (MDC) has the following tasks:
- to connection the DE to the propeller shaft during ahead and astern operation
- to interrupt the connection to the DE while PTI operation
- to interrupt the connection between DE and propeller shaft while the DE is running
and the propeller shaft is stopped
The multi-disc clutch is operated by pressurised oil and controlled by the pressure -
accumulating valve (15, 16), the 4/2-way valve (20), (see part 10 - connection scheme
6815519/0).

3.1.3.7 Multi-disc clutch (MDC) PTI

The outer disc carrier is flanged at the spur gear (item 4212) and driven by the pinion shaft
(item 4010). With engaged multi-disc clutch (MDC, item 4213) the inner disc carrier is
connected with the pinion shaft (item 4201) of the intermediate stage.
The multi-disc clutch has the following tasks:
- to interrupt the connection to the PTI while DE operation
- to connection the PTI to the propeller shaft during operation
The multi-disc clutch is operated by pressurised oil and controlled by the pressure -
accumulating valve (15, 16), the 4/2-way valve (20), (see part 10 - connection scheme
6815519/0).
3.2 Hydraulic Description
3.2.1 General
Note: The oil system is depicted in the connection schemes 6815519/0.
Item nos. with asterisks (*) identify such parts which are not part of the RENK
scope of supply.
Different identification marks refer to such component groups which are built-
on the gear unit and others which are separately mounted and have to be
connected by the yard.
Hydraulic-components are depicted in the piping scheme see part 10.
Depending on the relevant operating condition, the lube oil is supplied by:
- Built-on lube oil pump (2), secondary running
- Electric lube oil pump (3) = double pump (3+4)
The control oil for engagement of the multi-disc clutches is supplied by:
- Built-on control oil pump (1), primary running
- Electric control oil pump (4) = double pump (3+4)
ATTENTION: Before each start the gear unit system has to be prelubricated
by way of the electric double pump (3+4)!
Not even for test purposes it is admissible to start without the
electric double pump (3+4).
3.2.1.1 Primary built-on control oil pump

The primary built-on control oil pump (1) which is driven by a spur gear stage (item 2100
and 4501) is flanged to the gear unit casing at the DE 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!

3.2.1.2 Secondary built-on lube oil pump

The secondary built-on lube oil pump (2) which is driven by a spur gear stage (item 4306
and 4501) is flanged to the gear unit casing at the output side. Under normal DE operation,
this pump and the built-on control oil pump (1) supports the lube oil supply to the gear unit.

3.2.1.3 Electric lube and control oil pump (double pump)

The double pumps (3+4) are mounted on the gear unit.
The electric driven double pump (3+4) supplies lube and control oil to the gear unit during
PTI operation and while the start and engaged DE operation (see part 2 - pressure
diagram).
The electric driven double pump (3+4) is driven by electric motor (5) controlled as a
function of pressure (pressure switch 95+96). The electric motor (5) is controlled
automatically by means of starter (140, not RENK supply).

3.2.1.4 Duplex oil filter

The duplex oil filter (8) is fitted on the top of the gear. Before the lube oil enters the gear
unit solid matters and metallic abrasion is retained by the duplex filter. Only one of the filter
halves is operating. Once the filter element is soiled, the lube 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 signal that the filter
element needs to be changed.


3.2.1.5 Oil cooler

The tube oil cooler (10) is fitted on the top of the gear.
Upon putting into operation of the gear unit plant, seawater (925) is supplied through the
oil cooler. In the oil cooler (10) the power loss which is absorbed by the gear unit is
transmitted to the cooling medium seawater.
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 Gear unit oil pressure regulation

Thanks to the pressure relief valve (17) the lube oil system is protected against excessive
oil pressure. The draining oil is led back into the casing. The pertinent valve is installed in
the pipeline upstream of the duplex oil filter (8).
Pressure regulation is ensured by an adjusting spindle.

3.2.1.7 Control block for multi-disc clutches

The multi-disc clutches are connected or disconnected via a 4/2-way valves (20) mounted
on the top side of the control block (item 7070). The valves must be actuated by
continuous current.
When connecting the multi-disc clutches (MDC), the pressure valves (15, 16) leads to a 2-
step increase of the control oil pressure with the result that no excessive torque is yielded
by the diesel engine and the PTI speeds does not drop inadmissible.
For a possible emergency actuation (current failure) manual engagement with 2-step
pressure increase is possible at 4/2-way valves (20) or pressure valves (15, 16). In case of
current failure the valves remains in the momentary position.
The multi-disc clutches may only be connected with running diesel engine or PTI (see
technical data, part 2). Further connection conditions see part 4!


3.2.2 Monitoring and control system

A series of switches and sensors for the alarm signals and indication instruments data is
passed to the control system of the ship.
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 (part 2), in the Connection scheme and in the Piping
scheme (part 10) and as well as in part 9!
3.2.2.1 Remote monitoring display

- Local monitoring by a light-emitting diode at the duplex oil filter (8);
- Pressure switches (90-92) are used to indicate the operation of the multi-disc
clutches (ENGAGED and DISENGAGED);
- Differential pressure switch (94) installed in duplex oil filter (8);
- Pressure switches (95+96) are used to START and STOP the electric double
pump (3+4);
- Pressure switch (97) is used to indicate lube oil pressure gear unit inlet for
disengaging MDC and emergency DE stop;
- Pressure switch (98) is used to indicate control oil pressure gear unit inlet for
disengaging MDC;
- Several pressure transmitter (100, 103) are used to indicate lube oil pressure and
control oil pressure for alarm and indication;
- Resistance thermometer (110) is used to indicate lube oil temperature for alarm and
indication;
- Several inductive proximity switches (115 - 117) are used to indicate for MDC diesel
engine “ENGAGED or DISENGAGED”;
- Inductive proximity switch (118) is used to indicate the start release for
diesel engine;
- Several inductive proximity switches (119 - 120) are used to indicate for MDC PTI
drive “ENGAGED or DISENGAGED”;
- Inductive proximity switch (125) installed in the tank is used to indicate low oil level
alarm;
- Speed transmitter (130) is used to indicate output shaft speed;

3.2.2.2 Local monitoring instruments

On delivery of the gear unit no instruments are connected. They are supplied separately
packed in a box (see chap. 6.5). The instruments may be connected to the corresponding
connection by means of a screwed coupling.
For local monitoring purposes of the oil temperature and oil pressure the following
instruments can be connected:
- pressure gauge 70
lube oil pressure upstream of duplex filter → connection no. 501
- pressure gauge 70
lube oil pressure gear unit INLET → connection no. 504
- pressure gauge 71
control oil pressure MDC at gear unit INLET – main propulsion
→ connection no. 508
- pressure gauge 71
control oil pressure MDC at operating indication DE drive -
main propulsion equal rotating
- pressure gauge 71
control oil pressure MDC at operating indication DE drive -
main propulsion contra rotating
- pressure gauge 71
control oil pressure MDC at operating indication PTI drive -
main propulsion

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

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

4.2 Operating and local instruments....................................................................3
4.2.1 Gear unit operating instruments ..............................................................3
4.2.2 Local monitoring instruments...................................................................3
4.3 Putting into service ........................................................................................4
4.3.1 Preparation..............................................................................................4
4.3.2 Initial operation ........................................................................................4
4.3.3 After putting into service..........................................................................5
4.4 Operation ......................................................................................................6
4.4.1 Diesel Engine operation ..........................................................................6
1. Normal operation ..............................................................................6
2. Local operation .................................................................................6
3. Emergency operation .......................................................................6
4.4.2 Stop of Diesel Engine..............................................................................8
4.4.3 Test of Diesel Engine ..............................................................................8
4.4.4 Propeller Trailing operation .....................................................................8
4.4.5 PTI operation...........................................................................................9
1. Normal operation ..............................................................................9
2. Local operation .................................................................................9
3. Emergency operation .......................................................................9
4.5 Alarm measures ..........................................................................................11
4.5.1 Lube oil pressure...................................................................................11
4.5.2 Lube oil temperature .............................................................................11
4.5.3 Control oil pressure ...............................................................................11
4.5.4 Differential pressure lube oil filter ..........................................................11
4.5.5 Oil level .................................................................................................12
4.6 Longer stop periods gear unit......................................................................12
4.6.1 General .................................................................................................12
4.6.2 Procedures at the oil cooler...................................................................12
Issue: 2004-01-22 - MT/Hu/Erh Type: PWS 18-E Revision: 2004-04-13 6954899/4 a 1/12
OPERATING 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!
OPERATING PART 4
4.2 Operating and local instruments
Note:
• Items nos. with up to 3 digits refers to the technical data and the connection
scheme.
• The item nos. with 4 numbers refers to assembly drawing.
4.2.1 Gear unit operating instruments

- Manual emergency actuation on 4/2-way valves (20) for multi-disc clutches
- Manual emergency actuation on 4/2-way valve (21) for pressure control block (15)
- Operating lever (change over lever) for duplex oil filter (8)
4.2.2 Local monitoring instruments
Note: The instruments are supplied separately packed in a box. For local monitoring
purposes of the oil temperature and oil pressure the following instruments can
be connected.
- Pressure gauge 70
• Lube oil pressure upstream of duplex filter → connection no. 501
• Lube oil pressure at gear unit INLET → connection no. 504
- Pressure gauge 71
• Control oil pressure multi-disc clutch gear unit inlet – main propulsion
• Control oil pressure multi-disc clutch at operating indication –
DE drive equal rotating
• Control oil pressure multi-disc clutch at operating indication –
DE drive contra rotating
• Control oil pressure multi-disc clutch at operating indication – PTI drive
- Thermometer 80
• Lube oil temperature upstream of oil cooler → connection no. 510
• Lube oil temperature gear unit INLET → connection no. 511
OPERATING PART 4
4.3 Putting into service
Note: Consider chap. 4.1!
4.3.1 Preparation
Before starting the plant, the gear unit must be checked for correct filling level.
Then the entire oil system must be cleaned by flushing.
Note: For the flushing the original oil shall be used.

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.
Furthermore it is recommended to check the oil for water contamination and the oil
purifying, if necessary.
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.
lf the water content exceeds 0,2% the oil must be separated.
4.3.1.1 Seawater cooling system

• if a continuous ventilation is not provided by a by-pass pipe, the cooler (10) must
be de-aerated during first start of the plant with the special plugs;
• 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;
4.3.2 Initial 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 engine and PTI, the engagement characteristic of the multi-
disc clutches must be recorded by oscillograph or equivalent instrumentation. At least the
following signals have to be recorded:
• Diesel engine speed
• PTI speed
• Propeller speed
• clutch control oil pressure (before multi-disc clutches)
OPERATING PART 4
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. 3 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.
The following load stages are recommended:
Minimum operating Load stages DE and PTI

time (min)
60 at 1/3 load
120 at 2/3 load
240 at full load
Note: The load must be increased gradually within each load stage. RENK
recommend increasing the load in steps of 20 rpm of the propeller speed.
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.
Check of tooth contact is possible with an endoscope via the respective inspection hole
(see chap. 5.5.5).
4.3.3 After putting into service

• After putting the ship into normal service it is recommended to check the anodes
of the oil cooler (10) 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;
OPERATING PART 4
4.4 Operation
Note: Consider chap. 4.1!

ATTENTION: For operation with the DE or PTI and engaged MDC the
propeller shaft must be connected. Operation with not connected
propeller shaft (which means completely unloaded gear) is not
permitted.
4.4.1 Diesel Engine operation

To start the diesel engine the following requirements must be met:
- Monitoring system activated
- Start electric driven pump (3+4)
- After a delay of 15 sec. check lube oil and control oil pressure at the pressure
transducer (100, 103). If alarm signal and/or emergency stop signal at the pressure
transducer (100, 103), check the plant
- Multi-disc clutches are “DISENGAGED” position
⇒ Remote indication via inductive proximity switch (118)
- Start diesel engine
- Connection of multi-disc clutch in “ENGAGED” position
(control valve 20/1 resp. 20/2)
⇒ max. speed of DE during engagement n = 700 - 1000 rpm
1. Normal operation
♦ electric control of valves (=energizing of the control valves) from the ship
control system;
2. Local operation
♦ electric control of valves (=energizing of the control valves) from the DE-LOP
(not by RENK);
3. Emergency operation
♦ manual actuation of valves on the gear unit in case of failure of the current
supply;
♦ in this case the valves must not be shifted explicitly into de-energized
condition, as no control from the vessel’s control system or from the DE-LOP
place;
♦ the manual shifting sequence is shown on the signs (see sign 1 – DE port
and sign 2 – DE starboard, sheet 7/12)at site;
ATTENTION: Here is no system shifting logic! The engaging conditions at site
must be observed! Wrong operation may cause damage!
- Multi-disc clutch in position “ENGAGED”
⇒ Remote indication via pressure switch (90, 91) and inductive proximity
switch (115 - 117)
- After a delay of 15 sec. check control oil pressure at the pressure transducer
(103/1). If alarm signal and/or emergency stop signal at the pressure switch (98),
open multi-disc clutch and stop DE. Check the plant.
OPERATING PART 4
sign 1 – DE port
sign 2 – DE starboard
OPERATING PART 4
4.4.2 Stop of Diesel Engine

To stop the diesel engine the following requirements must be met:
- Multi-disc clutch must be switched in position “DISENGAGED”
⇒ Signal via inductive proximity switch (118)
• continuous current 24 VDC (connection 930-935)
- Stop diesel engine!
4.4.3 Test of Diesel Engine

Diesel engine can be tested if the multi-disc clutch is disengaged and the following
indications are available:
- No alarm signal present
- Multi-disc clutches in position “DISENGAGED”;
4.4.4 Propeller Trailing operation

To trailing operation the following requirements must be met:
- Multi-disc clutches in position “DISENGAGED”;
OPERATING PART 4
4.4.5 PTI operation

To start the PTI the following requirements must be met:
- After a delay of 15 sec. check lube oil and control oil pressure at the pressure
transducer (100, 103). If alarm signal and/or emergency stop signal at the pressure
transducer (100, 103), check the plant
- Multi-disc clutch PTI-stage is “DISENGAGED” position
- Multi-disc clutches equal and contra rotating stage is “DISENGAGED” position
- Start PTI
- Connection of multi-disc clutch in “ENGAGED” position (control valve 20/3)
⇒ max. speed of PTI during engagement n = 75 to 450 rpm
1. Normal operation
♦ electric control of valves (= energizing of the control valves) from the ship
control system
2. Local operation
♦ electric control of the valves (= energizing of the control valves) from the
gear unit;
♦ first bring local PTI clutch switch to position "disengaged" and then bring PTI
selector switch (see fig. 1) from "REMOTE" to "LOCAL" position;
ATTENTION: By shifting over the selector switch the selected solenoid is
energized immediately, therefore please check and adjust
shifting position in advance!
♦ PTI clutch can be shifted on the switch (see fig. 1) of the PTI clutch in
"ENGAGED" or “DISENGAGED” position;
ATTENTION: Here is no system shifting logic! The engaging conditions must
be observed at site! Wrong operation may cause damage!
3. Emergency operation
♦ manual actuation of valves on the gear unit in case of failure of the current
supply;
♦ in this case the valves must not be shifted explicitly into de-energized
condition, as no control from the ship control system or from the local switch
takes place;
♦ the manual shifting sequence is shown on the signs (see sign 3) at site;
ATTENTION: Here is no system shifting logic! The engaging conditions at site
must be observed! Wrong operation may cause damage!
- Multi-disc clutch in position “ENGAGED”

⇒ Remote indication via pressure switch (92) and inductive proximity switch (120)
OPERATING PART 4
- After a delay of 15 sec. check control oil pressure at the pressure transducer
(103/2). If alarm signal and/or emergency stop signal at the pressure switch (98),
open multi-disc clutch and stop PTI. Check the plant.
sign 3 - PTI
Multi-Disc Clutch Manual Emergency Operation
fig. 1
view from aft
OPERATING PART 4
4.5 Alarm measures
4.5.1 Lube oil pressure – see Technical Data (lubricating oil pressure diagram)
Alarm Pressure transducer (100/1, 100/2)
Reduce load to idling operation as soon as alarm curve
has been attained. Check the plant.
Emergency stop Pressure switch (97)
When achieving the emergency stop curve, open multi-
disc clutch with 5 seconds delay and stop DE or PTI.
Overpressure Check the plant as soon as 7 bar are exceeded
4.5.2 Lube oil temperature

Alarm Resistance thermometer (110/1, 110/2
When achieving the alarm value check the plant.
Alarm value + 5°C Load reduction to idling operation.
Alarm value + 10°C Initiate emergency stop.
Under temperature Start diesel engine is not allowed before the oil
temperature is higher than 10°C.
Attention: The temperature is not controlled by RENK.
4.5.3 Control oil pressure

Alarm Pressure transducer (103/1, 103/2)
When achieving the alarm value, reduce load to idling
and check the plant.
Emergency stop Pressure switch (98)
When achieving the emergency stop curve open multi-
disc clutch.
4.5.4 Differential pressure lube oil filter

Alarm When triggering the differential pressure alarm (pressure
switch 94), the duplex filter must be immediately changed
over to another filter pot and the contaminated filter insert
must be cleaned.
OPERATING PART 4
4.5.5 Oil level

Alarm Inductive proximity switch (125)
If the oil level under the min. marking drops, the alarm is
triggered (delay app. 60 sec.). The plant has to be
stopped. The oil level as well as the plant must be
checked.
Continuation of operation only after refilling of oil until the
level of the dip stick is reached.
4.6 Longer stop periods gear unit
4.6.1 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 for at least 30 min. electric driven
pump (3+4);
• the multi-disc clutches has to be operated with local manual emergency;
ATTENTION: Only at standstill propeller shaft!
Note: These procedures have to be repeated monthly!
4.6.2 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 instruments on the gear unit ...........................................................3
5.3 Maintenance work .........................................................................................4
5.3.1 Timetable for routine maintenance work ..................................................4
5.3.2 Maintenance points ..................................................................................6
5.4 Lubricants......................................................................................................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 Check or change anode of oil cooler......................................................10
5.5.4 Clean filter at pressure valves (15, 16 and 17).......................................11
5.5.5 Inspection of toothing .............................................................................12
5.5.6 Oil level check and oil filling ...................................................................14
5.5.7 Initial oil change .....................................................................................15
5.5.8 Oil analysis.............................................................................................15
5.5.9 Oil change ..............................................................................................15
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 instruments on the gear unit

The following values can be read at the measuring instruments (see chap. 6.5) of the
reduction gear and be compared with the theoretical values (see tech. data chap. 2.2). To
this effect, the pipe union must be disconnected form the corresponding connection
(connection no. see piping scheme and number at gear unit) and screwed the local
instrument to be checked. Optionally the following values can be read at the indication
instruments:
- Pressure gauge (70)
• Lube oil pressure upstream the duplex oil filter (8) – connection no. 501
• Lube oil pressure at gear unit INLET – connection no. 504
- Pressure gauge (71)
• Control oil pressure multi-disc clutch at gear unit INLET
main propulsion – connection no. 508
• Control oil pressure multi-disc clutch “DE drive”
main propulsion equal rotating – connection no. 515
• Control oil pressure multi-disc clutch at operating indication “DE drive”
main propulsion contra rotating – connection no. 514
• Control oil pressure multi-disc clutch at operating indication “PTI drive”
main propulsion – connection no. 516
- Thermometer (80)
• Lube oil temperature upstream oil cooler - connection no. 510
• Lube oil temperature for gear unit INLET - connection no. 511
MAINTENANCE PART 5
5.3 Maintenance work
5.3.1 Timetable for routine maintenance work
Note: Instrument nos. up to 2 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 Oil lines and water Visual check pipes and flanges for leaks
connections Visual check for condition
2 Electric cables Visual check for leaks
3 Seals on input DE and
output shaft Visual check the light-emitting 500 hours
4 Duplex oil filter (8) (LED see chap. 5.5.2) or
Note: If the light-emitting diode (LED) 30 days
light up red, the filter must be switched
over and the contaminated filter side
must be cleaned (see part 9).
Change over for testing function
switching armature (see part 9)
5 Oil cooler (10) Check condition of anode
(see chap. 5.5.3) 3 months
Inspect the tubeside (see chap. 9.2.5)
6 Oil cooler (10) Inspect the shellside (see chap. 9.2.5) 6 months
1) 1)
7 Pressure relief valve Clean the dirty oil filter (500 hours
(15), pressure valve (see chap. 5.5.4 and part 9) after initial
(16) and pressure relief operation)
valve (17)
8 Gear unit oil First oil change (see chap. 5.5.7 below 2 500 hours
Check oil level (see chap. 5.5.6) or
Analyse oil quality (see chap. 5.5.8) 6 months
9 Toothing Check of toothing by means of

inspection cover or by endoscope
(see chap. 5.5.5)
5000 hours
10 Oil cooler Clean the oil cooler (see part 9) or
11 All instruments and Check fixing and tighten all equipment 1 years
equipment
12 Foundation bolts Check tightness and condition
MAINTENANCE PART 5
Point
Maintenance item Work to be carried out Frequency
no.
13 Gear oil Change oil (see chap. 5.5.9) 10000 hours
or
2 years
14 Pressure valve (16) and Check valve seats and piston guide for
pressure relief valve wear (see part 9)
(15, 17) 15000 hours
15 Built-on pumps (1+2) Check condition and/or replace for a or
and electrical driven general overhaul (see part 9) 3 years
pumps (3+4)
16 E-motor (5) Change grease (details see part 9)
17 Basic overhaul 1. Check bearings
For this maintenance a 2. Visual inspection of all gears and
suitable workshop and rotating elements
a specialist of RENK is 30000 hours
required; 3. Check discs and clutch parts or
necessary spare parts (replacement only if necessary) 6 years
are available at the 4. Change grease at electric motor (5)
manufacturer 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
top view
8 7 = maintenance point
902
= connection no
15
4
10 6 5
902
3
8
3
7 14
7
7
14
14
15
16 15
MAINTENANCE PART 5
5.4 Lubricants
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 en-/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 150 as per
DIN 51519 or diesel motor oils of the Viscosity Class SAE 40 as per DIN 51511, as
present in the main- or auxiliary diesel have to be applied.
Table for standard oils ISO VG 150/SAE 40:
Viscosity Class Viscosity Class
Producer Producer
ISO VG 150 respectively SAE 40 ISO VG 150 respectively SAE 40
Falcon CLP 150

Agip Agip BLASIA 150 DEA Astron HLP 150
DEA Cronos SAE 40
ARAL Aral Degol BG 150 ESSO EXXMAR 12 TP40
BP BP Energol GR-XP 150 FINA FINA Giran 150
Castrol ALPHA ZN 150

Castrol Castrol ALPHA SP 150 Mobil Mobilgear 629
Chevro Chevron NL Gear Compound 150 Shell Sirius FB Oel 40

Chevron Delo SHP 40 Shell Shell Gadinia Oel 40
n
MAINTENANCE PART 5
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. 5.4) 160 litre unit!
2 E-motor of Grease 1) Total app. Change Pay attention to
double pump Shell Alvania R 3 0.1 kg grease instruction plates on
(3, 4) the motor and to the
operating manual
(see part 9)!
3 Sealing faces Sealing - - For housing face
compound sealing!
Hylomar SQ32/M
4 Screws Fixation - - For internal screws
compound connections!
Loctite 243
(see chap. 6.3.4)
5 Cleaning Weral 560 - - For cleaning from
(or petroleum- dirt and grease
based solvent) parts at the repair
works!
6 Cleaning oil - - - Products for
cooler chemical cleaning
(see part 9) 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 duplex oil filter

- Consider chap. 5.5.1 and detail descriptions see part 9!
- 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 view
LED`s light red

or green
5.5.3 Check or change anode of oil cooler

- Consider chap. 5.5.1 and maintenance point 5 (see chap. 5.3.2)!
- Always drain the tube side circuit with the drain screw N6 before removing the
anodes
- Remove the anodes N7 (3x) and check wear or change provided destroy the anode
- Reassembly takes place in opposite sequence
Note: Detail descriptions see part 9!
1x anode N7 top view cooler 2x anode N7
water OUT
water IN
2x drain screw N6
(under side cooler)
MAINTENANCE PART 5
5.5.4 Clean filter at pressure valves (15, 16 and 17)

- Consider chap. 5.5.1 and maintenance point 7 (see chap. 5.3.2)!
- Remove adaptor (item 10)
- Remove snap ring (item 13) and reassembly filter (item 8)
- Clean filter (cleaning agent see chap. 5.4.4)
- Check sealing ring (item 23) and change if necessary
- Reassembly takes place in opposite sequence
Note: Detail descriptions see part 9!
top view valve block
16
15
17 23
13
MAINTENANCE PART 5
5.5.5 Inspection of toothing

- Consider chap. 5.5.1
- Item nos. to description sees fig. 2 and assembly drawing see part 10.
⇒ Inspection of the preliminary toothing stage:

- Loosen screws (item 1087) and remove inspection cover (item 1086);
- Check pinion (item 2050) and spur gear (item 2100) toothing;
⇒ Inspection of the planetary toothing z-stage (input):

- Remove plug screw (item 1942/A);
- Introduce endoscope into the support ring via the bore (item 2341). Thereupon turn
input until the teeth of ring gear (item 2340) and planet gear (item 2308) can be
checked (gap between planet gears);
⇒ Inspection of the planetary toothing p-stage (output):

- Remove the plug screw (item 2616);
- Introduce endoscope through the hole and turn output until the bore becomes
visible in the inner disk carrier (item 2602). Thereupon turn output shaft until the
bore coincides in the output shaft (item 2345);
Check sun pinion toothing (item 2211) and planet gear toothing (item 2508);
⇒ Inspection of the toothings PTI-stage:

- Remove plug screw (item 1942/B);
- Introduce endoscope through the hole and check the pinion toothing (item 4201),
intermediate gear toothing (item 4301) and outer toothing of the ring
gear (item 2340);
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 seals for damage and replace them if necessary.
• Reassembly takes place in opposite position.
MAINTENANCE PART 5
fig. 1
fig. 2
item 1942/B
PTI
INPUT DE
item 2616
OUTPUT
item 1942/A
item 1086, 1088
item 1099
MAINTENANCE PART 5
5.5.6 Oil level check and oil filling
a) Oil level check:
The oil level is checked by means of the dipstick (item 1099, see fig. 2) 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 tester (125) triggers alarm.
b) Oil filling:
- The gear unit has been conceived as oil collecting tank.
- The gear unit must be filled (connection 902, see chap. 5.3.2) with gear oil
according to lubricants (see chap. 5.4).
- Remove plug screw (item 1904, M42x1.5).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 (fig. 3) when the gear unit and the electrical lube and control oil pumps
(3, 4) are at standstill.
Note: After longer standstill periods and for initial putting into operation the electrical
double pump (3, 4) has to be operated for a few minutes and to be stopped
before the oil level can be checked.
- Close the fill opening.
fig. 3
max
Oil level
markings
min
MAINTENANCE PART 5
5.5.7 Initial oil change

The first oil change must be performed after the first 2.500 operating hours or six months,
whichever occurs first.
5.5.8 Oil analysis

Analyse the oil after 2.500 operating hours or six months at the latest. The oil sample
should be taken with the plant in operation (oil at normal operating temperature) or
immediately after a shutdown. 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 and the electrical lube and control oil pump (3, 4) is
stopped;
- Hold recipient under the drain on the duplex oil filter (8, 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)
5.5.9 Oil change

Further oil changes after every 10.000 operating hours or every 2 years.
If the oil analysis (see chap. 5.5.8) 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 .............................................................................................................6
6.3.1 General note ..............................................................................................6
6.3.2 Repair information......................................................................................6
6.3.3 Screws tightening torque’s.........................................................................7
6.3.4 Securing of screws with Loctite..................................................................8
6.4 Adjustment work ...............................................................................................9
6.4.1 Adjust pressure valves (15, 16, 17) ...........................................................9
6.4.2 Adjust time relay of the multi-disc clutches ..............................................10
6.5 Instrument list .................................................................................................11
Issue: 2004-04-05 - MT/Hu/Erh Type: PWS 18-E Revision: 6954893/4 1/11

REPAIRS PART 6
6 Operational failures, Repairs
6.1 Safety information

When working on the gear system and with housekeeping repair work the following safety
regulations must always be observed.
- All operating and repair 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).
Note: Check all instruments/sensors at regular intervals and compare the values
determined with those listed in the Technical Data, chap. 2.2.
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 Note: In order to check the lubricating oil pressure the pressure
pressure too gauge 70 (connection - no. 501) is connected via the screw
low or too connection coupling. The pressure gauge 70 is separately
high packed in a instrument box.
Leakage’s in the piping Check for piping or exchange
system
Duplex filter (8) strongly Change over duplex filter and
contaminated clean the dirty element
(see part 9)
Built-on lube oil pump (2) Change over (automatic
deficient controlled) to electrical driven
pump (3+4, see chap. 4.4)
Repair or overhaul pump
Clogged tooth sprays Remove tooth sprays and clean
Check oil viscosity Oil change (see chap. 5.5.9)
(see chap. 5.5.8)
Pressure relief valve (17) Readjust (see tech. data part 2
wrongly adjusted or deficient or chap. 6.4.1), check filter (see
chap. 5.5.4) or replace pilot valve
(see part 9)

REPAIRS PART 6
cons.
no.
3 Lube oil Note: In order to check the lube oil temperature the
temperature thermometer 80 (connection - no. 511) is connected via the
too high screw connection coupling. The thermometer 80 is separately
packed in a instrument box.
Oil cooler (10) contaminated Check cooling water inlet and
Cooling water quantity too outlet temperature;
small or cooling water inlet Check cooling water supply;
temperature too high Clean oil cooler (see part 9)
4 Gear unit Roller bearing damaged; ATTENTION!

noises Toothing damaged; Reduce power and/or put plant
Propeller alignment out of operation, demand for a
RENK AG specialist.
5 Multi-disc 4/2-way valves (20) blocked Check voltage supply

clutches connection; Change over by
(MDC) does means of manual emergency
not open or actuation (see chap. 4.4 and
close part 9)
4/2-way valves (20/1-20/3) Replace operating 4/2-way valve
defective
Multi-disc clutch plates worn Replace clutch plates (only for
RENK AG specialist
Control oil pressure too low see cons. no. 6
6 Control oil Leakage in the piping system Make tight or exchange flange
pressure too control oil joints or pipes
low or too high
(details Built-on control oil pump (1) Change over (automatic
accumulating deficient controlled) to electrical driven
valve, see part pump (3+4, see chap. 4.4)
9) Repair or overhaul pump
Pressure valves (15, 16) Readjust (see tech. data part 2
wrongly adjusted or deficient or chap. 6.4.1), check filters (see
chap. 5.5.4) or replace pilot valve
(see part 9)

REPAIRS PART 6
cons.
no.
7 Control oil Note: In order to check the control oil pressure the pressure
pressure gauge 71 (connection - no. 508) is connected via the screw
increase time connection coupling. The pressure gauge 71 is separately
too short or packed in a instrument box.
too long
Time relay (135) out or Adjust time relay (see tech. data
adjustment chap. 2.2; for adjustment work
see chap. 6.4.2)
Time relay (135) defective Replace time relay
8 Electric motor Electric connection Check terminals, lines and fuses

(5) interrupted
Thermistor safety switch Reconnect after a certain cooling
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

• When ordering spares the procedure must be according to part 8.
• 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 torque’s 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 pressure valves (15, 16, 17)

- Consider chap. 6.3 and part 9
- Remove protection cap
- Loosen counter nut
- Turn pressure regulating spindle:
♦ Pressure increase: turn to the right
♦ Pressure reduction: turn to the left
- Tighten counter nut
- Mount protection cap
Note: For adjusting data refer to part 2, chap. 2.2!
top view gear unit 16
output 15
17
protection cap
16
15
17

REPAIRS PART 6
6.4.2 Adjust time relay of the multi-disc clutches
- Consider chap. 6.3

- For adjustment work of time relay (135) time setting on the relay (installed in
terminal box K1 of the gear unit) must be regulated.
♦ Remove cover of potentiometer
♦ Setting range is marked on the nameplate
♦ Adjust operating time new by using screw driver
potentiometer
- For adjusting data refer to technical data, see part 2.

REPAIRS PART 6
6.5 Instrument list
Item Qyt. Parts identification Denomination
1 1 6807414 Thermometer (80) = 0 to 100°C

2 1 6807412 Pressure gauge (70) = 0 to10 bar
3 1 6807413 Pressure gauge (71) = 0 to 40 bar
4 2 6806898 High pressure hose
5 2 6806899 Pressure gauge connection
6 1 6807505 Instrument case
Note: Instruments with accessories item 1 to 5 are into

instrument case item 6!

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
7.1.2 Loose delivered parts.................................................................................2
7.1.3 Transportation............................................................................................3
7.2 Preservation at delivery.................................................................................4
7.2.1 General ......................................................................................................4
7.2.2 Interior preservation ...................................................................................4
7.2.3 Exterior preservation..................................................................................4
7.2.4 Period of corrosion protection ....................................................................5
7.2.5 Renewal of gear unit preservation .............................................................5
7.2.5.1 Renewal of interior preservation.........................................................5
7.2.5.2 Renewal of exterior preservation........................................................5
7.2.6 Removal of gear unit preservation .............................................................6
7.2.6.1 Removal of the exterior preservation..................................................6
7.2.6.2 Removal of the interior preservation...................................................6
7.2.7 Supply sources ..........................................................................................6
7.3 Installation and Installation check..................................................................7
7.3.1 Foundation design .....................................................................................7
7.3.2 Preparation ................................................................................................7
7.3.3 Alignment of the gear unit towards the propeller shaft ...............................8
7.3.3.1 Radial displacement ...........................................................................9
7.3.3.2 Axial displacement ...........................................................................10
7.3.3.3 Inner alignment ................................................................................10
7.3.3.4 Fitting of chocks ...............................................................................11
7.3.4 Alignment of the diesel engine towards the gear unit...............................11
7.3.4.1 Displacement input...........................................................................12
7.3.4.2 Axial displacement ...........................................................................12
7.3.5 Final jobs after alignment.........................................................................12
7.4 Sea-water system .......................................................................................13
7.4.1 General ....................................................................................................13
7.4.2 Installation................................................................................................13
7.4.3 Sea water flow .........................................................................................13

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 QTY Denomination Parts Dimension Weight
no. identification kg
1 1 Port gear unit 6459252 2.500
PWS 18-E see drawing 6459278/0
2 1 Starboard gear unit 6459253 (see part 10) 2.500
PWS 18-E
7.1.2 Loose delivered parts

Following equipment /parts are supplied as loose parts:
Item QTY Denomination Parts Dimension Weight
no. identification kg
7110 2 Tank complete assembly - 934x608x600 120
state with following parts:
Item no. 7100-7103 and
7120-7126
(nos. see piping scheme
6815626/0)
0020 1 Instrument case 6811314 460x310x170 5

SUPPLY
7.1.3 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).
As for the rest, the instructions and rules of the freight carries must be adhered to.
fig. 1 – view from aft
traverse
min. dimension 1200x1200 mm
hanging hole ∅60

for rod
frame

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 150 (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 150. 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.
Flush the gear unit with preservation oil for approx. 10 minutes. For this purpose the
electrically double pump (3, 4) is to be used.
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).
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).

SUPPLY
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.
ATTENTION! Gear unit is demagnetized!

The treated parts are not allowed to get connected with magnets.
Dial gauges with magnetic base are only allowed to be held
externally. It is recommended o work with demagnetized tools at the
assembly. Consider notes to assembly drawing see part 10!
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) it is essential to consider
the forces which result form elastic coupling (maker Renolds).
Special screws (supply MTU) fit between the frame (supply MTU) and the gear unit at each
foundation screw.
7.3.2 Preparation
It must be checked whether the frame bores for gear unit fixation coincide with the gear unit
bores. For this purpose the gear unit is to be placed on the set screws and aligned towards
the propeller shaft.
Before the actual alignment work of the gear unit commences, the propeller shaft must be
moved into its final position duly considering the installation length of the elastic coupling
and the special alignment instructions given by the yard. Axial offset as a consequence of
thermal growth of the propeller shaft and the gear unit shaft as well as other axial offset
must be taken into account.
Unless the coupling provided between DE and gear unit has already been firmly connected
with the gear unit input shaft, it must be flange connected to the gear unit shaft now.
In doing so, attention has to be paid to it that the weight of the DE-side coupling part does
not impose any load on the gear unit (support the DE-side coupling part).
Adhere to the instructions given on the installation drawing (see part 10).

SUPPLY
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
7.3.3 Alignment of the gear unit towards the propeller shaft

The axial, radial and angular positions must be considered for alignment of the gear unit
shaft.
Radial alignment
In order not to exhaust the displacement capacity of the elastic coupling by circumstances
which can be determined by exact calculations, displacements due to thermal growth and
bearing clearances of the propeller shaft and the gear unit should be considered suitably
during radial alignment. Alignment in cold and unloaded condition is not made to zero but to
that value which results from the difference between the propeller shaft and gear unit shaft
displacement.
Special attention is to be paid to the fact that both influences have to be known by all
means. The consideration of only one influence (impeller shaft or gear unit displacement) is
impermissible. The offset experienced by gear unit output shafts as a consequence of
thermal growth and the bearing clearance is summarised on the following pages.
The instructions of the elastic coupling maker also have to be considered.
The correct radial and angular alignment between propeller and gear unit output shaft is
verified by means of dial gauges (consider attention chap. 7.3) as shown in fig. 2. A special
measuring strap is used to determine the radial offset (radial run-out) and the angular offset
(axial run-out) between the propeller side coupling part and the output shaft. The difference
determined between the theoretical and actual values must not exceed 0.1 mm for the radial
shaft offset (0.2 mm deflection on dial gauge) and 0.02 mm per 100 mm flange diameter
difference for the gap (i.e. 0.0002 rad. on dial gauge).
Two dial gauges, offset by 180° to one another, are used to determine the axial run-out.

SUPPLY
fig. 2
elasic coupling
PROPELLER GEAR UNIT
After completion of the alignment process, the final values have to be recorded and checked
later in warm operating condition (50°C).
Axial alignment
The gear unit output shaft is equipped with an axial bearing. The axial offset of the gear unit
output shaft is indicated under chap. 7.3.3.2. The axial offset of the propeller shaft
(mechanical offset and thermal growth) also must be considered.
The instructions of the elastic coupling maker also have to be considered.
7.3.3.1 Radial displacement

Radial displacement of the gear unit output shaft by heat dilatation at temperature difference
∆t =30°C (see from aft).
view aft
M
0.05
M: Position of the shaft at cold condition without transmission of power

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

SUPPLY
7.3.3.2 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 and the axial bearing clearance:
+0.1 mm (growth in aft direction)
7.3.3.3 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. 3) are grinded
a little bit; this is not damage; it was needed for workshop hardness test;
fig. 3

SUPPLY
7.3.3.4 Fitting of chocks

After alignment of the gear unit towards the propeller shaft, the plant frame (MTU supply)
and the ship foundation must be fitted at first without clearance.
Note: Consider the MTU description!
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 coupling.
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 (consider attention chap. 7.3 and see fig. 4).
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. 0.0002
rad).
fig. 4
GEAR UNIT elastic coupling DIESEL ENGINE

SUPPLY
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).
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).
view aft
K
0.11
M: Position of the shaft at cold condition without transmission of power

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

The axial therminal growth the gear output shaft by heat dilatation at temperature
difference ∆t = 30°C:
-0.04 mm (growth in ahead direction)
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
8.2 Mechanic parts list ........................................................................................3
8.2.1 Port gear unit .............................................................................................3
8.2.2 Starboard gear unit ....................................................................................7
8.3 Hydraulic parts list.......................................................................................11
8.3.1 Port gear unit ...........................................................................................11
8.3.2 Starboard gear unit ..................................................................................14

8 Main parts list
8.1 Introduction
8.1.1 Division
The main parts list is divided in:
• Mechanic parts list see chap. 8.2
- Port gear unit see chap. 8.2.1
- Starboard gear unit see chap. 8.2.2
• Hydraulic parts list see chap. 8.3
- Port gear unit see chap. 8.3.1
- Starboard gear unit see chap. 8.3.2
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.
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: 80119109
- Product no: see type plates gear unit
- Gear unit serial no: see type plates gear unit
- Item no: 2210
- Denomination Sun Pinion, z-stage
- Parts identification 6459317
- Quantity 1

8.2 Mechanic parts list
8.2.1 Port gear unit

Product no.: 6459252
Assembly drawing: 6459455/0
Item no. Denomination Parts identification RENK/Orig. Manufacturer QTY Weight
1002 Housing 6459357 1 226

1003 Housing 6459361 1 52,9
1004 Cover 6459358 1 24,5
1005 Cover 6459359 1 27,4
1006 Cover 6459360 1 15,1
1007 Cover 6459363 1 3,3
1030 Sealing cover 6459330 1 1
1035 Rotary shaft lip type seal 1219498 DIN3760-AS125X150X12-FKM 2 0,1
1044 Cover sealing 6459312 1 2,5
1049 Rotary shaft seal 1222982 DIN3760-AS210X240X15-FKM 2 -
1070 Oil supply bushing 6459348 1 2,3
1073 Rectangular ring 6459798 4 0,2
1074 Sealing ring 6568220516 1 -
1076 Tooth spray 6458974 1 0,8
1077 Sealing ring 6568240233 2 -
1078 Sealing ring 6568240319 2 -
1079 Sealing ring 6568240336 2 -
1087 Gasket 6459800 2 -
1096 Gasket 6459802 1 -
1902 Vent 2452002 1 0,1
1941 Sealing ring 6561900716 DIN7603-A21X26-CU 2 -
2012 Alig. roller bearing 6324290218 DIN635-23218EAS.M 1 4,5
2013 Cyl. roller bearing 6450479 DIN5412-NJ2218E-M-C3 1 3,2
2050 Pinion 6459328 1 20,3
2051 Output flange 6459329 1 14,2

2100 Gear shaft 6459327 1 67,6

2210 Sun Pinion, z-stage 6459317 1 38
2211 Sun Pinion, p-stage 6459316 1 16,9
2212 Straight pin 6459778 12 0,1
2220 Oil supply ring 6459318 1 2,2
2223 Shaft 6459332 1 1,4
2302 Planet shaft 6459336 5 2,9
2304 Fitting key 6459460 5 0,1
2306 Plain bearing 6458965 5 7,6
2308 Planet gear, z-stage 6459335 5 17
2312 Grooved ball bearing 6447963 DIN625-61856MA/M 1 5,4
2313 Grooved ball bearing 1216540 DIN625-61840M.C3 1 2,7
2330 Planet carrier 6459323 1 84,5
2332 Straight pin 6458985 15 0,1
2333 Inner disc carrier 6459324 1 43,3
2340 Ring gear, z-stage 6459320 1 67
2345 Output shaft 6459304 1 61
2346 Planet Carrier half 6459319 1 65,6
2347 Straight pin 6459502 6 0,1
2401 Thrust washer 6459306 1 57,5
2404 Rectangular ring 6458514 1 0
2408 Grooved ball bearings 6314290107 DIN625-61848M.C3 1 4,5
2420 Piston 6458280 1 7,6
2421 Rectangular ring 6458515 1 -
2430 Outer disc carrier 6458273 1 30
2450 Outer clutch disc 1002853 7 6,5
2451 Inner clutch disc 1000330 6 4,6
2452 Pin 6458401 28 -

2453 Compression spring 1000629 168 -

2502 Planet shaft 6459338 6 1,8
2504 Fitting key 6459460 6 0,1
2506 Plain Bearing, p-stage 6458967 6 4
2508 Planet Gear, p-stage 6459337 6 6,9
2520 Ring gear 6459311 1 30,6
2521 Flinger 6459470 2 0,2
2601 Inner disc carrier 6459310 1 38
2620 Piston 6458280 1 7,6
2630 Outer disc carrier 6459308 1 67,5
2652 Pin 6459782 28 -
3010 Tap.roller bearing 6324803701 ISO355-T4DB170M 2 3,5
3014 Oil supply ring 6459314 1 1,9
3020 Output flange 6459307 1 45
3022 Sealing ring 6568340211 1 -
3024 Sealing ring 6568340421 1 -
4010 Gear shaft 6458993 1 12,3
4011 Pinion shaft 6459457 1 8
4012 Fitting key 6290716918 DIN6885-B14X9X63 1 0,1
4102 Alig. roller bearing 6324290310 DIN635-22310E.M 1 1,9
4201 Pinion shaft 6459349 1 25
4202 Fitting key 6459460 1 0,1

4204 Fitting key 6459788 DIN6885-AB22X14X117 2 0,3

4208 Plain bearing 6458971 1 6,2
4212 Gear shaft 6459350 1 16,8
4213 Multi-disc clutch 6458970 1 45
4215 Flange 6459491 1 4,7
4220 Bearing 6459629 1 0,7
4221 Alig. roller bearing 6324290314 DIN635-21314E.M 1 3
4301 Pinion shaft 6458992 1 44,2
4501 Gear shaft 6459628 1 2,3
5001 Pump pinion 6458981 1 2,6
5002 Cyl. roller bearing 6325707069 DIN5412-NU208E-M-C3 1 0,4
5003 Groov. ball bearing 6314109913 DIN625-6208M.C3 1 0,4
5010 Fitting key 6290706715 DIN6885-A10X8X45 1 -
5011 Coupling 6459791 1 1,2

8.2.2 Starboard gear unit

Assembly drawing: 6459455/0
1002 Housing 6459357 1 226

1003 Housing 6459361 1 52,9
1004 Cover 6459358 1 24,5
1005 Cover 6459359 1 27,4
1006 Cover 6459360 1 15,1
1007 Cover 6459363 1 3,3
1030 Sealing cover 6459330 1 1
1035 Rotary shaft lip type seal 1219498 DIN3760-AS125X150X12-FKM 2 0,1
1044 Cover sealing 6459312 1 2,5
1049 Rotary shaft seal 1222982 DIN3760-AS210X240X15-FKM 2 -
1074 Sealing ring 6568220516 1 -
1076 Tooth spray 6458974 1 0,8
1077 Sealing ring 6568240233 2 -
1078 Sealing ring 6568240319 2 -
1079 Sealing ring 6568240336 2 -
1087 Gasket 6459800 2 -
1096 Gasket 6459802 1 -
1902 Vent 2452002 1 0,1
2050 Pinion 6459328 1 20,3
2051 Output flange 6459329 1 14,2
2100 Gear shaft 6459327 1 67,6


2210 Sun Pinion, z-stage 6459317 1 38
2211 Sun Pinion, p-stage 6459316 1 16,9
2212 Straight pin 6459778 12 0,1
2220 Oil supply ring 6459318 1 2,2
2223 Shaft 6459332 1 1,4
2302 Planet shaft 6459336 5 2,9
2304 Fitting key 6459460 5 0,1
2306 Plain bearing 6458965 5 7,6
2308 Planet gear, z-stage 6459335 5 17
2312 Grooved ball bearing 6447963 DIN625-61856MA/M 1 5,4
2313 Grooved ball bearing 1216540 DIN625-61840M.C3 1 2,7
2330 Planet carrier 6459323 1 84,5
2332 Straight pin 6458985 15 0,1
2333 Inner disc carrier 6459324 1 43,3
2340 Ring gear, z-stage 6459320 1 67
2345 Output shaft 6459304 1 61
2346 Planet Carrier half 6459319 1 65,6
2347 Straight pin 6459502 6 0,1
2401 Thrust washer 6459306 1 57,5
2404 Rectangular ring 6458514 1 0
2408 Grooved ball bearings 6314290107 DIN625-61848M.C3 1 4,5
2420 Piston 6458280 1 7,6
2430 Outer disc carrier 6458273 1 30
2452 Pin 6458401 28 -

2502 Planet shaft 6459338 6 1,8

2504 Fitting key 6459460 6 0,1
2506 Plain Bearing, p-stage 6458967 6 4
2508 Planet Gear, p-stage 6459337 6 6,9
2520 Ring gear 6459311 1 30,6
2521 Flinger 6459470 2 0,2
2601 Inner disc carrier 6459310 1 38
2620 Piston 6458280 1 7,6
2630 Outer disc carrier 6459308 1 67,5
2652 Pin 6459782 28 -
3010 Tap.roller bearing 6324803701 ISO355-T4DB170M 2 3,5
3014 Oil supply ring 6459314 1 1,9
3020 Output flange 6459307 1 45
3022 Sealing ring 6568340211 1 -
3024 Sealing ring 6568340421 1 -
4010 Gear shaft 6458993 1 12,3
4011 Pinion shaft 6459457 1 8
4012 Fitting key 6290716918 DIN6885-B14X9X63 1 0,1
4201 Pinion shaft 6459349 1 25
4202 Fitting key 6459460 1 0,1
4204 Fitting key 6459788 DIN6885-AB22X14X117 2 0,3

4208 Plain bearing 6458971 1 6,2

4212 Gear shaft 6459350 1 16,8
4213 Multi-disc clutch 6458970 1 45
4215 Flange 6459491 1 4,7
4220 Bearing 6459629 1 0,7
4301 Pinion shaft 6458992 1 44,2
4501 Gear shaft 6459628 1 2,3
5001 Pump pinion 6458981 1 2,6
5002 Cyl. roller bearing 6325707069 DIN5412-NU208E-M-C3 1 0,4
5003 Groov. ball bearing 6314109913 DIN625-6208M.C3 1 0,4
5010 Fitting key 6290706715 DIN6885-A10X8X45 1 -
5011 Coupling 6459791 1 1,2

8.3 Hydraulic parts list
8.3.1 Port gear unit

Piping scheme: 6815626/0
6101 Compensator 6815936 1 -

6103 Gasket 1001970 EN1514-IBC-DN50-PN6 2 -
6126 Compensator 6815936 1 -
6146 Compensator 6815936 1 -
6207 Check valve 6721008632 1 0,8
6227 Check valve 6721008632 1 0,8
6237 Check valve 6816023 2 -
6407 Check valve 6721008632 1 0,8
6413 Gasket 1001963 EN1514-IBC-DN20-PN40 2 0
6418 Check valve 1100610 1 0,1
6521 Resistance thermometer 6816017 2 -
(110)
6541 Pressure switch (90) 6816007 1 -

6543 Pressure switch (91) 6816008 1 -

6545 Pressure switch (92) 6816009 1 -
6547 Pressure switch (93) 6816010 1 -
6549 Pressure switch (95) 6816011 1 -
6550 Pressure switch (96) 6816012 1 -
6552 Pressure switch (97) 6816013 1 -
6554 Pressure switch (98) 6816014 1 -
6556 Pressure transmitter (100) 6812026 2 -
6558 Pressure switch (103) 6816015 2 -
6602 Compensator 6815935 1 -
7020 Electrical double pump 6815670 1 -
(3+4)
7030 Built-on control oil pump (1) 6815668 1 -
7034 Sealing ring 6568340436 1 -
7040 Built-on lube oil pump (2) 6815669 1 -
7050 Oil cooler (10) 6815775 1 -
7060 Double filter (8) 6815699 1 -
7068 Sealing ring 6568220226 2 -
7070 Valve block 6815694 1 -
7073 4/2-way valve (20) 6816303 3 -
7074 Pressure valve (15) 6816300 1 -
7075 Pressure valve (16+21) 6816301 1 -
7076 Pressure valve (17) 6816302 1 -
7077 Inductive proximity switch 6807333 6 -
(115-120))
7080 Transmitter (130) 6812685 2 -
(125)
7100 Compensator 6815937 1 -

7500 Terminal box 6816079 1 -

7502 Bumper 6816080 4 -
7504 Switch 6816401 2 -
7525 Varistor 6813932 7 -
7526 Diode 7954006014 7 -
7530 Time relay 6816081 1 -
7531 Relais 6810067 10 -
7551 Terminal box (K11) 6814010 2 -

8.3.2 Starboard gear unit

Piping scheme: 6815626/0
6101 Compensator 6815936 1 -

6126 Compensator 6815936 1 -
6146 Compensator 6815936 1 -
6207 Check valve 6721008632 1 0,8
6227 Check valve 6721008632 1 0,8
6237 Check valve 6816023 2 -
6407 Check valve 6721008632 1 0,8
6413 Gasket 1001963 EN1514-IBC-DN20-PN40 2 0
6418 Check valve 1100610 1 0,1
6521 Resistance thermometer 6816017 2 -
(110)
6541 Pressure switch (90) 6816007 1 -
6543 Pressure switch (91) 6816008 1 -

6545 Pressure switch (92) 6816009 1 -

6547 Pressure switch (93) 6816010 1 -
6549 Pressure switch (95) 6816011 1 -
6550 Pressure switch (96) 6816012 1 -
6552 Pressure switch (97) 6816013 1 -
6554 Pressure switch (98) 6816014 1 -
6556 Pressure transmitter (100) 6812026 2 -
6558 Pressure switch (103) 6816015 2 -
6602 Compensator 6815935 1 -
7020 Electrical double pump 6815670 1 -
(3+4)
7030 Built-on control oil pump (1) 6815668 1 -
7034 Sealing ring 6568340436 1 -
7040 Built-on lube oil pump (2) 6815669 1 -
7050 Oil cooler (10) 6815775 1 -
7060 Double filter (8) 6815699 1 -
7068 Sealing ring 6568220226 2 -
7070 Valve block 6815694 1 -
7073 4/2-way valve (20) 6816303 3 -
7074 Pressure valve (15) 6816300 1 -
7075 Pressure valve (16+21) 6816301 1 -
7076 Pressure valve (17) 6816302 1 -
(115-120))
7080 Transmitter (130) 6812685 2 -
(125)
7100 Compensator 6815937 1 -
7500 Terminal box 6816079 1 -

7502 Bumper 6816080 4 -

7504 Switch 6816401 2 -
7525 Varistor 6813932 7 -
7526 Diode 7954006014 7 -
7530 Time relay 6816081 1 -
7531 Relais 6810067 10 -
7551 Terminal box (K11) 6814010 2 -

COMPONENTS PART 9
TABLE OF CONTENTS
Chap. Designation Item no. Tool no. Drawing no. Sheet
9.1 Mechanic components
9.1.1 Multi-disc clutch 4213 -

• Service Instructions 777-009 11 1 to 16
• Installation drawing 6460346/3 1 to 1
9.2 Hydraulic components
9.2.1 Built-on control oil pump, primary 7030 1

• Operating Notes on Gear Pumps L39-BW 1 to 3
• Installation drawing MZ3-2511-334374-6 1 to 1
• Assembly drawing FZ3-1020-333262-4 1 to 1
• Parts list 334647-5 1 to 1
9.2.2 Built-on lube oil pump, secondary 7040 2
• Operating instructions for gear pumps BA3-6NNN-112//4 1 to 4
• Installation drawing MZ3-6476-417993 1 to 1
• Assembly drawing FZ3-6476-417993 1 to 1
• Parts list 418270 1 to 2
9.2.3 Electrical driven double pump 7020 3, 4
• Operating Notes on Gear Pumps see chap. 9.2.1
• Installation drawing MZ2-0315-418242 1 to 1
• Parts list to installation drawing 418242 1 to 1
• Parts list pumps 418241 1 to 3
9.2.3.1 Electric motor 7020 5
• Operating Instructions N-R 435 en 09.03 1 to 33
9.2.4 Double filter 7650 12
• Manual and maintenance instructions 20320-4C 1 to 3
• Assembly drawing with parts list 2117 K 1 to 2
• Clogging indicator 1615C 1 to 2

COMPONENTS PART 9
Chap. Designation Item no. Tool no. Drawing no. Sheet
9.2.5 Oil cooler 7050 10

• Instructions for installation, start up and …. 7ZZ00P0000010 1 to 17
• Installation drawing P13-0-1201 1 to 1
• Parts list P13-0-1201 L=600 1 to 1
• Recommendations for Installation 6954234/4 1 to 2
9.2.6 Control block 7070 -
• Assembly drawing FZ4-4999-418774 1 to 1
• Technical data sheet TD 0-4999-418774 1 to 3
9.2.6.1 Pressure valve 7074 15
• Description DBV40 1 to 8
• Installation and assembly drawing MZ4-2169-418330 1 to 1
• Pilot valve with parts list 6-0000-1821777-6 1 to 2
• Pilot cartridge with parts list 6-0000-180260-2 1 to 3
• Description see chap. 9.2.6.1
• Pressure relief valve with parts list 6-0000-180101-8 1 to 2
• Pilot cartridge with parts list 6-0000-180094-5 1 to 3
• Directional control valves NG 6 Series D 6/6 1 to 11
• Description see chap. 9.2.6.1
• Pilot valve with parts list FZ6-0000-180366-7 1 to 2
• Pilot cartridge with parts list FZ6-0000-412594 1 to 3
9.2.6.4 4/2-way valve 7073 20
• Installation drawing with technical data 3-7455 e 1 to 2

Betriebsanleitung
Hydraulisch geschaltete
Lamellenkupplung
KMK-S
Service Instructions
Hydraulically operated
multi-disc clutch
KMK-S
Nr. / No. 777-00911

Datum / Date 04.2002
DD- 771.160
Diese Betriebsanleitung soll den BenutĆ

zer dazu befähigen, das Stromag-ProĆ
dukt sicher und funktionsgerecht zu
handhaben, rationell zu nutzen und
sachgerecht zu pflegen, so daß die GeĆ
fahr einer Beschädigung oder FehlbeĆ
dienung ausgeschlossen wird.
Stromag-Produkte entsprechen dem
Qualitätsstandard nach DIN ISO 9001.
This service manual shall enable the

user to operate the Stromag product saĆ
fely and effectively, to use it sensibly and
to maintain it properly so as to exclude
the possibility of any damage or incorĆ
rect operation.
Stromag products comply with the QuaĆ
lity Standard to DIN ISO 9001.
Antriebstechnik The German wording prevails for sense
and tenor of these instructions.
von Stromag
Hydraulisch geschaltete Lamellenkupplung
Hydraulically operated multi-disc clutch
KMK-S
Nr./No. 777-00911
Inhalt Kapitel Content Chapter

Technische Daten 1 Technical data 1
Daten am Außenumfang der Kupplung 1.1 Data on the outer periphery of the clutch 1.1
Drehmoment, Drehzahl, weitere techn. Daten 1.2 Torque, speed and other technical data 1.2
Bohrungsabmessungen, Anschlußbefestigung 1.3 Bore dimensions, connections 1.3
Einsatzbereich und bestimmungsgemäße Application range and utilization
Verwendung 1.4 as per specification 1.4
Sicherheitshinweise 2 Safety guidelines 2

Arbeitssicherheits-Symbol 2.1 Symbol for safety at work 2.1
Achtungshinweis "Achtung!" 2.2 Instructions "Caution" 2.2
Arbeitssicherheitshinweise 2.3 Safety instructions for working 2.3
Transport 3 Transportation 3
Verpackung 3.1 Packing 3.1
Anlieferungszustand 3.2 Delivery condition 3.2
Empfindlichkeit 3.3 Sensitivity 3.3
Zwischenlagerung 3.4 In-process stocking 3.4
Lieferumfang 3.5 Delivery extent 3.5
Aufbau, Wirkungsweise, Konstruktionsmerkmale 4 Construction, functioning, constr. characteristics 4

Abbildung mit Positionsangaben Figure with item numbers and
sowie Benennung der Einzelteile 4.1 designation of the single parts 4.1
Wirkungsweise und Konstruktionsmerkmale 4.2 Functioning and constructional characteristics 4.2
Versorgungsanschlüsse 4.3 Supply connections 4.3
Druckölzuführung in der Welle 4.3.1 Hydraulic conduct into the shaft 4.3.1
Kühlölzuführung in der Welle 4.3.2 Cooling oil conduct into the shaft 4.3.2
Ein- und Ausbau 5 Assembly and dismantling 5

Einbauvorgang 5.1 Assembly 5.1
Montagegenauigkeit 5.2 Mounting accuracy 5.2
Abmessungen, Platzbedarf und Gewichte 5.3 Dimensions, space requirement and weight 5.3
Ausbauvorgang 5.4 Dismantling 5.4
Inbetriebnahme 6 Setting into service 6
Betrieb 7 Operation 7
Betriebsbedingungen 7.1 Service conditions 7.1
Druck- und Kühlflüssigkeiten 7.2 Hydraulic and cooling liquids 7.2
Filterung und Ölwechsel 7.3 Filtering and oil change 7.3
Einschaltdauer, Schalthäufigkeit und Schaltzeiten 7.4 Duty cycle, switching frequency, switching times 7.4
Störungsabhilfe 7.5 Trouble shooting 7.5
Instandhaltung 8 Maintenance 8
Pflege- und Kontrollarbeiten 8.1 Maintaining and inspection works 8.1
Demontage der Kupplung 8.2 Dismantling of the clutch 8.2
Arbeitssicherheitshinweise 8.2.1 Safety instructions for working 8.2.1
Auswechseln des Lamellenpaketes 8.2.2 Exchange of the disc pack 8.2.2
Auswechseln der Dichtungen 8.2.3 Exchange of the sealings 8.2.3
Ersatzteilhaltung, Kundendienst 9 Spare parts stocking, after-sales service 9

Ersatzteilhaltung 9.1 Spare parts stocking 9.1
Daten für Ersatzteilbestellung 9.2 Data for spare parts stocking 9.2
Ersatzteil- und Kundendienstanschrift 9.3 Address for spare parts orders
and after-sales service 9.3
Entsorgungshinweis 10 Hints for waste management 10
Aufgeführte Normen und Richtlinien 11 Listed standards and regulations 11

1
KMK-S
Nr./No. 777-00911
1. Technische Daten 1. Technical Data

1.1 Daten auf der Kupplung 1.1 Data on the clutch
Folgende Daten befinden sich auf dem Außenumfang The following data is embossed on the outer periphery
der Kupplung: of the clutch:
Stromag-Auftrags-Nummer Stromag Order-Ref.-No.

Lieferdatum Mon./Jahr Delivery date month/year
Stromag-Artikel-Code Stromag Article Code
Baureihe und Größe Series and size
1.2 Drehmoment, Drehzahl sowie weitere techniĆ 1.2 Torque, speed and other technical data
sche Daten
Kupplungstype und -größe sowie die auftretenden The clutch type and size as well as the occurring torĆ
Drehmomente, die max. zulässige Drehzahl, AnziehĆ ques, the max. admissible speed, the wrench torque of
drehmoment der Befestigungsschrauben und weitere the fastening screws and other technical data are stated
technische Daten sind der für den jeweiligen Auftrag on the dimensional drawing which is binding for the perĆ
verbindlichen Maßzeichnung zu entnehmen. tinent order.
Diese wird der Auftragsbestätigung als Anlage beigeĆ This drawing is attached to the order acknowledgement
fügt und kann auch zusätzlich von unserem KundenĆ and can also be inquired at our after-sales service (the
dienst angefordert werden, Anschrift s. Kap. 9.3. address is given in chap. 9.3).
1.3 Bohrungsabmessungen, Anschlußbefestigung 1.3 Bore dimensions, connections

Die verbindlichen Abmessungen für die Bohrung, der The binding dimensions for the bore, fitting key and
Paßfedernut und der Anschlußbefestigung sind der connections are stated on the dimensional drawing as
Maßzeichnung, wie im Kapitel 1.2 erwähnt, zu entnehĆ mentioned in chap. 1.2. The fitting key is made to DIN
men. Die Paßfedernut wird nach DIN 6885 Bl. 1, ToleĆ 6885/1, tolerance P9. To keep the leakage oil quantity
ranz P9 gefertigt. Um die Leckölmenge gering zu halĆ as low as possible, the shaft fit n6 or m6 has to be adheĆ
ten, ist die Wellenpassung n6 oder m6 einzuhalten. red to.
1.4 Einsatzbereich und bestimmungsgemäße VerĆ 1.4 Application range and utilization as per specifiĆ
wendung cation
! Die hydraulisch geschaltete LamellenĆ

! The hydraulically operated multi-disc
kupplung ist ausschließlich zum Einsatz unter den clutch is designed only to be used in compliance
vorgegebenen technischen Daten nach Kap. 1.2 und with the corresponding technical data as per chap.
Betriebsbedingungen nach Kap. 7.1 vorgesehen. 1.2 and the service conditions as per chap. 7.1.
Die Kupplung mit der Reibpaarung Stahl/Sinterlamelle The clutch has friction combination steel/sintered disc
darf nur im Naßlauf eingesetzt werden. and must be used only in wet operation.
Diese Kupplung ist ein nicht verwendungsfertiges GeĆ This clutch is a unit not ready for utilisation. To fulfill its
rät, das zur Erfüllung seiner Funktion mit weiteren KomĆ function it has to be connected to other components. It
ponenten verbunden werden muß und nur zum VerĆ must be used only to link and separate an energy flux
knüpfen und Trennen eines Energieflusses in Form in form of a torque transmission.
einer Drehmomentübertragung eingesetzt werden
darf.
Ferner sind die vom Hersteller vorgeschriebenen Ein- The instructions for mounting, dismantling, setting into
und Ausbau-, Inbetriebnahme- und InstandhaltungsĆ service and maintenance given by the manufacturer
bedingungen einzuhalten. must be adhered to.
Die Nichtbeachtung dieser Bedingungen oder jeder The non-observance of these instructions or any utiliĆ
darüberhinausgehende Gebrauch gilt als nicht bestimĆ zation exceeding these instructions will be considered
mungsgemäß. as "not according to specification".
Für hieraus resultierende Schäden haftet der Hersteller The manufacturer will not be liable for any possibly reĆ
nicht; das Risiko hierfür trägt allein der Benutzer. sulting damage; the user will bear sole responsibility in
such cases.
Soll die Kupplung außerhalb dieses vertraglichen EinĆ Should the clutch be used outside the contracted appliĆ
satzbereiches eingesetzt werden, ist der Kundendienst cation range, consult the after-sales service of the
der Stromag AG zu Rate zu ziehen, da sonst die GeĆ Stromag AG; otherwise the warranty will no longer apĆ
währleistung entfällt, Anschrift s. Kap. 9.3. ply, address see chap. 9.3.
2
KMK-S
Nr./No. 777-00911
2. Sicherheitshinweise 2. Safety Guide Lines

2.1 Arbeitssicherheits-Symbol 2.1 Symbol for safety at work
! Dieses Symbol finden Sie bei allen ArbeitssiĆ

! This symbol denotes all the safety instrucĆ
cherheits-Hinweisen in dieser Betriebsanleitung (BA), tions in this manual which deal with danger to life and
bei denen Gefahr für Leib und Leben von Personen beĆ limb of personnel. These instructions must be adhered
steht. Beachten Sie diese Hinweise und verhalten Sie to and particular caution exercised in these cases. All
sich in diesen Fällen besonders vorsichtig. Geben Sie users must be familiarised with the safety instructions.
alle Arbeitssicherheits-Hinweise auch an andere BeĆ
nutzer weiter.
Achtung! Caution!
2.2 Achtungshinweis 2.2 Instructions
Dieses "Achtung!" steht an den Stellen in dieser BA, die The term "Caution!" denotes those sections in this maĆ
besonders zu beachten sind, damit die Richtlinien, VorĆ nual which require special attention, in order that the
schriften, Hinweise und der richtige Ablauf der Arbeiten guidelines, recommendations and correct procedures
eingehalten werden, sowie eine Beschädigung und are complied with to prevent damaging or destroying
Zerstörung der Kupplung verhindert wird. the clutch.
2.3 Arbeitssicherheitshinweise 2.3 Safety instructions for working

Folgende Arbeitssicherheitshinweise sind besonders The following recommendations are of particular imporĆ
zu beachten: tance:
Die Kupplung ist nach dem Stand der Technik gebaut The clutch has been manufactured to the highest up to
und betriebssicher. Von diesem Gerät können aber GeĆ date standard and is operationally safe. However, the
fahren ausgehen, wenn es von unausgebildetem PerĆ clutch can become a risk to safety when used improĆ
sonal unsachgemäß oder zu nicht bestimmungsgemäĆ perly by untrained personnel or for an application it is
ßem Gebrauch eingesetzt wird. not designed for.
Jede Person, die im Betrieb des Anwenders mit Ein- Every person involved in assembling, dismantling,
und Ausbau, Inbetriebnahme, Bedienung und InstandĆ commissioning, operating and maintaining (inspecting,
haltung (Inspektion, Wartung, Instandsetzung) der servicing and repairing) the clutch must be authorised,
Kupplung befaßt ist, muß autorisiert, entsprechend adequately trained and instructed. Each such person
ausgebildet und eingewiesen sein. Sie muß die komĆ must have read and understood this instruction maĆ
plette BA und besonders die Sicherheitshinweise geleĆ nual, especially in respect to the safety instructions.
sen und verstanden haben.
Für Schäden und Betriebsstörungen, die sich aus der We do not accept liability for damage or malfunctioning,
Nichtbeachtung der BA ergeben, übernehmen wir keiĆ resulting from non-adherence to this manual.
ne Haftung .
Der Anwender ist verpflichtet, die sicherheitstechniĆ The user is obliged to adhere to the requirements conĆ
schen Anforderungen nach DIN EN 982 bei Entwurf, cerning safety to DIN EN 982 on designing, construcĆ
Konstruktion und Bau der hydraulischen Anlage zu beĆ tion and manufacture, which are relevant for the operaĆ
rücksichtigen, die für den Betrieb der Kupplung erforĆ tion of the clutch.
derlich sind.
Reparatur- und Wartungsarbeiten dürfen nur von Repair and maintenance works must be carried-out by
Fachkräften oder unterwiesenen Personen durchgeĆ skilled and trained workmen only meeting the minimum
führt werden, die die Mindestkriterien für die Eignung requirements for aptitude and qualification according to
und Fähigkeit entsprechend DIN 31000 / VDE 1000 erĆ DIN VDE 1000-10.
füllen.
Es ist jede Arbeitsweise zu unterlassen, welche die SiĆ Any work process involving the product which impairs
cherheit der Kupplung beeinträchtigt. safety is to be avoided.
Der Anwender ist verpflichtet, eintretende VeränderunĆ The user is obliged to inform the supplier immediately
gen an der Kupplung, welche die Sicherheit beeinträchĆ of any change occuring to the product which adversely
tigen, dem Lieferanten sofort zu melden, Anschrift s. affects safety, address see chap. 9.3.
Kap.9.3.
Der Anwender ist verpflichtet, die Kupplung immer nur The user is obliged to only operate the clutch when it is
in einwandfreiem Zustand zu betreiben. functioning correctly.

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Nr./No. 777-00911
Eigenmächtige Umbauten und Veränderungen, welche Unauthorised changes and modifications which impair
die Sicherheit beeinträchtigen, sind ebenso wie der EinĆ safety, as well as the use of non-authentic components
satz fremder Zubehörteile nicht gestattet. is not permitted.
Um die Gefährdung von Personen, Haustieren und GüĆ To exclude any danger to people, domestic animals and
tern durch bewegte Teile auszuschließen, sind vom AnĆ goods by parts in motion, the user has to take protective
wender geeignete Schutzmaßnahmen nach DIN measures according to DIN 31000 / VDE 1000.
31000/VDE 1000 zu ergreifen.
Zur Vermeidung von gefährlichen Einflüssen aufgrund To avoid dangerous influences due to heating of the
der Erwärmung der Kupplung und im Fehlerfall sind units and in case of a failure, the user has to take suitĆ
vom Anwender geeignete Schutzmaßnahmen nach able protective measures according to DIN 31000 / VDE
DIN 31000 / VDE 1000 durchzuführen. 1000.
Achtung! Caution!
Für den Betrieb gelten in jedem Fall die In every case the local safety and acciĆ
örtlichen Sicherheits- und UnfallverhütungsvorĆ dent prevention regulations are also applicable, the
schriften. Der Anwender hat für die Einhaltung dieĆ user must ensure that these are complied with.
ser Vorschriften zu sorgen.
Gegenüber Darstellungen und Angaben dieser BA sind We reserve the right to make modifications of a techniĆ
technische Änderungen, die zur Verbesserung der cal nature to this manual if required for clutch developĆ
Kupplung notwendig werden, vorbehalten. ment.
Wir empfehlen, diese Anleitung als Bestandteil in die We recommend that these instructions are incorporaĆ
BA des Anwenders (Maschinenherstellers) aufzunehĆ ted into the service manual of the user (machine manuĆ
men. facturer).
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Nr./No. 777-00911
3. Transport 3. Transportation
(Einzelteile mit Positionsangaben siehe Kap. 4.1) (Single parts with item designation as per chapter.4.1)
3.1 Verpackung 3.1 Packing

Mitentscheidend für die Verpackungsart ist der TransĆ The type of packing depends on the transportation
portweg. Die auf der Verpackung angebrachten BildzeiĆ route. The symbols marked on the packing must be adĆ
chen sind zu beachten. hered to.
3.2 Anlieferungszustand 3.2 Delivery condition

Die Kupplung wird montiert geliefert. The clutch is supplied in mounted condition.
Achtung! Caution!
Der Außenkörper (2) ist lose auf das The outer body (2) is loosely fitted
Lamellenpaket (7, 8) aufgesteckt. onto the disc pack (7, 8).
3.3 Empfindlichkeit 3.3 Sensitivity

Beim Transport der Kupplung ist besonders vorsichtig Be particularly careful on transportation of the clutch in
zu verfahren, um Schäden durch Gewalteinwirkung order to avoid damage due to external force or careless
oder unvorsichtiges Be- und Entladen zu verhindern. loading and unloading. In relation to the type and duraĆ
Je nach Art und Dauer des Transportes sind entspreĆ tion of transportation provide corresponding transporĆ
chende Transportsicherungen vorgesehen. Während tation devices. During transportation avoid shocks as
des Transportes sind Kondenswasserbildung aufgrund well as the generation of condensation water due to
großer Temperaturschwankungen sowie Stöße zu verĆ temperature fluctuations.
meiden.
3.4 Zwischenlagerung 3.4 In-process stocking

Alle Teile, bis auf die Außenlamellen (8), sind durch eine All parts, with the exception of the outer discs (8), are
Oberflächenbehandlung gegen Korrosion geschützt. protected against corrosion by a surface refinement.
Die Bohrung in dem Innenkörper (1) ist mit einem KorroĆ The bore in the inner body (1) is provided with a prevenĆ
sionsschutzmittel versehen. tive against corrosion
Der Lagerraum für eine Zwischenlagerung muß trocken The store for in-process stocking must be dry and not
sein und darf keinen großen Temperaturschwankun Ć subject to high temperature fluctuations. When proĆ
gen unterliegen. Bei sachgemäßer Lagerung kann die perly stored, the clutch can be stocked up to 8 months.
Kupplung bis zu 8 Monaten eingelagert werden.
Soll die Kupplung länger als 8 Monate zwischengelaĆ Should it be intended to stock the clutch for a period exĆ
gert werden, so ist ein weiterer Korrosionsschutz vorzuĆ ceeding 8 months, another protection against corroĆ
nehmen. Angaben hierzu erhalten Sie von unserem sion has to be provided. Please consult our after-sales
Kundendienst, Anschrift s. Kap. 9.3. service, address see chap. 9.3.
Achtung! Caution!
Die Reibflächen und die DichtungsĆ The friction faces and the seal running
laufflächen dürfen nicht mit Korrosionsschutzmittel faces must not be treated with any preventive
behandelt werden. against corrosion.
3.5 Lieferumfang 3.5 Delivery extent

Die Vollständigkeit der Lieferung ist beim Empfang an On receipt check the consignment for completeness
Hand der Packliste zu überprüfen. Evtl. TransportschäĆ (see packing list). Possible damage during transportaĆ
den und/oder fehlende Teile sind sofort schriftlich zu tion and/or missing parts must be advised immediately
melden. and in writing.

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4 Aufbau, Wirkungsweise, Konstruktionsmerkmale

Construction, functioning and constructional characteristics
4.1 Abbildung mit Positionsangaben sowie Benennung der Einzelteile (gleichzeitig Ersatzteilliste)
Figure with item numbers and designation of the single parts (also spare parts list)
4.1.1 Langsschnitt mit Positionsangaben
Longitudinal section with item numbers
2 5 8 7 16,17 3 15
14
19
Druckölbohrung
Hydraulic oil bore
1
Kühlöhlkanal
Cooling oil channel
12
11
Bild / Fig. 1 DD-_771161
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Nr./No. 777-00911
4.1.2 Benennung der Einzelteile / Designation of the single parts

(gleichzeitig Ersatzteilliste / also spare parts list)
Position Bezeichnung Anzahl

Item Designation Quantity
1 Innenkörper / Inner body 1
2 Außenkörper / Outer body 1
3 Kolben / Piston 1
4 Zylinder / Cylinder 1
5 Druckscheibe / Pressure plate 1
7 Innenlamelle / Inner disc 8
8 Außenlamelle / Outer disc 7
11 Zyl.-Schraube / Cyl. screw 8
12 Zyl.-Schraube / Cyl. screw 9
14 Dichtring / Seal ring 1
15 Dichtring / Seal ring 1
16 Druckfeder / Pressure spring 16
17 Druckfeder / Pressure spring 16
19 Rundschnurring / Round cord ring 1
4.2 Wirkungsweise und Konstruktionsmerkmale 4.2 Functioning and constructional characteristics
Achtung! Caution!
Die hydraulisch geschaltete LamellenĆ The hydraulically operated multi-disc
kupplung KMS ist nur für den Naßlauf geeignet und clutch KMS is suitable for wet operation only and
somit nur innerhalb eines Gehäuses einsetzbar. must be used within a housing.
Wirkungsweise und Konstruktionsmerkmale werden The functioning and the constructional characteristics
anhand von Bild 1 wie folgt beschrieben: are described as follows -see fig. 1:
Der Zylinder (4) und die Druckscheibe (5) sind mit dem The cylinder (4) and the pressure plate (5) are rigidly
Innenkörper (1) durch die Zylinderschrauben (11) fest screwed to the inner body (1) by means of the cyl.
verschraubt. Zwischen Druckscheibe (5) und Kolben screws (11). Between pressure plate (5) and piston (3)
(3) sind verzahnte Innenlamellen (7) und AußenlamelĆ there are arranged toothed inner discs (7) and outer
len (8) angeordnet, die sich in entsprechenden VerzahĆ discs (8) which guide in the pertinent toothings of the
nungen des Außenkörpers (2) bzw. des Innenkörpers outer body (2) or inner body (1) resp. The piston (3) is
(1) führen. Auf dem Innenkörper (1) und in dem Zylinder centered on the inner body (1) and in the cylinder (4).
(4)wird der Kolben (3) zentriert. Der Kolben (3) kann The piston (3) can move axially and together with the cyĆ
sich axial bewegen und bildet mit dem Zylinder (4) und linder (4) and theinner body (1) it forms a piston space.
Innenkörper (1) einen Kolbenraum. Wird Öl unter hyĆ When now leading oil under hydraulic pressure to the
draulischem Druck dem Kolbenraum der Kupplung piston space of the clutch through a bore in the shaft
durch eine Bohrung in der Welle und des Innenkörpers and the inner body (1), the piston (3) starts to move
(1) zugeführt, beginnt sich der Kolben (3) axial zu beweĆ axially until the disc pack (7, 8), which supports to the
gen, bis das Lamellenpaket (7, 8), welches sich an der pressure plate (5), is compressed. By the accordingly
Druckscheibe (5) abstützt, zusammengepreßt ist. occurring frictional engagement between the inner
Durch den nun entstehenden Reibschluß zwischen den discs (7) and the outer discs (8), a torque is transmitted
Innenlamellen (7) und den Außenlamellen (8) wird ein from the inner body (1) to the outer body (2).
Drehmoment vom Innenkörper (1) auf den AußenkörĆ
per (2) übertragen.

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Nr./No. 777-00911
Bei Wegnahme des hydraulischen Drucks wird die On cancellation of the hydraulic pressure, the torque
Drehmomentübertragung beendet und die SchraubenĆ transmission is finished and the cyl. pressure springs
druckfedern (16, 17) bringen den Kolben (3) in seine (16, 17) re-set the piston (3) to its initial position.
Ausgangsstellung zurück. Die Innenlamellen (7) besitĆ The inner discs (7) dispose of a sine waving (spring efĆ
zen eine Sinuswellung (Federeffekt), wodurch das LaĆ fect) pressing the disc pack specificly apart. By this forĆ
mellenpaket gezielt auseinandergedrückt wird. Durch ced release the idle run heating is kept as low as possiĆ
diese Zwangslüftung wird die Leerlauferwärmung so ble. With particularly long idle run times the occasional
gering wie möglich gehalten. Bei besonders langen reduction of the cooling oil quantity after every switĆ
Leerlaufzeiten ist die zeitweise Verminderung der ching is a means to reduce further the low idle run torĆ
Kühlölmenge nach jeder Schaltung ein Mittel, das geĆ que in the released disc pack (7, 8).
ringe Leerlaufdrehmoment im gelüfteten LamellenpaĆ
ket (7, 8) noch weiter zu reduzieren.
Die Außenlamellen (8) mit einem speziellen Reibbelag The outer discs (8) with a special friction lining dispose
verfügen über eine gezielt gestaltete OberflächenauflöĆ of a specificly formed surface structure which allows to
sung, die es erlaubt, auch bei hoher thermischer BelaĆ convey a sufficient quantity of cooling oil from inside to
stung genügend Kühlöl von innen nach außen durch outside through the disc pack (7, 8) even with high therĆ
das Lamellenpaket (7, 8) zu fördern, damit ein Teil der mal load, so that a portion of the frictional heat can be
Reibwärme aufgenommen und abgeführt werden absorbed and dissipated.
kann.
Eine Verschleißnachstellung der Kupplung ist nicht erĆ A wear re-adjustment of the clutch is not necessary.
forderlich. Der während des Betriebes auftretende LaĆ The disc wear occurring during operation is balanced
mellenverschleiß wird durch den nachrückenden KolĆ by the following piston (3)
ben (3) ausgeglichen.
Im ausgeschalteten Zustand der Kupplung übt die In disengaged condition of the clutch, the residual oil
Restölmenge im Zylinderraum eine Axialkraft, hervorĆ quantity in the cylinder space exercises an axial force
gerufen durch eine Fliehkraft bei Rotation der Kupp- onto the piston (3), originating from a centrifugal force
lungsinnenteile, auf den Kolben (3) aus. Die SchrauĆ due to rotation of the clutch inner parts. The cyl. presĆ
bendruckfedern (16, 17) sind so ausgelegt, daß die sure springs (16, 17) are designed in such a way that
Kupplung nicht selbsttätig einschaltet, solange die the clutch does not engage automatically as far as the
maximal zulässige Drehzahl (siehe Kapitel 1.2) nicht max admissible speed (see chap. 1.2) is not exceeded.
überschritten wird.
4.3 Versorgungsanschlüsse 4.3 Supply connections

Die Kupplung wird mit Druck- und Kühlöl durch die The clutch is supplied with pressure oil and cooling oil
Kupplungswelle des Anwenders versorgt. Die DruckölĆ through the clutch shaft of the user. The hydraulic conĆ
leitung zur Kupplungswelle muß kurz und ohne scharfe duct to the clutch shaft must be short and free from
Biegung oder Querschnittsverengung sein. Um die sharp bends or cross section contractions. To protect
Kupplung vor unzulässigen Druckspitzen zu schützen, the clutch against inadmissible pressure peaks, a presĆ
ist der Einbau eines Druckbegrenzungsventils vorzuseĆ sure relief valve has to be mounted. Place the manomeĆ
hen. Das Druckmanometer ist so nah wie möglich an ter as close as possible to the clutch.
die Kupplung zu setzen.
Bei Planung, Auslegung und Installation der VersorĆ On planing, determination and installation of the supply
gungsleitungen sind die Richtlinien nach DIN EN 982 zu conducts, adhere to the regulations as per DIN EN 982.
berücksichtigen.
4.3.1 Druckölzuführung in der Welle 4.3.1 Hydraulic conduct in the shaft

Der Querschnitt der Wellenbohrung sollte ca. 1,2 bis 1,5 The cross section of the shaft bore should be 1.2 to 1.5
mal größer sein als die Summe der Druckölbohrungen times larger than the sum of the hydraulic bores in the
in dem Innenkörper (1) der Kupplung. Anzahl und BohĆ inner body (1) of the clutch. The number and diameter
rungsdurchmesser sind der Maßzeichnung (siehe KaĆ of bores are stated on the dimensional drawing (see
pitel 1.2) zu entnehmen. chap. 1.2).
4.3.2 Kühlölzuführung in der Welle 4.3.2 Cooling oil conduct in the shaft
Der Querschnitt der Wellenbohrung für das Kühlöl muß The cross section of the shaft bore for the cooling oil
der angegebenen Kühlölmenge entsprechen. Diese must comply with the stated cooling oil quantity, which
wird bei der Auslegung der Kupplung vom Hersteller is fixed by the manufacturer on determination of the
festgelegt. clutch.
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Nr./No. 777-00911
5. Ein- und Ausbau 5. Assembly and dismantling

(Einzelteile mit Positionsangaben siehe Kap. 4.1) (Single parts with item numbers see chapter 4.1)
Achtung! Caution!
Die Kupplung darf nur von autorisierĆ The clutch must only be operated,
tem, ausgebildetem und eingewiesenem Personal maintained and repaired by accordingly authorized,
bedient und gewartet werden. Dieses Personal muß trained and instructed people. Each such person
die komplette BA gelesen, verstanden und eine speĆ must have read and understood the complete inĆ
zielle Unterweisung über auftretende Gefahren erĆ struction manual and must have been informed in
halten haben. particular about possible risks and danger.
5.1 Einbauvorgang 5.1 Assembly

Das Gehäuse muß vor der Montage der Kupplung sorgĆ Before mounting the clutch clean the housing carefully.
fältig gereinigt werden. Die Kupplung ohne AußenkörĆ Push the clutch without outer body (2) onto the shaft
per (2) auf die Welle aufschieben und gegen axiale VerĆ and secure it against axial offset. When pushing it onto
schiebung sichern. Bei dem Aufschieben auf die Welle the shaft, assure that the hydraulic conduct bores in the
darauf achten, daß die Druckölzuführungsbohrungen clutch shaft and in the clutch are congruent. Push the
in der Kupplungswelle und in der Kupplung deckungsĆ outer body (2) with its internal toothing over the toothing
gleich sind. Der Außenkörper (2) ist mit seiner InnenverĆ of the outer discs (8). The outer body (2) centers at the
zahnung über die Verzahnung der Außenlamellen (8) adjacent component and must be screwed and pin-
zu schieben. Der Außenkörper (2) zentriert sich an das connected to it. (The wrench torque of the connection
angrenzende Bauteil und muß mit diesem verschraubt screws is stated on the dimensional drawing and in the
und gegebenenfalls verstiftet werden. (AnziehdrehmoĆ VDI-regulations 2230).
ment der Anschlußschrauben der Maßzeichnung oder
der VDI-Richtlinie 2230 entnehmen).
5.2 Montagegenauigkeit 5.2 Mounting accuracy

Der Rundlauf der Welle, auf der die Kupplung montiert The tolerances of shaft on which the clutch is mounted,
wird, sowie Koaxilität und Planlauf des angrenzenden as well as the coaxiality and run-out of the adjacent
Bauteils müssen der Toleranzklasse "N" der DIN 42955 component must comply with tolerance class "N" of
entsprechen. DIN 42955.
5.3 Abmessungen, Platzbedarf und Gewichte 5.3 Dimensions, space requirement and weight
Die verbindlichen Abmessungen, die Masse (Gewicht) The binding dimensions, the mass (weight) and the
sowie weitere technische Daten sind der für den jeweiĆ other technical data are stated on the dimensional draĆ
ligen Auftrag verbindlichen Maßzeichnung zu entnehĆ wing which is binding for the pertinent order. This draĆ
men. Diese wird der Auftragsbestätigung als Anlage wing is attached to the order acknowledgement and
beigefügt und kann auch zusätzlich von unserem KunĆ can also be inquired at our after-sales service (address
dendienst angefordert werden, Anschrift s. Kap. 9.3. is given in chap. 9.3).
5.4 Ausbauvorgang 5.4 Dismantling
! Hydrauliksysteme stehen unter Druck. Bei

! Hydraulic systems are subject to pressure.
unsachgemäßen Ausbau kann das Hydrauliksystem With inexpert dismantling, the hydraulic system can
explodieren und schwere Unfälle verursachen. explode and can cause heavy accidents.
Um dieses Explosionsrisiko zu vermeiden, muß das To avoid this explosion hazard, the hydraulic system
Hydrauliksystem vor dem Ausbau der Kupplung must be depressurized before dismantling the
drucklos gemacht werden. clutch.
Das Abziehen der Kupplung von der Welle ist nur mit Removal of the clutch from the shaft is to be made only
Hilfe der im Zylinder (4) und/oder in der Druckscheibe by the pull-of bores arranged on front side in the cylinĆ
(5) stirnseitig plazierten Abziehbohrungen durchzufühĆ der (4) and/or in the pressure disc (5).
ren.
Achtung! Caution!
Beim Ausbau der Kupplung besteht When dismantling the clutch, pay atĆ
Gefahr von Ölaustritt. tention to oil outlet.

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Nr./No. 777-00911
6. Inbetriebnahme 6. Setting into service

(Einzelteile mit Positionsangaben siehe Kap. 4.1) (Single parts with item designation as per chapter 4.1)
Vor der Erst-Inbetriebnahme ist das gesamte HydrauĆ Before initial setting into service, wash the entire hyĆ
liksystem vor Anschluß an die Kupplung zu spülen. draulic conduct before connecting it to the clutch.
Dieser Spülvorgang ist ebenfalls nach einem AusĆ Carry-out this washing also after an exchange of the
tausch der Dichtungen (14, 15, 19) durchzuführen. sealings (14, 15, 19). Here as well the washing oil must
Auch hierbei darf das Spülöl nicht in den Druckraum geĆ not enter into the pressure space.
langen.
7. Betrieb 7. Operation
! Unabhängig von nachfolgenden HinweiĆ

! Independent from the following hints, the
sen gelten für den Betrieb der Kupplung in jedem legal safety prescriptions for prevention of accident
Falle die am Einsatzort gesetzlich vorgeschriebenen prescribed for the particular application case apply
Sicherheits- und Unfallverhütungsvorschriften. to the operation of the clutch.
Der Anwender hat für die Einhaltung dieser VorĆ The user is held responsible to adhere to these preĆ
schriften zu sorgen. scriptions.
7.1 Betriebsbedingungen 7.1 Service conditions

Die Betriebsbedingungen, die für einen störungsfreien The service conditions which are to be adhered to in orĆ
Betrieb der Kupplung einzuhalten sind, werden nachĆ der to maintain the faultless operation of the clutch, are
folgend aufgeführt: listed below:
Die Ölzulauftemperatur im Betriebszustand darf +80°C With sevice condition, the oil inlet temperature must not
nicht überschreiten und +20°C nicht unterschreiten. exceed +80° and must not fall below +20°C.
Die relative Feuchtigkeit der Umgebungsluft soll 50% The relative humidity of the ambient air shall not exceed
bei 40°C nicht überschreiten. Bei niedrigeren TemperaĆ 50% at 40°C. With lower temperatures, higher air humiĆ
turen können höhere Luftfeuchtigkeiten zugelassen dities may be admissible, e.g. 90% at 20°C.
werden, z. B. 90% bei 20°C.
Die Umgebungsluft soll nicht durch Staub, Rauch, agĆ The ambient air should not be polluted by dust, vapour,
gressive Gase und Dämpfe oder Salzgehalt verunreiĆ agressive gas and fume or salt content.
nigt sein.
Die Kupplung darf nicht in das Ölbad eintauchen. Diese The clutch must not immerse into oil bath. This inadmisĆ
unzulässige Maßnahme setzt das Leerlaufdrehmoment sible measure increases the idle-run torque and conĆ
und somit die Erwärmung der Kupplung herauf. sequently the heating of the clutch.
7.2 Druck- und Kühlflüssigkeiten 7.2 Hydraulic and cooling liquids

Der störungsfreie Betrieb -insbesondere das ReibverĆ The faultless operation -in particular the friction behaĆ
halten- hängt in starkem Maße vom Einsatz geeigneter viour- strongly depends on the utilisation of suitable
Öle ab. oils.
Vorzugsweise sind zum Schalten der Kupplung und For the switching of the clutch and cooling of the discs,
Kühlen der Lamellen Schmieröle nach der Stromag- preferably use lubrication oils according to the Stromag
Werksnorm TM 000.327 zu verwenden. Der ISO ViskoĆ works standard TM 000.327. The ISO viscosity range to
sitätsbereich nach DIN 51519 sollte innerhalb von ISO DIN 51519 should be within ISO VG 15 to ISO VG 100.
VG 15 bis ISO VG 100 liegen.
Diese Tabelle kann bei unserem Kundendienst angeforĆ This table can be inquired at our after-sales service,
dert werden, Anschrift s. Kap. 9.3. address as per chap. 9.3.
7.3 Filterung und Ölwechsel 7.3 Filtering and oil exchange

Im Hydrauliksystem muß auf Sauberkeit und gute FilteĆ Pay very special attention to cleanness and good filteĆ
rung unbedingt geachtet werden, um Funktionsfehler ring in the hydraulic system in order to exclude faulty
auszuschließen. Empfohlene Filtermaschenweite operation. Recommended filter mesh width: 10-25 mm.
10-25 mm.
Spätestens 500 Betriebsstunden nach der ErstinbeĆ 500 service hours after initial setting into service at the
triebnahme ist eine sachgemäße Reinigung des Öles latest, carry-out an appropriate cleaning of the oil or an
oder ein Ölwechsel durchzuführen. In Abständen von oil exchange. Further oil exchanges are required in inĆ
8000 Betriebsstunden oder höchstens 2 Jahren sind tervals of 8000 service hours or max. 2 years.
weitere Ölwechsel erforderlich.
Diese Maßnahmen führen zu einer Verringerung des By these measures, the disc wear is reduced.
Lamellenverschleißes.
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7.4 Einschaltdauer, Schalthäufigkeit und SchaltzeiĆ 7.4 Duty cycle, switching frequency and switching
ten times
Die Kupplung ist unter Einhaltung der zulässigen The clutch is determined in compliance with the admisĆ
Schaltarbeit, Reibflächenbelastung, WärmespeicheĆ sible switching work, friction face load, heat accumulaĆ
rung usw. ausgelegt. tion, etc.
Für einen störungsfreien Betrieb sind die technischen To assure a trouble-free operation, adhere to the techĆ
Daten gem. Kapitel 1.2 einzuhalten. nical data as per chap. 1.2.
7.5 Störungsabhilfe / Trouble shooting

(Einzelteile mit Positionsangaben s. Kap. 4.1 / Single parts with item numbers as per chap. 4.1)
Störung Mögliche Ursachen Erforderliche Maßnahmen
Trouble Possible cause Required measures
Drehmoment der Kupplung nicht Zulässiger Verschleiß überschritten Lamellenpaket austauschen (s. Kap. 8.2)
ausreichend Admissible wear exceeded Replace the disc pack (see chap. 8.2)
Insufficient clutch torque Betriebsüberdruck ist zu klein Ursache prüfen und für Abhilfe sorgen
Insufficient service excess pressure Check cause and find a remedy
Kupplung wird zu warm Betriebsüberdruck ist zu klein Ursache prüfen und für Abhilfe sorgen
Clutch heats too much Insufficient service excess pressure Check cause and find a remedy
Kühlöldruck ist zu hoch oder Volumenstrom Ursache prüfen und für Abhilfe sorgen
zu klein
Excessive cooling oil pressure or insufficient Check cause and find a remedy
volume flow
Kühlöl ist zu dickflüssig, es tritt Leerlauf- Kühlöl entsprechend Kap. 7.2 vorsehen
wärme auf
Cooling oil too viscous, idle run heat occurs Provide cooling oil as per chap. 7.2
8. Instandhaltung 8. Maintenance
8.1 Pflege- und Kontrollarbeiten 8.1 Maintenance and inspection works

(Einzelteile mit Positionsangaben siehe Kap. 4.1) (Single parts with item designation as per chapter 4.1)
Bei Wartungs- und Inspektionsarbeiten ist das Kapitel When carrying-out maintenance and inspection works
2 "Sicherheitshinweise" zu beachten. pay attention to chapter 2 "Safety guide-lines".
Auf Grund der unterschiedlichen Betriebsverhältnisse Because of the varying service ratios the exact intervals
kann im voraus nicht festgelegt werden, wie oft eine InĆ for inspection, maintenance or repair cannot be fixed in
spektion, Wartung und Instandsetzung erforderlich ist. advance.
Höhere Belastungen der Kupplungen (z.B. durch DrehĆ Higher charges of the clutch (e.g. by torque, switching
moment, Schalthäufigkeit, Umgebungstemperatur frequency, ambient temperature etc.) require shorter
usw.) erfordern kürzere Wartungsintervalle. maintenance intervals.
Daher ist zunächst die Kupplung hinsichtlich ihrer FunkĆ Therefore observe the clutch for its functional safety
tionssicherheit (z.B. Leckölverluste, LamellenverĆ (e.g. loss of leakage oil, disc wear, temperature etc.)
schleiß, Temperatur usw.) zu beobachten und die WarĆ and adapt the maintenance intervals accordingly (exĆ
tungsintervalle sind auf Grund der gewonnenen perience).
Erkenntnisse entsprechend anzupassen.
Leckölverluste an den Dichtungen sind grundsätzlich Generally leakage oil losses at the sealings cannot be
nicht zu vermeiden. Daher ist die Druckölpumpe entĆ avoided. Therefore dimension the oil pressure pump
sprechend zu dimensionieren. accordingly.

11
KMK-S
Nr./No. 777-00911
8.2 Demontage der Kupplung 8.2 Dismantling of the clutch

8.2.1 Arbeitssicherheitshinweise 8.2.1 Safety instructions for working
! Der Zylinder (4) und die Druckscheibe (5)

! The cylinder (4) and the pressure plate (5)
stehen unter hohem Federdruck! are subject to high spring pressure!
Um Unfälle und daraus resultierende Verletzungen To avoid accidents and resulting hurt and injury, we
zu vermeiden, empfehlen wir dringend, die DemonĆ recommend urgently to ask the manufacturer or an
tage vom Hersteller oder von einem KundendienstĆ after-sales engineer to carry-out the dismantling.
monteur vornehmen zu lassen.
Wenn ein Lamellenpaket- und/oder DichtungswechĆ When it is absolutely necessary to replace the disc
sel unumgänglich ist, sollte nach Punkt 8.2.2 oder 8.2.3 pack and/or the sealings, proceed as described in the
vorgegangen werden. chapters 8.2.2 or 8.2.3.
Vor beiden Arbeitsgängen ist das Hydrauliksystem Before starting with any of these works depressurize the
drucklos zu machen. hydraulic system.
8.2.2 Auswechseln des Lamellenpaketes 8.2.2 Exchange of the disc pack

1. Die Kupplung gem. Kap. 5.4 ausbauen. 1. Dismantle the clutch as per chap. 5.4.
2. Zwei gegenüberliegende Zylinderschrauben entĆ 2. Remove two opposite cyl. screws and screw two
fernen und in die frei werdenden GewindebohrunĆ longer cyl. screws into the now free threaded bores.
gen zwei längere Zylinderschrauben einschrauben. These dismantling auxiliary screws are not included
Diese Demontagehilfsschrauben gehören nicht in the delivery extent.
zum Lieferumfang.
3. Die restlichen Zylinderschrauben (11) gleichmäßig 3. Loosen uniformly the remaining cyl. screws (11)
Zug um Zug lösen und entfernen. Dabei fangen die step by step and remove them. The two dismantling
beiden Demontagehilfsschrauben die DruckĆ auxiliary screws will hold the pressure plate (5).
scheibe (5) auf.
4. Die beiden Demontagehilfsschrauben und die 4. Remove the two dismantling auxiliary screws and
Druckscheibe (5) entfernen. SchraubendruckfeĆ the pressure plate (5). Take away the cyl. pressure
dern (16, 17) herausnehmen und sorgfältig aufbeĆ springs (16, 17) and stock them carefully
wahren.
5. Das Lamellenpaket ist nun frei zugänglich und kann 5. Now the disc pack is freely accessible and can be
gegen ein neues ausgetauscht werden. Dabei ist replaced by a new one. Pay attention to the correct
auf die richtige Schichtung von Innen- und AußenĆ arrangement of the inner and outer discs (7, 8) as
lamellen (7, 8) gem. Bild 1 zu achten. per fig. 1.
Verzahnung des Innenkörpers (1) auf Verschleiß Check the toothing of the inner body (1) for wear. In
kontrollieren. Bei Schaltmarkierungen über 0,1 mm case of switching marks exceeding 0.1 mm depth,
Tiefe ist der Innenkörper (1) auszutauschen. replace the inner body (1).
6. Schraubendruckfedern wieder in ihre Bohrungen 6. Re-fit the cyl. pressure springs into their bores. Fit
legen.In zwei gegenüberliegende Bohrungen der two cyl. screws, see section 2, as mounting auxiliary
Druckscheibe (5) zwei Zylinderschrauben, s. AbĆ screws into two opposite bores of the pressure
schnitt 2, als Montagehilfsschrauben stecken und plate (5), and with them press the armature plate (5)
damit die Druckscheibe (5) gegen den Federdruck onto the centering in the inner body (1) against the
auf die Zentrierung im Innenkörper (1) drücken. spring pressure.
12
KMK-S
Nr./No. 777-00911
7. Mit Hilfe von vier Zylinderschrauben (11) die DruckĆ 7. Press the pressure plate (5) onto the centering up
scheibe (5) bis zum Anschlag auf die Zentrierung to limit stop using four cyl. screws (11) and protect
drücken und die Zylinderschrauben (11) dabei mit the cyl. screws (11) by liquid screw protection. ReĆ
flüssiger Schraubensicherung sichern. Die beiden move the two mounting auxiliary screws and reĆ
Montagehilfsschrauben entfernen und durch die place them by the two remaining cyl. screws (11).
zwei restlichen Zylinderschrauben (11) ersetzen. Protect all cyl. screws (11) by liquid screw protecĆ
Alle Zylinderschrauben (11) mit flüssiger SchrauĆ tion. The wrench torque for the screws (11) is stated
bensicherung sichern. Das Anziehdrehmoment für on the dimensional drawing or in the regulation VDI
die Schrauben (11) ist der Maßzeichnung oder der 2230.
VDI Richtlinie 2230 zu entnehmen.
8. Montageschritte 4 und 5 gem. Kap. 5.1 durchfühĆ 8. Follow the mounting steps 4 and 5 as per chap. 5.1.
ren.
8.2.3 Auswechseln der Dichtungen 8.2.3 Exchange the sealings

1. Demontage der Druckscheibe s. Kap. 8.2.2, AbĆ 1. Dismantle the pressure plate as per chap. 8.2.2,
schnitt 1 - 4. section 1 - 4.
2. Zylinderschrauben (12) entfernen und Zylinder (4) 2. Remove the cyl. screws (12) and take the cylinder
vom Innenkörper (1) abziehen. (4) from the inner body (1).
3. O-Ring (19) aus Zylinder (4) entfernen und durch 3. Remove the O-ring (19) from the cylinder (4) and
neuen ersetzen. replace it by a new one.
Kolben (3) vom Innenkörper (1) abziehen Take the piston (3) from the inner body (1).
4. Dichtung (15) und (14) aus Kolben (3) entfernen. 4. Remove the sealing (15) and (14) from the piston
Vor der Montage der neuen Dichtungen müssen (3). Before mounting the new sealings remove careĆ
Staub, Schmutz, Späne und sonstige FremdpartiĆ fully any dust, pollution, chips and other foreign parĆ
kel sorgfältig entfernt werden! ticles!
Keine scharfkantigen Werkzeuge verwenden! Do not use any sharp-edged tool!
Wo immer möglich, Montagehilfen verwenden. Wherever possible, use mounting devices.
Dichtungsflächen am Kolben (3), Innenkörper (1) Before mounting oil or grease the sealing faces at
und Zylinder (4) sind, wie die Dichtungselemente the piston (3), inner body (1) and cylinder (4); the
selbst, vor der Montage einzuölen oder einzufetten. same applies to the sealing elements themselves.
5. Dichtung (15) durch Schieben über die 5. Expand the sealing (15) by pushing it over the leaĆ
Einführungsschräge am Kolben (3) aufweiten und ding-in bevel at the piston (3) and let it snap into
in die Nut einschnappen lassen. the keyway.
Zur Montageerleichterung können zum Aufweiten To facilitate the mounting it is also possible to use
auch zwei Kalibrierbänder eingesetzt werden, die two calibration tapes for expansion; these tapes
den Gleitring an zwei Stellen im Abstand von ca. surround the gliding ring at two points in a distance
120_ umfassen und ihn ziehend in die Nut ein- of approx. 120° and let it snap into the keyway by
schnappen lassen. drawing it.
6. Dichtung (14) in die Nut der Kolbenbohrung einleĆ 6. Insert the sealing (14) into the keyway of the piston
gen. bore.
7. Montage der Druckscheibe s. Kap. 8.2.2, Abschnitt 7. Mount the pressure plate as per chap. 8.2.2, section
6 - 8. 6 - 8.

13
KMK-S
Nr./No. 777-00911
9 Ersatzteilhaltung und Kundendienst 9 Spare parts stocking and after-sales service
9.1 Ersatzteilhaltung 9.1 Spare parts stocking

Eine Bevorratung der wichtigsten Ersatz- und VerĆ To assure the continuous functioning and readiness for
schleißteile ist eine wichtige Voraussetzung für die stänĆ operation of the clutch, it is necessary to keep on stock
dige Funktion und Einsatzbereitschaft der Kupplung. the most important spare parts as well as parts subject
to normal wear.
Verschleißteile sind Innenlamellen (7), Außenlamellen Parts subject to wear are the inner discs (7), outer discs
(8), Dichtungen (14, 15, 19) und SchraubendruckfeĆ (8), sealings (14, 15, 19) and cyl. pressure springs (16,
dern (16, 17) (Positionsangaben siehe Kap. 4.1). 17) (Item numbers as per chap. 4.1).
Nur für die von uns gelieferten Original-Ersatzteile We only accept liability for the original spare parts supĆ
übernehmen wir eine Gewährleistung. plied by ourselves.
Wir machen ausdrücklich darauf aufmerksam, daß der We express clearly that the assembly and/or utilisation
Einbau und/oder die Verwendung nicht von uns gelieĆ of other parts than the original spare parts supplied by
ferter Original-Ersatzteile die konstruktiv vorgegebeĆ ourselves, can change infavourably the characteristics
nen Eigenschaften der Kupplung negativ verändern of the clutch prescribed by the construction and that
und dadurch die aktive und/oder passive Sicherheit beĆ thereby the direct and/or indirect safety can be affected.
einträchtigen kann.
Für Schäden, die durch die Verwendung von Nicht- For damage caused by the utilisation of not original
Original-Ersatzteilen und -Zubehör entstehen, ist jeĆ spare parts and accessories, any liability of the Stromag
de Gewährleistung seitens der Stromag AG ausgeĆ AG is excluded.
schlossen.
Bitte beachten Sie, daß für Eigen- und Fremdteile oft Please bear in mind that often special manufacturing
besondere Fertigungs- und Lieferspezifikationen beĆ and delivery specifications apply to own as well as to foĆ
stehen und wir Ihnen stets Ersatzteile nach dem neueĆ reign parts and that we always offer spare parts to the
sten technischen Stand und nach den neuesten geĆ up-dated technical conditions and the up-dated legal
setzgeberischen Vorschriften anbieten. prescriptions.
9.2 Daten für Ersatzteilbestellung 9.2 Data for spare parts orders
Zur Ersatzteilbestellung bedienen Sie sich bitte der ErĆ When ordering spare parts please refer to the spare
satzteilliste in Kap. 4.1. parts list in chapter 4.1.
Es sind folgende Angaben erforderlich: The following information is required
Auftrags-Nr. siehe Kap. 1.1 Order-Ref.-No. see chapter 1.1
Baureihe und Größe siehe Kap. 1.1 Series and size of see chapter 1.1
der Kupplung the clutch
Position und Benennung siehe Kap. 4.1 Item and designation of see chapter 4.1
des Ersatzteiles the spare part
Stückzahl Quantity
9.3 Kundendienstanschrift 9.3 Address of the after-sales service

Unsere Anschrift für den Kundendienst und den ErsatzĆ Our address for the after-sales service and the sales
teilvertrieb: of spare parts is:
Stromag AG Stromag AG
59411 Unna, Postfach 2123 D-59411 Unna, Postfach 2123
59425 Unna, Hansastr. 120 D-59425 Unna, Hansastr. 120
Telefon (02303) 102-0 Telephone (02303) 102-0

Telefax (02303) 102-467 Telefax (02303) 102-467
Benötigen Sie einen Service-Monteur, so wenden Do you need the delegation of a service engineer?
Sie sich bitte unter der obigen Anschrift an unseren Please contact us under our above address:
"Technischen Kundendienst." Attention "After-Sales Service".
14
KMK-S
Nr./No. 777-00911
10 Entsorgungshinweis 10 Hints for waste management

Sollten Sie Fragen zur umweltverträglichen Entsorgung The environmental representative of Stromag AG is at
des Stromag-Produktes nach Wegfall der Nutzung haĆ your disposal to answer to your questions regarding the
ben oder Hilfestellung zu diesem Thema benötigen, so environmentally friendly waste management of StroĆ
steht Ihnen der Umweltbeauftragte der Stromag AG als mag products after their utilisation or to grant you any
Ansprechpartner zur Verfügung. Wenden Sie sich bitte assistance required. Please consult our after-sales
an unseren Kundendienst, Anschrift s. Kap. 9.3. service; the address is given in chap. 9.3.
11 Aufgeführte Normen und Richtlinien / Listed standards and regulations

Die Kupplung entspricht den einschlägigen Normen und Richtlinien, insbesondere folgenden:
The clutch complies with the usual standards and regulations, in particular with:
Titel / Title DIN VDE VDI

Paßfedern und Nuten / Fitting keys and keyways 6885 - -
Rundlauf d. Wellenenden, Koaxialität u. Planlauf des Befestigungsflansches 42955 - -
Tolerances of shaft extension run-out and of mounting flange
ISO-Viskositätsklassifikation / ISO viscosity classification 51519 - -
Allgemeine Leitsätze für das sicherheitsgerechte Gestalten techn. Erzeugnisse 31000 1000 -
General guidelines for safety-pertinent designing of technical products
Sicherheitstechnische Anforderungen an fluidtechnischen Anlagen und Bauteilen - DIN - -
Hydraulik EN
Safety specifications for fluid technical systems and components - hydraulics 982
Systematische Berechnungen hochbeanspruchter Schraubenverbindungen - - 2230
Systematic calculation of high-duty bolted joints

15
Rev.02
BA3-6NNN-112//4
Operating instructions for gear pumps Web/15.01.01
Series R4,0; R4,5; R6,0 FL-Z-UNI-... Sheet 1 (4)
Before the gear pump is taken into service the operating instructions must be carefully
read. No warranty claims will be accepted for gear pump faults and damage occuring as
a result of insufficient knowledge of the operating instructions.
Contents Sheet
1 General 1
2 Safety 1
3 Transportation and intermediate storage 2
4 Description of the gear pump 3
5 Mounting / Installation 3
6 Commissioning 3
7 Dismantling 3
8 Maintenance 3
9 Spare parts 4
10 Operational disturbances 4
1 General
The gear pump is intended for installation in a machine or for assembly with other machinery components to be
assembled into a machine unit. Commissioning of the pump is prohibited until it has been proved beyond doubt
that the machine into which these gear pump is to be mounted or of which these gear pump shall form an integral
part is in conformity with the applicable provisions of the EU Machinery Guidelines 98/37/EG.
1.1 Application
The gear pump is to be used for the lube oil supply of industrial gearboxes in the framework of contractually
agreed application limits. Any use or application of the gear pump exceeding this intended functional scope is
deemed to be in contradiction to the intended purpose and is therefore prohibited. The manufacturer shall not be
held liable for damage as well as any consequential damage that might occur as a result of such misuse. The risk
of using in any such application lies solely with the client.
Prerequisite for a correct functioning, operational safety and a long service life is, primarily, that the medium
conveyed is clean, does not attack the gear pump material and does not contain additives that lead to or promote
wear.
1.2 Technical data
Technical data of the gear pump shall apply as specified in the dimensional drawing (MZ...).
1.3 Warranty
Our liability for defects of the products supplied has been laid down in our general conditions of supply. No liability
will be assumed for damage caused if these operating instructions are disregarded.
2 Safety
These operating instructions contain basic notes that must be observed in mounting and operating. It is therefore
indispensable that these operating instructions are read by the fitter as well as applicable personnel/operator
before carrying out mounting and commissioning work. The operating instructions must always be available at the
place where the machine/plant is operated. Attention must be paid not only to the general notes on safety
described in this main safety section but also to the specific safety instructions prescribed in other paragraphs.
2.1 Symbols used in this operating instructions
This danger sign identifies general safety issues related to the protecting of personnel.
Notes intended to safeguard the gear pump have been signified by this symbol.
Form 229589-7
Rev.02
BA3-6NNN-112//4
2.2 Qualification and training of personnel
Personnel entrusted with operation and mounting must be suitable qualified for this work. Area of responsibility,
competence and supervision of personnel must have been clearly defined by the operator. If the personnel lacks
the required technical knowledge appropriate training and teaching must be initiated. Moreover, the operator must
insure that the contents of the operating instructions has been clearly understood by the staff concerned.
2.3 Danger associated with disregarding these notes on safety
Any failure to observe the safety instructions may endanger not only the personnel and machine but also the
environment. Please note that claim for damages may become forfeited if the safety instructions are not duly
followed.
In particular, a failure to observe these instructions may give rise to the following dangerous situations:
• Failure of important functions of the machine/plant.
• Ineffectiveness of prescribed methods of maintenance and repair.
• Hazards for personnel by mechanical or chemical influences.
• Environmental risks due to leakage of harmful substances
2.4 Working in a safety-conscious manner
The safety notes included in the operating manual, any applicable national regulation governing accident
prevention as well as in-house working, operating and safety instruction issued by the operator must by dully
observed.
2.5 Safety Instructions for operator/staff
• In the event that hot and cold machinery parts create danger these components must be safeguarded by the
plant owner to prevent accidental contact.
• Any leakage of hazardous media conveyed in the system (e.g. of explosive, toxic, hot nature) must be
discharged in such a manner that no danger to persons or the environment can occur. Any applicable legal
provisions have to be duly observed.
2.6 Safety instructions regarding mounting work
The operator must take due care that all mounting work is exclusively performed by authorised and qualified
expert personnel that has informed itself sufficiently by having studied these operating instructions thoroughly.
Basically, all work carried out on the machine must be performed when the machine is at a standstill.
All safety protective systems have to be replaced or make fully function able as soon as the work has been
completed.
Before re-commissioning the system the remarks given in section 6 -Commissioning - must be carefully read.
2.7 Valve conversion and use of original spare parts
A conversion of, or modifications to the gear pump are exclusively permissible if agreed to by the manufacturer.
If unauthorized spare parts are used, no liability for consequences that may arise will be assumed.
2.8 Inadmissible operating modes
The operational safety of the gear pump supplied is only warranted if it is used as described under section 1 -
General - of these operating instructions. The maximum values prescribed in section 1.2 - Technical data - must
by no means be exceeded.
3 Transporting and intermediate storage
As a rule, the gear pump is installed shortly after it has been delivered. Special measures to be taken for packing,
preservation etc. must be separately agreed upon.
Form 229589-7
Rev.02
BA3-6NNN-112//4
4 Description of the gear pump

(see sectional drawing FZ...)
The gear pump is a rotating displacement pump. When the shaft rotates the gearteeth of wheel and annulus
engage with each other, ie. the tooth gaps of wheel and annulus are reciprocally occupied. On the suction side,
the resulting gap space fills with medium due to the vacuum that builds up. On the delivery side the medium is
displaced by the teeth engaging with the gap spaces (axial displacement). The gearbox housing can be turned
through 180° so that the flow direction of the gearbox can be maintained in the event the rotational direction
changes. The gear pump consists essentially of casing (1), end cover (2), gear casing (3) as well as the gear shaft
(4) and the annulus (5). The housing and end cover are fitted with plain bearings that are lubricated by means of
the medium conveyed. The static sealing between casing and end cover is effected by a o-ring (10). A shaft
sealing is not existing, the exiting bearing oil (pressureless) enters the sump of the gearbox.
5 Mounting / Installation
The flange connection surfaces of the gear pump as well as the relevant mating surfaces must
be free from damage, paint remnants and other contamination. At greatest cleaness is to be
watched.
Drive elements such as couplings and gearwheels must not be driven onto the shaft by hammering, otherwise
gear pump damage may occur. The pipework must be laid to avoid undue stresses. The size of the gear pump
suction connection does not govern the cross sectional area of the piping. In most cases a suction line cross
section will be sufficient that matches the gear pump inlet cross section. It is nevertheless recommendable to
determine all elements of resistance in the system (gravity suction head, pressure losses in the piping and across
piping components - non-return valve, bends etc.) to check whether there is a cavitation hazard. The suction line
must be absolutely tight. Any unusual noise may be indicative of air being sucked into the gear pump or of the
pump operating in the cavitation range. Both operating states are intolerable for a constantly operating gear pump.
The direction of flow is marked on the end cover of the pump by means of a cast-on arrow.
6 Commissioning
Prior to commissioning the fastening bolts must be tightened as prescribed (see MZ...).
In the event difficult intake conditions are encountered the gear pump has to be mounted in such a position that
some residual fluid remains in the pump. Should this be impossible the gearwheels of the pump must be wetted
with the conveyed fluid prior to commissioning.
7 Dismantling
There is always a residual amount of liquid in the gear pump. If a non-return valve has been
integrated into the suction line and/or if suction and delivery lines are arranged such that the
gear pump cannot run dry all hollow spaces of the gear pump remain filled with liquid.
Therefore, appropriate steps must be taken when dismantling the pump to collect this liquid.
Depending on the type of medium conveyed exiting liquids may endanger man and
environment! For that reason effective steps must be taken in conformity with the safety data
sheets of the respective liquids.
8 Maintenance
At present, no intervals for preventive maintenance or replacement of the gear pump have been defined. This can
only be decided on after the gear pump has been technically released and the product monitored for a sufficient
period of time.
Form 229589-7
Rev.02
BA3-6NNN-112//4
9 Spare parts
Due to the tailored design of the gear pump no spare parts will be supplied but exclusively the complete pump
unit.
10 Operational disturbances
Error Source of error Test
Not supply output System Liquid level?
Suction route? (closed, leaky)
Gear pump Is the toothing wetted with liquid?
Is the pin of the turning limit fixed?
When turning the shaft by hand, does the pin
contact the stop audibly?
Noise System Liquid level?
Suction route? (necked, leaky)
Gear pump Damage of o-ring?
Check operating parameters
Pressure fluctuates System Liquid level?
Gear pump Rotational speed is to low
Form 229589-7
Operating Instructions
N – R 435 en 09.03
for totally enclosed fan–cooled (TEFC) and internally cooled (ODP)
three–phase motors with squirrel cage
for low voltage, with antifriction bearings
BN.A–071 to BN.A–315
A..A–071..–.. to 800..–..
J..A–160..–.. to 800.. –..
LOHER GmbH
P.O. Box 1164 • 94095 RUHSTORF
Hans–Loher–Str. 32 • 94099 RUHSTORF
GERMANY
Phone +49 8531 39–0 • Fax +49 8531 32895
E–Mail: info@loher.de
http://www.loher.de
Table of contents
Page
1. Safety and commissioning instructions. . . . . . . . . . . . . . . . . . . . . . . . . . . 2
2. Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
3. Transport . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
4. Installation and commissioning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
5. Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .14
6. Additional equipment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
7. Three–phase motors as centrifugal drive for heavy starting . . . . . . . . . . . . . 18
8. Spare parts. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
9. Storage instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
10. Faults and remedies . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
11. Operating instructions for brake motors with spring–loaded
single–disk brake . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
12. EC Declaration of Conformity. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
Appendix 1; Grease life and grease quantities . . . . . . . . . . . . . . . . . . . . . . . 30
Appendix 2; Alignment check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
Subject to modifications
Loher GmbH 2003
All rights reserved
N–R 435 en 09.03 Page 1 of 31

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”.
Page 2 of 31 N–R 435 en 09.03

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.
N–R 435 en 09.03 Page 3 of 31

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.
Page 4 of 31 N–R 435 en 09.03

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.
N–R 435 en 09.03 Page 5 of 31

Description
2.3 Cooling
2.3.1 Surface cooling (TEFC) for the Type A..A–...–.. except A.WA–132..–.. to A.WA–560..–..
Design for fin–, hollow–fin– or tube cooling, where an external fan takes in the cooling air through
the openings in the fan cover and presses the air over the surface or through the cooling tubes of
the stator housing. In case of hollow–fin or tube cooling the heat dissipation is supported by a
closed cooling air circuit inside the motor.
2.3.2 Internal cooling for the Type J..A–... except JNWA–... and JNRA–...
In case of motors with enclosure IP 23 the cooling air (ambient air) is taken in by internal fans
through air inlet openings, is led over the heat–generating elements in the motor and is blown out
through air outlets.
2.3.3 Internal cooling with mounted–on air–water heat exchanger for the Type JNWA–...
The motors are equipped with air–water circuit coolers. The cooling air led through the heat ex-
changer and motor is recooled in the heat exchanger and the heat loss is dissipated through the
cooling water. The heat exchangers are provided with special ribbed tubes.
2.3.4 Internal cooling with mounted–on air–to–air heat exchanger for the Type JNRA–...
The motors are equipped with air–to–air heat exchanger. The cooling air led through the heat
exchanger and motor is recooled in the heat exchanger and the heat loss is dissipated through
the cooling medium air.
2.3.5 Water jacket cooling for the Type A.WA.–132..–.. to A.WA.–560..–..
The stator housing has a double casing. For water channelling it is sub–divided by spirals where
the cooling water passes through. This results in a good heat dissipation. Additionally, this reduces
the danger that suspended matters carried along in the water can deposit.
2.4 Motor frame

2.4.1 Construction for surface cooling (TEFC), hollow–fin cooling or tube cooling
(Type A..A–...–.. except A.WA–132..–.. to A.WA–560..–..)
Depending on the frame size the stator frame and end shields are made of grey cast iron or steel.
The fan cover is made of sheet steel. The stator frame surface is provided with cooling fins, hollow
fins or tubes and attached terminal box.
2.4.2 Construction for internal cooling (ODP) for the Type J..A–... except JNWA–... and
JNRA–...
Depending on the frame size the stator frame and end shields are made of cast iron or steel. The
stator frame has an even surface with attached terminal box. There are distance fins between sta-
tor jacket and stator pack allowing the internal cooling.
2.4.3 Construction for internal cooling with air–water heat exchanger for the Type JNWA–...
The stator frame and end shields are of steel. The stator frame surface is plain with
mounted–on terminal box. Between the stator jacket and the stator core there are spacing ribs
making possible the internal cooling. An air–water circuit cooler is mounted onto the ventilation
openings.
2.4.4 Construction for internal cooling with air–to–air heat exchanger for the Type JNRA–...
Like for the internal cooling with air–water heat exchanger, however, an air–to–air heat ex-
changer is mounted onto the ventilation openings.
2.4.5 Construction for water jacket cooling (Type A.WA.–132..–.. to A.WA.–560..–..)
Stator frame and end shields are made of grey cast iron or steel.
The stator housing is designed as double casing, through which the cooling water is led.
The housing is provided with inlet and outlet for the cooling water.
Page 6 of 31 N–R 435 en 09.03

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.
N–R 435 en 09.03 Page 7 of 31

Transport
3. Transport
For handling during transport the stator construction of the motor is equipped with lifting eyes,
where the lifting hooks can be fixed.
Check whether screwed lifting eyes are securely tightened.
Lift motors only by using these lifting eyes. Several lifting eyes must always be used
together.
Lifting of the motors on other parts (e.g. shaft ends) is not permitted, since this might result in
considerable damages.
The lifting eyes are only suitable for the motor weight. Additional loads attached to the
motor must never be lifted using these eyes.
3.1 Check before installation

Check whether the motor has been damaged during transport. If the packing is damaged to such
an extent that a motor damage is to be assumed, the packing should be removed in the presence
of a representative agent of the carrier.
3.2 Bearing lock

(for motors with cylindrical roller bearings only.)
The rotor of the motor is locked in order to avoid damages to bearings caused by vibrations
at standstill:
– by red marked locking screws in the bearing cap
– or by a transport locking mechanism fixed to the shaft end.
Before the motor is mounted, the locking screws must be loosened by 10 mm and the transport
locking device must be removed (see instruction plate on the motor).
After this, it must be possible to turn the shaft by hand.
We recommend loosening of the bearing lock only after the drive element has been fitted.
The transport locking mechanism has to be reused for further transports.
Prevent failures and thus avoid damages to persons and property.
The person responsible for the installation has to make sure, that
– safety– and operating instructions are available and observed
– operating conditions and technical data acc. to the order are observed
– protective equipment is used
– specified maintenance work is carried out.
Page 8 of 31 N–R 435 en 09.03

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.
N–R 435 en 09.03 Page 9 of 31

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).
Page 10 of 31 N–R 435 en 09.03

4.2 Connection, insulation resistance

Connection must only be made by an expert and in accordance with the valid safety regulations.
The relevant installation– and operating instructions as well as national and international rules have
to be observed.
Observe data on the rating plate!

Compare type of current, mains voltage and frequency!
Check wiring diagram!
Observe rated current for setting of the protective switch!
Connect motor in accordance with the wiring diagram provided in the terminal box!
The motor must be protected against excessive heating, e.g. by means of a motor protective
switch.
For earthing the motor is provided with an earthing terminal, which depending on the mounting ar-
rangement is either located on the frame resp. on the flange end shield. In addition all motors have
a protective conductor terminal inside the terminal box.
As protection against dust and humidity unused cable entries in the terminal box must have a tor-
sionproof seal. All terminal screws and nuts have to be securely tightened to avoid excessive
transition resistances (see paragraph 4.6).
Protective measures are to be taken.
In case of terminal boards with U–shaped terminal washers the

conductors to be connected have to be bent in U–shape and
placed underneath the terminal washers. See sketch!
In case of motors with terminal boxes which have ground surfaces between cover and base a thin
grease film is to be applied for sealing and against corrosion.
After longer storage periods or standstill (see page 18) the insulation resistance of the winding must
be measured phase against phase and phase against ground before putting into operation.
Humid windings might cause creeping 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.
Cable–, lead entries and connecting cables must be suitable for ambient temperatures occur-
ring.
4.3 Rotational direction and designation of the terminals acc. to

DIN VDE 0530–8/IEC 60034–8
4.3.1 In standard design surface cooled (TEFC) motors up to frame size 355 and internally cooled
(ODP) motors up to frame size 315 are suitable for both directions of rotation.
Motors suitable for one rotational direction only are identified by an arrow on the motor for the
correct direction. Terminals U1, V1, W1 connected to phase L1, L2, L3 (in alphabetical se-
quence or natural sequence) always result in clockwise rotation. This rule applies to all motors,
even if they are not suitable for clockwise direction.
N–R 435 en 09.03 Page 11 of 31

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.
Page 12 of 31 N–R 435 en 09.03

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
N–R 435 en 09.03 Page 13 of 31

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.
Page 14 of 31 N–R 435 en 09.03

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.
N–R 435 en 09.03 Page 15 of 31

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.
Page 16 of 31 N–R 435 en 09.03

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
N–R 435 en 09.03 Page 17 of 31

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.
Page 18 of 31 N–R 435 en 09.03

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:
N–R 435 en 09.03 Page 19 of 31

Spare parts
Version with forced ventilation and electronic speed monitoring:
1.00 Stator, complete 4.34 Resilient preloading ring, NDE

1.03 Stator core with winding 4.36 Grease guide disk, NDE
1.06 Stator housing 4.38 Centrifugal disk, NDE
1.10 Mounting feet, unmachined (1 pair) 4.42 Felt packing ring, NDE
4.44 Outside gasket, NDE
2.00 Rotor, complete (balanced) 4.46 Inner gasket, NDE
3.01 End shield, DE 5.01 External fan, complete

3.02 Flange shield, DE 5.10 Fan cover, complete
3.08 Flange disk, DE 5.14 Protective grid, complete
3.21 End shield, NDE 5.30 Spring fastener
5.60 Motor for forced ventilation
4.01 Bearing, DE 5.65 Front shim
4.05 Bearing, NDE
4.10 Outside bearing cap, DE 6.03 Base of terminal box
4.12 Inner bearing cap, DE 6.04 Upper part of terminal box
4.14 Resilient preloading ring, DE 6.05 Terminal box cover
4.16 Grease guide disk, DE 6.07 Bushing plate
4.18 Centrifugal disk, DE 6.08 Cable gland, lower part
4.22 Felt packing ring, DE 6.09 Cable clamp
4.24 Outside gasket, DE 6.10 Cable entry
4.26 Inner gasket, DE 6.11 Cable gland, upper part
4.30 Outside bearing cap, NDE 6.15 Terminal board, complete
4.32 Inner bearing cap, NDE 6.16 Bushing terminal
Page 20 of 31 N–R 435 en 09.03

Spare parts
6.17 Accessory terminal

6.20 Clamping
6.28 Cable gasket
7.01 Slot–type initiator

7.02 Mounting angle
7.11 Bolted connection
7.12 Segmental disk
7.16 Metal tube
The parts shown are available in different sets depending on type, size, mounting and enclosure. They are available
from our works. All other parts such as bolts, spring washers etc. are available anywhere.
When ordering spare parts, please state:
Spare part designation

Motor type
Serial number
Example:
3.01 End shield, DE
ANLA–200LB–08
8 386 388
1. Einlagerungsvorschriften
N–R 435 en 09.03 Page 21 of 31

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.
Page 22 of 31 N–R 435 en 09.03

Recommended heating circuits and maximum heating currents
a) D b) Y
IMAX = 65 % Ir IMAX = 75 % Ir
9.1.2.2 On motors with bearing lock this one has to be removed before commissioning.
9.1.2.3 Antifriction bearings, lubrication

If adequately stored for a longer time it can be assumed that within 2 years the lubricating
grease in the bearings is not affected. Motors with permanent lubrication can be put into oper-
ation after having checked the insulation resistance of the winding and a short trial run.
For motors with insulation class F a lithium–saponified antifriction bearing grease with a drip-
ping point of at least 180 °C (356 °F) is used for normal ambient temperatures.
For the motors with insulation class H and certain special motors, the used special lubricating
grease is indicated on an instruction plate attached to the motor.
9.1.2.4 For motors with a regreasing device it is advisable to regrease both bearings shortly after com-
missioning at running motor.
Grease type, grease quantity and regreasing intervals are marked on an additional plate at-
tached to the motor.
The data for grease service life with regreasing intervals can surely be expected for motors in
enclosure IP 55. The bearing is protected against the ingress of fine dust and of water in all
directions, e.g. for outdoor installation without additional protection.
For motors with enclosure IP 44 and IP 54 these data apply with the restriction that the envi-
ronmental load by dust and water is not exceeding the limits of DIN EN 60034–5 with tests ac-
cording to DIN EN 60034–5.
9.1.3 For motors which are transported and stored in assembled condition with the machine
to be driven the following must be observed:
9.1.3.1 Storage
The free shaft ends must be greased before installation of the motors as well as all of the other
blank metal parts, e.g. foot– and flange surfaces or supporting faces of terminal boxes and
covers.
As protection against dust and humidity, grease seals with antifriction bearing grease are to be
installed at the shaft opening.
b) A humidity–absorbing substance (e.g. Branogel) is to be filled into the terminal boxes of the
motors.
c) The machines are to be stored dry, dustfree and at room temperature.
d) For further measures the specifications according to the items 9.1.1.2 – 9.1.1.4 are appli-
cable.
A bearing lock is not necessary, if the bearings are preloaded by means of belt drive (9.1.1.3).
N–R 435 en 09.03 Page 23 of 31

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.
Page 24 of 31 N–R 435 en 09.03

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.
N–R 435 en 09.03 Page 25 of 31

Faults and remedies
10. Faults and remedies
Fault Possible causes Remedy

Bearing is too hot Bearing noise*) Motor runs
unevenly
Too much grease in bearing Remove excess grease
Bearing dirty Replace bearing
Belt tension too high Reduce belt tension
Coupling forces are pulling or Realign motor, correct coupling

pushing
Coolant temperature above 40°C Adjust temperature of cooling air

(104°F)
Not enough grease in the bearing Grease according to specifications
Motor incorrectly mounted Check mounting type of motor
Bearing grease dark coloured Check bearing currents
Scoring at bearing inner race, e.g. Replace bearing, avoid vibrations

caused by motor start with locked at standstill
bearing
Unbalance caused by coupling Exact balancing
Motor fastening unstable Check fastening
*) If remedies described are insufficient, we recommend to replace the bearings.
Fault Possible causes Remedy

High Protective
Motor does Motor is too
decrease in device
not start hot
speed triggers
Countertorque too high Check motor– and load torque
Mains voltage too low Check mains conditions
Phase interruption Check mains supply
Observe wiring diagram and rating

Wrong winding connection
plate
Overload Compare data on rating plate
Too many starts per hour Observe rated duty type
Check ventilation passages, check

Insufficient ventilation
direction of rotation
Check cooling water inlet and

Insufficient cooling
outlet temperature
Ventilation passages or water Clean

chambers dirty
Short–circuit of winding or terminal

Measure insulation resistance
board
Starting time exceeded Check starting conditions
Page 26 of 31 N–R 435 en 09.03

Operating instructions for brake motors
with spring–loaded single–disk brake
11. Operating instructions for

brake motors with spring–loaded single–disk brake (Type AB.A–...–..)
Description
The maintenance–free brake is rest current–operated and in released condition it is operable in any fitted position
as long as required and is suitable for both directions of rotation. The asbestos–free brake linings are highly wear–
resistant.
Attention! The friction surfaces must not get into contact with oil or grease.
Air gap adjustment

Air gap ”SLü” is adjusted according to Table 1. If a readjustment should be required, the correct air gap ”SLü” is restor-
able by turning the readjusting bushes (4).
If the motor is designed with a manual release, it must be observed that dimension ”S” between the self–locking
nuts and the armature disk is equally adjusted on both sides. If the air gap ”SLü” is required to be readjusted, how-
ever, nothing may be changed on the manual release.
N–R 435 en 09.03 Page 27 of 31

Operating instructions for brake motors
with spring–loaded single–disk brake
Braking torque adjustment

As delivered the brake is adjusted to the rated braking torque. A reduction of the braking torque is possible by
unscrewing the adjusting ring (1) up to Dimension ”O1”.
For braking torque adjustment it is required to remove the fan cowl (3). In case of the design with manual re-
lease part (2) must be unscrewed before.
Reduction of braking torque per detent according to Table 1
Table 1: Lenze brakes Type BFK 458
Brake size 06 08 10 12 14 16 18 20 25
Rated braking torque [Nm] 4 8 16 32 60 80 150 260 400
SLü [mm] 0.2 0.2 0.2 0.3 0.3 0.3 0.4 0.4 0.5
S [mm] 1.0 1.0 1.0 1.5 1.5 1.5 2.0 2.0 2.5
Reduction per detent [Nm] 0.2 0.35 0.8 1.3 1.7 1.6 3.6 5.6 6.2
O1 max [mm] 4.7 4.7 7.6 9.6 11 10 14.9 16.4 18.3
Please request the operating and maintenance instructions for spring–loaded single–disk brakes, if required.
Page 28 of 31 N–R 435 en 09.03

EC Declaration of Conformity
12. EC Declaration of Conformity
N–R 435 en 09.03 Page 29 of 31

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.
Page 30 of 31 N–R 435 en 09.03

Appendix 2
Servicebericht / Service report Seite /

Page
Überprüfung der Ausrichtung / ...
Alignment check
Servicenr. / Service No.: Bestellnr. / Order No.:
Typ / Type: Seriennr./ Serial No.:
Kupplungstyp / Coupling type: Durchmesser / Diameter:
Empfohlene Ausrichtgenauigkeit / Recommended accuracy for alignment*

Drehzahl / Speed Parallelversatz / Parallel offset Winkelversatz / Angular offset
(rpm) (1/100 mm) 1/100 mm pro / 1/100 mm each
750 9 9
1500 6 5
3000 3 2.5
Gemessene Werte an der Kupplung / Measured values at the coupling

Parallelversatz / Offset Winkelversatz / Angular offset
Messung /
Measure-
ment
Bemerkungen / Comments
* Falls keine Werte vom Kupplungshersteller vorgeschrieben sind / If no values were specified by the coupling manufacturer
N–R 435 en 09.03 Page 31 of 31

Satz MediCom – Druck LOHER 09.03 Printed in Germany
LOHER GmbH
P.O. Box 1164 • 94095 RUHSTORF
Hans–Loher–Str. 32 • 94099 RUHSTORF
GERMANY
Phone +49 8531 39–0 • Fax +49 8531 32895
E–Mail: info@loher.de
http://www.loher.de
Manual and maintenance instructions Sheet No.
for INTERNORMEN pressure filters, change-over 20320-4C
DU 63, 101, 251, 401, 631, 635, 1001, 1950, 1050, 2050, related specifications Page 1/3
This manual is effective for all filters of the type DU 63, 101, 251, 401, 631, 635, 1001, 1950, 1050, 2050 and related specifications. It
contains certain requirements and instructions which ensure unobjectionable operation of the filter. It can be completed with specific
additional instructions by the operator himself if necessary.
1. Safety instructions
- Prior to operating the filter, manual and maintenance instructions have to be read carefully.
- Follow the instructions of this manual under any circumstances!
- The manufacturer does not assume liability for any damage, which occurs due to disregarding these instructions.
- If operations are carried out differently, the safety of the pressurized device can not be assured!
- Operating conditions given in the data sheet, especially excess pressure, temperature range and operating fluid, have to be followed
unconditionally. Variation of these parameters can cause damage to important pressure holding parts and sealing. Also take in
consideration the compatibility of filter components with the operating fluid.
- Under working conditions the filter housing is pressurized. Do not try to loosen or remove any part of the filter or the filter housing
during operation. The operating fluid could escape at high pressure and high temperatures.
This does not apply for parts of the decompressed or the turned off side of the filter (see „Maintenance“).
- Leaking operating fluid always bears the danger of injuries and burns!
- Do not open the filter housing until you made sure it is not pressurized any more!
- Touching parts of the filter may cause burning, depending on the operating temperature.
- When exchanging the filter keep in mind that it might have operating temperature. Danger of burning!
- Always wear safety goggles and gloves when working on the filter!
- If you come into contact with the operating fluid please follow the instructions of the fluid manufacturer!!
- Only use original spare parts.
2. Installation
Note safety instructions!
When removing a new filter from its box it is ready for installation. It is placed on a level area and attached (DU 63) or screwed (DU
101-2050) to it.
Afterwards remove protective caps from connections and connect those to the present pipe work.
Appropriate pipe work (pipes, hoses) ensures that drain and air-bleed valves are connected to proper containers. For these purposes
original INTERNORMEN-Technology drain and air-bleed valves can be used.
When installing the filter please make sure, that:

- sufficient fixation of the filter is assured
- the clogging indicator is accessible and can be checked easily.
- the connections for draining, air-bleeding and pressure measurements can be accessed easily.
- there is enough room above the filter to remove and replace elements.
- no dirt, particles, other contamination or fluids enter the filter.
- both inlet and outlet of the filter are connected to the pipe work correctly.
- counterflanges or screw joints of the pipe system and the filter have to be angled precisely and connected that same way (if
counterflanges or pipe joints are canted or under tension switching filters can be aggravated and it might harm pressure
tightness)
Fitting the counterflanges for DU 101-2050
- the following torques have to be applied when fastening the counterflanges

Type DU 63* DU 101 DU 251 DU 401 DU 631/635 DU 1001/1950 DU 1050/2050
Connection ¾“ 1“ 1 ¼“ 1 ½“ 2“ 2“ 2 ½“ 3“ 4“
Moment [Nm] 100 ±15 10 ±2 12,5 ±3 25 ±5 28 ±6 28 ±6 40 ±8 71 ±15 100 ±25
- sufficient measures were taken to prevent corrosion.
- the filter is protected from other mechanical influences (such as impacts and hits).
EDV 11/02 - Englisch
Friedensstrasse 41, 68804 Altlussheim, Germany

phone +49 - (0)6205 - 2094-0 e-mail sales@internormen.com
fax +49 - (0)6205 - 2094-40 url www.internormen.com
3. Initial operation
3.1 Prior to initial operation
Prior to the initial operation of the system or the machine, which means prior to filling in any fluid, check the internal condition of the
filter. Proceed as follows:
- Open the filter housing by removing the lit. Check the cleanness of the housing, the presence of an element, the sealing, etc..
- Close the housing tight.
3.2 Filling and air-bleeding

Prior to the initial operation, the filter has to air-bleed as follows:
- Turn the switch of the filter to the middle position. The lever of the DU 63/635/1050/2050 is right in the middle between the two stops.
The stop-pin of the DU 101-1950 also is positioned right between the two stops.
- Fill both sides of the filter using the regular operating fluid flow.
- Open the locking screws on the side of the top edge of the filter (DU 63) or on top the filter lit (DU 101-2050). Wait until it leaks fluid
without any bubbles and there is no more sound of air escaping.
- afterwards tighten the locking screws again.
After this process you can direct the flow of the fluid, which is supposed to be filtered, to pass through either side of the filter. This is
done simply by turning the lever or the switch. To recognize which side is operating at the moment, just note the following:
DU 101/251/401/631/1001/1950: The stop-pin of the switch is pointing at the side which is operating at the moment.
DU 63/635/1050/2050: The lever itself points at the side which is operating at the moment.

4. Maintenance / Inspection
Also please note all particular site-related instructions for inspection.
Using filters equipped with clogging indicators it is necessary to exchange or clean the element if the signal “Clogged filter” is emitted
(also note the data sheet or the instructions of the clogging indicators).
Contaminated elements have to be replaced as soon as possible! If a clogged element is not removed it may cause severe damage to
the entire system!
Attention!
Always exchange elements with sealing. If a cleaned metal mesh element type „G“ is reused replace its sealing. The exact
markings can be found in spare part lists for each element.
4.1 Replacing the filter element

Maintenance or the exchange of contaminated filter elements has to be performed as follows:
- Open the shut-off valve for pressure equalization.
- Switch the filter to the opposite side.
- Close the shut-off valve.
- Open the air-bleed valve of the discharged side of the housing in order to equalize the pressure with the surrounding atmosphere.
- Open the drain-valves to drain the filter
- Open the lit of the discharged side of the filter housing.
- Loosen and remove the element by light swaying and pulling.
- If necessary cover or close the adaptor end inside the housing and clean the entire inside.
- Close the drain valve and remove the cover of the adaptor end if present.
- Check the sealing of the filter lit and replace the O-ring if necessary.
- Take the replacing element, make sure the serial number matches the number of the old element, and insert it into the housing (prior
check if the elements sealing are undamaged and tighten them)
- Close the filter with it’s lit.
- finally perform the steps described in 3.2 “Filling and air-bleeding”
4.2 Cleaning the filter element

Metal mesh filter elements can be recycled after cleaning. This cleaning procedure can be performed based on the cleaning instructions
for INTERNORMEN metal mesh filter elements on sheets no. 21070-4 and 39448-4.
When removing and reinserting the element please proceed as described in 4.1 “Replacing the filter element”.
The maintained side of the filter is now ready to operate at full strain again.
In addition to that it is possible to maintain or replace the clogging indicator if necessary. Both the DU 101 and the DU 251 separate this
device from the pressurized system when it’s switch is brought into the middle position.
Attention!
Independent from a necessary change of the element, the switching armature has to be actuated at least once per three weeks
in order to maintain full operatibility.
5. Additional information
In addition to the regular clogging indication, the pressure drop, which is evidence for contamination, can be monitored and checked.
On filters DU 101-2050 certain miniature measuring devices with a G ¼ A inside thread can be connected to the flanges. For this
purpose it is necessary to install measuring connections with M16 screw joints.

PRESSURE FILTER, change-over Sheet No.
Series DU 101-401 DN 32-50 PN 32 2117 K
1. Type index:
1.1. Complete filter: (ordering example)
DU. 251. 10VG. 30. E. P. -. FS. 8. -. -. AE
1 2 3 4 5 6 7 8 9 10 11 12
1 series:
DU = pressure filter, change-over
2 nominal size: 101, 251, 401
3 filter-material and filter- fineness:
80 G = 80 µm, 40 G = 40 µm, 25 G = 25 µm stainless steel wire mesh,
25 VG = 20 µm(c), 16 VG = 15 µm(c), 10 VG = 10 µm(c), 6 VG = 7 µm(c), 3 VG = 5 µm(c) Interpor fleece (glass fibre)
25 P = 25 µm, 10 P = 10 µm paper
4 resistance of pressure difference for filter element:
16 = ∆p 16 bar, (01.N 100) 30 = ∆p 30 bar, (01NL. 250, 400)
5 filter element design:
E = single-end open
S = with by-pass valve ∆p 2,0 bar
S1 = with by-pass valve ∆p 3,5 bar
6 sealing material:
P = Nitrile (NBR) V = Viton (FPM)
7 filter element specification:
- = standard VA = stainless steel
8 connection:
FS = SAE-flange connection 3000 PSI
9 connection size:
6 = 1 ¼ “ (DU 101) 8 = 2“ (DU 251/401)
10 filter housing specification:
- = standard
11 internal valve:
- = without
12 clogging indicator or clogging sensor:
- = without, OP = visual, see sheet-no. 1628
AOR = visual, see sheet-no. 1606, OE = visual-electrical, see sheet-no. 1628
AOC = visual, see sheet-no. 1606, VS1 = electronical, see sheet-no. 1607
AE = visual-electrical, see sheet-no. 1609, VS2 = electronical, see sheet-no. 1608
1.2. Filter element: (ordering example)
01NL. 250. 10VG. 30. E. P. -
1 2 3 4 5 6 7
1 series:
01N. = standard filter element according to INTERNORMEN factory spec ification
01NL. = standard filter element according to DIN 24550, T3
2 nominal size: 100 (01N.); 250, 400 (01NL.)
3 - 7 see type index-complete filter
,
Pos I: left filter-side in operation 2. Accessories:

Pos II: right filter-side in operation - measure- and bleeder connections, see sheet-no. 1650
- evacuation and bleeder-conections, see sheet-no. 1651
- counter flanges, see sheet-no. 1652
- shut-off valve, see sheet-no. 1655
3. Dimensions:
type connection SAE-connection size A B C D E F G H J K L M N O P Q R S T U V weight kg
DU 101 DN 251) SAE 1 ¼“ 463 310 210 265 55 80 22 16 95 180 60 100 50 140 115 140 115 12 30,2 58,7 M10, 19 deep 23
DU 101 DN 32 SAE 1 ¼“
DU 251 DN 402) SAE 2“ 522 380 260 319 84 100 - 19 130 241 97 110 76 155 130 185 160 13,5 42,9 77,8 M12, 18 deep 40
DU 251 DN 50 SAE 2“
DU 401 DN 50 SAE 2“ 632 530 410 469 84 100 - 19 130 241 97 110 76 155 130 185 160 13,5 42,9 77,8 M12, 18 deep 50
Changes of measures and design are subject to alteration!
1)
by counter flange BFS.6.A.33,7x2,6.St.P.3000 Instaed of P (Nitrile) also V (Viton) can be chosen.
2)
by counter flange BFS.8.A.48,3x3,7.St.P.3000 Friedensstrasse 41, 68804 Altlussheim, Germany
EDV 08/03 phone +49 - (0)6205 - 2094-0 e-mail sales@internormen.com
4. Spare parts: 6. Technical data:
item designation qty. dimension/article no. qty. dimension/article no. qty. dimension/article no. temperature range: - 10°C to + 80°C (for a short time + 100°C)
DU 101 DU 251 DU 401 operating medium: mineral oil, other media on request
max. operating pressure: 32 bar
1 filter element 2 01N. 100 2 01NL. 250 2 01NL. 400 test pressure: 64 bar
32 x 3,5 40 x 3 40 x 3 connection system: SAE-flange connection 3000 PSI
housing material: GGG 40.3
2 O-ring 2 304378 (NBR) 2 304389 (NBR) 2 304389 (NBR) sealing material: Nitrile (NBR) or Viton (FPM), other materials on request
304401 (FPM) 305482 (FPM) 305482 (FPM) installation position: vertical
mini-measuring connections: G¼
76 x 4 115 x 3 115 x 3
evacuation-or bleeder connections: G½
3 O-ring 2 305599 (NBR) 2 303963 (NBR) 4 303963 (NBR) volume tank DU 101: 2x 0,9 l
310291 (FPM) 307762 (FPM) 307762 (FPM) DU 251: 2x 2,5 l
DU 401: 2x 3,7 l
24 x 3 24 x 3 24 x 3
4 O-ring 1 303038 (NBR) 1 303038 (NBR) 1 303038 (NBR) Classified under the Pressure Vessel Directive 97/23/EC for mineral oil (fluid group 2), Article 3, Para. 3.
Classified under ATEX Directive 94/9/EC according to specific application (see questionnaire sheet-no. 34279-4)
304397 (FPM) 304397 (FPM) 304397 (FPM)
60 x 2,5 95 x 3 95 x 3
5 O-ring 2 305601 (NBR) 2 305808 (NBR) 2 305808 (NBR) 7. Symbols:
310267 (FPM) 304828 (FPM) 304828 (FPM)
6 screw plug 8 G½ 304678 without indicator with electrical with visual - with visual -
7 screw plug 2 G¼ 305003 indicator electrical indicator electrical indicator
AE 30 and AE 40 AE 50 and AE 60 AE 70 and AE 80
8 clogging indicator, visual 1 AOR or AOC see sheet-no. 1606
9 clogging indicator, visual 1 OP see sheet-no. 1628
10 clogging indicator, visual-electrical 1 OE see sheet-no. 1628
11 clogging indicator, visual-electrical 1 AE see sheet-no. 1609
12 clogging sensor, electronical 1 VS1 see sheet-no. 1607
13 clogging sensor, electronical 1 VS2 see sheet-no. 1608
14 O-ring 1 15 x 1,5 315357 (NBR)
315427 (FPM)
with visual with visual - with electronical with electronical
15 O-ring 1 22 x 2 304708 (NBR) indicator electrical indicator clogging sensor clogging sensor
304721 (FPM) AOR/AOC/OP OE VS1 VS2
16 O-ring 2 14 x 2 304342 (NBR)
304722 (FPM)
17 screw plug 2 G¼ 305003
18 pressure balance valve 1
item 17 execution only with clogging indicator or clogging sensor
5. Description: 8. Pressure drop flow curves: Precise flow rates see ‘INF-Expert-System Filter’, respectively
Pressure filters, change-over series DU 101-401 are suitable for operating pressure up to 32 bar. ∆p- curves; depending on filter fin eness and viscosity.
Pressure peaks can be absorbed with a sufficient margin o safety.
A three-way-change-over valve which is integrated in the middle of the housing makes it possible to switch from the dirty filter-side to the clean filter-
side without interrupting operat ion.
The filter element consist of star-shaped, pleated filter material which is supported on the inside by a perforated core tube and is bonded to the end 9. Test methods: Filter elements are tested according to the following ISO standards:
caps with a high-quality adhesive. The flow direction is from outs ide to the inside. ISO 2941 Verification of collapse/burst resistance
These filters can be installed as suction filters. ISO 2942 Verification of fabrication integrity
Filter finer than 40 µm should use throw-away elements made of paper or Interpor fleece (glass fibre). Filter elements as fine as 5 µm(c) are available; ISO 2943 Verification of material compatibility with fluids
finer filter elements on request. ISO 3723 Method for end load test
INTERNORMEN-Filter elements are known as elements with a high intrinsic stability and an excellent filtration capability, a high dirt-retaining capacity ISO 3724 Verification of flow fatigue characteristics
and a long service life. ISO 3968 Evaluation of pressure drop versus flow characteristics
INTERNORMEN-Filter are suitable for all petroleum based fluids, HW-emulsions, most synthetic hydraulic fluids and lubrication oils. ISO 16889 Multi-pass method for evaluating filtration perfo rmance
Approvals according to TÜV, and the major „Shipyard Classification Societies“ D.N.V.; B.V.; G.L.; L.R.S.; R.I.N.A.; A.B.S. and others are possible.
E 2117 K
CLOGGING INDICATOR Sheet No.
Series AE (visual-electrical, thread execution) 1615 C
1. Clogging indicator AE
1.1. Type index: (ordering example)
AE. 30. 1,5. P. -. -
1 2 3 4 5 6
1 series:
AE = clogging indicator, visual-electrical
2 version:
30-80 = see table below
3 indicator-pressure difference: ∆p-nominal
1,5 = 1,5 bar
2,5 = 2,5 bar
5,0 = 5,0 bar
4 sealing material:
P = Nitrile (NBR)
V = Viton (FPM)
5 material:
- = standard
VA = stainless steel
6 execution:
- = standard
2. Technical data:
temperature range: -10°C to +80°C
(for a short time +100°C)
max. operating pressure: 420 bar
max. pressure difference: 160 bar
installation position: vertical
version luminous contact voltage max. rupturing capacity max. switching current connection
indication (resistive load) (resistive load) protection
30 - ...... 175V DC 3 VA 0,25 A
...... 125V AC 3 Watt 0,25 A line adapter
40 - contact maker ...... 175V DC 20 VA 1,0 A DIN 43650-A/PG11
and contact breaker ...... 230V AC 10 Watt 0,5 A
50 1x LG 1) 120V DC 3 VA 0,03 A with 120V DC
120V AC 3 Watt 0,03 A with 120V AC DIN 14050-IP 65
60 1x LG 230V AC 10 Watt 0,04 A with 230V AC
70 2x LED 2) 24V DC 3 VA 0,08 A with 24V DC
80 2x LED 24V DC 20 VA 0,75 A with 24V DC
1)
LG = glow lamp
2)
LED = light emitting diode
Changes of measures and design are subject to alteration!

EDV 12/03

3. Spare parts:
item qty. designation dimension article-no. type
1 1 O-ring 14 x 2 304342 (NBR)
304722 (FPM) AE version 30 - 80
2 1 O-ring 22 x 2 304708 (NBR)
304721 (FPM)
3 1 line adapter 312492 AE version 30 and 40
1 line adapter 315012 AE version 70 and 80
with LED 24V
1 line adapter DIN 43650-A 315010 AE version 50
with LG 120V
1 line adapter 315010 AE version 60
with LG 230V
4. Symbols:
hydraulic-electrical symbol connection configuration for LG connection configuration for LED
version version version version version version

30 and 40 50 and 60 70 and 80 50 60 70 and 80
p1 = measure connection supply

p2 = measure connection output
5. Description:
The AE 30 and AE 40 pollution indicators are electrical differential pressure indicators.
The AE 50 to AE 80 pollution indicators are combined optical and electrical differential pressure indicators. These differential
pressure indicators can be fitted to all pressure filters p ≤ 420 bar for which there is a corresponding assignment on the relevant
dimension drawing. As the degree of pollution of the filter element rises, so the difference between the entry pressure p1 and the
exit pressure p2 of the filter increases. Depending on this pressure difference and irrespective of the operating pressure, in the
pollution indicators
- AE 30 and AE 40, two electrical signals (contact maker/contact breaker) are triggered
- AE 50 and AE 60, two electrical signals (contact maker/contact breaker) are triggered and one optical signal is formed
- AE 70 and AE 80, two electrical signals (contact maker/contact breaker) are triggered and two optical signals are formed.
A metering piston subjected to the entry and exit pressure moves against a metering spring according to the pressure differential.
Depending on the path a permanent magnet integrated in the metering piston activates a reed contact (electromagnetic switch)
and triggers the electrical signal. The electrical and optical indication is effected as a digital signal at the given switching pressure.
Versions 50 to 80 of the pollution indicator are fitted with additional LED displays. The optical LED signal becomes visible
according to the selected version in the translucent cover plate of the line box on the pollution indicator.
In the pollution indicators
- AE 50 and AE 60, the neon lamp signals that the filter element needs to be changed
- AE 70 and AE 80, the green LED signals the normal operating state ( filter element not yet polluted to an unacceptable level),
while the red LED signals that the filter element needs to be changed.
6. Operating instructions:
Normally filters are supplied with mounted clogging indicator. When retrofitting - the filter is to be discharged of the operating
pressure.
- dismantling the screw plug out of the bare hole which is foreseen for the clogging indicator
- screw in the clogging inidcator into the bare hole (starting torque 125 Nm)
It is necessary to make sure the availability and the right positioning of sealing parts
- O-ring 22 x 2 and
- O-ring 14 x 2
as well as a dirt-free mounting. The electrical contacts are to be connected according to the graphical symbol shown on the type
plate of the clogging indicator.
7. Maintenance:
The device is maintenance-free, however, note that no cleaning fluids and solvents get on the transparent cap of the optical
indicator.
E 1615 C
Instructions for installation, start-up
and maintenance of a
Bloksma heat exchanger.
P-type (P/PF, IV/MV)
Article number of this manual: 7ZZ00P0000010
Bloksma B.V.
P.O. Box 1003
1300 BA Almere
The Netherlands
Tel. +31 (0)36 5492300

Fax +31 (0)36 5492390
e-mail: service@bloksma.nl
web: www.bloksma.nl
Rev. 01
Instruction manual P-type Heat exchanger
TABLE OF CONTENTS
Page
Glossary………………….……………………………………………... 3
1 Introduction.…………………………………………………………… 4
1.1 Remarks…………………………………………………………………. 4
1.2 Guarantee and liability…………………………………………………... 4
1.3 Environment.……………………………………………………………. 4
1.4 Safety……………..…………………………………………………….. 4
1.5 Inhibitors………………………………………………………………… 4
2 Installation and start-up………………………………………………. 5
2.1 Receipt…………………………………………………………………... 5
2.2 Installation..……………………………………………………………... 5
2.3 Start-up…………………………………….……………………………. 6
3 Maintenance..…………………………………………………………... 7
3.1 Inspection and cleaning intervals….……………………………………. 7
3.2 Anodic protection…….…………………………………………………. 7
3.3 Cleaning of the heat exchanger………….……………………………… 7
3.3.1 Mechanical cleaning of the tubeside…………..……………………….. 7
3.3.2 Chemichal cleaning of the shell-/tubeside………………………………. 7
3.4 Shut down periods………………………………………………………. 8
3.5 Assembling and disassembling of the heat exchanger………………….. 9
3.6 Instructions for gaskets and bolting…..………………………………… 12
3.6.1 Gaskets….……………………………………………………………….. 12
3.6.2 Bolting………………………………………………………..………… 12
4 Trouble shooting & repairs………..………………………………….. 13
4.1 Thermal performance too low..…………………………………………. 13
4.2 Leaking tubes / tube-tubesheet-connection……………………………... 13
4.3 Leaking gaskets….……………………………………………………… 13
5 Spare parts & tools…………………………………………………….. 14
Appendix A: Instructions for conservation
Appendix B: Adresses
Appendix C: Constructional directions for entering a P-type heat
exchanger in a piping design
The P-type heat exchanger can be subdivided into four sizes: P10, P13, P20 and P28.
The number indicates the shell size in centimeters. The construction of the P10 is slightly
different from the others. When necessary this manual has special texts (indicated with: “For
P10 only:”) which apply to the P10 only.
There are two models (P10 only in MV): the IV (Industrial Version) and the MV (Marine
Version). Main difference is the anodes in the tubeside circuit of the MV. It is pointed out in
the text when there are differences between the two models.
In addition this manual applies to P-heat exchangers with plain tubes as well as PF heat
exchangers with bundles with fins.
2
Rev. 01
Glossary
Refer to the figure(s) in the paragraph “Assembling and disassembling of the heat exchanger”
for an explanation of the designation of parts of the heat exchanger in the text.
Conditioned circuit Closed circuit with a non-corrosive medium.
Unconditioned circuit Open circuit (for instance seawater) or a closed circuit

with a corrosive medium.
Coating Layer protecting the coated material against corrosion.

The coating separates the coated part from the corrosive
medium.
Inhibitor Additive to a medium flowing through the heat

exchanger which –expressly tailored to that medium-
reduces the quickness of chemical reactions like
corrosion.
Anodes / anodic protection Introducing a base metal to a more precious metal (on
purpose) in order to protect this metal. The part serving
as anode is being sacrificed.
3
Rev. 01
1 Introduction
1.1 Remarks
• Read this instruction manual before proceeding.
• Important documents besides this instruction manual are the order confirmation, the
specification sheet, the drawing(s) and the sheet with constructional directions (appendix
C). In the specification sheet the design pressures and temperatures are listed that must of
course not be exceeded.
1.2 Guarantee and liability

The “General conditions of Bloksma B.V.” are applicable. Also refer to the confirmation of
the order for possible additions.
Not covered by the guarantee are loss of performance and/or damage to the heat exchanger as
a result of:
• not following the instructions in this manual
• replacement with non-original parts
• every form of corrosion
1.3 Environment
• The environmental laws and rules of the area where the heat exchanger is installed, always
have to be respected.
• Always be on the alert to the possibility of leakage.
• When disposing of the unit at the end of its lifespan, see to it that this takes place
according to the then applicable regulations.
1.4 Safety
Some symbols are used in the text to underline safety aspects:
Pay attention: depending on the application the heat exchanger will be hot during operation
Maintenance and repair: depressurize both circuits of the heat exchanger and let them cool
down to ambient temperature.
In connection with safety every Bloksma heat exchanger is tested under higher pressure than
the design pressure before it leaves the factory. This applies to heat exchangers that are not
tested by a certification agency.
1.5 Inhibitors
There can be reasons to add an inhibitor to one of the circuits of the heat exchanger. Contact a
specialised company, which can also check for harmfulness of the inhibitor to the materials of
the heat exchanger (see specification sheet). Follow the instructions of the supplier for use of
the inhibitor.
4
Rev. 01
2 Installation and start-up
2.1 Receipt
At receipt check the packaging and the heat exchanger:
• report any damage to Bloksma
• compare the data on the nameplate, confirmation of the order and on the drawing
• check whether or not the correct instruction manual is present by comparing the article
number on the cover sheet with the article number of the instruction manual on the
confirmation of order
Always store the heat exchanger in a dry room, free of large temperature changes. When the
heat exchanger is not being put into operation immediately after receipt, follow the
“Instructions for conservation” (Appendix A).
2.2 Installation
Warning: Beware of any rust preventive layers (see “Instructions for conservation”) that
might still be present in the heat exchanger before proceeding.
• Remove all protective plugs and covers from the connecting flanges prior to installation of
the heat exchanger.
• A 1- or 3-pass model (tubeside) has to be mounted in such a way that shell- and tubeside
will be in counterflow.
• Check whether the positions of the vent and drain connections on the heat exchanger
correspond with the mounting position of the heat exchanger.
• In models with body side wire connections, check to see if the couplings with which the
lines are fastened do not touch the bundle.
• Mount the heat exchanger level and square on a flat surface in order for the pipe
connections to be made without forcing.
• Do not weld anything to the heat exchanger.
• Mount one support in a fixed position, while the other one is mounted in such a way that it
is able to slide in the direction of the longitudinal axis of the heat exchanger. The heat
exchanger will thus be able to expand under thermal stress.
• When installing types bigger than P10 vertically, the waterbox at which the position of the
tubesheet is fixed 1 , has to be located on top.
• Before connecting piping to the heat exchanger flanges, make sure that the gasket surface
is clean and free from scratches and other defects. Always use new gaskets, of the correct
type and tighten the bolts crosswise.
• Take care when lifting the heat exchanger. Use at least two hoops around the shell of the
heat exchanger for lifting purposes.
• Check for the presence and correct positions of drain/vent connections in both circuits.
• Install the heat exchanger and the piping in such a manner that there is still enough room
to disassemble (part of) the heat exchanger (tubebundle, drain plugs, etc.).
1
On a 2-pass model the side of the heat exchanger at which the position of the tubesheet is fixed is always the
side where the tubeside medium enters and exits the heat exchanger. On 1-pass models this is the side on which
fixation plates are bolted between waterbox and shell (on the other side distance rings are bolted between shell
and waterbox). Furthermore the side of the heat exchanger where the serialnumber is, is also the side with the
fixed tubesheet.
5
Rev. 01
2.3 Start-up
Do not exceed the design temperatures and design pressures as stated on the nameplate and
specification sheet. Avoid abrupt temperature fluctuations; these can cause leaking of tube-to-
tubesheet or other connections.
• Make sure that the cold medium circulation is established first, followed by the gradual
introduction of the hot medium.
• Vent both circuits.
• Vent both circuits again when the operating temperatures and pressures are reached.
• Check for leakage.
Do not deviate from the flows as stated on the specification sheet. Higher or lower velocities
can cause erosion or corrosion respectively.
Avoid standstill: at non-conditioned circuits this may cause corrosion. In case of standstill
follow the instructions for shut down periods.
If the heat exchanger is equipped with anodic protection (see specification sheet) you will
have to inspect the anodes (or part that functions as anode) when you are starting up the heat
exchanger after a shut down period.
6
Rev. 01
3 Maintenance
If necessary refer to “Assembling and disassembling of the heat exchanger” for

(dis-)assembling instructions.
3.1 Cleaning and inspection intervals

Preventive maintenance of the heat exchanger is a user responsibility. The tubeside circuit is
usually the more fouling side of the heat exchanger. Because the degree of fouling strongly
depends on the operating conditions we recommend the following:
• Inspect the tubeside at least quarterly.
• Inspect the shellside at least twice a year.
With the results of these inspections you will be able to determine the required cleaning
intervals. Always keep performing regular inspections.
3.2 Anodic protection

Not applicable for IV models.
The MV models of P-type heat exchangers are fitted with anodic protection: the tubeside
circuit is provided with anodes. When inspecting the tubeside of the heat exchanger also
inspect the state of the anodes (always drain the tubeside circuit before removing the anodes).
3.3 Cleaning of the heat exchanger
3.3.1 Mechanical cleaning of the tubeside

The tubes can be cleaned with a tube brush. Use original Bloksma brushes only; these have
the correct dimensions and are of a suitable material. Other brushes may damage the
protective layer that is in the normal course of events present on the tubewalls.
3.3.2 Chemichal cleaning of the shell-/tubeside

Warning: Chemical cleaning may damage the heat exchanger. Make sure your supplier of a
cleaning agent verifies and confirms the compatibility of his product with the materials of the
heat exchanger (see specification sheet).
Cleaning of the shellside will normally be necessary seldom.
The shell- as well as the tubeside can be cleaned by circulating a chemical solution through
the heat exchanger. Another possibility is disassembling of the heat exchanger and
submerging the tubebundle in a tank filled with a chemical solution. Remove any plastic
partitions (on 2- or 3-pass heat exchangers to divide the tubeside circuit) from the tubesheet(s)
first.
7
Rev. 01
There are several international companies (example in Appendix B) which supply equipment
and fluids for chemical cleaning of heat exchangers. Their specialized cleaning centres,
situated at ports all over the world, are able to give you a cleaning advise or to clean the heat
exchanger for you. To give an idea of the possibilities, an example of a cleaning procedure is
given below.
Please note: The cleaning advice below is just an example. Cleaning methods and
procedures, as well as fluids for cleaning will differ depending on the materials of the heat
exchanger (see specification sheet) and the application.
This cleaning advise is meant for waterheaters/coolers.
Descalant NF (inhibited cleaning agent)

• Submerge the tubebundle (time is dependend on the degree of fouling)
in a tank with dissolved cleaning agent
• After cleaning neutralize the tubebundle and the cleaning agent with a
special neutralizing fluid
• Flush the tubebundle with fresh water
• Dry the tubebundle
3.4 Shut down periods

During shut down periods longer than a week the heat exchanger has to be drained completely
and dried by means of preheated compressed air. In fact this also has to be done during short
shut down periods (longer than a day) when there is risk of freezing, and it also applies when
a corrosive medium is used in the heat exchanger. After draining a corrosive medium, the heat
exchanger has to be rinsed with fresh water.
Stopping of the flows, cooling down and draining of the heat exchanger has to be done in a
manner to minimize thermal stresses on the heat exchanger.
Never stop one of the flows of the heat exchanger while the other one stays in operation,
because of the risk of boiling.
8
Rev. 01
3.5 Assembling and disassembling of the heat exchanger

The circumferences of the tubesheets are fitted with three grooves. The two outer grooves
carry O-rings (sealing between shell- and tubeside). At one of the tubesheets the middle
groove is for the fixation of the position of the tubebundle by means of ‘fixationplates’ (this
tubesheet is called the fixed tubesheet).
1 Tubesheet 4 Shell
2 O-ring 5 Tubes
3 Fixationplate
Figure 1: Schematic drawing of tubesheet construction
For P10 only: Instead of fixationplates the P10 has a metal spring ring in the middle groove
of the tubesheet. As soon as the bolts are untightened the position of the tubebundle is no
longer fixated. Tubeside inspection or cleaning remains possible, but extra attention is
required because the tubebundle is not fixed anymore. Except when performinge a pressure
test, we recommend to drain both circuits.
9
Rev. 01
For tubeside inspection, shellside pressure testing or cleaning of the tubes with a
tubebrush, only the tubeside connections and the waterboxes (these are the parts
on both ends of the shell, on which the tubeside connections are made) need to be
removed (follow step 1 and 3). Pay attention: when the nuts are untightened the
fixationplates are also untightened, so the tubebundle comes loose. In order to fixate the
tubebundle temporarily, fasten the fixationplates with the nuts.
For shellside inspection (for instance), the tubebundle has to be removed completely
(follow step 1, 2 and 3), and both circuits have to be drained.
When assembling as well as disassembling follow the “Instructions for gaskets and bolting”.
Step 1: Tubeside disassembling
• depressurize both circuits

• let both circuits cool down to ambient temperature
• drain the tubeside circuit, by opening the drain in the lowest point and the vent in the
highest point
• mark the position of all parts that will be disassembled, so they can be mounted in the
correct position later on
In case the heat exchanger is placed vertical, disassemble the upper waterbox first. This is the
side with the fixationplates. Fasten the fixationplates immediately with the nuts before
proceeding. For P10 only: A vertically placed P10 will always have to be disassembled
completely because the the tubebundle does not stay in position.
• remove the waterboxes by untightening the nuts (the fixationplates come loose as well)
• 2- or 3-pass heat exchangers have plastic partitions on the tubesheet(s) for dividing the
tubeside circuit; mark their position and remove them
• mount the fixationplates again with the nuts (not necessary when the tubebundle is going
to be removed (see step 2))
• remove the first O-ring from both tubesheets
• only for a pressure test: pressurize the shellside again. Depressurize the shellside again
after the pressure test. For P10 only: Remember that the tubebundle is not fixated!
10
Rev. 01
Step 2: Removing the tubebundle

• drain the shellside circuit, by opening the drain in the lowest point and the vent in the
highest point
• mark the position of the tubebundle
• move the tubebundle to one side until the second O-ring shows (do not move the
tubebundle further than necessary) and remove this O-ring
• move the tubebundle to the other side and remove the second O-ring on this side as well
• carefully pull the tubebundle from the shell
• support the tubebundle at the baffles when lifting it, but be careful not to bend the baffles
(this will affect the thermal performance of the heat exchanger)
Step 3: Assembling
• assemble the heat exchanger in reversed order (pay attention to the earlier made marks):
Mounting of the tubebundle (only in case it was removed):
• push the tubebundle in the shell (let it stick out of the shell a little bit)
• mount the inner O-ring on the first tubesheet
• move the tubebundle further and let it stick out a little bit on the other side of the shell
• mount the inner O-ring on the second tubesheet
Hint: when it is difficult to move the tubebundle through the shell because the already
mounted O-ring is hard to compress, you can use a strip between tubesheet and waterbox and
then tighten two of the four bolts and nuts
• move the tubebundle in its final position
Tubeside assembly:
• mount the outer O-rings on both sides
• mount the plastic partitions on the tubesheets of 2- or 3-pass models
• mount the fixationplates (for P10 only: mount the metal spring ring)
• mount the waterboxes and all connections
• start-up the heat exchanger again:

• make sure that the cold medium circulation is established first, followed by the gradual
introduction of the hot medium
• vent both circuits
• vent both circuits again when the operating temperatures and pressures are reached
• check for leakage
11
Rev. 01
3.6 Instructions for gaskets and bolting
3.6.1 Gaskets
Two types of gaskets are being used in this heat exchanger:
O-rings : After disassembling the heat exchanger never use the old O-rings again. Replace
them with original Bloksma O-rings.
Warning: The O-rings have to be lubricated with a special O-ring lubricant (O-ring silicone
paste or Parker O-lube) for easy assembly and a good sealing capacity. Lubricants not suited
for O-rings can affect the sealing capacity of the O-ring (for instance do never use vaseline).
Any warranty claim will be rejected when unsuited lubricants are used.
Soft metal rings : After disassembly of the heast exchanger never use the old soft metal rings
again. Replace them with new ones for good sealing.
3.6.2 Bolting
Check bolts and nuts for damages. Tighten the bolts crosswise (see figure 2). This also applies
to connecting piping to the heat exchanger. Make sure the gasket surface is clean (remove dirt
and any corrosion residues) and undamaged.
Figure 2: (Un-)bolting sequence
12
Rev. 01
4 Trouble shooting & repairs
4.1 Performance too low

Check:
• whether all connections have been made according to the drawing
• whether the heat exchanger and the system have been properly vented
• whether the flows are according to the specification (check all valves, lines and pumps, as
well as the flow directions)
• whether the shell- as well as the tubeside have been cleaned recently (fouling can cause a
drop in performance and an increased pressure loss; an increased pressure drop is a good
indication that cleaning is necessary)
• whether the heat exchanger has been reassembled properly after disassembly
(the plastic partitions on the tubesheet(s) of 2- or 3-pass heat exchangers; the position
of the tubebundle (this might accidentally be mounted rotated 180° around its axis))
4.2 Leaking tubes / tube-to-tubesheet connection

It is often very hard to determine whether leakage occurs because of a leaking tube or because
of a leaking tube-to-tubesheet connection. The shellside of the heat exchanger can be
hydrotested, after disassembling the tubeside. Follow the instructions in “Assembling and
disassembling of the heat exchanger”. Subsequently pressurize the shellside. After
hydrotesting depressurize and drain the shellside again. Assemble the heat exchanger again.
The tubes are roller expanded into the tubesheet. It is either not possible (finned tubebundles)
or relatively complicated (unfinned tubebundles) to replace a leaking tube, but it can be
plugged with soft copper Bloksma plugs (other materials are too hard and may cause leakage
of the adjacent tube-to-tubesheet connections) in both tube ends. A maximum of
approximately 10% plugged tubes will not influence the thermal performance of the heat
exchanger too much. Contact Bloksma when more than 10% of the tubes is plugged.
4.3 Leaking gaskets

• Check the gasket surfaces.
• Remove dirt or corrosion residues
• Mount new gaskets
It is possible to determine which of the O-rings is leaking, by determining the medium that is
leaking from the heat exchanger.
13
Rev. 01
5 Spare parts & tools
Available spare parts and tools for P-type heat exchangers:
• Set of gaskets (four O-rings)

• Soft copper plugs
• Nylon tube brush
• Bolts / nuts
• Complete tubebundle
• For P10 only: Metal spring ring
• Fixationplates (for types > P10)
• Plastic partitions (not for 1-pass heat exchangers)
• Water box
• Cover
• Anode
When ordering spare parts, please refer to the Bloksma drawing number (listed on name
plate).
14
Rev. 01
Appendix A: Instructions for conservation
Standard conservation (controlled conditions)

All heat exchangers supplied by Bloksma are treated with a rust preventive layer (on both
shell- and tubeside). This layer will protect the heat exchanger when it is stored at controlled
conditions, i.e. inside, in a dry room at constant temperature . When these conditions are
met, the heat exchanger can be stored without special treatment for a longer period (up till 24
months).
The rust preventive layer can be removed with a mineral solvent (petroleum).
Advise for conservation (uncontrolled conditions)

When the above mentioned storage conditions are not met, you will have to fill the heat
exchanger with an inert gas and all openings have to be closed airtight (additionally silica gel
can be added to absorb liquids). Alternatively, the heat exchanger can be treated with a rust
preventive liquid of a type suited for long term conservation.
When necessary contact a specialised company. Take the materials of the heat exchanger (see
specification sheet) into consideration. Be aware that in uncontrolled storage conditions large
amounts of water can accumulate in the heat exchanger as a result of condensation.
15
Rev. 01
Appendix B: Adresses
Chemichal cleaning and products for chemichal cleaning
Ashland Chemical Nederland B.V.

Drew Marine Division
Malledijk 20
3208 LA Spijkenisse
The Netherlands
Telephone : + 31 (0)181-457074
Telefax : + 31 (0)181-625792
Internet: www.ashchem.com
16
Rev. 01
Appendix C: Constructional directions for including a P-type heat

exchanger in a piping design.
Pay attention to the following points:
• Level and square mounting possibility.
• Bends in the piping have to be located at a distance of at least three times the nominal diameter of
the pipe from the inlet of the heat exchanger.
• When a vaporizing cryogenic medium is used, the heat exchanger has to be placed under an angle
of 3° - 10°, in order for the vapor to be able to exit the heat exchanger, helped by natural
circulation.
• Check if vent and drain connections are present in both circuits of the heat exchanger (when not
on the heat exchanger then make them in the piping).
• Put a filter (with a permeability of 3 mm.) before the inlet of both circuits of the heat exchanger.
• Stress- and vibration free mounting possibility of the connections and the supports (fit expansion
bellows and/or silencer blocks when necessary).
• Disassembling possibility of the tubebundle (and other parts like drain and vent plugs).
• Expansion possibility of lockable liquid circuits.
• Danger of freezing of liquid circuits.
• The design data of the heat exchanger on the specifiationsheet2 and the drawing. For instance the
flows: deviating from them can cause unacceptable high or low velocities. A (temporary) lower
flow is acceptable when caused by a controlsystem and a conditioned circuit is involved. Avoid
standstill (unless the heat exchanger is drained and flushed with fresh water).
• When adding an inhibitor to one of the fluids in the heat exchanger, always check whether this
inhibitor can be harmful for the materials of the heat exchanger (see specification sheet).
• Make sure that in case of flow control (with conditioned circuits only) this is done gradually (no
‘on-off-control’).
• Although this will almost never occur in practice, Bloksma reserves the right (according to TEMA
RGP-RCB-2) to plug a maximum of 1% of the tubes.
• Always check whether both fluids are compatible with the materials of the heat exchanger;
Bloksma chooses the materials judging on the fluids specified by the customer, but is often not
well informed about possible contaminations, higher or lower than normal degrees of acidity and
other for the choice of materials important proprties.
• Check whether the materials of the connecting piping are compatible with the materials of the heat
exchanger (when the materials of the bundle are, from a corrosion point of view, weak in
comparison with the materials of the piping, the bundle will corrode faster than expected).
2
In connection with the applied materials the instruction manuals refer to the specification sheet of the heat
exchanger. Therefore always keep the specification sheet.
17
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

--------------------------------------------------------------------------------------
RICKMEIER WP P A R T S L I S T Page 1
PRESSURE RELIEF VALVE Date 18.11.03
DBV40(25)-B-FL-P40(40)-FL-PII-SCF Rev.0/02.09.03
--------------------------------------------------------------------------------------
Object-no. : 418330
Flow diagr. :
Documentation : MZ
--------------------------------------------------------------------------------------
Pos Qty Designation Object-no. Rev.
--------------------------------------------------------------------------------------
1 1 VALVE BOX 417354
DBV40(25) FL
EN-GJS-400-15
2 1 PILOT VALVE 182177-6

DB9 SO
EN-GJL-250
7 1 DIREKTIONAL VALVE 408414

1 818 509 301
8 1 409859
HFC3/8
METALL
10 1 ADAPTOR 411046
DBV40(25)
11SMNPB30+C
12 1 CIRCLIP 408607
DIN 472-45X1,75
FEDERSTAHL
13 1 SNAP RING 260428-8

DIN 7993-B16
FEDERSTAHL
14 4 CHEESE-HEAD-SCREW 250524-6
DIN 912-M8X50-8.8
STAHL
16 3 O-RING 411044
DIN 3771A-9,19X2,62-FPM75 (2-110)
FPM75
18 1 O-RING 258395-3
DIN 3771A-58,42X2,62-FPM75 (2-141)
FPM75
19 2 O-RING 258424-1
DIN 3771A-47,22X3,53-FPM75 (2-225)
FPM75
21 1 SCREWD PLUG 251528-6

DIN 908-G3/8A-ST
STAHL
22 1 SEALING RING 258499-3

DIN 7603-A 17X21-CU
CU

DIN 7603-A 30X36-CU
CU
PRESSURE VALVE Date 18.09.03
DBV40(25)-S-P20(40)-FL-CII-M-SCF Rev..0/26.02.03
Object-no. : 411038
Flow diagr. :
Documentation : MZ
-------------------------------------------------------------------------------------
Pos Quantity Designation Object-no. Rev.
-------------------------------------------------------------------------------------
DBV40(25) FL-S
EN-GJS-400-15
2 1 VALVE COVER 411045

DBV40 (100X80X20)
EN-GJS-400-15
3 1 PRESSURE RELIEF VALVE 180101-8

DB6 AO F 20 BT SV
11SMNPB30+C
4 1 DIRECTIONAL VALVE 410978

0 810 091 254 (NG6, 24V DC)
5 1 MANUAL OVERRIDE 284967-7

1833343015-MIT GUMMIKAPPE-NG6
6 1 PLUG 281051-3
GDM2011 SCHWARZ
MIT DICHTUNG

1 818 509 301
8 1 409859
HFC3/8
METALL
10 1 ADAPTOR 411046
DBV40(25)
11SMNPB30+C
12 1 CIRCLIP 408607
DIN 472-45X1,75
FEDERSTAHL
13 1 SNAP RING 260428-8

DIN 7993-B16
FEDERSTAHL
DIN 912-M8X25-8.8
STAHL
DIN 912-M5X75-8.8
STAHL
16 3 O-RING 411044
DIN 3771A-9,19X2,62-FPM75 (2-110)
FPM75
Form 229589-7
PRESSURE VALVE Date 18.09.03
DBV40(25)-S-P20(40)-FL-CII-M-SCF Rev..0/26.02.03
--------------------------------------------------------------------------------------
Pos Quantity Designation Object-no. Rev.
--------------------------------------------------------------------------------------
18 1 O-RING 258395-3
DIN 3771A-58,42X2,62-FPM75 (2-141)
FPM75
19 2 O-RING 258424-1
DIN 3771A-47,22X3,53-FPM75 (2-225)
FPM75

DIN 908-G3/8A-ST
STAHL

DIN 7603-A 17X21-CU
CU

DIN 7603-A 30X36-CU
CU
25 1 SCREWED PLUG 251495-8

DIN 908-M10X1-ST
STAHL
26 1 COMPRESSION SPRING 255653-8

WP-N 8-1344-1,25X7,65X32X14,5-D
DIN 17223-D
27 1 BALL 256680-0
DIN 5401-6,5G28

DIN 7603-A 10X13,5-CU
CU
29 4 WASHER 252478-3
DIN 125-A4,3-ST
ST
Form 229589-7
Industriehydraulik
Industrial Hydraulics
Hydraulique industrielle
Wegeventile NG 6 Serie D
Directional control valves NG 6 Series D
Distributeurs NG 6 Série D
6/6
1.0
Ausgabe
Version
Version
2 Industrial Hydraulics
4
1
y yy yyy
1 3-Kammer-System mit zusätz- 1 3-chamber system with additional 1 Système à 3 chambres avec un
licher Schieberführung für hohe spool guidance for high perfor- guidage supplémentaire du tiroir
Leistungsdaten mance data pour des performances élevées
2 Druckdichte Magnete mit 2 Pressure tight solenoids with 2 Electro-aimants étanches à bobine
auswechselbarer Spule interchangeable coil interchangeable
Erhöhte Magnetkräfte Increased solenoid forces Forces élevées
3 Optimierte Kanalführung für 3 Optimized flow paths for low 3 Guidage de canal optimisé
geringe Druckverluste losses of pressure permettant de réduire les pertes
de charge
4 Handnotbetätigung 4 Manual override
mit Rückstellfeder with return spring 4 Commande manuelle de secours
avec ressort de rappel
Industrial Hydraulics 3
y
Inhalt Seite
Sachmerkmalleiste 4
Vorzugstypen 5
Gewichte 8
Zubehör 9
Magnet-Ersatzteile 10
Wegeventil elektrisch betätigt 11
Kenngrößen 12
Kennlinien 15
Einsteckblende 18
Wegeventil mit 8 Watt-Magnet 19
Abmessungen 23
Magnet mit Explosionsschutz 25
Wegeventil hydraulisch betätigt 29
Wegeventil pneumatisch betätigt 31
Wegeventil mechanisch betätigt 34
Wegeventil manuell betätigt 36
Anschlussplatten, Lochbild 38
Gerätesteckdosen 41
Dichtungssatz 42
yy
Contents Page
Characteristics bar 4
Preferred types 5
Weights 8
Accessories 9
Solenoid spare parts 10
Directional control valve electrically operated 11
Specifications 13
Curves 15
Restrictor 18
Directional control valve with 8 Watt solenoids 19
Dimensions 23
Solenoid flameproof 25
Directional control valve hydraulically operated 29
Directional control valve pneumatically operated 31
Directional control valve mechanically operated 34
Directional control valve manually operated 36
Subplates, Mounting hole 38
Plug connectors 41
Set of seals 42
yyy
Sommaire Page
Rangée de codification de caractéristiques 4
Types préférentiels 5
Poids 8
Accessoires 9
Pièces de rechange pour électro-aimant 10
Distributeur à commande électrique 11
Caractéristiques 14
Courbes 15
Gicleur 18
Distributeur avec electro-aimant 8 Watt 19
Cotes d’encombrement 23
Electro-aimant antidéflagrant 25
Distributeur à commande hydraulique 29
Distributeur à commande pneumatique 31
Distributeur à commande mécanique 34
Distributeur à commande manuelle 36
Embases, Plan de pose 38
Connecteurs 41
Pochette de joints 42
y yy yyy
Sachmerkmalleiste Characteristics bar Rangée de codification
de caractéristiques
10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26
0 8 1 W V 0 6 P 1 V 1 0 0 1 W S 0 2 4 / 0 0 – D 0 –
10 Dichtungsart 10 Seal quality 10 Qualité des joints

V Standard Fluor-Elastomer V Standard Fluor-Elastomer V Standard Elastomère fluoré
FPM (Viton® Dupont) FPM (Viton® Dupont) FPM (Viton® Dupont)
N NBR (Perbunan® Bayer) N NBR (Perbunan® Bayer) N NBR (Perbunan® Bayer)
11 Betätigungsart 11 Type of control 11 Mode de commande
1 elektrisch 1 electrical 1 électrique
2 hydraulisch 2 hydraulic 2 hydraulique

mechanisch mechanical mécanique
4 4 4
durch Rollenstößel (roller tappet) par poussoir à galet
6 pneumatisch 6 pneumatic 6 pneumatique
manuell manual manuelle
7 7 7
(Handhebel) (hand lever) par levier
mit Rastung with detent: avec crantage
7 7 7
nG bei Pos. 15 nG at Pos. 15 n
G à Pos. 15
12/14 Sinnbild 12/14 Symbol 12/14 Symbole
000 siehe Seite 5 ... 8 000 see page 5 ... 8 000 voir page 5 ... 8
001 001 001
· · ·
· · ·
15/16 Stromzuführung 15/16 Power supply 15/16 Raccordement électrique

Nicht im Lieferumfang enthalten Not included in scope of delivery Non compris dans la fourniture
WS Winkelsteckverbindung WS Plug connector WS Connecteur coudé selon
ISO 4400 ISO 4400 ISO 4400
JS Jet-Stecker JS Jet-connector JS Jet-connecteur
17/22 Magnetspannungen 17/22 Solenoid voltage 17/22 Tensions de l’électro-aimant
Standardsp. Sondersp. Standard Special Standard Spéciales
= ~* = ~ = ~* = ~ = ~* = ~
012/00 024/50 096/00 048/50 012/00 024/50 096/00 048/50 012/00 024/50 096/00 048/50
F 024/00 115/50 110/00 F 024/00 115/50 110/00 F 024/00 115/50 110/00
048/00 230/50 048/00 230/50 048/00 230/50
205/00 205/00 205/00
23 23 23
– Handnotbetätigung Standard – Manual override, standard – Cde. man. de secours standard
C Blockierte Handnotbetätigung C Manual override, blocked C Cde. man. de secours bloquée
E Magnet explosionsgeschützt E Solenoid flameproof E Electro-aimant anti-déflagrant
(Euro-Norm) (Euro-Norm) (Euro-Norm)
24 Serie 24 Series 24 Série
D für alle Betätigungsarten D for all types of control D pour tous modes de commande
25/26 Zusatzangaben 25/26 Additional data 25/26 Dispositifs additionnels
0 Standard, ohne Steckdose 0 Standard 0 Standard, sans connecteur
9 Handnotbetätigung 9 Manual override 9 Cde. man. de secours
mit Gummikappe with rubber cap avec protection
11 Schieber mit Feinsteuerkerben 11 Spool with metering notches 11 Tiroir avec rampes de progressivité
66 Handnotbetätigung mit Raste 66 Manual override with detent 66 Cde. man. de secours avec cran
(bei Wechselstrom nur für (with AC, only permissible (en cas de courant alternatif, uni-
2-Stellungsventile zulässig) for 2-position valves) quement autorisée pour distribu-
teurs à 2 positions)
* Die Wechselstrom-Magnete 115/50 * AC-solenoids 115/50 can be used * Electro-aimants prévus pour
können auch mit 115/60 bzw. with 115/60 and 230/50 can be fonctionnent en:
230/50 auch mit 230/60 betrieben used with 230/60 voltage supply. – 115/50 ou 115/60
werden. – 230/50 ou 230/60.
y yy yyy
Vorzugstypen Preferred types Types préférentiels
Diese sind mit einer 10-stelligen These are assigned a 10-digit EDP Ces types possèdent un code
EDV-Nummer belegt. Bisher nicht be- number. Previously unassigned valve informatique à 10 chiffres. Les com-
legte Ventilkombinationen werden mit combinations are described in the binaisons distributeurs non encore
der Sachmerkmalleiste beschrieben. characteristics bar. pourvues de ce code sont décrites
par la rangée de codification de
caractéristiques.
0 81 WV 06 P1V ... D0 « 0 810 …

1 WS 2 4 6 7 E
Sinnbild mit Übergang 012/00 024/50 024/00
Symbol with transition 024/00 115/50** 048/00
Nr. Symbole avec transitoire 205/00 230/50** 205/00
000 A B 091 200 – 091 365 091 526 091 588
091 201 091 433 091 379 –
P T 091 498 091 434 –
001 091 202 091 435 091 607 091 366 091 381 091 589
A B 091 203 091 436 091 380 –
091 205 091 437 –
001 * P T
091 292 –
091 293 091 608
– –
002 091 206 091 574 091 367 091 383 091 590
A B 091 207 091 438 091 382 –
091 210 091 439 091 591
002 * – –
P T
– –
– –
004 091 211 091 440 091 368 091 385 091 592
A B 091 212 091 441 091 384 091 593
091 214 091 442 –
004* – –
P T
091 276 –
– –
005 A B 091 215 –
091 216 091 443
P T – 091 444
006 A B 091 609 –
091 217 091 445
P T 091 218 091 446
010 A B 091 221 091 449 091 541 091 333 091 525 091 387 091 595
091 222 091 450 091 386 –
P T 091 224 091 451 –
A B
011* 091 614 –
091 225 091 452
P T 091 294 091 453
A B
012 091 226 091 454 091 358 091 334 091 369 091 389 091 597
091 227 091 455 091 388 –
P T 091 231 091 456 –
A B
014 091 232 – 091 370
091 233 091 460
P T 091 235 091 461
y yy yyy
** In Sachmerkmalleiste bei Stelle ** In characteristics bar at position ** Dans la rangée de codification de
25, 26 n
11 mit Feinsteuerkerben. 25, 26 n11 with metering notches. caractéristiques aux positions 25, 26
** Die Wechselstrom-Magnete ** AC-solenoids 115/50 can be n
11 avec rampes de progressivité.
115/50 können auch mit 115/60 used with 115/60 and 230/50 ** Electro-aimants prévus pour
bzw. 230/50 auch mit 230/60 can be used with 230/60 voltage fonctionnent en:
betrieben werden. supply. – 115/50 ou 115/60
– 230/50 ou 230/60.
0 81 WV 06 P1V ... D0 « 0 810 …

1 WS 2 4 6 7 E
016 091 236 – 091 335
A B 091 237 091 462
– 091 463
016* P T
– –
091 295 –
– –
017 A B – –
091 238 –
P T – –
018 091 239 – 091 390
A B 091 240 091 464 –
– 091 465
018* 091 546 –
P T
091 296 –
– –
019* – –
091 297 –
– –
020 091 241 – 091 359 091 371 091 599
091 242 091 466 –
– 091 467 –
022 A B – –
091 243 –
P T – –
024 A B 091 244 –
091 245 091 468
P T – 091 469
026 A B – –
091 246 091 470
P T – 091 471
027 091 247 – – 091 600
A B 091 248 091 472 091 391 –
– 091 473 –
027* P T
– –
091 298 –
– –
028 A B 091 570 –
091 287 –
P T – –
032 A B 091 250 –
091 251 –
P T – –
033 A B 091 252 –
091 253 091 474
P T – 091 475
036 A B 091 290 –
091 254 –
P T – –
A B
038 091 255 –
091 256 –
P T – 091 568
y yy yyy
25, 26 n
– 230/50 ou 230/60.
0 81 WV 06 P1V ... D0 « 0 810 …

1 WS 2 4 6 7 E
039 – –
A B 091 257 –
– –
039* P T
091 299 –
– –
– –
A B
040 – –
091 284 091 476
P T – –
042 A B – –
091 258 091 477
P T – –
045 091 259 – –
A B 091 260 091 478 091 601
– 091 479 –
045* – –
P T
091 300 –
– –
052 A B – –
091 261 –
P T – –
061 A B 091 262 –
091 263 091 480
P T – –
062 A B – –
091 542 –
P T – –
064 A B – –
091 264 –
P T – –
068 A B 091 265 – 091 578
091 266 091 481
P T – 091 482
070 – –
A B 091 268 –
– –
070* P T
– –
– –
– –
071 A B 091 524 –
091 269 –
P T – –
072 A B – –
091 271 –
P T – –
078 A B 091 272 –
091 273 091 483
P T – 091 484
080 A B – –
091 274 –
P T – –
083 A B – –
091 275 –
P T – –
y yy yyy
25, 26 n
– 230/50 ou 230/60.
0 81 WV 06 P1V ... D0 « 0 810 …

1 WS 2 4 6 7 E
A B
085 – –
091 286 –
P T – –
A B
087 – –
091 277 –
P T – –
089 – –
A B 091 278 –
– –
089* P T
– –
091 304 –
– –
090 A B – –
091 279 –
P T – –
091 Leckölabführung intern – –
internal drain 091 280 091 486
drain interne – 091 487
A B
905 – –
091 281 –
P T – –
911 A B
– –
091 283 –
P T – –
920 A B – – 091 337
– –
P T – –
y yy yyy
25, 26 n
– 230/50 ou 230/60.
Gewichte
Weights
Poids
= 11,5 kg
~ 11,5 kg
E 12,3 kg
= 11,9 kg
~ 11,9 kg
E 14,0 kg
11,3 kg
11,5 kg
11,5 kg
11,3 kg
11,5 kg
12,0 kg
y yy yyy
Zubehör Accessories Accessoires
Nicht im Lieferumfang des Ventils Not included in scope of delivery Non compris dans la fourniture
enthalten. of valve. du distributeur
Sinnbild Seite
Symbol Page
Symbole Page kg «
Stecker Standard grau A 41 0,1 1 834 484 058
Plug connectors grey
Connecteurs gris
schwarz B 1 834 484 057
black
noir
mit Leuchtdioden 15 ... 30 V= A 1 834 484 136
with LED B 1 834 484 137
avec diode électroluminesc.
mit Leuchtdioden 230 V~ A 1 834 484 103
with LED
avec diode électroluminesc.
mit Freilauf- u. Leuchtdiode A 1 834 484 138
with free-wheeling diode B 1 834 484 139
and LED 15 ... 30 V=
avec diode de roue libre
ou électroluminescente
mit Gleichrichter A 1 834 484 134
with rectifier B 1 834 484 135
avec redresseur
Jet 0,1 1 834 484 094
1 834 484 095
Anschlussplatten Gewinde M 14 x 1,5 38 0,7 1 815 503 378

Subplates Thread M 18 x 1,5 1 815 503 377
Embases Filetage G1/4 1 815 503 340
G3/8 1 815 503 336
G1/2 0,9 1 815 503 373
Anschlüsse seitlich G3/8 1,8 1 815 503 365
Side ports
Orifices latéraux
f (4 x) M 5 x 30 DIN 912-10.9 2 910 151 166
y yy yyy
Magnet-Ersatzteile Solenoid spare parts Pièces de rechange
pour électro-aimant
U [V] f [Hz] « WS
1 012/00 1 837 001 226
024/00 1 837 001 227
Spule 8 Watt 024/00 1 837 001 219
Coil 028/00 1 837 001 457
Bobine 048/00 1 837 001 229
096/00 1 837 001 232
110/00 1 837 001 233
205/00 1 837 001 305
2 **115/50 1 837 001 255
**230/50 1 837 001 256
024/50 1 837 001 252
042/50 1 837 001 253
048/50 1 837 001 254
3 JS 1)
012/00 1 837 001 223
024/00 1 837 001 224
mit/with/avec 012/00 1 837 001 270
Bi-Diode 024/00 1 837 001 271
4 CS 2)
024/00 1 837 001 257
5 KS 3)
012/00 1 837 001 421
024/00 1 837 001 432
Handnotbetätigung Standard* 1 833 343 009
Manual override standard*
Cde. secours standard*
Mutter
Nut mit Gummikappe 1 833 343 015
with rubber cab
n
9 Ecrou
avec protection
Blockierte Handnotbetätigung 1 833 343 013

Manual override blocked
n
C
Cde. secours bloquée
Handnotbetätigung mit Raste*** 1 833 343 018

Manual override with detent***
n
66
Cde. secours avec crantage***
y yy yyy
*** Im Lieferumfang des Ventils *** Included in scope of delivery *** Comprise dans la fourniture du
enthalten. of valve. distributeur.
*** Die Wechselstrom-Magnete *** AC-solenoids 115/50 can be used *** Electro-aimants prévus pour
115/50 können auch mit 115/60 with 115/60 and 230/50 can be fonctionnent en:
bzw. 230/50 auch mit 230/60 used with 230/60 voltage supply. – 115/50 ou 115/60
betrieben werden. – 230/50 ou 230/60.
*** Not in connection with a.c. coils.
*** Nicht in Verbindung mit Wechsel- *** Pas en combinaison avec des bo-
stromspulen. *1) Jet plug version suitable for mobile bines à tension alternative.
applications with special tightness
*1) Jet-Stecker-Ausführung geeignet requirements. *1) La version connecteur Jet convient
für mobile Anwendungen mit pour des applications mobiles
besonderen Dichtheits-An- *2) Canon-Connector. avec exigences d’étanchéité
forderungen. particulières.
*3) Kostal-Connector.
*2) Canon-Stecker. *2) Connecteur-Canon.
*3) Kostal-Stecker. *3) Connecteur-Kostal.

Dichtungssatz
Set of seals
Pochette de joints
y yy yyy
Der Dichtungssatz enthält die in der The set of seals contains the items Les pochettes de joints comprennent
Zeichnung erwähnten Positionen. shown in the illustration. les repères indiqués sur le plan.
Weitere Teile siehe Ersatzteilliste See spare-parts list for further parts, Pour les autres pièces, se reporter
(CD-ROM) « 1 987 760 010. (CD-ROM) « 1 987 760 010. à la liste de pièces de rechange,
(CD-ROM) « 1 987 760 010.
800/37 3,5 + 1,5 NM
35 + 5 NM
800/6
800/6
800/7
800/37
«
FPM (Viton® Dupont) 1 810 210 803
w 9,25 x 1,78 (4 x) Pos.-Nr. 800/7
NBR (Perbunan® Bayer) 1 810 210 120
Dichtungssatz FPM (Viton® Dupont) 1 817 010 310
Set of seals NBR (Perbunan® Bayer) 1 817 010 311
Pochette de joints
--------------------------------------------------------------------------------------
PRESSURE RELIEF VALVE Date 18.11.03
DBV40(25)-B-P8(12)-FL-PII-SXF Rev.0/02.09.03
--------------------------------------------------------------------------------------
Object-no. : 414654
Flow diagr. :
Documentation : MZ
--------------------------------------------------------------------------------------
Pos Qty Designation Object-no. Rev.
--------------------------------------------------------------------------------------
DBV40(25) FL
EN-GJS-400-15
2 1 PILOT VALVE 180366-7

DB9 SO
EN-GJL-250

1 818 509 301
8 1 409859
HFC3/8
METALL
10 1 ADAPTOR 411046
DBV40(25)
11SMNPB30+C
12 1 CIRCLIP 408607
DIN 472-45X1,75
FEDERSTAHL
13 1 SNAP RING 260428-8

DIN 7993-B16
FEDERSTAHL
DIN 912-M8X50-8.8
STAHL
16 3 O-RING 411044
DIN 3771A-9,19X2,62-FPM75 (2-110)
FPM75
18 1 O-RING 258395-3
DIN 3771A-58,42X2,62-FPM75 (2-141)
FPM75
19 2 O-RING 258424-1
DIN 3771A-47,22X3,53-FPM75 (2-225)
FPM75

DIN 908-G3/8A-ST
STAHL

DIN 7603-A 17X21-CU
CU

DIN 7603-A 30X36-CU
CU
DRAWING APPENDIX PART 10
TABLE OF CONTENTS
10.1 Drawings mechanic
Drawing no.
Installation drawing 6459278/0 sheet 1 to 2
Assembly drawing 6459455/0 sheet 1 to 2
Mass scheme 6459277/3
10.2 Drawings hydraulic
Drawing no.
Piping scheme 6815626/0 sheet 1 to 2
Connection scheme 6815519/0
Scheme gear wiring 6815520/0 sheet 1 to 2

Operating Instruction PWS 18-E (Gearbox) SEL 12 PDF

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Operating Instruction PWS 18-E (Gearbox) SEL 12 PDF

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COVER SHEET WITH TABLE OF CONTENTS

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

Issue: 2004-04-14 - MT/Hu/Erh Type: PWS 18-E Revision: 6954890/4 1 /5

Gear unit type: PWS 18-E

Customer: MTU Friedrichshafen GmbH

Contract no.: 740799

Code: HN Hunt Class

Shipyard: Vosper Thornycroft

RENK order no.: 80119109

RENK product no.: Gear unit port 6459252

Serial no.: see type plates

Year of manufacture of the gear unit 2004

Issue: 2004-04-14 - MT/Hu/Erh Type: PWS 18-E Revision: 6954890/4 2 /5

Issue of the Operating Instruction:

Issue Customer address + RENK Number and Issue data Employee

First issue MTU Friedrichshafen GmbH 10x English 2004-05-28 MT/Erhard

Department MT 1x English 2004-05-28 MT/Erhard

Issue: 2004-04-14 - MT/Hu/Erh Type: PWS 18-E Revision: 6954890/4 3 /5

Documents modified (1st amendment):

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

no. Designation Sheet Issue Designation Sheet Issue

Issue: 2004-04-14 - MT/Hu/Erh Type: PWS 18-E Revision: 6954890/4 4 /5

Issue: 2004-04-14 - MT/Hu/Erh Type: PWS 18-E Revision: 6954890/4 5 /5

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

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

Issue: 1999-10-29 - MT/Hu/Erh Revision: 2003-02-04 6954079/4 a 1 /7

1 General operating and safety information

1.1 General operating information

Issue: 1999-10-29 - MT/Hu/Erh Revision: 2003-02-04 6954079/4 a 2 /7

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: 2003-02-04 6954079/4 a 3 /7

• 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!

1.2.2 Notes and explanation of notice

Issue: 1999-10-29 - MT/Hu/Erh Revision: 2003-02-04 6954079/4 a 4 /7

Issue: 1999-10-29 - MT/Hu/Erh Revision: 2003-02-04 6954079/4 a 5 /7

Issue: 1999-10-29 - MT/Hu/Erh Revision: 2003-02-04 6954079/4 a 6 /7

1.2.7 Remaining dangers for the user and protective measures

Issue: 1999-10-29 - MT/Hu/Erh Revision: 2003-02-04 6954079/4 a 7 /7

2 TECHNICAL DATA ...........................................................................................2

2.1 Gear unit main data.......................................................................................2

2.2 Technical data 6815538/4 to

Issue: 2004-03-18 - MT/Hu/Erh Type: PWS 18-E Revision: 6954891/4 1 /2

2.1 Gear unit main data

2.1.1 Input diesel engine (DE)

2.1.2 Input PTI

2.1.3 Hydraulic data

Issue: 2004-03-18 - MT/Hu/Erh Type: PWS 18-E Revision: 6954891/4 2 /2

Supply Supply Suction

Built-on control oil pump

Built-on lube oil pump

Lube oil pump, electrical driven

Control oil pump, electrical driven

Order no: 80119109

Flender/ ANGA 440 V